Win Progress.,Co - LTD (Pharkant Branch) : D13A Engine Receiving/Delivering Inspection Form
Win Progress.,Co - LTD (Pharkant Branch) : D13A Engine Receiving/Delivering Inspection Form
Win Progress.,Co - LTD (Pharkant Branch) : D13A Engine Receiving/Delivering Inspection Form
Action plan
Action plan
1
in 2 plane , so measure in 4 points)
[Tightening torque;1st=111lbf ft
B
2 A
B
STD=108.00 108.06 A
3
2nd=120degree]
1
B
2 99.00 99.07
A
2
B
A
1
B
Big End 3 99.00 99.07
A
2
B
A
1
Bearing B
4 99.00 99.07
A
2
B
A
1
B
5 99.00 99.07
A
2
B
A
1
B
6 99.00 99.07
A
2
B
A
1
B
1 57.00
A
2
B
A
Limit of Clearance=0.08mm
1
Diameter(Measure at 2point and 2planes)
B
2 57.00
A
2
Clearnce =Small end bearing dia-piston pin dia
B
A
1
B
Small 3 57.00
A
End 2
B
A
1
Bearing B
4 57.00
A
2
B
A
1
B
5 57.00
A
2
B
A
1
B
6 57.00
A
2
B
Check the connecting rod parallel alignment to all connecting rods
Note! Same side piston arrow marking and conneting rod front marking.
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 108.00 107.98
A
4 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 108.00 107.98
A
5 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 108.00 107.98
A
6 2
B
Ovality(A-B) 0.08
Taper(1-2) 0.05
A
1
B
Diameter 108.00 107.98
A
7 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
7 Vibration damper
Step 1 35±5 Nm(25.8lbf ft)
Step 2 90 ± 10 Nm(66.4 lbf ft)
8 Flywheel(D13A)
Step 1: 60 ±5 Nm (44.3 lbf ft)
Step 2: 120±10°
11 Stiffening frame
Step 1: Bolts 1-24 (in numerical order) 45±5 Nm (33 lbf ft)
Step 2: Bolts 1-24 (in numerical order) 60±5°
24 ± 4 Nm
12 Oil pan
Secure the oil sump with screws A and B 24±4 Nm (17.7 lbf ft)
Tighten the screws from the centre outwards 24±4 Nm (17.7 lbf ft)
Finish by check-tightening screws A and B 24±4 Nm (17.7 lbf ft)
Drain plug, oil sump 60 ± 10 Nm(44 lbf ft)
13 Bearing cap of camshaft
Step 1: 15 ±5 Nm (12lbf ft),90°±5°
>Bearing cap rocker arm shaft
Step 2: 60 ±5 Nm (44 lbf ft)
Step 3: 15 ±5 Nm (12 lbf ft) + 120°±5°
Step 4: loosen the bolts
Step 5: 15 ±5 Nm (12lbf ) + 120°±5°
>VEB 24 ±4 Nm (18 lbf ft)
14 Oil cooler
Step 1; Tighten the bolts in order 1,2,3,4 5±1 Nm(3.7lbf ft)
Step 2; Tighten the bolts inorder 1,2,3,4,1 27±4 Nm(20 lbf ft)
21 Preheater
10±2 Nm(7.4 lbf ft)
step 1.....
step 2..... 24 ±4 Nm (18lbf ft)
1 Preparation
(i)Prepare the tools as follow
General Tools
Allen Wrench-8mm,Wrench 14mm,Hammer
Special Tools
LT-176,9990176 ,11666043 ,11666041 ,LT-149 ,Magnetic ,9998263 or LT-139,LT-36,Pressure gauge
2 Mounting in work stand
Fixture(1) Bolt down on the cylinder head.
Lift up the cylinder head(2) and secure it in work stand(3).
3 Valves, removing
Install LT-149 in the copper sleeve and secure it in the holes with
unit injector's attaching bolts.
Press down the valve washer and remove the valve collets(4).
Remove the valve washer(5), springs(6) and valves(7).
Remove the remaining valves in the same way.
Remove the valve seals(8) and guide pins for the valve yokes.
Valve Collets Deform or Damage
Valve Washer Deform or Damage
Valve Spring Deform or Damage
Valve Wear or Damage
4 Valves Guide and Valve Seat, removing
Remove the Valve Guide(9).(By using Press)
Remove the Valve Seat(10).(By using Welding or Other)
Valve guide Wear or Damage
Valve seat Wear or Damage
5 Cylinder head, checking for leaks
Install LT-96 on the cylinder head's underside.
Install pressure plates.
Install the hole for the coolant temperature sensor.
Before pressure gauge 9996662 is used, it shall be checked
The pressure becomes 50 kPa (7.3 psi) (0.5 bar).
Hold the pressure for 1 minutes.
Increase the pressure to 150 kPa (21.8 psi) (1.5 bar).
Check after 2 minutes.
Head Surface Deform or Crack
Copper sleeve Leakage
6 Copper Sleeve, removing
Tap out the copper sleeve(11) with a 10 mm (0.394 in) drift.
_____
Win Progress Co.,Ltd.(Pharkant Branch)
Engine Head Specification Check Sheet
D13A Cylinder Head Customer
M\C Model S\N
Check Sheet Engine Model S\N
Disassembly Working Hour Date
Assembly Reference Service Report No
Unit=mm
Item Piston Check Point Wear limit Actual Clearance
1 Inlet 0.03-0.05
Exhaust 0.04-0.06
Inlet 0.03-0.05
Radial 2
Exhaust 0.04-0.06
Clearance of
Inlet 0.03-0.05
Valve Guide 3
Note Exhaust 0.04-0.06
-Valve Seal Inlet 0.03-0.05
4
must be Exhaust 0.04-0.06
removed Inlet 0.03-0.05
5
Exhaust 0.04-0.06
Inlet 0.03-0.05
6
Exhaust 0.04-0.06
STD limit Actual Clearance
Inlet 0.9-1.4 1.6mm
1
Exhaust 1.2-1.7 2mm
Inlet 0.9-1.4 1.6mm
The depth of 2
Exhaust 1.2-1.7 2mm
valves(center) Inlet 0.9-1.4 1.6mm
from the 3
Exhaust 1.2-1.7 2mm
cylinder head
Inlet 0.9-1.4 1.6mm
sealing 4
surface Exhaust 1.2-1.7 2mm
Inlet 0.9-1.4 1.6mm
5
Exhaust 1.2-1.7 2mm
Inlet 0.9-1.4 1.6mm
6
Exhaust 1.2-1.7 2mm
Dia,.C Depth,D Actual
Inlet 45 11.8±0.1
1 Exhaust 43 11.2±0.1
Inlet 45 11.8±0.1
2 Exhaust 43 11.2±0.1
Inlet 45 11.8±0.1
Valve seat's 3 Exhaust 43 11.2±0.1
position Inlet 45 11.8±0.1
4 Exhaust 43 11.2±0.1
Inlet 45 11.8±0.1
5 Exhaust 43 11.2±0.1
Inlet 45 11.8±0.1
6 Exhaust 43 11.2±0.1
Valve steam diameter must be 8mm-8mm( Inlet,Exhaust)
Inlet..... 24.5°± 0.2
A
Valve seat Exhaust..... 39.5°
angle Inlet..... 25°
B
Exhaust..... 40°
Valve guides Height above cylinder head's spring face: Inlet=24.5±0.2mm, Exhaust=24.5±0.2mm.
Clearance valve stem-guide ( Dry valve stem )
Inlet..... max 0.7 mm
Exhaust..... max 0.7 mm
Inlet 72-74mm
Length
unload
exhaust(in) 70-71mm
,
Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ Supervisior Sign_ _ _ _ _ _ _ _ _ _
Engineer/Mechanic Name_ _ _ _ _ _ _ _ _ _ Supervisior Name_ _ _ _ _ _ _ _ _ _
Win Progress Co.,Ltd(Pharkant Branch)
Engine Overhauling Check Sheet
Customer
D13A Cyliner Block
M/C Model S/N
Disassembly Engine Model S/N
Assembly WH Date
Unit=mm
Piston cooling nozzle NO.1 NO.2 NO.3 NO.4 NO.5 NO.6
Condition check(OK/NOK)
1st 111lbf.ft
Tighting torque for main caps without bearing
2nd 120'
STD(mm) Limit(mm) Plane point 1 point 2 Comment
A
Diameter(Measure in 2 point and also
1
in 2 plane , so measure in 4 points)
[Tightening torque;1st=111lbf ft
B
A
2
B
STD=113.00 113.06 A
3
2nd=120degree]
B
2 103.80 103.87
A
2
B
A
1
B
3 103.80 103.87
connectin A
2
g rod B
without A
bearing 1
B
4 103.80 103.87
A
2
B
A
1
B
5 103.80 103.87
A
2
B
A
1
B
6 103.80 103.87
A
2
B
A
1
B
1 57.00
A
2
B
A
Limit of Clearance=0.08mm
1
Diameter(Measure at 2point and 2planes)
B
2 57.00
A
2
B
Clearnce =Small end bearing dia-piston pin dia
A
1
B
3 57.00
Small End A
2
B
A
Bearing 1
B
4 57.00
A
2
B
A
1
B
5 57.00
A
2
B
A
1
B
6 57.00
A
2
B
Check the connecting rod parallel alignment to all connecting rods
Note! Same side piston arrow marking and conneting rod front marking.
Engineer/Mechanic Sign_ _ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Sign_ _ _ _ _ _ _ _ _ _ _ _ _
Engineer/MechanicName_ _ _ _ _ _ _ _ _ _ _ _ _ Service Supervisior Name_ _ _ _ _ _ _ _ _ _ _ _ _
Win Progress Co.,Ltd.(Pharkant Branch)
Engine Overhauling Check Sheet
D 13A Crankshaft Customer
M/C Model S/N
Check Sheet Engine Model S/N
Disassembly Working Hour Date
Assembly Reference Service Report No.
Unit=mm
Item Check Point STD Limit Point Plane Actual Clearance
A
1
B
Diameter 99.00 98.98
A
1 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 99.00 98.98
A
2 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
Big End Bearing Journal
A
1
B
Diameter 99.00 98.98
A
3 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 99.00 98.98
A
4 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 99.00 98.98
A
5 2
B
Ovality(A-B) 0.01
Taper(1-2) 0.02
A
1
B
Diameter 99.00 98.98
A
6 2
B
Ovality(A-B) 0.08
Taper(1-2) 0.05
1
in 2 plane , so measure in 4 points)
B
A
2
B
A
3
B
A
4 70 70.1
Cam Bearing
B
A
5
B
A
6
B
A
7
B
STD(mm) Limit(mm) Plane point 1 point 2 Comment
A
Diameter(Measure in 2 point and also
1
in 2 plane , so measure in 4 points)
B
A
2
B
A
Diameter of cam shaft
3
B
A
4 70 69.98
B
A
5
B
A
6
B
A
7
B