ADJUSTMENT ELECTRONIC GOVERNORS

ADJUSMENT ELECTRONIC GOVERNORS E6 bis E30 "HEINZMANN"(TERAKIT di MWM TBD 232)

1.set magnetic pick-up gap 0,5mm-0,8mm
2.set feed back.hubungkan volt meter dengan range 10volt pada test point dan switch-on voltage supply.(mesin off/jangan di start)set sampai 1,5volt-stop potensiometer.lalu gerakan actuator secara manual ke posisi bb max dan set 5volt dengan max potensiometer bb...seting akan saling mempengarui kedua(2)potensiometer ulangi sampai nilainya tercapai(toleransi.0,1volt).dan jika bb dibatasi linkage,lepas linkage pada saat seting
3.set frequency
-putar set point potensiometer counter clockwise ke stop
-putar max speed potensio 20 putaran counter clockwise
-putar min speed potensio counter clockwise
-start mesin(over speed protection harus bekerja)dan jika mesin tidak hidup,atur set point potensio clockwise kekanan dan max.speed potensio clockwise kekanan sampai mesin mulai hidup.
-putar set point potensio clockwise kestop.
-set max.speed potensio clockwise ke max.speed
-putar set point potensio clockwise ke stop
-set min.speed potensio clockwise ke"min. speed"
4.speed set point potensiometer and gain---in medium position.
-stability,derivative,gas gain,fast response,damping---ke stop
-droop switch---ke zero droop
-diesel/gas selector,with diesel engines---ke diesel position
-diesel/gas selector dengan carburator atau gas engine---ke gas position
5.start mesin.jika putaran mesin tidak stabil(hunting)...putar gain counter clockwise sampai putaran mesin stabil.
-putar speed point clockwise perlahan sampai achir stop tercapai.
-set max.operating speed dengan max.speed potensiometer.(hati2 pengaman over speed dalam keadaan bekerja)
6.-putar2 perlahan gain clockwise hingga hunting sampai kembali stabil putaran mesin
-putar2 perlahan stability clockwise hingga hunting sampai kembali stabil.
-putar2 perlahan derivative clockwise hingga hunting sampai kembali stabil.
7.jika governor linkage flutter(akan menurun),putar damping potensiometer clockwise kekanan untuk menahan/memulihkan flutter jika test response pada perubahan beban yang diinginkan.putar fast response potensiometer clockwise perlahan sampai led antara damping potensiometer clockwise "on" kemudian putar lagi kekiri hingga "off"lagi
8.setting gas gain.
-bebani mesin kira2 60% dari max.beban
-putar gas gain clockwise hingga mesin hunting...kemudian putar kekiri lagi sampai putaran mesin kembali stabil.
9.putar speed set point potensiometer dan set "lower"operasional speed(kecepatan operasi rendah)dengan min.speed potensiometer clockwise.
-test mesin melebihi putaran penuh dan beban range dan set ulang governor jika perlu.
-jika bersamaan governor pembagi beban/unit pengukur digunakan maka min.speed potensiometer harus diputar clockwise kekanan ke"stop"
10.setting droop.
-selector ke posisi droop.
-set droop pada potensiometer charge dan discharge mesin beberapa kali...cheek droop dan atur jika perlu .jika system dioperasikan dengan dan tanpa droop yang diinginkan maka external droop potensiometer dan switch dua(2)arah diperlukan.
-dalam hal ini putaran diatur pada posisi zero droop tanpa beban---tidak akan ada perubahan kecepatan.

"lampu control dibawah potensiometer akan on sementara mesin stationary"

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H.P.COMPRESSOR REAVELL SAT-4H/5H/6H/7H.MK8

all sat compressor are single acting,three stage,two crank machines,except for the SAT7H,the second stage is above the first stage with the third stage above its own crosshead.on the sat7h,however,the third stage is above the first with the second stage above its own crosshead......


-valve assemblies in the first and second stages are of the flat plate,low lift type while the third stage valves are of the thimble type.all valve assemblies are easily accessible for maintenance and replacement when required

tecnical details:.....(K.A)
operating pressure range :
-sat4h....................83-310bar(1200-4500psig)
-sat5h....................83-310bar(1200-4500psig)
-sat6h....................83-240bar(1200-3500psig)
-sat7h....................83-205bar(1200-3000psig)

-sump capacity:sat4h/sat5h/sat6h/sat7h......(litre)1.9/5.7/8.0/14.9(3.25/10//14/26pints)
-cylinder lubricator capacity...............1 litre(1.7 pints)
-cylinder lubricator feed rates:
.second stage..........2drops in 3minutes....4drops in 5minutes
.third stage...........2drops in 3minutes....4drops in 5minutes

-water test pressure:
..1st stage cooler sat4h/5h/6h/7h...10.3bar(150psig)
..2nd stage cooler sat4h/5h/6h/7h...76bar(1100psig)/76bar(1100psig)/69bar(1000psig)/69bar(1000psig)
..3rd stage cooler sat4h/5h/6h/7h...465bar(6750psig)/465bar(6750psig)/386bar(5600psig)/345bar(5000psig)
..water jacket sat4h/5h/6h/7h.......7.9bar(55psig)

-running clearance(inches):
..piston(plunger)vertical stage 1/2/3....0.015-0.030/0.030-0.065/0.040-0.080
..piston ring gaps stage 1/2.............0.007-0.017/0.003-0.008
..piston ring width stage 1/2............0.002-0.004(max0.006)/0.0005-0.0025(max0.004)
..piston(plunger)diametral stage 1/2/3...0.0006-0.007(max0.011)/0.004-0.005(max0.007)/0.0005-0.0007(max0.0015)
..crosshead diametral clearance...........0.004-0.005(max0.007)
..small-end bearing diametral.............0.0015-0.0025(max0.005)
..big-end bearing diametral...............0.003-0.0035(max0.006)
..big-end bearing end float...............0.005-0.007(max0.011)
..main bearing diametral..................0.0035-0.0045(max0.007)
..crankshaft end float....................0.014-0.016(max0.024)

-torque setting:........ sat4h/.....5h/.....6h/.....7h (lbf.ft)
..main bearing housing..1/2".....27/.....27/...../.....
........................5/8"......./......./55...../55
..big end bearing bolt..7/16".....23/....../....../......
........................5/8"......../60...../60...../60
..bursting disc cover...1/4".......3/....../....../......
........................3/8"......../11...../...../......
........................1/2"......../......./27...../27
..crankcase doors.......3/8"......11/....../....../......
........................1/2"......../27..../27..../27
first stage valve cover.3/8"......11/....../....../......
........................1/2"......../27...../27...../......
........................5/8"......../......./......./55
..second stage valve cover.3/4"...../......./......./90
..first stage cylinder cover.1/2...27/27...../27...../......
(with 2nd,3rd stagevcylinder blocks).5/8".....55/....../55...../55
..1st stage cylinder block to crankcase.3/4"..../....../......./90
..1st stage suction flange....5/16"......6/....../....../......
..............................3/8"......../11...../...../......
..............................1/2"......../......./27...../27
..1st,2nd stage cooler cover outer end.5/8".....55/....../....../.....
.......................................3/4"......./90...../90...../90
..1st,2nd stage cooler cover driving end.5/8"...55/....../...../......
..1st,2nd stage cooler cover flange......1/2"...27/.....27/27...../27
..3rd stage cooler cover.................3/8"...../......./......./11
.........................................1/2"...../27/...../27...../......

-maintenance:
.after the first running time:
-----15 hours.....check that alignment and belt tensioning in correct
-----100 hours....drain and change crankcase oil
-----250 hours....remove and examine all suction and delivery valve,
..................check that all safety devices are in good condition
..................bursting disc(s)corrosion rod...etc
-every 500hours(12weeks).....check that alignment and belt tension in correct
-every 1000hours(25weeks)....remove and service all suction and delivery valve
...if,after the first two valve inspection all appears well,the removal and service
of all valves may be extended to every 1000 hours
....drain crankcase oil
....if necessary clean cylinder lubricator sight feed glasses
-every 2000hours:examine connecting rod big end bearing and crank pins
..if these are not in good condition examine the main bearing
..examine ball valves and springs in cylinder lubricator system
..check prssure gauge for correct readings
-every 8000hours:
..the comprssor should be given full mechanical check

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COMP AIR H5336.2/H5436.2N2/H5436.2. HIGH PRESSURE....(K..A)

-technical data
-pressure and temperature
-running clearance
-critical torque wrench settings


-H5336.90*vee..............................single acting,three stage
-H5436.90*booster..........................single acting,three stage
-H5436.90*vee...............................single acting,four stage
-cooling.......................................................water
-direction or rotation,viewed from drive end..........anti clockwise
-number of valves........one combined suction and delivery per stage
-type of valve...................................flat plate,low lift
-mounting..........................three point,anti-vibration mounts
-maximum compressor air intake temperature......................45*c
-maximum water inlet temperature................................37*c
-speed maximum/minimum..............................1500/750 rev.min
-pressure H5336.2 maximum/minimum......................85 bar/40 bar
-pressure H5436.2 maximum/minimum....................350 bar/140 bar
-maximum water pressure........................................5 bar
-oil pressure...........................................2.0-2.75 bar
-crank case oil capacity....................................45 litre
-piston stroke hH5336.2/H5436.2N2B2/H5436.2...............75/75/75mm
-first stage cylinder bore H5336.2/H5436.2.................185/185mm
-second stage cylinder bore H5336.2/H5436.2N2B2/H5436.2...95/95/95mm
-third stage cylinder bore H5336.2/H5436.2N2B2/H5436.2....45/45/45mm
-fourth stage cylinder bore H5336.2/H5436.2N2B2/H5436.2...22/22/22mm

water test pressure:
.first stage cooler..........10.3 bar
.second stage cooler...........55 bar
.third stage cooler...........285 bar
.fourth stage cooler..........690 bar
.water jacket................10.3 bar

pressure acceptance levels:
-H5336.2---------------1st/-------2nd/--------3rd
--------------------2.5-2.9/---12.8-13.9/---27.5 bar
--------------------2.6-3.0/---13.5-15.2/---41.3 bar
----------------------2.7-3.1/---14.2-15.9/---55 bar
---------------------2.75-3.2/---14.8-16.5/---69 bar
---------------------2.75-3.2/---15.7-17.4/---85 bar

-H5436.2N2B2-----2nd/---------3rd/-----------4th
-------------16.3-17.9/-----66.1-74.1/-----137.8 bar
-------------16.5-18.2/-----73.0-81.3/-----206.8 bar
-------------16.7-18.4/-----79.9-89.9/-----257.7 bar
-------------17.0-18.7/-----86.8-96.5/-----344.7 bar

-H5436.2---------1st/-----------2nd/------------3rd/----------4th
---------------2.7-3.1/------16.3-17.9/-------66.1-74.1/-----137.8 bar
---------------2.7-3.1/------16.5-18.2/-------73.0-81.3/-----206.8 bar
---------------2.7-3.1/------16.7-18.4/-------79.9-88.9/-----257.7 bar
---------------2.7-3.1/------17.0-18.7/-------86.8-96.5/-----344.7 bar

--------------------------maximum stage temperature..............250*c
--------------------------maximum final delivery..................70*c

-RUNNING CLEARANCE:(mm)
.piston(plunger)vertical clearance stage 1.......0/0.9....max.permissible 0.9
...................................stage 2......0.4/0.9...max.permissible 0.9
...................................stage 3.....0.45/1.0...max.permissible 1.0
...................................stage 4.....0.35/1.46..max.permissible 1.46
.piston ring gaps stage 1 taper.......0.2/0.45............max.permissible 1.63
..................stage 1 scraper.....0.2/0.45............max.permissible 1.43
..................stage 2 taper.......0.1/0.23............max.permissible 1.47
..................stage 2 scraper.....0.1/0.23............max.permissible 1.27
..................stage 3 plain......0.05/0.18............max.permissible 1.32
..................stage 4 plain.......0.2/0.4.............max.permissible 1.32
.piston ring axial stage 1 taper.....0.04/0.09............max.permissible 0.29
...................stage 1 scraper...0.05/0.10............max.permissible 0.30
...................stage 2 taper.....0.02/0.08............max.permissible 0.28
...................stage 2 scraper...0.05/0.10............max.permissible 0.30
...................stage 3 plain.....0.03/0.09............max.permissible 0.29
...................stage 4 plain.....0.03/0.07............max.permissible 0.20 piston ring groove width stage 1 taper....4.80/4.83.......max.per.........4.91
.........................stage 1 scraper..8.01/7.99.......max.per.........8.09
.........................stage 2 taper....3.23/3.20.......max.per.........3.31
.........................stage 2 scraper..4.83/4.80.......max.per.........4.91
.........................stage 3 plain....2.05/2.01.......max.per.........2.13
.........................stage 4 plain....2.05/2.01.......max.per.........2.13
piston/plunger diameter above top ring stage 1....184.77/184.74...max...184.69
.......................................stage 1....184.54/184.49...max...184.44
.......................................stage 2.....94.91/94.98....max....94.83
.......................................stage 3.....44.93/44.90....max....44.85
.......................................stage 4....21.955/21.945...max.....21.9
cylinder/liner diameter ...............stage 1....185.05/185.00...max...185.11
.......................................stage 2.....95.04/95.00....max....95.10
.......................................stage 3.....45.03/45.00....max....45.09
.......................................stage 4.....22.01/22.00....max....22.07
crosshead diametrical clearance........stage 3......0.06/0.13.....max.....0.19
.......................................stage 4......0.06/0.13.....max.....0.19
small end bearing diametrical clearance in con-rod stage 1...0.01/0.05.max.0.1
.......................................stage 2,3,4...............needle roller
.............................in piston stage 1....0.003/0.013.....max.....0.03
....................................stage 2,3,4...0.025/0.044.....max.....0.09
big end bearing diametrical clearance stage 1,2,3,4...0.066/0.12..max.....0.24
small end bearing end float...........stage 1.......0.15/0.64.....max......1.0
......................................stage 2,3,4...0.15/0.55.....max......1.0
main bearing diametrical clearance..................0.05/0.14.....max......0.2
crankshaft end float................................0.66/0.23.....max.....0.75
coupling face distance for direct coupled sets.......2.0/6.0......max......6.0

torque wrench settings:
-big end bearing bolts.........................M16.....203Nm/150lbs.ft
-1st&2nd stage cooler cover....................M10.......54Nm/40lbs.ft
-3rd stage cooler cover........................M16.....236Nm/174lbs.ft
-1st stage valve cover.........................M12.......41Nm/30lbs.ft
-2nd stage valve cover.........................M12.......41Nm/30lbs.ft
-3rd stage valve cover.........................M20.......95Nm/70lbs.ft
-4th stage valve cover.........................M20......108Nm/80lbs.ft
-4th stage valve cover(5436H)..................M20......122Nm/90lbs.ft
-1st stage cylinder to crankcase...............M12.......95Nm/70lbs.ft
-2nd stage cylinder to crankcase...............M12.......95Nm/70lbs.ft
-3rd&4th stage crosshead to crankcase..........M12.......95Nm/70lbs.ft
-3rd&4th stage cylinder to crosshead guide.....M12.......95Nm/70lbs.ft
-flywheel bolt.................................3/4UNF..162Nm/120lbs.ft
-3rd stage piston to crosshead.................M8........27Nm/20lbs.ft
-d/e main bearing housing to crankcase.........M12.......95Nm/70lbs.ft
-o/e main bearing housing to crankcase.........M12.......95Nm/70lbs.ft
-o/e cover.....................................M8........27Nm/20lbs.ft
-crank case door...............................M10.......54Nm/40lbs.ft
-cooler body to cylinder.......................M12.......95Nm/70lbs.ft
-bursting disc cover...........................M10.......54Nm/40lbs.ft
-coller door...................................M10.......27Nm/20lbs.ft
-1st stage valve...............................M10.......21Nm/16lbs.ft
-2nd stage valve...............................M8.........11Nm/8lbs.ft
-3rd stage valve...............................M6..........6Nm/5lbs.ft
-4th stage valve...............................M5..........3Nm/2lbs.ft
-motor belt housing............................M12.......95Nm/70lbs.ft
-motor bracket to crankcase....................M16.....162Nm/120lbs.ft
-oil pump......................................M8........27Nm/20lbs.ft
-cylinder lubricator........................3/8unf.......35Nm/26lbs.ft

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H.P.COMPRESSOR REAVELL MK7 (four cylinder,four stage)

H.P.COMPRESSOR REAVELL TC31/2 MK7 (HPC MK7) is a four stage tandem,two crank,single acting machine..the compressor has a single crankshaft with two lines running gear phased 180 degrees apart.the cylinder are arranged so that the FOURTH stage cylinder is above the FIRST stage cylinder AND the THIRD stage cylinder above the SECOND stage cylinder..SECOND and THIRD stage PISTON are cast integral.while the FOURTH stage carries a PLUNGER wich is secured to the top of the FIRST stage PISTON..
-TWO oil lubrication systems:a main,forced lubrication systems suplies the main running gear and FIRST and SECOND stage piston and cylinders,while a SECONDARY system lubricates the THIRD and FOURTH stage cylinders
-SEPARATORS are fitted after each compression stage and are automatically drained through diaphragm drains valves at 30-minute interval
-THE COMPRESSOR is designed to deliver 40 cu.ft.of free air per minute againts a pressure of 4000 lbf/in2.when running at 1000 rpm
-PERFORMANCE DATA.....


PERFORMANCE DATA:...................(SRI)
-compressor speed...................1000 rev/min
-air pressure:
.1st stage..........................30-35 lbf/in2(2.25 bar)
.2nd stage..........................220-230 lbf/in2(15.5 bar)
.3rd stage..........................950-960 lbf/in2(65.5 bar)
.4th stage..........................4000 lbf/in2(276 bar)
-oil pressure.......................35-38 lbf/in2(2.6 bar)
-oil pressure minimum...............20 lbf/in2(1.37 bar)
-oil pressure cut-out setting.......10 lbf/in2(0.69 bar)

RELIEF VALVE SETTINGS:..............(SRI)
-first stage relief valve...........55 lbf/in2(3.75 bar)
-second stage relief valve..........320 lbf/in2(21.8 bar)
-third stage relief valve...........1300 lbf/in2(88.5 bar)
-fourth stage relief valve..........4200 lbf/in2(286 bar)
-water relief valve.................25 lbf/in2(1.7 bar)
-first and second stage cooler bursting disc...........80 lbf/in2(5.45 bar)

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PROBLEMS PERKINS 1000 SERIES

PROBLEM and POSSIBLE CAUSES:.......


-PROBLEM:..............CHECKS BY THE USER/CHECKS BY THE WORKSHOP PERSONIL
1.the starter motor turns the engine too slowly....1,2,3,4,/.........
2.the engine does not start........................5-17/34,36-38,40,42-44
3.the engine is difficult to start.................5,7-17,19/34,36-39,42-44
4.not enough power.................................8-13,16-21/34,36-39,42-44,61-64
5.misfire..........................................8-10,12,13,15,20,22/34,36-41,43
5.high fuel consumption....................11,13,15,17-19,21,22/34,36-40,42-44,63
6.black exhaust smoke.....................11,13,15,17,19,21,22/34,36-40,42-44,61,63
7.blue or white smoke......................4,15,21,23/36-39,42,44,45,52,58,62
8.the pressure of the lubricating oil is too low.............4,24-26/46-51,59
9.the engine knocks..................9,13,15,17,20,22,23/36,37,40,42,44,46,52,53,60
10.the engine runs erratically.......7-13,15,16,18,20,22,23/34,38,40,41,44,52,60
11.vibration...............................13,18,20,27,28/34,38-41,44,52,54
12.the pressure of the lubricating oil is too high......4,25/49
13.the engine temperatur is too high...............................11,13,15,19,27,29,30,32/34,36-39,52,55,56,57,64
14.crank case pressure.............31,33/39,42,44,45,52
15.bad compression.................11,22/37,39,40,42-45,53,60
16the engine starts and stop.......10-12/....

-LIST OF POSSIBLE CAUSES-
1.battery capacity low
2.bad electrical connections
3.fault in starter motor
4.wrong grade of lubricating oil
5.starter motor turns engine too slowly
6.fuel thank empty
7.fault in stop control
8.restriction in a fuel pipe
9.fault in fuel lift pump
10.dirty fuel filter element
11.restriction in filter/cleaner or air induction system
12.air in fuel system
13.fault in atomisers of an incorrect type
14.cold start system used incorrectly
15.fault in cold start system
16.restriction in fuel thank vent
17.wrong type or grade of fuel used
18.restricted movement of engine speed control
19.restriction in exhaust pipe
20.engine temperature is too high
21.engine temperature is too low
22.valve tip clearances are incorect
23.to much oil or oil wrong specification use in wet type oil cleaner
24.not enough lubricaating oil in sump
25.defective gauge
26.dirty lubricating oil filter element
27.fan damaged
28.fault in engine mounting of flywheel housing
29.too much lubricating oil in sump
30.restriction in air or water passages of radiator
31.restriction in breather pipe
32.insufficient coolant in system
33.vacuum pipe leaks or fault in exhauster
34.fault in fuel injection pump
35.broken drive on fuel injection pump
36.timing of fuel injection pump is incorrect
37.valve timing is incorrect
38.bad compression
39.cylinder heat gasket leaks
40.valves are not free
41.wrong high-pressure pipes
42.worn cylinder bore
43.leakage between valves and valve seats
44.piston rings are not free or they are worn or broken
45.valve stems and/or guides are worn
46.crankshaft bearings are worn or damaged
47.lubricating oil pump is worn
48.relief valve does not close
49.relief valve does not open
50.relie valve springs is broken
51.fault in suction pipe of lubricating oil pump
52.piston is damaged
53.piston height is incorrect
54.flywheel housing or flywheel is not aligned correctly
55.fault in thermostat or thermostat is of an incorrect type
56.restriction in coollant passages
57.fault in water pump
58.valve stem seal is damaged (if there is one fitted)
59.restriction in sump strainer
60.valve sping is broken
61.turbocharger impeller is damaged or dirty
62.lubricating oil seal of turbocharger leaks
63.induction system leaks (turbocharged engine)
64.turbocharger waste-gate does not work correctly (if there is one fitted)

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PERKINS -1000 series-

-INDENTIFICATION:
-SCHEDULES:
-PROBLEMS:
-GENERAL DATA:

engine indetification:1006-60TWG1:
-1006........6cylinder engine
-60..........6 litre engine
-T...........turbocharged
-TW..........turbocharged,but with an air to water inter cooler
-G...........generating set
-1...........rating code number
-AA..........four cylinder,naturally aspirated
-AB..........four cylinder,turbocharged
-AC..........four cylinder,compensated
-AD..........four cylinder,turbocharged and intercooled
-AG..........four cylinder,naturally aspirated,belt driven coolant pump
-AH..........four cylinder,turbocharged,belt driven coolant pump
-YA...............six cylinder,naturally aspirated
-YB...............six cylinder,turbocharged
-YC...............six cylinder,compensated
-YD...............six cylinder,turbocharged and intercooled

SCHEDULES:
-A...........first service at 20/40 hours
-B...........every day/8 hours
-C...........every 200 hours/6 mounths
-D...........every 400 hours/12 mounths
-E...........every 2000 hours
-OVERHAUL....every 8000 hours

OPERATION:
1.check the amount of coolant..........................................(A,B)
2.check the concentration of the coolant...............................(D)
3.clean the sendiment chamber and the strainer of the fuel lift pump....(D)
4.check the tension and condition of the drive belt.....................(A,C)
5.check for water in the pre filter.....................................(C)
6.renew the elements of the fuel filter.................................(D)
7.ensure that the atomisers are cheked,ensure that the idle speed is cheked and adjusted,if it is necessary.............................................(E)
8.check stanadyne fuel injection pump for governor operation............(D)
9.check the amount of lubricating oil in the sump.......................(B)
10.check the lubricating oil pressure at the gauge......................(A,B)
11.renew the engine lubricating oil.....................................(A,D)
12.renew the canisters(s)of the lubricating oil filter..................(A,D)
13.renew the canister of the lubricating oil filter(six cylinder naturally aspirated engines with a single filter canister.........................(A,C)
14.clean the engine breather system,clean the air cleaner or empty the dust bowl of the air filter..........................................................(E)
15.extremely dusty condutions..........................................(A,B)
16.normal conditions....................................................(C)
17.clean or renew the air filter element,if it has not been indicated earlier...(D)
18.ensure that the turbocharge impeller and turbocharger compressor casing are cleaned..................................................................(E)
19.clean the compressor air filter.......................................(C)
20.ensure that the exhauster or compressor is cheked.....................(E)
21.ensure that the valve tip clearance of the engine are checked and,if necessary,adjusted.......................................................(A,E)
22.ensure that the valve tip clearance of the engine are checked and,if necessary,adjusted (high rated engines...................................(A,D)
23.ensure that the altenator and the starter motor are checked...........(E)

GENERAL DATA ENGINE:
-AA,AB,AC,AD,AG,AH......................4 cylinder engine
-YA,YB,YC,YD............................6 cylinder engine
-CYLINDER ARRANGEMENT...................in line
-CYCLE..................................four stroke
-INDUCTION SYSTEM:.......
-AA,AG,YA...............................naturally aspirated
-AB,AH,YB...............................turbocharged
-AC,YC..................................altitud compensanted
-AD,YD..................................turbocharged,intercooled
-COMBUSTION SYSTEM......................direct injection
-BORE...................................100mm(3.937in)
-STROKE.................................127mm(5.00in)
-COMPRESSION RATIO:........
.AA,AG,YA,YC............................16.5:1
.AB,AC,AD,AH,YB,YD......................16.0:1
-CUBIC CAPACITY:...........
.AA,AB,AC,AD,AG,AH......................4 litres(243in3)
.YA,YB,YC,YD............................6 litres(365in3)
-FIRING ORDER:.............
.AA,AB,AC,AD,AG,AH......................1,3,4,2.
.YA,YB,YC,YD............................1,5,3,6,2,4.
-VALVE CLEARANCE(hot or cold):
.INLET..................................0.20mm(0.0008in)
.EXHAUST................................0.45mm(0.018in)
-LUBRICATING OIL PRESSURE(minimum at maximum engine speed and normal engine temperatur):
.engines without piston cooling jets.....207Kpa(30lb/in2)2.1Kgf/cm2
.engines with piston cooling jets........208Kpa(40lb/in2)2.5Kgf/cm2





-

Read More..

mtu 8v/12v.183 TE 52/62/72/92/93 (BASIS:MERCEDEC-BENZ OM 400)

-ENGINE POWER:
1.8v 183 TE 52------------300KW at 1500RPM/367KW at 1800RPM
..12V 183 TE 52-----------455KW at 1500RPM/55OKW at 1800RPM
2.8v 183 TE 62------------365KW at 2000RPM
..12v 183 TE 62-----------550KW at 2000RPM
3.8v 183 TE 72------------405KW at 2100RPM
..12v 183 TE 72-----------610KW at 2100RPM
4.8v 183 TE 92------------490KW at 2300RPM
..12v 183 TE 92-----------735KW at 2300RPM
5.8v 183 TE 93------------564KW at 2400RPM
..12v 183 TE 93-----------864KW at 2400RPM

8/12----------number of cylinder
v-------------vee configuration
183-----------engine series-100 times displacement of one cylinder in litre
T-------------exhaust turbocharging
E-------------intercooling in split-circuit coolant system
5/6/7/9-------marine engine
2/3-----------design index

OVERLOAD CAPABILITY FOR TRANSIENT LOAD RESPONCE-------10*



SPECIFICATION:
-operating method.................four-stroke cycle single-acting
-combustion method................direct injection
-mode of super charging...........exhaust turbocharging
-cooling method...................liquid-cooled
-cylinder arrangement.............90*vee
-bore.............................128mm
-piston stroke....................142mm
-displacement,cylinder.............1.831
-displacement total 8v/12v.........14.621/21.931
-compression ratio.................14.25:1
-firing order 8v...................1-5-7-2-6-3-4-8
-firing order 12v..................1-12-5-8-3-10-6-7-2-11-4-9
-nozzle pressure(new spring).......200bar-208bar
-nozzle pressure(run-in spring)....185bar
-final compression pressure at 120rpm,1000 mbar and engine coolant temperature of.5*.............................20bar-28bar
-MEAN PISTON SPEED:
.7.10 at 1500rpm
.8.52 at 1800rpm
.9.47 at 2000rpm
.10.87 at 2300rpm
.11.40 at 2400rpm
-valve inlet clearance cold engine.....0.40mm
-valve exhaust clearance cold engine...0.60mm
-inlet valve opens..................17* before TDC
-inlet valve closes.................29* after BDC
-exhaust valve opens................71* before BDC
-exhaust valve closes...............13* after TDC
-OIL CAPACITY:
.lower mark 8v/12v..................28 litre/41 litre
.upper mark 8v/12v..................34 litre/50 litre
.for initial filling total 8v/12v...38.5 litre/54.5 litre
.for oil change total 8v/12v........37.5litre/53.5 litre


OPERATIONAL DATA:
8v 183 TE 52 with 1500rpm/with 1800rpm:
-engine oil pressure,measured before engine-at rated speed.........3.5 limit value 3.0 bar/4.0 limit value 3.5bar
-engine coolant pressure measured before engine coolant pump...1.2 limit value 1.0 bar/1.2 limit value1.0 bar
-change air pressure,measured after intercooler............................limit value -0.15bar/-0.15bar
-intake depression,measured at compressor inlet.........................20 limit value 35mbar/20 limit value 35mbar
-exhaust back pressure,measured at exhaust manifold..................30 limit value 50mbar/30 limit value 50mbar
-starting air pressure.compressor air starting,measured before compressor air starter.....19-30 bar
-engine oil temperatur measured befor engine...........................95*c limit value 105*c/95*c limit value105*c
-engine coolant temperatur,measured after engine.....................87*c limit value 95*c/87 limit value 95*c
-exhaust bulk temperatur,measured befor exhaust turbocharger.....limit value +30*c/limit value 30*c
-change air temperatur,measured befor cylinder.......................37*c limit value47*c/37*c limit value 47*c
.12v 183 TE 52 with 1500rpm/with 1800rpm:
-engine oil pressure,measured before engine-at rated speed.....3.5 bar limit value 3.0 bar/4.0 bar limit value .3.5 bar
-engine coolant pressure,measured before engine coolant pump coolant system sealed with breather valve locked in position........................................................1.2 bar limit value 1.0 bar/1.2 bar limit value 1.0 bar
-change air pressure,measured after intercooler............limit value -0.15 bar/limit value -0.15bar
-intake depression,measured at compressor inlet.....20 mbar limit value 35 mbar/20 mbar limit value 35 mbar
-exhaust back pressure,measured exhaust manifold..30 mbar limit value 50 mbar/30 mbar limit value 50 mbar
-starting air pressure,compressor starting.....................19 bar-30 bar/19 bar-30 bar
-engine oil temperatur,measured before engine.............95*c limit value105*c/95*c limit value 105*c
-engine coolant temperatur measured after engine.........87*c limit value 95*c/87*c limit value 95*c
-exhaust bulk temperature,measured before exhaust turbocharger....limit value +30*c/limit value +30*c
-change air temperatur,measured before cylinder............37*c limit value47*c/37*c limit value 47*c
-air per start attempt(approx.2 seconds),engine preheated-with compressor air starting.....0.18 m3/0.18 m3
-fuel at continuous power and using a fuel which conforms......210 g.kwh-214 g.kwh /214 g.kwh-218 g.kwh
-engine oil consumption in consumtion operation,referenced to fuel consumtion.....0.5%-1.0%/0.5%-1.0%

Read More..

maintenance frequency chart MTU 8v/12v 183 TE 52/62/72/92/93

application grop:
-1A.......vessels with unrestricted continuous operation
-1B.......fast vessels with high load factors
-1DS......fast vessels with low load factors
-3A.......on board power generation,continuous duty
MAINTENANCE FREQUENCY CHART:.....



-MAINTENANCE ECHELON:.........................1A.......1B....1DS...3A
1.W1.....operational checks,daily.....................X........X.......X........X
2.W2.....operating hours/mounths................250/6....250/6 250/6 250/6
3.W3.....operating hours/year...................500/1....500/1...500/1...500/1
4.W4.....operating hours/years.................1000/2...1000/2...1000/2..1000/2
5.W5.....operating hours/years.................3000/6...3000/4...3000/4..3000/6
6.W6.....operating hours/years................12000/18..6000/8...6000/8..24000/18

MAINTENANCE TASK SCEDULE:
-one-time operations after the FIRST 50 operating hours.with a NEW ENGINE
-after W5 maintenance or after W6 major overhaul
1.attachments.................check tightness of securing screws and nuts
2.valve gear..................check valve clearance
3.fuel pre-filter.............clean /replace filter elements
4.fuel duplex filter..........replace filter elements
5.engine coolant pump.........check relief bore for obsstruction
6.coolants pump...............check v-belt condition and tension
7.engine oil..................change
8.engine oil filter...........replace filter elements

MAINTENANCE ECHELON W1:
1.exhaust system..............check exhaust gas colour and drain condensat
2.air filter..................check restrition indicator,replace filter necessary
3.fuel pre-filter.............drains water and contaminants
4.engine coolant..............check level
5.raw water system............check filter for contamition
6.engine oil..................check level
7.monitoring system...........carry out lamp test
8.engine operation............check runing noises,engine and external pipework for leaks,speeds,pressure and temperatures
9.compressed air system.......check operating pressure and drain condensate
10.compressed air-filter......drains condensate
11.air starter lubricator.....check oil supply

MAINTENANCE ECHELON :.............................................W..2..3..4..5
1.intake air line............check emergency air shut-off flaps.........x..x..x..x
2.coolant pump...............check v-belt condition and tension........x..x..x..x
3.engine oil...change.category 1/2/3(250/500/750 operating hours)..x..x..x..x
4.engine filter oil .........drain oil sludge,replace filter-
-elements and sealing rings,check for metallik residues................x..x..x..x
5.compressed-air filter......clean filter or replace element..............x..x..x..x
6.valve gear.................check valve clearance...........................x..x..x
7.exhaust system.............check exhaust pipe and insulation......x..x..x
8.fuel pre-filter............flush..........................................x..x..x
9.fuel duplex filter.........replace filter elements........................x..x..x
10.engine coolant pump.......check relief bore for obstructions.............x..x..x
11.lubrication point.........lubricate......................................x..x..x
12.engine coolant............take sample and analyse-change coolant.........x..x..x
13.engine coolant syatem.....check fluid level monitor function.............x..x..x
14.coupling..................check condition................................x..x..x
15.crank case ventilation....replace oil separator=2000 hours..................x..x
16.cylinder..................check compression pressure........................x..x
17.air filter................check filter for damag(visual inspectio)..........x..x
18.fuel injector.............remove,check,replace sailing rings................x..x
19.fuel pre-filter...........clean,replace filter element......................x..x
20.coolant pumps.............replace v-belt=2000 hours.........................x..x
21.engine coolant system.....check hoses,replace coolant hoses=4 years.........x..x
22.engine mounts.............check rubber mounts,tightness screws and nuts.....x..x
23.gearbox mounting..........check rubber mounts.tightness screws and nuts.....x..x
24.monitoring system.........check funtion of monitoring units.................x..x
25.wiring....................check security and condition......................x..x
26.intercooler...............remove,clean,leak test,replace seals.................x
27.coolant cooler............remove,clean,leak test...............................x
28.valve gear................remove,check rocker arms,tappets,pushrod of..........x
29.cylinder head.....remove,check valve,valve guide,valve seat,valve steam........x
30.runing gear...............check cylinder liner wear pattem.....................x
31.gear train................check(visual inspection).............................x
32.turbocharger....remove,disassemble,clean,check parts,replace bearings..........x
33.air ducting...............remove,clean,replace seals...........................x
34.exhaust pipe work.........clean,crack-test,replace seals.......................x
35.fuel injection pump.......check delivery amount and timing.....................x
36.fuel injector.............replace injection nozzle.............................x
37.engine coolant pump.......disassemble,check parts replace seals................x
38.raw water pump............disassemble,check parts replace seals................x
39.coolant thermostat........replace..............................................x

MAINTENANCE ECHELON W6:
-requires complete engine disassembly for repair/overhaul of all relevant parts,or the instalation of an overhaul d engine.

Read More..

TIMING GEAR CAT 3412C

PEMASANGAN GEAR CRANKSHAFT-IDLER GEAR-CAMSHAFT GEAR-FUEL INJECTION PUMP DRIVE GEAR...



1.FUEL INJECTION PUMP DRIVE GEAR
2.CAMSHAFT GEAR
3.WATER PUMP DRIVE GEAR
4.GEAR FOR ATTACHMENT DRIVE GROUPS
5.IDLER GEAR ASSEMBLY
6.TIGHTEN 5 BOLTS TO A TORQUE OF...............55-+7Nm(40-+5 lb.ft)
7.DIAMETER OF THE SHAFT........................63.500mm-+0.013mm(2.5000in-+.0005in)
8.END CLEARACE(NEW)............................0.31mm-0.17mm(.012in-.007in)
9.PLATE THE LUBRICATION GROOVE MUST BE AGAINTS THE GEAR.
10.CAM SHAFT GEAR
11.DISTANCE THAT BEARING IS INSTALLED FROM THE FACE OF IDLER GEAR...1.12mm-+0.25mm(.44in-.010in)
12.DIAMETER OF THE SHAFT(NEW)........34.943mm-+0.013mm(1.3757in-+.0005in)
.BORE IN BEARING(AFTER ASSEMBLY).....35.034mm-+0.038mm(1.3793in-+.0015in)
13.ENGINE OIL PUMP IDLER GEAR.TIGHTEN THE BOLT THAT HOLDS IDLER GEAR TO A TORQUE OF..............................55-+7Nm(40lb.ft-+5lb.ft)
14.ENGINE OIL PUMP DRIVE GEAR.TIGHTEN THE BOLT THAT HOLDS THE DRIVE GEAR TO A TORQUE..........................55-+7Nm(40lb.ft-+5lb.ft)

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MAGNETIC PICK-UP CAT 3412C

ADJUSTMENT MAGNETIC PICK-UP CAT 3412C.
1.DISTANCE BETWEEN END OF MAGNETIC PICK-UP and GEAR.....0.56mm-0.84mm(.022in-.033in)
2.NUTS TIGHT TO A TORQUE OF.............................45-+7Nm(33-+5 lb.ft)

CATATAN:
-JARAK UKUR ANTARA MAGNETIC PICK-UP dengan RODA GIGI FLYWHEEL SETELAH DITENTUKAN SESUAI UKURAN DALAM KEADAAN MESIN STOP.UNTUK PENGENCANGAN NUTS SESUAI TORQUE SEBELUM DIKENCANGKAN HARAP MAGNETIC PICK-UP DIPUTAR BALIK 1/2 PUTARAN -+30 DERAJAT(DEGREES) BARU NUTS DIKENCANGKAN SESUAI TORQUE

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BEDAH CATERPILLAR 3412C 735 BHP/584 BKW

CAT 3412C mesin ini digunakan untuk penggerak generator dengan kapasitas 500kva,450v,60hz,1800rpm.berikut data.....


model:............................ 3412c.12 cylinder
type..............................4 cycle
asppiration.......................turbocharged
bore/stroke in/mm.................5.4(137.2)/6.0(152.4)
displacement cu.in/litre................1649/27.0
engine speed rpm........................1800
maximum fuel consumption us.gal/hr(litre/hr)...32.5/123.o
rasio kompresi..........................15.6:1
valve per cylinder......................4
timing order............................1-4-9-8-5-2-11-10-3-6-7-12
valve lash setting INLET/EXHAUST........0.38mm(.15 in)/0.76mm(.30 in)



ROCKER ARM:
-BORE IN ROCKER ARM FOR SHAFT(NEW)........24.803mm-+0.013mm(.9765 in-+.0005in)
-DIAMETER OF SHAFT(NEW)...................24.750mm-+0.013mm(.9744 in-+.0005in)

VALVE:
-HEIGHT TO TOP OF DOWEL...................53.3mm-+0.5mm(3.10in-+0.02in)
-DIAMETER OF DOWEL........................11.008mm-+0.003mm(.4334in-+.002in)
-BORE IN BRIDGE FOR DOWEL.................11.13mm-+0.05mm(.438in-+.002in)
-BORE IN HEAD FOR DOWEL...................10.968mm-+0.020mm(.4318in-+.0008in)
-DIAMETER OF VALVE LIFTER.................27.896mm-+0.013mm(1.10050in-+.00075in)
-BORE IN BLOCK FOR VALVE LIFTER...........27.9527mm-+0.0190mm(1.10050in-+.00075in)

CYLINDER BLOCK:
1-BORE IN THE BLOCK FOR THE CAMSHAFT BEARING(7 BORES).....76.835mm-+0.018mm(3.0250in-+.0007in)
2-BORE IN THE BLOCK FOR THE MAIN BEARING.....
STANDARD SIZE(NEW).....129.891-+0.013mm(5.1138in-+.0005in)
-LARGER THAN ORIGINAL SIZE.....130.526mm-+0.013mm(5.1388in-+.0005in)

CRANKSHAFT:
-DIAMETER OF CRANKSHAFT JOURNAL(BEARING SURFACE)FOR CONECTINGROD
1-ORIGINAL SIZE JOURNAL...97.028mm-+0.020mm(3.8200in-+.0008in)
2-UNDERSIZE JOURNAL 0.64mm(0.25in)...96.393mm-+0.020mm(3.7950in-+.0008in)
3-UNDER SIZE JOURNAL 1.27mm(0.050in)...95.758mm-+0.020(3.7700in-+.0008in)
-DIAMETER OF CRANKSHAFT JOURNAL(BEARING SURFACE) FOR MAIN BEARING:
1-ORIGINAL SIZE JOURNAL..................120.650mm-+0.020mm(4.7500in-+.0008in)
2-UNDERSIZE JOURNAL 0.64mm(0.025in)......120.015mm-+0.020mm(4.7250in-+.0008in)
3-UNDERSIZE JOURNAL 1.27mm(0.050in)......119.380mm-+0.020mm(4.7000in-+.0008in)

CAMSHAFT:
-DIAMETER OF JOURNAL FOR THE CAMSHAFT BEARING(NEW).....69.850mm-+0.013mm(2.7500in-+.0005in)
-BORE IN FRONT and REAR BEARING FOR THE CAMSHAFT.....69.969mm-+0.048mm(2.7547in-+0.0019in)
-BORE IN THE INNER BEARING FOR THE CAMSHAFT.....69.982mm-+0.061mm(2.7552in-+.0024in)

PIN PISTON and PISTON PIN BORE:
-PIN PISTON DIAMETER................50.795mm+0.005mm(i.9998in+0.0002in)
-BORE IN PISTON FOR PIN.............50.814mm+0.004mm(2.0006in+0.0002in)

-BORE IN LINER(NEW).................137.185mm+0.025mm(5.401in+0.001in)

VALVE and VALVE SEAT:
-DIAMETER OF VALVE HEAD EXHAUST......41.81mm-+0.13mm(1.646in-+.005in)
-DIAMETER OF VALVE HEAD INLET........44.98mm-+0.13mm(1.771in-+.005in)
-DIAMETER OF VALVE STEM(NEW).........9.441mm-+0.010mm(.3717in-+.0004in)
-BORE IN VALVE GUIDE.................9.487mm-+0.025mm(.3735in-+.0010in)
-DEPTH OF BORE IN HEAD FOR VALVE SEAT INSERT...13.01-+0.35mm(.512-+.014in)
-DIAMETER OF VALVE SEAT INSERT FOR EXHAUST VALVE...42.850-+0.013mm(1.6870-+.0005)
-BORE IN HEAD FOR VALVE SEAT INSERT FOR EXHAUST VALVE...42.774-+0.025mm(1.6840-+.0010in)
-DIAMETER OF VALVE SEAT INSERT FOR INLET VALVE...46.025mm-+0.013mm(1.8120in-+.0005in)
-BORE IN HEAD FOR VALVE SEAT INSERT FOR INLET VALVE...45.949-+0.025mm(1.8090-+.0010in)
-OUTSIDE DIAMETER OF THE FACE OF THE VALVE SEAT INSERT:
.EXHAUST SEAT...........40.41mm-+0.13mm(1.591in-+.005in)
.INLET SEAT.............44.04mm-+0.13mm(1.734in-+.005in)
-THICKNESS OF VALVE LIP EXHAUST VALVE.....2.03mm(0.080in)
-THICKNESS OF VALVE LIP INLET VALVE.......2.51mm(0.099in)
-MAXIMUM PERMISSBLE DIMENSION(NEW):
.BELOW RECESSED FROM MACHINE FACE.....1.22mm(0.048in)
.ABOVE EXTENDED FROM MACHINE FACE.....0.04mm(0.0016in)
-MAXIMUM PERMISSIBLE DIMENSION (RECONDITIONED):
.BELOW RECESSED FROM MACHINE FACE.....1.70mm(0.067in)
.ABOVE EXTENDED FROM MACHINE FACE.....0.04mm(0.0016in)

CONNECTING ROD:
-BORE IN CONNECTING ROD FOR PISTON PIN BEARING.....55.436mm-+0.013(2.1825in-+.0005in)
-BORE IN BEARING FOR PISTON PIN................50.830mm-+0.008mm(2.0012in-+.0003in)
-DIAMETER OF PISTON PIN........................50.795mm-+0.005mm(1.9998in-+.0002in)
-BORE IN BEARING FOR CRANKSHAFT................97.119mm-97.175mm(3.8236in-3.8258in)
-BORE IN CONNECTING ROD FOR BEARING............103.500mm+0.013mm(4.0748in+0.0005in)

CLEARANCE DATA:
-DISTANCE BETWEEN OF MAGNETIC PICK-UP and GEAR.....0.56mm-0.84mm(.022in-.033in)
-INLET VALVE LASH.............................0.38mm(.015in)
-EXHAUSTVVALVE LASH...........................0.76mm(.030in)
-BEARING FOR CONNECTINGROD and CRANK-PIN JOURNAL...............0.071mm-0.168mm(.0028in-.066in)
-MAXIMUM PERMISSIBLE CLEARANCE BEARING and JOURNAL.....0,25mm(.010in)
-BEARING FOR MAIN BEARING and CRANKSHAFT JOURNAL.......0.091mm-0.186mm(0.0036in-.0073in)
-MAXIMUM PERMISSIBLE CLEARANCE BEARING and JOURNAL.....0.025mm(.010in)
-CAM-SHAFT.............................................0.10mm-0.25mm(.004in-.010in)
-RING PISTON:
1.TOP RING.....................0.724mm-+0.19omm(.0285in+.0075in)
2.INTERMEDIATE RING............1.080-+0.190mm(.0425in-.0075in)
3.OIL CONTROL RING.............0.08mm(.0003in)
-PISTON PIN....................................0.007mm-0.033mm(.0003in-.0013in)
-CONNECTING ROD BEARING and CRANKSHAFT.........0.0071mm-0.168mm(.0028in-.0066in)
MAXIMUM PERMISSIBLE CLEARANCE..................0.25mm(.010in)

TORQUE BOLT:
-EXHAUST MANIFOLD:
1.FOR EIGHT EXHAUST MANIFOLD STUDS IN EACH CYLINDER HEAD.....3/8in BOLT 35-+5Nm(26-+4lb.ft)
2.REMAINING 3/8in BOLT(2)......................................45-+7Nm(33-+5lb.ft)
-CYLINDER HEAD 3/4in BOLT:
1.14 IN NUMBER SEQUENCE TO...................................270-+25Nm(200-+20lb.ft)
2.14 IN NUMBER SEQUENCE TO...................................470-+20Nm(345-+15lb.ft)
3.14 IN NUMBER SEQUENCE AGAIN TO.............................470-+20Nm(345-+15lb.ft)
-ROCKER ARM 3/4in BOLT:
1.15-26 IN NUMBER SEQUENCE TO................................270-+25Nm(200-+20lb.ft)
2.15-26 IN NUMBER SEQUENCE TO................................450-+20Nm(330-+15lb.ft)
3.15-26 IN NUMBER SEQUENCE AGAIN TO..........................450-+20Nm(330-+15lb.ft)
-HOLE THE PISTON COOLING TUBES...............................25-+7Nm(18-+5lb.ft)
-HOLE THE CAPS FOR THE MAIN BEARING..........................258-+14Nm(190-+10lb.ft)
-CONNECTING ROD BOLT(NUTS)...................................80-+8Nm(60-+6lb.ft)
-OIL PUMP,IDLER GEAR.........................................55-+7Nm(40-+5lb.ft)

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MAINTENANCE SCEDULE CUMMINS DIESEL

MAINTENANCE SCHEDULE CUMMINS DIESEL,,,,,,,



DAILY OR EVERY 20 HRS:
-CHECK. ENGINE OIL,GEAR BOX OIL,FUEL and WATER.LEVEL
-DRAIN.FUEL and WATER SEPARATOR
-CHECK COOLANT LEVEL
-RECORD THE OPERATING TEMPERATURE and PRESSURE:OIL,WATER

EVERY 3 MOUNTHS or 250 HRS:
-CHANGE ENGINE OIL
-CHANGE ENGINE OIL FILTER
-INSPECT AIR SYSTEM
-INSPECT THE WIRING
-CHECK MOUNTING BOLT,HOSES and CLAMPS FOR CONDITION TIGHTNESS

EVERY 6 MOUNTHS OR 500 HRS:
-CHANGE ENGINE OIL
-CHANGE FUEL and OIL FILTER
-CHECK ANTIFREEZE CONCENTRATION
-INSPECT THE AIR CLEANER

EVERY 12 MOUNTHS or 1000 HRS:
-ADJUST ENGINE VALVE LASH CLEARANCE
-CHECK FAN BELT and FAN BELT TENSIONER BEARING
-CHECK TURBOCHARGER
-CHECK COOLANT HEATER
-CHECK SAFETY ALARMS
-CHANGE MARINE GEAR BOX OIL
-FLUSH THE.MARINE GEAR BOX OIL COOLER
-FLUSH THE WATER COOLER
-FLUSH THE HEAT EXCHANGER

EVERY 24 MOUNTHS or 2000 HRS:
-REPLACE ANTIFREEZE and FLUSH COOLING SYSTEM

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ABBREVIATIONS USED IN THIS MANUAL

ABBREVIATIONS USED IN THIS MANUAL(istilah atau singkatan)........


AFC..............................AIR FUEL CONTROL
API..............................AMERICAN PETROLEUM INSTITUTED
ASTM.............................AMERIKAN SOCIETY OF TESTING and MATERIALS
*C...............................CENTIGRADE
C.I.D............................CUBIC INCH DISPLACEMENT
CPL..............................CONTROL PARTS LIST
cST..............................CENTISTOKES
DCA..............................DIESEL COOLANT ADDITIVE
E.C.S............................EMISSION CONTROL SYSTIM
EPA..............................ENVIRONMENTAL PROTECTION AGENCY
*F...............................FAHRENHEIT
FT-LB............................FOOT POUND
OEM..............................ORIGINAL EQUIPMENT MANUFACTURER
ppm..............................PARTS PER MILLION
psi..............................POUNDS PER SQUARE INCH
RPM..............................REVOLUTIONS PER MINUTE
S.A.E............................SOCIETY OF AUTOMOTIVE ENGINEERS
Hg...............................MERCURY
HP...............................HORSE POWER
H2O..............................WATER
in-lb............................INCH POUND
Kg...............................KILOGRAMS
Km...............................KILOMETERS
KPa..............................KILO PASCAL
M................................METRE
MM...............................MILLIMETRE
MPa..............................MEGAPASCAL
MPQ..............................MILES PER QUART
N*m..............................NEWTONE-METRE

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CUMMINS ENGINE 4B3.9-M/4BT3.9-M TURBO/6BT5.9-M TURBO

CUMMINS 4B3.9-M/4BT3.9-M/6BT5.9-M MESIN ini biasa digunakan untuk kapal baik 4cylinder atau 6cylinder data teknis sama perbedaan ada dijumlah cylinder.adapun datanya...


MODEL:4B3.9-M /4BT3.9-M/6BT5.9-M
TYPE..............................................4 CYCLE.IN-LINE
ASPIRATION........................................NATURALLY/TURBOCHARGED
BORE/STROKE.......................................4.02 IN / 4.72 IN
DISPLACEMENT......................................3.9 LITRE
MAIMUM TORQUE CAPACITY OF FRONT OF CRANKSHAFT.....210lb-ft/285nm
CRANKSHAFT END CLEARANCE-RANGE....................0.0054-0.0104 IN (0.137-0.264mm)
CLEARANCE MAGNETIC PICKUP -FLYWHEEL...........0.771-1.067mm(0.028-0.042 inch)
MODEL 4B3.9-M NATURALLY ASPIRATED:
brake horse power output-bhp(kw)..................80 (60)
shaft horse power output-shp(kw)..................78 (58)
engine speed-rpm..................................2800
cruise engine speed-rpm...........................2500
fly wheel torque-lb.ft(nm)........................150 (203)
piston speed-ft/min(m/s)..........................2203 (11.2)
brake mean effective pressure-psi(kpa)............95 (652)
maximum fuel consumption-us.gal/hr(litre/hr)......4.5 (17.0)
intake air flow-cfm(litre/s)......................145 (68)
exhaus gas flow-cfm(litre/s)......................448 (212)
exhaus gas temperature-f(c).......................1200.f (649.c)



MODEL 4BT3.9-M TURBOCHARGED:

BRAKE HORSE POWER OUTPUT-BHP(KW)......................150(112)

SHAFT HORSE OOWER OUTPUT-SHP(KW)......................146(109)

ENGINE SPEED-RPM.............................................................2800

CRUISE ENGINE SPEED-RPM..............................................2500

FLYWHEEL TORQUE-lb-ft(Nm).............................................281(381)

PISTON SPEED-Ft/min(m/s).....................................................2203(11.2)

BRAKE MEAN EFFECTIVE PRESSURE-PSI(kPa)................177(1220)

MAXIMUM FUEL CONSUMPTION-US.GAL/hr(LITRE/hr)..7.7(29.1)

INTAKE MANIFOLD PRESSURE-in.hg(mm.hg).....................24.6(624.8)

INTAKE AIR FLOW-CFM(LITRE/s).......................................260(122.7)

EXHAUST GAS FLOW-F*(C*)...............................................960(516)



MODEL 6BT5.9-M. 6CYLINDER. 4 CYCLE IN-LINE.TURBOCHARGED:

BRAKE HORSE POWER OUTPUT-BHP(KW).......................210(157)

SHAFT HORSE POWER OUTPUT-SHP(KW)........................204(152)

ENGINE SPEED-RPM..............................................................2600

CRUISE ENGINE SPEED-RPM...............................................2300

FLYWHEEL TORQUE-lb-ft(Nm).............................................424(575)
PISTON SPEED-ft/min(m/s)......................................................2045(10.4)

BRAKE MEAN EFFECTIVE PRESSURE-PSI(kPa)................178(1227)

MAXIMUM FUEL CONSUMPTION-US-gal/hr(LITRE/hr).....10.9(41.3)

INTAKE MANIFOLD PRESSURE -in.hg(mm.hg).....................49.0(1245)

INTAKE AIR FLOW-CFM(LITRE/s)........................................510(241)

EXHAUST GAS FLOW-CFM(LITRE/s)....................................1230(581)

EXHAUST GAS TEMPERATURE-F*(C*).................................835(446)



VALVE INTAKE CLEARACE.............................................0.254mm(0.010 inch)

VALVE EXHAUST CLEARANCE.......................................0.508mm(0.20 inch)

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ANALISA PEMBUANGAN ASAP MESIN DISEL DETROIT 16V-71RC

untuk analisa warna gas pembuangan asap dari mesin ini temperatur dari air pendingin sebaiknya sudah dalam temperatur kerja yaitu 160 derajat farenheit minimum.warna asap......


ASAP HITAM atau ABU-ABU:
-bahan bakar dan udara, lebih banyak bahan bakar mungkin disebabkan filter udara yang kotor sehingga suply udara berkurang
-jendela emergency stop diperiksa apakah benar terbuka
-waktu pembakaran timing kurang tepat
-bahan bakar tidak sesuai standar atau terkontaminasi
-kerusakan pada pipa kenalpot yang menyebabkan tekanan gas buang tinggi
ASAP BIRU:
-minyak pelumas ikut terbakar disebabkan 1.piston pin retainer tidak kedap,2.ring piston oil upper half/lower half gap/side sudah diatas limit yang diijinkan
-kebocoran pelumas didalam blower air intake
ASAP PUTIH:
-tip spray/nozzle pengabutan tidak sempurna
-timing pembakaran terlambat
-clearace piston dengan cylinder liner sudah diatas limit

DAN GAS BUANG YANG SEMPURNA NYARIS TIDAK BERASAP.

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DETROIT-16V-71RC-457hp-2 stroke diesel

mesin disel 16 cylinder 2 langkah ini merupakan ciri kas buatan general motor(GM)dimana suplai pemasukan udara disuplai melalui blower udara(super charger)yang dikaitkan dengan putaran cam shaft dan sistim pembuangan udara diatur dengan dobel rocker arm,dobel valve bridge,4 exhaust valve dan satu rocker arm injector,menggunakan governor hidraulis ..mesin ini biasa digunakan pada kapal untuk penyediaan lstrik dengan daya 300 kw untuk generator nya,berikut ini data pembangkit listrik dan mesin...


GENERATOR:DAYA=300kw,VOLT=450 vac,PHASE=3phase,FREKUENSI=60 cycle

MESIN:
type.........................16v-71rc
max.power....................457 hp
speed........................1800rpm
bore/stroke..................4.25/5.00 inches
compression ratio............17:1
total displacement...........1134.8 cubic inches
main bearing.................10
brake mean effective pressure.88 psi

TABLE OF SPECIFICATIONS&CLEARANCES.
CYLINDER BLOCK:
block bore.........................4.6260"-4.6270"
cylinder liner counterbore.........5.0460"-5.0510"
main bearing bore..................4.8120"-4.8130"

CYLINDER LINER:
outside diameter...................4.6250"-4.6260"
inside diameter....................4.2495"-4.2511"
clearance-liner to -block bore.....0.0020"-.0030"
out-of-roundness--inside diameter..0.0020"-.0030"

CRNKSHAFT:
journal diameter-connecting rod....2.9990"-3.0000"
journal diameter main bearing......4.4990"4.5000"

MAIN BEARING:inside diameter.......4.5016"-4.5040"
clearance bearing to journal.......0.0016"-.0041"

CONNECTING ROD:
inside diameter upper bushing......1.5015"-1.5020"
side clearance between rods........0.0080"-.0160"
connecting rod BEARING diameter inside....3.0014"-3.0034"
clearace bearing to crankshaft journal....0.0014".0044"

PISTON & RING PISTON:
at top diameter...........................4.2230"-4.2260"
at skirt bottom...........................4.2428"-4.2450"
clearance piston skirt-to liner...........0.0045"-.0083"
GAP RING PISTON:
gap top ring..............................0.0230"-.0380"
gap rings 2,3,4...........................0.0180"-.0430"
gap oil rings.............................0.0080"-.0230"

PISTON PINS:
piston pin diameter.......................1.4996"-1.5000"
pin-to piston bushing clearace............0.0025"-0.0034"
pin-to rod bushing clearance..............0.0015"-0.0024"
piston pin BUSHING INSIDE diameter........1.5025"-1.5030"

CYLINDER HEAD:
exhaust valve insert counterbore diameter....1.2600"-1.2610"
exhaust valve seat outside diameter..........1.2615"-1.2625"
valve head to cylinder head..................0.0230"-0.0060"
exhaust valve guide height above cyl.head....0.8800"-0.8800"
inside - diameter............................0.3125"-0.3135"
clearance--stem-to-guide.....................0.0020"-0.0035"

STANDARD BOLT AND NUT TORQUE SPECIFICATIONS:
injector control shaft bracket bolts............1/4-20-torque.10-12lb-ft
cam follower guide bolts........................1/4-20-torque.12-15lb-ft
air box cover bolts.............................5/16-18-torque.8-12lb-ft
oil pan bolt....................................5/16-18-torque.10-12lb-ft
exhaust valve break adjusting screw lock nut....5/16-24-torque.20-25lb-ft
adler gear bearing retaining bolt...............5/16-24-torque.24-29lb-ft
injector clamp bolt.............................3/8-16-torque.20-25lb-ft
camshaft end bearing bolt.......................3/8-16-torque.35-40lb-ft
flywheel housing bolt...........................3/8-26-torque.25-30lb-ft
crankshaft frot cover...........................3/8-16-torque.25-30lb-ft
exhaust manifold outlet flang nuts(brass).......3/8-24-torque.25-30lb-ft
water manifold cover nuts.......................3/8-24-torque.20-25lb-ft
camshaft intermediate bearing lock screw........3/8-24-torque.15-20lb-ft
balance weight to camshaft gear bolt............3/8-24-torque.15-18lb-ft
balance to camshaft gear plain nut..............3/8-24-torque.18-22lb-ft
blower drive support bolt and nuts..............3/8-24-torque.25-30lb-ft
balance weight to camshaft gear slotte3d nut....3/8-24-torque.28-32lb-ft
accesory drive hub/disc to camshaft gear bolt...3/8-24-torque.45-50lb-ft
flywheel housing bolt...........................3/8-24-torque.25-30lb-ft
exhaust manifold nuts...........................7/16-20-torque.30-25lb-ft
connecting rod nut (lubrite)....................7/16-20-torque.60-70lb-ft
connecting rod nut (plain)......................7/16-20-torque.65-75lb-ft
rocker arm bracket bolts........................1/2-13-torque.90-100lb-ft
idler gear and dummy hub bolt...................1/2-13-torque.80-90lb-ft
rocker shaft break bolt.........................1/2-13-torque.90-100lb-ft
flywhell housing bolt...........................1/2-13-torque.90-100lb-ft
crankshaft front cover..........................1/2-13-torque.80-90lb-ft
flywheel bolts..................................9/16-18-torque.180-190lb-ft
main bearing bolt...............................5/8-11-torque.180-190lb-ft
cylinder head bolt/nut..........................5/8-11-torque.175-185lb-ft
crankshaft end bolt.............................1-14-torque.290-310lb-ft
camshaft nut....................................1-1/8-18-torque.300-325lb-ft
blower drive gear hub nut.......................1-7/16-16-torque.50-60lb-ft

GRAFIK PEMERIKSAAN SISTIM BERDASARKAN JAM KERJA MESIN:
-SETIAP MESIN AKAN DISTART PERIKSA:
1.engine oil
2.coolant and filter
3.fuel tank,fuel strainer and filter
-SETIAP 8.JAM:
1.air cleaner
-SETIAP 50.JAM:
1.air starter system
-SETIAP 100.JAM:
1.tacho meter drive
-SETIAP 200.JAM:
1.throttle control
-SETIAP 300.JAM:
1.fuel strainer and filter
2.air cleaner and air starter system
-SETIAP 500.JAM:
1.hose,coolant system and filter
2.heat exchanger electrodes and core
3.over speed governor
4.flexible coupling
-SETIAP 1000.JAM:
1.coolant and filter
2.heat exchanger electrodes and cor
3.air box drains
4.crankcase breather
5.blower screen
6.TUNE-UP engine
SETIAP 2000.JAM:
1.air starter system
-SETIAP 4500.JAM:
1.ALTERNATOR

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MWM TBD 232-V8

perakitan engine 232-v8 yang perlu diperhatikan clearance TAPPET karena sistim lubrikan oil rocker arm diinjeksikan dari tappet kelubang tengah pussrod selanjutnya ke bush rocker arm dan clearance bearing bush SHAFT BALANCING karena sistim lubrikan diinjeksikan dari bearing bush depan masuk kelubang shaft selanjutnya ke bearing bush ke 2,3,4.disamping clearance bearing lainnya......


BEARING CLEARANCES:
main bearing radial :0,12-0,17 mm
thrush bearing radial/axial :0,12-0,17/0,12-026 mm
connecting rod bearing radial/axial :0,09-0,135/0,50-080 mm
connecting rod bushes piston pins -radial:0,05-0,08 mm
camshaft bearing -radial/axial :0,06-0,11/0,10-0,29 mm
BEARING FOR COMPENSATION:
of masses 6cyl -radial/axial :0,06-0,11/0,10-0,29 mm
of masses 8cyl -radial/axial :0,06-0,11/0,05-0,20 mm
rocker arm bush -radial/axial :0,02-0,07/0,05-0,46 mm
CYLINDER HEAD:
valve seat of measured from cylinder head bottom to lower edge of valve plate:
normal :1,20-1,50 mm
max permissible :1,8 mm
limit measure overhouling :2,0 mm
valve guide bore :11,000-11,018 mm
valve stem dia :10,955-10,970 mm
ROCKER ARM clearance shaft and bush-radial/axial:0,020-0,07/0,05-0,46 mm
PISTON clearance distance from upper edge of piston to upper edge of collar of cylinder liner :1,15-1,40 mm
PISTON RING clearance :0,4-0,6 mm. max permissible:1,3-1,5 mm
GUDGEON PIN AND BUSH clearance:0,05-0,08 mm. max permissible:0,2 mm

TIGHTENING TORQUE FOR IMPORTAN SCREWS IN mkp:
shaft for injection pump drive:m8-10,9 t.3,0+0,5
camshaft whell :m8-10,9 t.3,0+0,5
rocker arm bracket :m10-10,9 t.6,5+0,5
vibration damper :m12-8,8 t.7,5+0,5
injection valve fixing screw :m10-8,8 t.2,5+0,5
flywheel housing :m12-8,8 t.7,5+0,5
v.belt pulley on crankshaft :m14-10,9 t.14,0+1
coupling or injection timer :m14x1.5 t.8,0+1
connecting rod screw :m16x1.5 t.23,0+1
flywheel :m16x1.5 t.22,0+1
cylinder head :m16x1.5 t.19,0-21,0
bearing cover :m18-10,9 t.28,0+1
bearing journal for fan drive :m14x1.5 t.15,0+1
suporting base of cooler :m12-8,8 t.7,5+0,5
suporting base of cooler :m12-10,9 t.11,5+0,5
oil pan fastening :m8-8,8 t.2,5+0,5
vibration damper :m16x1.5 t.22,5+1

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Bedah mesin MWM 232-V6/V8/V12-d/td/tbd

mesin mwm tipe D/TD/TBD-232-V6/V8/V12 data teknis sama,tipe tbd 232-v8 biasa digunakan untuk penggerak GENERATOR,mesin ini menggunakan GOVERNOR electrik(ECU),disisi kiri crankshaft ditambahkan SHAFT BALANCING(putaran:2xputaran crankshaft/4xputaran camshaft) yang berfungsi untuk peredam getaran,untuk sitim pelumasan minyak lincir menggunakan dua(2)pompa minyak,dua(2)turbocharger.data ...



bore/stroke :120/130 mm
swept volome of acylinder :1,47 dm
compression space of a cylinder:94,8 cm3
compression ratio :16,5
turbo supercharging :2x3LD(KKK)
sarter 1:elektik starter 24v
2:distributor air starter
piston:-normal dia :119,865-119,875 mm
-rep stage 1 :120,365-120,375 mm
-rep stage 2 :120,865-120,875 mm
piston ring:-normal dia :120 mm
-rep stage 1 :120,5 mm
-rep stage 2 :121 mm
gudgeon pin :44,995-45,0 mm
connectingrod:-crank pin:-normal dia :89,942-89,964 mm
-rep stage 1 :89,692-89,714 mm
-rep stage 2 :89,442-89,484 mm
-rep stage 3 :89,192-89,214 mm
-rep stage 4 :89,042-88,904 mm
dia OF bor for connecting rod bearing shell :96,000-96,022 mm
Connecting rod BEARING bore:-normal dia :90,054-90,077 mm
-rep stage 1 :89,804-89,827 mm
-rep stage 2 :89,554-89,577 mm
-rep stage 3 :89,304-89,327 mm
-rep stage 4 :89,054-89,077 mm
crank case:-dia of tappet holes :20,200-20,221 mm
-dia of the hole of bearing cover :108,000-108,022 mm
-bor of cylinder liner:-upper fit :140,000-140,040 mm
-lower fit :137,000-137,040 mm
-bor of the cam shaft:-normal dia :52,000-52,030 mm
-rep 1&2 :+0,25&+0,50 mm
bearing bore for BALANCE WEIGHT:-6 cyl.engine :57,0-57,019 mm
-8 cyl.engine :65,0-65,010 mm
crank shaft:bearing pin dia:-normal :99,942-99,064 mm
-rep stage 1 :99,692-99,714 mm
-rep stage 2 :99,442-99,464 mm
-rep stage 3 :99,192-99,214 mm
-rep stage 4 :98,942-98,964 mm
bore of bearing :-normal :100,084-100,112 mm
-rep stage 1 :99,834-99,862 mm
-rep stage 2 :99,584-99,612 mm
-rep stage 3 :99,334-99,362 mm
-rep stage 4 :99,084-99,112 mm
dia of bearing balance weight:-6 cyl.inside :52,0-52,019 mm
-8 cyl.inside :60,0-60,019 mm
cam shaft:dia of bearing -normal :51,02-51,94 mm
-2 repair stage:0,25 ech
dia of the pin for the cam shaft toothed wheel :51,071-51,090 mm
dia of the bore of cam shaft toothed wheel :52,000-52,030 mm
cylinder liner:-normal :120,000-120,022 mm
-rep stage 1 :120,500-120,522 mm
-rep stage 2 :121,000-121,022 mm
CLEARANCE:
bearing clearance:-main bearing-radial :0,12-0,17mm
-thrust bearing-radial/axial :0,12-0.17 /0,12-0,26 mm
-connecting rod bearing-radial/axial:0,09-0,135/0,50-0,80 mm
-connecting rod bush piston pin-radial :0,05-0,08 mm
-cam shaft bearing-radial / axial :0,06-0,11/0,10-0,29 mm
-bearing for compensation:
of masses-6cyl-radial/axial:0,06-0,11/0,10-0,29 mm
-8cyl-radial/axial:0,06-o,11/0,05-0,20 mm
-rocker arm bush -radial/axial :0,02-0,07/0,05-0,46 mm
cylinder head:
valve seat off measured fromcylinder head
bottom to lower edge of valve plate:-normal :1,20-1,50 mm

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PERAKITAN mesin diesel MWM tbd440-8k-1030kw

Langkah awal setelah pengukuran bor for main bearing,crankshaft,camshaft,pin piton bus,bor of connecting rod bearing,piston,pin piston,liner,rocker arm bus,rocker shaft,valve in/ex,gap/side ring piston.langkah berikutnya....


langkah 1.pemasangan main bearing
2.pemasangan crankshaft
3.pemasangan ring piston ke piston
4.pemasangan piston ke connecting rod
5.pemasangan liner ke cylinder frame/blok mesin
6.masukan piston ke liner dan pemasangan connecting rod pin
7.pemasangan oil pump + sistim
8.pemsangan camshaft
9.gear camshaft
10.crankcace/calter
11.cylinder head + sistim
12.injection pump,nozzle + sistim
yang perlu diperhatikan pada waktu pemasangan komponen adalah clearances,torsi schedule for major bolt(kekencangan baut2) .
TORSI SCHEDULE:-main bearing cover mounting :long bolt-20Nm+4x60*(derajat)
:short bolt-20Nm+2,5x60*(derajat)
-conrod bearing cover 1st stage/2nd stage:15/36+1x60*
-cylinder head:20Nm+3,5x60*(derajat)
-flywheel:40/50Nm+1x60*(derajat)
BEARING RADIAL CLEARANCE:-main and thrush bearing:0,20-0,279mm
-connecting rod bearing :0,20-0,25 mm
-piston pin bearing :0,1-0,14 mm
-camshaft :0,072-0,161mm
-rocker arm :0,040-0,072mm
-valve stem,in/ex :0,05-0,108mm
-piston andcylinder on lower stem end:0,337-0,397mm
AXIAL CLEARANCE:-thrust bearing :0,11-0,25mm
-connecting rod bearing:0,7-0,835mm
-camshaft :0,2-0,3 mm
-rocker arm :0,1-0,3 mm
GAP CLEARANCE :-piston ring :0,9-1,15 mm
-helical spring ring:0,9-1,15mm
LONGITUDINAL PISTON RINGS IN CLEARANCE,GROOVE 1:0,11-0,142mm
                                                                                        GROOVE 2+3:0,07-0,102mm
                                                                                        GROOVE 4:0,043-0,078mm

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Bedah mesin diesel MWM tbd440-8k-1030kw

pada dasarnya mesin bensin/diesel baik kapasitas besar/kecil memakai matrial dan komponen nyaris sama.yang dimaksud bedah mesin adalah pengenalan:data teknis,data komponen/parts,data ukur,data torsi bolt,data clearances.yang berguna untuk menentukan laik masing2 komponen
sebagai contoh kita buka data mwm 440.....


DATA TEKNIS:d/td/tbd440-6.d/td/tbd440-8
bore/stroke :230/270 mm
volome/cylinder :11,2 ltr
compresi rasio :1:15/14/13
compresi pressure:40/64/78 bar
injection pressur:350 bar
lube oil BEFORE filter:max 4 bar
lube oil AFTER filter : 2,5 bar
turbocharger :BBC VTR 200

DATA UKUR:D/TD/TBD 440-6/8
CYLINDER BLOK:
- bores for main bearing :220,0 - 220,029 mm
- bores for camsaft housing :150,0 - 150,040 mm
- bores of mounting cylinder :264,0 - 264,032 mm
liner of top frame
- bores of mounting cylinder :262,0 - 262,032 mm
liner of below in frame
- cylinder liner outside top/below:263,92 -263,97 / 261,92 -261,97 mm
- cylinder liner inside :230,0 -230,04
- bores of camshaft in housing :90,0 -90,035
- camshaft bearing journal :89,874 -89,928
PISTON:
-distance from upper edge of cylinder liner:1,4 -2,5 mm
-diameter of piston lower end :229,643 -229,663 mm
-height of piston ring. grove 1:4,10 -4,12
grove 2/3:4,06 -4,08
grove 4 :8,03 -8,05
CONNECTING ROAD:
-bores for piston pin bush :115,0 -115,022 mm
-bores FOR connecting rod bearing:190,0 -190,029 mm
-bores OF connecting rod bearing :175,225 mm
PISTON PIN BEARING:
-piston pin dia :100,0 -100,01 mm
-piston pin bush - bore :100,11 -100,14 mm
-piston pin bush outside :115,054 -115,076mm
CRANKSHAFT:
-main bearing journal diameter :199,971 - 200,0 mm
-thrust bearing journal diameter :199,971 - 200,0 mm
-dia OF connecting rod pin :174,975 - 175,0 mm
-main bearing bush bore :200,20 -200,25 mm
CYLINDER HEAD:
-rocker arm shaft :44,984 - 44,985 mm
-rocker arm bush inside :45,10 -45,12 mm
-rocker arm bush outside :52,041 -52,060 mm
-rocker arm bore :52,0 - 52,019 mm
-dia of valve inlet/exhaust :77,0 - 77,2 mm
-CLEARANCE INLET/EXHAUST VALVE :0,4 mm
-valve seat ring in/ex outer dia :80,146 - 80,176 mm
-bore FOR valve seat ring in cylinder head:80,0 - 80,019 mm
BEARING CLEARANCES RADIAL:
-main and trush bearing :0,20 - 0,279 mm
-connecting rod bearing :0,20 - 0,25 mm
-piston pin bearing :0,1 - 0,14 mm
-camshaft :0,072 - 0,161 mm

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GOVERNOR

GOVERNOR berfungsi sebagai stabilitas putaran/kecepatan mesin,macam sistim governor terbagi:pneumatic,sentrifugal,elektrik...


PNEUMATIC digerakan oleh udara dari blower pada mesin yang memakai udara untuk pendingin mesinnya,SENTIFUGAL digerakan oleh putaran mesin yang terkait dengan trottle untuk melawan pegas jika terjadi beban kejut pada kecepatan mesin sitim ini ada yang terpasang didalam injection pump dan diluar mesin yang kecepatan putaran dikaitkan dengan camsaft,ELEKTRIK SISTIM dipakai servo motor dihubungkan denga trottle untuk melawan pegas dikendalikan oleh elektrik modulyang dipancarkan dari magnetic pickup,frekuensi pulsa dari magnetic pickup merespon speed control unit untuk mengatur servo motor.sistim ini sering digunakan untuk GENERATOR karena sangat sensitif beban kejut.

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injection pump

injection pump adalah pompa tekanan tinggi untuk distribusi bahan bakar dari injeksi PLUNGER ke NOZZLE...


INJECTION PUMP ada 3sistim:1.rotary sistim,2.inline sistim,3.line sistim.rotary digunakan mesin dibawah 5000cc,inline digunakan mesin diatas 5000cc,sedang line sistim(plunger,valve,nozzle satu line)seperti digunakan pada mesin detroid disel,cummins,sammyong.untuk sitim rotary PLUNGER/PUMP ELEMENT didalam pompa hanya ada satu sedang valve preasure tergantung jumlah cylinder mesin,sedang pompa inline dalam satu pompa jumlah PLUNGER/PUMP ELEMENT DAN VALVE PRESURE tergantung jumlah cylinder mesin

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PISTON MASTER CYLINDER CLUTCH

master cylinder clutch adalah cylinder hidraulis yang terpasang pada kopling mobil modern,yang berfungsi meringankan injakan kaki si pengemudi.didalam master cylinder terpasang PISTON yang menekan minyak rem ke cylinder clutch selanjutnya menekan clutch assy.PISTON/PLUNGER pada master clutch diujungnya terdapat seal dan support yang berfungsi menutup lubang pemasukan minyak waktu pedal kopling ditekan sehingga tekanan minyak menuju cylinder clucth

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PISTON CYLINDER REM

PISTON cylinder rem terdapat pada  MASTER cylinder dan wheel cylinder,piston yang ada di master gunanya menekan minyak rem ke piston yang ada di drum wheel cylinder selanjutnya piston menekan sepatu rem.pada umumnya PISTON master menggunakan sistim tandem yaitu tekanan minyak yang dihasilkan PISTON1 yang berada di belakang disamping menekan ke piston wheel cylinder roda belakang juga menekan PISTON2 master yang berada didepan dan tekanan minyak rem yang dihasilkan untuk menekan piston wheel cylinder roda depan.pada umumnya minyak rem yang dipakai ber standart DOT3 (tidak mengandung unsur air) meskipun minyak rem larut dengan air.....namanya minyak tapi tidak larut dengan MINYAK

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PISTON POWER STEERING

PISTON power steering fungsi kerja hanya sebagai pembagi tekanan oil dua arah yaitu kekanan/kekiri,karena power steering bekerja pada 2 sistim yaitu hidraulis dan mekanik.power steering biasa terpasang pada alat2 berat seperti FORKLIFTyti,TRACTOR,LOADER dll.tapi sejalan tuntutan modernisasi power steering dipakai untuk mobil modern seperti truck,mobil sedan,bahkan mobil kecil

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PISTON GEARBOX MATIC

piston gearbox matic lokasi/posisi ada didalam DRUM CLUTCH,sistim kerjanya piston didorong tekanan oil dari pompa oil yang ada didalam gearbox melalui control valve D/R(maju/mundur).sehingg terjadi perapatan clutch plate dan clutch disch

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PISTON PUMP

PUMP(pompa)PISTON water&oil high pressure untuk..


pompa air piston(water jet)dipakai untuk penyemprotan petisida tanaman,pencucian mobil (max press 35bar).pompa oil piston digunakan untuk menggerakan motor oil mobil crane/derek,mobil beton molen,hydraulis(max press>200bar)

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PISTON MESIN

PISTON terbuat dari almunium campuran(almunium alloy)tahan gesek,tahan panas sampai temperatur tertentu,bentuk fisik..


mesin bensin/diesel perbedaan ada dikepala piston,untuk mesin 2stroke hanya ada ring compresi sedang 4stroke ada tambahan ring oli skrap gunanya untuk pelumasan badan piston,dan fisik piston oval(tidak bulat 100%),kalau diukur dengan mikro meter bagian yang sejajar dengan PIN PISTON lebih mengecil gunanya supaya pada waktu memuai karena panas, piston tidak macet/lengket ke dinding cylinder dan supaya ada celah untuk pelumasan antara dinding cylinder>< piston

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PISTON COMPRESSOR

COMPRESSOR terbagi 2jenis:1.compressor refrigerant 2.compressor udara(air compressor),compressor udara terbagi 3jenis:


1.LOW PRESSURE(press max15 bar)2.MEDIUM PRESSURE(piston 2stage press max 40 bar,piston 3stage press max 70 bar)3.HIGH PRESSURE(piston 4stage press max 300 bar)

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Bagian-bagian Mesin

bagian-bagian mesin:

Silinder terdapat pada blok mesin. Blok mesin biasanya terbuat dari besi cor kelabu. Karena besi cor kelabu memiliki daya tahan aus yang cukup baik selain itu harganya cukup murah. Sebagai perbandingan: harga besi cor kelabu di Indonesia ± Rp 5000,00 /kg, sedangkan besi cor nodular ± 7500,00/kg-nya. Saluran air pendingin (water jacket) tercetak didalam blok mesin dan mengelilingi setiap silinder. Beberapa jenis mesin menggunakan cylinder liner yang di masukkan (pressed) ke dalam blok mesin, sehingga apabila aus dapat diganti. Sistem ini biasa disebut sistem wet liners (apabila dinding luar cylinder liner bersentuhan langsung dengan air pendingin) dan dry liners (apabila dinding luar cylinder liners tidak bersentuhan langsung dengan air pendingin). Paduan aluminium saat ini makin banyak digunakan sebagai bahan blok mesin, terutama untuk mesin-mesin yang berukuran kecil, dengan tujuan untuk mengurangi berat, sehingga akan diperoleh power to weight ratio yang baik.

Crankshaft (kruk as/poros engkol) biasanya terbuat dari steel forging (baja yang ditempa). Besi cor nodular juga dapat dipakai sebagai bahan crankshaft pada mesin-mesin tugas ringan. Crankshaft dipasang pada blok mesin dan disangga oleh main bearing. Jumlah main bearing maksimum adalah jumlah silinder + 1. Crankshaft memiliki poros-poros eksentrik, yang biasa disebut crank throw. Connecting rod (batang penghubung/stang seher) dipasang pada setiap crank throw. Pada setiap main bearing dan crankthrow dipasang journal bearing (metal) yang terbuat dari bronze, babbit, atau aluminium. Crankcase (ruangan crankshaft) tertutup rapat pada bagian bawahnya oleh oil pan (karter) yang biasa terbuat dari aluminum cor atau plat baja yang dipress. Oil pan berfungsi sebagai penampung oli untuk sistem pelumasan.

Piston(torak) terbuat dari paduan aluminium, sedangkan pada mesin-mesin besar berkecepatan rendah biasanya terbuat dari besi cor. Piston berfungsi sebagai penyekat silinder sekaligus mentransmisikan tekanan gas hasil pembakaran ke crank throw dengan perantaraan connecting rod. Connecting rod biasanya terbuat dari baja atau material paduan lainnya (aluminium, titanium, dll). Connecting rod terpasang pada piston dengan perantaraan piston pin yang terbuat dari baja. Piston pin biasanya berlubang untuk mengurangi beratnya. Piston biasanya dilengkapi dengan ring piston yang berfungsi sebagai penyekat gas hasil pembakaran agar tidak bocor ke dalam crankcase sekaligus juga berfungsi sebagai pengatur aliran oli untuk melumasi dinding silinder.

Cylinder head(kepala silinder) berfungsi untuk menutup silinder, dan terbuat dari paduan aluminium atau besi cor. Cylinder head harus kuat dan kaku sehingga gaya-gaya dari gas hasil pembakaran yang beraksi ke cylinder head dapat didistribusikan secara merata ke blok mesin. Komponen-komponen cylinder head terdiri dari busi (untuk motor bensin) atau fuel injector (untuk motor diesel) dan komponen-komponen mekanisme katup.

Katup(valve) biasanya terbuat dari baja paduan yang ditempa (forged alloy steel) atau keramik (hasil pengembangan/penelitian insinyur-insinyur di mercedes benz). Pendinginan katup buang yang beroperasi pada temperatur sekitar 700° C dapat dicapai dengan mengisikan sodium pada lubang stem katup. Dengan proses evaporasi dan kondensasi sodium dapat menghantarkan panas dari kepala katup yang panas ke daerah stem katup yang lebih dingin. Stem katup bergerak naik turun di dalam valve guide (bushing katup). Sebuah pegas katup dipasang pada setiap valve stem dengan menggunakan spring washer dan split keeper, yang berfungsi menahan katup agar tetap tertutup.

Camshaft(noken as/poros bubungan) terbuat dari besi cor atau baja tempa dan setiap cam berfungsi untuk membuka atau menutup katup. Permukaan cam biasanya dikeraskan agar ketahanan aus-nya meningkat. Untuk motor 4 langkah, kecepatan putar camshaft adalah setengah dari kecepatan putar crankshaft.

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