Professional Documents
Culture Documents
OM D Series 02 A
OM D Series 02 A
OM D Series 02 A
4LND-D1
4LTD-D
CONTENTS
CHAPTER 1 FEATURE···························································································································· 1
CHAPTER 2 ENGINE BODY ··················································································································· 2
[1] CYLINDER BLOCK ······································································································ 2
[2] HEAD COVER ············································································································· 2
[3] CYLINDER HEAD········································································································ 3
[4] INJECTION SYSTEM ·································································································· 3
[5] PISTON ························································································································ 4
CHAPTER 3 LUBRICATING SYSTEM ···································································································· 5
[1] OIL COOLER ················································································································ 5
CHAPTER 4 COOLING SYSTEM ············································································································ 6
[1] THERMOSTAT·············································································································· 6
[2] BOTTOM BYPASS SYSTEM························································································ 7
CHAPTER 5 FUEL SYSTEM ··················································································································· 8
[1] GOVERNOR ················································································································ 8
[2] NOZZLE ······················································································································· 9
CHAPTER 6 INTAKE SYSTEM ············································································································· 10
[1] INTAKE AIR HEATER································································································· 10
CHAPTER 7 TROUBLESHOOTING ········································································································ 11
CHAPTER 8 SERVICING SPECIFICATIONS ·························································································· 15
CHAPTER 9 TIGHTENING TORQUES···································································································· 21
CHAPTER 10 CHECKING, DISASSEMBLING AND SERVICING····························································· 22
[1] CHECKING AND ADJUSTING ····················································································· 22
(1) Engine Body ··········································································································22
(2) Lubricating System ································································································23
(3) Cooling System ····································································································· 23
(4) Fuel System ·········································································································· 26
(5) Turbocharger ·········································································································29
[2] REMOVING EXTERNAL COMPONENTS ···································································· 30
(1) External Parts ········································································································ 30
(2) Turbocharger ··········································································································30
[3] DISASSEMBLING AND ASSEMBLING ·········································································31
(1) Cylinder Head and Valves ····················································································· 31
(2) Thermostat············································································································· 34
(3) Injection Pump Unit ······························································································· 35
(4) Water Pump ·········································································································· 36
(5) Gear Case ············································································································· 36
(6) Piston and Connecting Rod ·················································································· 38
(7) Flywheel and Crankshaft ························································································41
[4] SERVICING ··················································································································· 43
(1) Cylinder Head ········································································································ 43
(2) Idle gear and Camshaft·························································································· 49
(3) Piston and Connecting Rod ···················································································· 52
(4) Crankshaft ·············································································································· 54
(5) Cylinder Liner ·········································································································· 57
(6) Oil Pump ················································································································· 58
Operation & Maintenance Manual for Diesel Engine
CHAPTER 1 FEATURE
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2 HEAD COVER
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3 CYLINDER HEAD
These engines employs two valve systems,
the cylinder head can provide appropriate air
suction and give an optimum swirl.
(1) Intake (2) Exhaust
4 INJECTION SYSTEM
4LND-D1 and 4LTD-D engines adopt the
Side Direct Injection System, in which the
injection nozzle is positioned bevel at the side of
the cylinder.
This system serves to inject fuel bevel at the
side of the cylinder. By doing so, injected fuel
and suction air can be mixed more uniformly,
leading to more stable, higher combustion
performance. In other words, cleaner emission,
higher power output, lower fuel consumption,
lower operating noise and higher start-up
performance have been achieved.
(1) Intake Valves (2) Exhaust Valves
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Operation & Maintenance Manual for Diesel Engine
5 PISTON
Piston skirt is coated with Graphite(1),
which reduces the piston slap noise as so well
the entire operating noise.
Graphite:
The molybdenum disulfide serves as
a solid lubricant, like a molybdenum disulfide
or Teflon. This material helps to resist metal
wears even with little lube oil.
(1) Graphite
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2 NOZZLE
Exhaust and noise regulations are
becoming increasingly strict, particularly reduction
of NOx (nitrogen oxides) and particulates.
The nozzle holder has been developed to
reduce NOx (nitrogen oxides) and particulates from
direct injection diesel engine exhaust.
Features
The nozzle holder limits needle valve lift at
initial valve opening to throttle the injection
quantity. Main injection occurs when the in-
line pressure has increased sufficiently to
move the needle valve through its full lift.
This gives the following features.
x Improved engine stability at low and
intermediate speeds.
x Decreased engine hunting and surge.
x Decreased noise at idling.
x Decreased idling speeding because of
improved engine stability.
x Stabilized fuel injection characteristics from
the injection pump and nozzle system, and
easier matching of governor system, and
easier matching of governor characteristics
to engine demand.
(1) Fuel inlet pipe (8) Oil return pipe joint
(2) Nozzle Holder Body (9) Adjusting washer
(3) Retaining Nut (10) High-pressure oil pipe
(4) Midbody (11) Pressure adjusting spring
(5) Needle valve body (12) Tappet
(6) Oil inlet pipe union (13) Guide pin
(7) Filter element (14) Needle valve
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CHAPTER 7 TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
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Reference
Symptom Probable Cause Solution
Page
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Reference
Symptom Probable Cause Solution
Page
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Reference
Symptom Probable Cause Solution
Page
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I.D. (Intake)
8.0 to 8.015 mm
Valve Guide 0.3150 to 0.3156 in
Free Length 46 mm
(outer) 1.8110 in
Tilt 0.8 mm
0.0315 in
Valve Spring Setting Load/ 53 to 59 N / 37.2 mm
Setting Length 5.41 to 6.02 N / 37.2 mm
(inner) 11.91 to 13.26 lbs / 1.5630 in
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Operation & Maintenance Manual for Diesel Engine
Alignment 0.03 mm
0.0012 in
Cam Height Intake 39.01 to 39.09 mm
1.5358 to 1.5390 in
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Operation & Maintenance Manual for Diesel Engine
Timing Gear:
Idle Gear to Crank Gear Backlash 0.112 to 0.224 mm
0.0394 to 0.0788 in.
Idle Gear to Cam Gear Backlash 0.112 to 0.224 mm
0.0394 to 0.0788 in.
Idle Gear Shaft to idle gear bushing Oil clearance 0.025 to 0.075 mm 0.2 mm
0.0010 to 0.0030 in 0.0079 in
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LUBRICATING SYSTEM
Item Factory Specification Allowable Limit
COOLING SYSTEM
Item Factory Specification Allowable Limit
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Operation & Maintenance Manual for Diesel Engine
FUEL SYSTEM
Item Factory Specification Allowable Limit
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Operation & Maintenance Manual for Diesel Engine
0.30 to 0.35 mm
Valve clearance Factory spec.
0.0118 to 0.0138 in
Valve arrangement
Adjustment cylinder IN. EX.
Location of piston
1st
When No.1 piston is at 2nd
compression top dead center 3rd
4th
1st
When No.1 piston is at 2nd
overlap position 3rd
4t
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Operation & Maintenance Manual for Diesel Engine
14.7 to 19.6 mm
Tightening torque Oil switch taper screw 1.5 to 2.0 in
10.8 to 14.5 psi
1.3 Cooling System
Fan Belt Tension
1. Measure the deflection (A), press the belt halfway
between the fan drive pulley at specified force 98 N.
2. If the measurement is not within the factory specifications,
loosen the alternator mounting screws and relocate the
alternator to adjust.
10.0 to 15.0 mm /39 N
Deflection (A) Factory spec.
0.394 to 0.591 in./ 39N
(A) Deflection
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Operation & Maintenance Manual for Diesel Engine
CAUTION
x When removing the radiator cap, wait at least ten minutes after the engine has stopped
and cooled down. Otherwise, hot water may gush out, scalding nearby people.
Radiator Cap Air Leakage
1. Set a radiator tester on the radiator cap.
2. Apply the specified pressure of 88 kPa.
3. Check if the pressure drops to less than 59 kPa in 10
seconds.
4. If the pressure is less than the factory specification, replace it.
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x Check the nozzle injection 8. Measure the time needed to decrease the pressure from 22 to 21 MPa.
pressure and condition after 9. If the measurement is less than allowable limit, replace the
confirming that there is nobody pump with new one or repair with an authorized pump service
standing in the direction where
shop.
the fume goes. 10 seconds
x If the fume from the nozzle Fuel tightness of
22 to 21 MPa
Factory spec. 220 to 210 kgf/cm 2
directly contacts the human delivery valve
3190 to 3045 psi
body, cells may be destroyed Allowable limit 5 seconds
and blood poisoning may be 22 to 21 MPa
220 to 210 kgf/cm 2
caused. 3190 to 3045 psi
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1.5 Turbocharger
Turbine Side
1. Check the exhaust port (3) and inlet port (5) side of
turbine housing (1) to see whether there is no exhaust
gas leak.
2. If any gas leak is found, retighten the bolts and nuts
or replace the gasket (2) / (4) / (6) with new one.
(1) Turbine Housing (4) Gasket
(2) Gasket (5) Inlet Port
(3) Exhaust Port (6) Gasket
Compressor Side
1. Check the inlet hose (1) of the compressor cover (3) to
see whether there is no air leak.
2. Check the loose connection or cracks in the suction side of
the intake hose.
3. If any air leak is found, change the clamp (2) or inlet hoses.
(1) Inlet Hose (3) Compressor Cover
(2) Clamp
Radial Clearance
1. If the wheel contact the housing, replace the turbocharger
assembly with new one.
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Operation & Maintenance Manual for Diesel Engine
CAUTION
x While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the
turbocharger.
NOTE
x When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other
impurities in the oil pipes.
x When the turbocharger assembly has been replaced, pour clean lubricating oil through the oil filler port of
the turbocharger.
x Before starting the engine, make sure that air cleaner is in position.
Oil Pipe
1. Remove the joint bolt and clamp and take off the pipe 1 (1).
2. Remove the bolts (4) and release the clamp (2).
3. Disconnect the oil pipe 2 (3).
(When reassembling)
x Pour clean lubricating oil through the oil filler port of the turbocharger.
x Replace the gasket with new one.
x Be careful not allowing dust, dirt and other impurities to come in the oil
pipes.
NOTE
x Tape or plug all openings to prevent other impurities
from damaging the oil cavities in the turbocharger.
(1) Oil Pipe 1 (2) Clamp (3) Oil pipe2 (4) Bolt
Turbocharger
1. Remove the bolt (1).
2. Take off the turbocharger assembly (2).
(When reassembling)
x Replace the gasket with new one. (1) Bolt (2) Turbocharger Assembly
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IMPORTANT
When replace the piston, piston pin bush, connecting rod
or crankpin bearing, select the cylinder head gasket
thickness to meet with the top clearance, refer to the
“Selecting Cylinder Head Gasket”.
NOTE
Mark the cylinder number to the tappets to pervert interchanging.
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Operation & Maintenance Manual for Diesel Engine
Valve
1. Remove the valve spring collets (1) after compressing the
valve spring (3) with the valve spring retainer (2).
(When reassembling)
x Install the valve spring with its small-pitch end downward
(at the head side).
x Wash the valve stem and valve guide hole, and smear
lubricating oil sufficiently.
x After installing the valve spring collets, lightly tap the
stem to assure proper fit with a plastic hammer.
( (1) Valve Spring Collet
2) Valve Spring Retainer
(3) Valve Spring
(4) Valve Stem Seal
(5) Valve
(6) Rocker Arm (7) Large Pitch (8) Smaller Pitch
(9) Install the spring with its smaller pitch end downward (at the head side)
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Operation & Maintenance Manual for Diesel Engine
3.2 Thermostat
Thermostat Assembly
1. Remove the thermostat cover mounting screw, and
remove the thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
x Apply a liquid gasket only at thermostat cover side of
the gasket (2).
x Attach the thermostat with its hole facing toward the
air suction side.
(1) Thermostat Cover (3) Thermostat Assembly
(2) Thermostat Cover Gasket
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Idle Gear
1. Remove the idle gear mounting screw (1).
2. Draw out the idle gear (2).
(When reassembling)
x When install the idle gear (2), be sure to place the 4th
cylinder piston at the top dead center in compression,
then, align all mating marks on each gear to assemble the
timing gears, set the idle gear last.
18.0 to 23.0 N·M
Tightening torque Idle gear mounting screw 1.8 to 2.3 kgf·m
13.3 to 17.0 ft-lbs
(1) Idle gear mounting screw (2) Idle gear
Camshaft
1. Remove the camshaft set screws and draw out the camshaft.
55 to 70 N.m
Tightening torque Camshaft set screw 5.6 to 7.1 kgf.m
40.5 to 51.6 ft-lbs
(1) Camshaft
(1) Plate
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Piston
1. Completely clean carbon in the cylinders.
2. Turn the flywheel and set a piston to the top dead center.
3. Pull out the piston upward by lightly tapping it from the
bottom of the crankcase with the grip of a hammer.
(When reassembling)
x Before inserting the piston into the cylinder, apply enough
engine oil to the cylinder.
x When inserting the piston into the cylinder, face the mark
(3) on the connecting rod to the injection pump.
IMPORTANT
x Do not change the combination of cylinder and
piston.
x When inserting the piston into the cylinder, place the
gap of each piston ring like the figure.
x Carefully insert the pistons using a piston ring
compressor (1). Otherwise, their chrome-plated section
of piston rings may be scratched, causing trouble
inside the liner.
x When inserting the piston in place, be careful not to get
the molybdenum disulfide coating torn off its skirt. This
coating is useful in minimizing the clearance with the
cylinder liner. Just after the piston pin has been press-
fitted, in particular, the piston is still hot and the coating
is easy to peel off. Wait until the piston cools down.
(1) Piston Ring Compressor (A) Top Ring Gap
(2) Molybdenum Disulfide Coating (B) Second Ring Gap
in piston skirt (C) Oil Ring Gap
(3) Mark (D) Piston Pin Hole
o
(a) 0.79 rad (45 ) (E) Injection Pump Side
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Flywheel Housing
1. Remove the flywheel housing.
(When reassembling)
x Apply liquid gasket ( Three B o n d 1217D or
e q u i p m e n t ) t o flywheel housing.
x Confirm that the liquid gasket coating surface is free of
water, dust and oil in order to maintain sealing effect.
x Be careful not to damage the oil seal when installing the
flywheel housing to the crankshaft.
x Tighten the flywheel housing mounting screws with even
force on the diagonal line.
NOTE
x When mounting the adhesive-applied parts, take care
to fit them to the mating parts.
x Assemble the adhesive-applied parts within ten minutes.
32 to 42 N.m
Flywheel housing
Tightening torque 3.3 to 4.3 kgf.m
mounting screw
23.6 to 31.0 ft-lbs
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Operation & Maintenance Manual for Diesel Engine
Crankshaft
1. Remove the main bearing case.
2. Remove the crankshaft
(When reassembling)
x Reassemble the main bearing case having the same
number as the one engraved on the crankcase, and set
the casting mark “F/W SIDE” on the main bearing case
facing towards the flywheel side.
x Reassemble the thrust bearing, with the oil groove facing
outside, into both side of the fourth main bearing case.
x Apply oil to the main bearing case screws and tighten them
to the specified torque.
118.0 to 137.0 N·M
Tightening torque Main bearing case screw 12.0 to 14.0 kgf·m
87.0 to 101.0 ft-lbs
(1) F/W SIDE Mark (4) 4th main bearing case
(2) Thrust bearing
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Operation & Maintenance Manual for Diesel Engine
4 SERVICING
4.1 Cylinder Head
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straight edge on the cylinder head’s four sides, and
two diagonal and as shown in the figure. Measure the
clearance with a feller gauge.
3. If the measurement exceeds the allowable limit, correct it
with a surface grinder.
IMPORTANT
x Be sure to check the valve recessing after correcting.
Cylinder head surface 0.04 mm
Allowable limit
flatness 0.0016in.
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Operation & Maintenance Manual for Diesel Engine
Valve Recessing
1. Clean the cylinder head, the valve face and seat.
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace
the valve.
If it still exceeds the allowable limit after replacing the
valve, replace the cylinder head.
(recessing)
Intake
0.55 to 0.85 mm
valve
Factory 0.0217 to 0.0335 in.
spec. (recessing)
Exhaust
Valve recessing 0.55 to 0.85 mm
valve
0.0217 to 0.0335 in.
(recessing)
Allowable
1.2 mm
limit
0.0472 in.
(1) Cylinder head surface (A) Recessing
(B) Protrusion
Valve lapping
1. Apply compound evenly to the valve lapping surface
2. Insert the valve into the valve guide. Lap the valve onto
its seat with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and
apply oil, then repeat valve lapping with oil.
4. Apply Prussian blue to the contact surface to check the
seated rate. If it is less than 70%, repeat valve lapping
again.
IMPORTANT
x When valve lapping is performed, be sure to check
the valve recessing and adjust the valve clearance
after assembling the valve.
(1) Correct (3) Incorrect
(2) Incorrect
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Operation & Maintenance Manual for Diesel Engine
1.2 to 1.7 mm
IN.
Factory 0.0472 to 0.0669 in.
Valve seat width
spec. 1.2 to 1.7 mm
EX.
0.0472 to 0.0669 in.
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Operation & Maintenance Manual for Diesel Engine
0.8 mm
Tilt (B) Allowable limit
0.0315 in.
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Operation & Maintenance Manual for Diesel Engine
14.0 to 14.018 mm
Tappet O.D. Factory spec.
0.5512 to 0.5519 in.
13.966 to 13.984 mm
Tappet guide bore I.D. Factory spec.
0.5498 to 0.5506in.
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Camshaft Alignment
1. Support the camshaft with V block on the surface plate and set a
dial indicator with its tip on the intermediate journal at right angle.
2. Rotate the camshaft on the V blocks and get the misalignment
(half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
camshaft.
0.03 mm
Camshaft alignment Allowable limit
0.0012 in.
Cam Height
1. Measure the height of the cam at its highest point with an outside
micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft.
Intake 39.01 to 39.09mm
Intake and exhaust Factory valve 1.5358 to 1.5390 in.
cam height spec. Exhaust 39.01 to 39.09mm
valve 1.5358 to 1.5390 in.
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Operation & Maintenance Manual for Diesel Engine
Oil clearance between idle gear shaft and idle gear bushing
1. Measure the idle gear shaft O.D. with an outside micrometer.
2. Measure the idle gear bushings I.D. with an inside
micrometer, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
bushing.
0.025 to 0.075 mm
Oil clearance Factory spec.
0.0010 to 0.0030 in.
between idle gear
0.2 mm
and idle gear bushing Allowable limit
0.0079 in.
45.0 to 45.025 mm
Idle gear bushing I.D. Factory spec.
1.7717 to 1.7726 in.
44.950 to 44.975 mm
Idle gear shaft I.D. Factory spec.
1.7697 to 1.7707 in
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Operation & Maintenance Manual for Diesel Engine
0.30 to 0.45 mm
Oil ring Factory spec.
0.0118 to 0.0177 in.
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Operation & Maintenance Manual for Diesel Engine
27.991 to 28.000 mm
Piston pin O.D. Factory spec.
1.1020 to 1.1024 in.
28.020 to 28.033 mm
Small end bushing I.D. Factory spec.
1.1031 to 1.1037 in.
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Operation & Maintenance Manual for Diesel Engine
4.4 Crankshaft
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the front
and rare.
3. If the measurement is exceeds the allowable limit, replace the
thrust bearings.
4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an oversize one referring to the table
and figure.
Crankshaft side 0.125 to 0.295 mm
Factory spec.
clearance 0.0049 to 0.0116 in.
(Reference)
x Oversize dimensions of crankshaft journal
0.2 mm 0.4 mm
Oversize
0.008 in. 0.016 in.
31.200 to 31.239 mm 31.400 to 31.439 mm
Dimension A
1.2283 to 1.2299 in. 1.2362 to 1.2378 in.
67.0 to 67.2 mm 67.1 to 67.3 mm
Dimension B
2.6378 to 2.6457 in. 2.6417 to 2.6496 in.
3.5 to 4.0 mm radius 3.5 to 4.0 mm radius
Dimension C
0.1378 to 0.1575 in. radius 0.1378 to 0.1575 in. radius
The crankshaft journal must be fine-finished to higher than Ra0.4.
Crankshaft Alignment
1. Support the crankshaft with V block on the surface plate and set a
dial indicator with its tip on the intermediate journal at right angle.
2. Rotate the crankshaft on the V block and get the
misalignment (half of the measurement)
3. If the misalignment exceeds the allowable limit, replace the
crankshaft.
0.025 mm
Crankshaft alignment Allowable limit
0.0010 in.
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Operation & Maintenance Manual for Diesel Engine
Oil clearance
0.050 to 0.108 mm
between crankpin Factory spec.
0.0020 to 0.0043 in.
and crankpin bearing
(Reference)
Undersize dimensions of crankpin
0.2 mm 0.4 mm
Undersize
0.008in. 0.016 in.
3.5 to 4.0 mm radius 3.5 to 4.0 mm radius
Dimension A
0.1378 to 0.1575 in. radius 0.1378 to 0.1575 in. radius
1.5 to 2.0 mm relief 1.5 to 2.0 mm relief
*Dimension B
0.0591 to 0.0787 in. relief 0.0591 to 0.0787 in. relief
55.781 to 55.800 mm 55.581 to 55.600 mm
Dimension C
2.1961 to 2.1968 in. 2.1882 to 2.1890 in.
The crankpin must be fine-finished to higher than Ra0.4
*Holes to be de-burred and edges rounded with 1.5 to 2.0 mm
(0.0591 to 0.0787) relief.
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Operation & Maintenance Manual for Diesel Engine
Oil clearance
between crankshaft 0.060 to 0.118 mm
Factory spec.
journal and 0.0024 to 0.0046 in.
crankshaft bearing
(Reference)
Undersize dimensions of crankshaft journal.
0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.
3.5 to 4.0 mm radius 3.5 to 4.0 mm radius
Dimension A
0.1378 to 0.1575 in. radius 0.1378 to 0.1575 in. radius
1.5 to 2.0 mm relief 1.5 to 2.0 mm relief
*Dimension B
0.0591 to 0.0787 in. relief 0.0591 to 0.0787 in. relief
64.781 to 64.800 mm 64.581 to 64.600 mm
Dimension C
2.5504 to 2.5512 in. 2.5426 to 2.5433 in.
The crankshaft journal must be fine-finished to higher than Ra0.4
*Holes to be de-burred and edges rounded with 1.5 to 2.0 mm
(0.0591 to 0.0787) relief.
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Operation & Maintenance Manual for Diesel Engine
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Maschinenbau Halberstadt – GmbH