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SERVICE STANDARDS/REPAIR LlMITS/MAINTENANCE
Part Name
Check/lnsaect
Standard ValueJMalntenance
Repair limit
Cylinder Head
1. Carbon deposit on the combustion
1. Remove carbon deposit and clean.
chamber
2. Scratch depth and distortion of the
2. Scratch depth or distortion is O.lmm (0.004in)
2. Repair (set /240·#400 sandpaper
mounting surface.
or more.
the suriace plate and pOlish the
surface for repair. Use #600 sandpaper
for finishing).
3. Corrosion in the mated surface.
3. Repair or replace depending on the situation.
4. Clogged cooling water passage.
4. Clean and remove foreign matters.
Cylinder
1. Deposit in the water jacket.
1. Clean and remove foreign matters.
2. Wear of the inside cylinder
2. 59.00mm (2.3228in)
2. 59.06mm (2.3252in) or more
diameter. Measure the bore with
(If
wear is
exceeding the repair limit,
a cylinder gauge
replace or bore the cylinder and finish
by honing. Over-sized piston is O.Smm.
refer to item 4).
3. Seizure
3. Replace or use an over-sized piston
after boring the cylinder.
4. Scratch and wearing down in the
4. When the liner cannot be repaired by means
4. Bore and hone to 059.5KO.Olmm
cylinder liner.
of #400·#600 sandpaper because it is
(02.3425 ±0.0004in).Use oversize
extremely scratched or scored, or the
piston and rings.
difference between the maximum wear and
minimum wear is 0.06mm (0.0024in) or more.
5. Mating suriaces of the cylinder and
5. When the depth of scratch or distortion
5. Use
1400
sandpaper on the suriace
cylinder head.
in/of the mating suriace is O.lmm (0.004in)
plate and pOlish the suriace. Use #600
or more.
sandpaper for finishing.
Piston
1. Outside Diameter
1. Diameter: 58.960mm (2.3213in)
1. Outer Diameter: 58.90mm (2.3189in)
or more.
0) Measure the diameter at a point
7mm above the lower end of the
piston skirt.
b) Piston Clearance
b) Piston clearance: 0.020·0.055mm
b) Piston Clearance: 0.15mm
(0.0008-0.0022in)
(0.0059in) or more
2. Carbon deposit on the piston crown
2. Remove carbon residuum and clean.
and in the piston ring groove.
3. Scratch on the sliding suriace.
3. Repair with #400·#600 sandpaper depending
on the situation.
4. Measurement of clearance between
4. Top: 0.04·0.08mm (0.0016·0.0031in)
4. Top: 0.10mm (0.004in) or more
the piston ring and ring groove.
2nd: 0.03·0.07mm (0.0012·0.0028in)
2nd: 0.09mm (0.0035in) or more
Oil: 0.01·0.18mm (0.0004· 0.0071in)
Oil: 0.21mm (0.0083in) or more
NOTE: To be replaced wifh a new oil ring, when
replacing with new top and/or second rings.
Sandpaper means water proof pap.,
5. Measurement of diameter of the
5.
Clearance between pin and hole
5. 0.04mm (0.0016in) or more
piston pin hole.
Loose: 0.002·0.012mm (0.00008·0.00005in)
Piston Ring
1. End Gap
1. Replace with new piston ring n wear of the
NOTE: Measurement of the end gap:
cylinder liner is within the repair limit.
when no ring gauge is available,
measure the lower part of the
cylinder bore.
a) Top
a) Top: 0.15·0.35mm (0.006·0.014in)
0) Top: 0.5mm (0.020in) or more
b) Second
b) Second: 0.30·0.50mm (0.012·0.020in)
b) Second: 07mm (0.028in) or more
c) Oil
c) Oil: 0.20.Q.7mm (0.008·0.028in)
c) Oil Ring: to be replaced with a new
oil ring. when replacing with new top
and/or second rings. Sandpaper
means water proof paper.
Piston Pin
1. Outer diameter
1. 16.00mm (0.6299in)
1. 15.97mm (0.629in) or less.
Crankshaft
1.Deflection of the crankshaft.
1. Less than 0.05mm (0.002in)·both ends.
1. 0.05mm (0.002in) or more.
Both the main bearings of the
crankshaft should be supported
with V·blocks.
2. Outer diameter of the crankpin.
2. 29.98mm (1.1803in)
2. 29.95mm (1.17910) or less.
3. Outer diameter of the bearing.
3. 31.99mm (1.2594in)
3. 31.97mm (1.259in) or less.
4. Oil clearance of the bearing.
4.0.012· 0.044mm (0.0005· O.OOI71n)
4. 0.06mm (0.002in) or more.
5. Side clearance of the crankshaft.
5. 0.1 • 0.2mm (0.004 ·0.008in)
5. 0.6mm (0.024in) or more.
-..v: WESTERBEICE
Engines &
Generators
12
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