Pt. Lotus SG Lestari C11 - Txe07368 (966H - Tal02635)

LEAK TESTheui
ENGINE REBUILD REPORT / SERVICE REPORT
GENERAL OVERHAUL
WO Number : 8500062172
Customer : PT. LOTUS SG LESTARI
Unit Model : C-11 (966H)
Serial Number : TXE07368 (TAL02635)
Arrangement : 234-7848
SMU Unit :
Date Service :
Location Service : BSD Branch
Branch : BSD Unit No :- Engine Model : C11
Dealer Code : J22X Model : 966H Engine SN : TXE07368
Customer : PT. LOTUS SG LESTARI Machine SN : TAL02635 Arrangement : 234-7848
Customer ID :259
1006860 Job No. : 8500062172 Service Meter : Hours
Dear Bapak/Ibu ...,
On behalf of everyone at PT Trakindo Utama, we would like to thank you for trusting us to excel your business. Our continuous
faith in the excellence of our products and services, something we are committed to and would never sacrifice, has led us to where
we are today.It’s always a pleasure serving you and we certainly look forward to doing that in the future.
There is always room for improvement, so if we can serve you better in anyway, please do inform us. Your feedback is very
important as we are constantly looking for ways to advance ourselves and our customers forward.
Thank you very much.
Best regards,
Widyo Prabowo
Hub Operation Manager
West Java Region
ENGINEREBUILD REPORT Page 2

Customer ID :259
SUMMARY OF ENGINE REPAIR
FAILURE OUTLINE
GOH Engine
BACKGROUND
Schedule Overhaul
THE CAUSE of FAILURE

General inspection shown engine normal condition
ENGINE RECONDITION DESCRIPTION

1. Disassembling & inspection damage component, inspect, measure, & replace fail component.
1.1. Dismantling engine conduct with safety and contamination control regulation.
1.2. Dismantling engine group and all components.
1.3. Inspect and measure components & give recommendation for part replacement.
1.4. Create recommendation for engine recondition. Major damage component: Injector, Tube,
Turbocharger, Piston, Connecting Rod, Liner, lifter, Valve, Spring Valve.
1.5. Reuse after disposition as request customer: Injector, Sensor, Switch.
2. Assembling engine components.

2.1. Assembling Machine & engine comply with safety and contamination control regulation.
2.2. Measure and documentation bearing clearance, gear back lash, shaft end play, and other critical
assembling points.
2.3. Replace seals, gaskets, and damage part as customer approval parts.
2.4. Fastener torque and tighten as factory specification.
3. Engine performance Test.

3.1. Test running engine comply with specification 0K-4835 or 286hp at 1800rpm.
3.2. Monitor all engine parameter, engine oil pressure, coolant temperature, and abnormal leaking.
3.3. Test load engine step by step till meet 286hp at 1800rpm or 100% from specification.
3.4. Check engine condition from leaks.
3.5. Check engine timing and check engine valve lash after running engine.
RECOMMENDATION
1. Operate engine as operation and maintenance manual (OMM).
2. Periodically PM engine as OMM.
3. Monitor engine SOS.
4. Stop engine if any abnormal engine noise.
5. Always use genuine part Caterpillar.

Customer ID :259

Customer ID :259
TABLE OF CONTENTS
VISUAL INSPECTION DISASSEMBLE AREA .......................................................................................................................................... 4
DAMAGE AND MISSING PARTLIST .................................................................................................................................................. 5
SUMMARY OF INSPECTION ................................................................................................................................................................ 6
INSPECTION RECORD ........................................................................................................................................................................... .
CYLINDER BLOCK ............................................................................................................................................................................. 7
CRANKSHAFT .................................................................................................................................................................................. 9
CAMSHAFT .................................................................................................................................................................................... 11
ENGINE SLIPPER & ROLLER VALVE LIFTER .................................................................................................................................... 13
CYLINDER LINER PROJECTION ....................................................................................................................................................... 14
PISTON .......................................................................................................................................................................................... 15
CONROD & PISTON PIN ...................................................................................................................................................... 16
CONROD ALIGNMENT ......................................................................................................................................................... 17
CYLINDER LINER ............................................................................................................................................................................ 18
CYLINDER HEAD ............................................................................................................................................................................ 19
ENGINE VALVE .................................................................................................................................................................... 20
VALVE GUIDE ...................................................................................................................................................................... 21
VALVE SPRING..................................................................................................................................................................... 22
VALVE ROTATOR ................................................................................................................................................................. 24
ROCKER ARM & SHAFT ................................................................................................................................................................. 25
VALVE BRIDGE ADJUSTMENT ............................................................................................................................................. 26
FAN DRIVE ..................................................................................................................................................................................... 27
BELT TIGHTENER ........................................................................................................................................................................... 28
OIL PUMP ...................................................................................................................................................................................... 29
WATER PUMP .................................................................................................................................................................................. .
FRESH WATER PUMP .......................................................................................................................................................... 30
AUXILIARY SEA WATER PUMP ............................................................................................................................................ 31
TURBOCHARGER ........................................................................................................................................................................... 32
AIR STARTING MOTOR .................................................................................................................................................................. 33
AIR STARTING MOTOR LINES .............................................................................................................................................. 34
AIR COMPRESSOR ......................................................................................................................................................................... 35

Customer ID :259
FUEL INJECTION PUMP & GOVERNOR ..............................................................................................................................................

FIP & GOVERNOR 3406 SERIES ........................................................................................................................................... 36
FIP & GOVERNOR 3408 & 3412 SERIES ............................................................................................................................... 37
FUEL INJECTION PUMP PEEC 3408 & 3412 SERIES ............................................................................................................. 38
DATA TEST FUEL INJECTION SCROLL & NEW SCROLL ......................................................................................................... 39
DATA TEST FUEL INJECTION SCROLL OLD ENGINE TYPE ..................................................................................................... 40
NOZZLE ......................................................................................................................................................................................... 41
INJECTOR ...................................................................................................................................................................................... 42
FUEL PRIMING PUMP ................................................................................................................................................................... 43
PISTON COOLING TUBE ................................................................................................................................................................ 44
FUEL TRANSFER PUMP .................................................................................................................................................................... .
FUEL TRANSFER PUMP EUI / HEUI TYPE ............................................................................................................................. 45
FUEL TRANSFER PUMP GEAR TYPE ..................................................................................................................................... 46
FUEL TRANSFER PUMP PISTON TYPE .................................................................................................................................. 47
FUEL RATIO CONTROL .................................................................................................................................................................. 48
TIMING ADVANCE ......................................................................................................................................................................... 49
AIR ACTUATOR .............................................................................................................................................................................. 50
H.E.U.I PUMP ................................................................................................................................................................................ 51
PSG................................................................................................................................................................................................... .
DATA TEST GOVERNOR PSG ............................................................................................................................................... 52
CHECK LIST GOVERNOR PSG ............................................................................................................................................... 53
ALTERNATOR ................................................................................................................................................................................ 54
ELECTRIC STARTING MOTOR ........................................................................................................................................................ 55
ELECTRIC SYSTEM ......................................................................................................................................................................... 56
PANEL GAUGE / MODULE ............................................................................................................................................................. 57
LEAK TEST COOLING SYSTEM ........................................................................................................................................................ 58
CRITICAL ENGINE ASSEMBLY CHECK LIST ........................................................................................................................................ 59
PREPARATION ENGINE START UP .................................................................................................................................................... 60
COMPLETION .................................................................................................................................................................................... 61
ENGINE SAFETY DEVICE TEST REPORT ............................................................................................................................................. 62
ENGINE TEST RECORD ...................................................................................................................................................................... 63
ATTACHMENT ................................................................................................................................................................................... 64
REFERENCES .................................................................................................................................................................... END OF PAGE

Customer ID :259
VISUAL INSPECTION DISASSEMBLE AREA

COMPONENT HARUS DALAM KEADAAN BERSIH SEBELUM / SETELAH DIBONGKAR
MAKE SURE THE ENGINE GROUP IS COMPLETELY CLEANED BEFORE / AFTER DISASSEMBLED
FOTO HARUS LENGKAP MEWAKILI KEADAAN ENGINE / KOMPONEN
PHOTO MUST REPRESENT ENGINE/COMPONENT CONDITION COMPLETELY
Dilakukan/Done Tidak/No
1. Photo Component : Sisi Depan, Sisi Belakang, Sisi Kanan, Sisi Kiri, Nama Plate, Damage/Missing
(Photo Front Side, Rear Side, Right Side, Left Side, Engine Name Plate, Damage/Missing)
√ -
2. Contoh Oli SOS / SOSOil Sample - √
3. Photo kondisi Damage/Repair & Missing part (isi Form Damage, Missing, Repair Part List)
(photo for Damage/repaire & Missing part (Fill Damage, Missing, Repaire Part List) √ -
Tambahan untuk Engine Problem ( Additional or Engine Problem) :
4. Pemeriksaan filter yang dipotong & Photo / Inspect & Photo cut filter - √
5. Pemeriksaan backlash clearance seluruh valve sebelum pembongkaran
Check all valve backlashclerance before disassemble
- √
6. Download Product Status and Parameter ECM Unit dan diserahkan ke Foreman/Supervisor
Download product Status ECM Unit and handed to Foreman/Supervisor - √
7. Memeriksa keberadaan Oli/Air pada Air Intake
Inspect Air-Intakes For Oil / Enty or Water Present - √
8. Memeriksa keberadaan oli/air akibat kebocoran/kerusakan
Inspect for oil / water present damage leaks etc. - √
9. Memeriksa torque dari Retaining Bolt Cyl. Head
- √
Inspecte The Torque Of The Head Retaining Bolts
10. Berikan Catatan yang mewakili kondisi aktual engine / component saat dibongkar - -
Note for actual conditions of the Engine / Component while Dismantling
SELURUH COMPONENT DIBERSIHKAN, DIKERINGKAN DAN DIBERI ANTI RUST

SERTA DILETAKKAN PADA KERANJANG/RAK/CABINET DAN DIBERIKAN KETERANGAN JOB
Make Sure All Components Are Cleaned, Dried And Coated With Anti_Rust Proved Warned Correctly
And Place Into The Back Cabinets Correct Are is
DATA DIATAS MERUPAKAN HASIL INSPEKSI SELAMA PEMBONGKARAN

The above data is actual inspected during dismanting
Inspected by, Supervised by,
(SIGIT G) (CHRISDIAN F)

Customer ID :259
CYLINDER BLOCK
Seg. # : - Cylinder Technician : Sigit G Foreman : Ending S
Opr. # : Block PN : Date : Date :
- 19/09/2019 19/09/2019
Forging Number Spacer Plate Use Not Use
TOP DECK SURFACE

No. Visual Inspection Actual Reason/Comment ,i.e : corroded, scratched, spalled, pitted, nicked
1. Seal / Ferrule seat area √
2. Liner seat area √
3. Bolt hole / thread √
FRONT SIDE SURFACE

1. Gasket contact √
2. Idler gear/shaft seat surface √
REAR SIDE SURFACE

2. Idler gear/shaft seat surface √
R/H SIDE SURFACE

3. Mounting Surface √
L/H SIDE SURFACE

3. Mounting Surface √
LOWER SIDE SURFACE

2. Balancer bearing surface √
INNER SIDE SURFACE

No. Visual Inspection Actual Reason/Comment ,i.e : corroded, scratched, fretting, pitted, nicked
1. Liner Side Wall surface √
2. Main bearing bore √
3. Jet spray contact surface √
Reusability Reason / Comment Action Required
Good Reuse
√

Customer ID :259
MAIN BEARING BORE

Specification (4.5669” ± .0005”) Inch Initial Specification
Dial Bore Gauge set to (4.5669”)Inch After Line Boring inchi @ lose
C B A
No. Alignment D
Front Rear Front Rear Front Rear
1. +.0005” +.0005” +.0005” +.0005” +.0005” +.0005” √ 0
2. +.0005” +.0005” +.0005” +.0005” +.0005” +.0005” √ 0
3. +.0005” +.0005” +.0005” +.0005” +.0005” +.0005” √ 0
4. +.0005” +.0005” +.0005” +.0005” +.0005” +.0005” √ 0
5. +.0005” +.0005” +.0005” +.0005” +.0005” +.0005” √ 0
6. +.0005” +.0005” +.0005” +.0005” +.0005” +.0005” √ 0
7. +.0005” +.0005” +.0005” +.0005” +.0005” +.0005” √ 0
8.
9.
VEE TYPE CYL. IN LINE CYL.

BLOCK BLOCK
TOP
TOP DECK
DECK HEIGHT
HEIGHT
CRANKSHAFT
CENTERLINE
TOP DECK HEIGHT FROM CRANKSHAFT CENTERLINE (see SEBF 8076)
Position Front Rear Difference Specification New Minimum Height
IN LINE 390 mm 389 mm - 387.00 mm -
R/H SIDE - - - - -
L/H SIDE - - - - -
Note : Make sure to calculate a half of actual Main Bearing bore to add tools reading.
TOP DECK SURFACE FLATNESS (see SEBF 8076)
Position Overall spec Overall actual Span distance Spec per span Actual reading per Span
IN LINE 0 0 - .002” 0
R/H SIDE - - - - -
L/H SIDE - - - - -
LINER SEAT ERROSION max. .001 inch
No Cylinder No Cylinder No Cylinder No Cylinder Reusability
1. 0 5. 0 9. - 13. -
2. 0 6. 0 10. - 14. - √
3. 0 7. - 11. - 15. -
4. 0 8. - 12. - 16. -
Reusability Reason / Comment Action Required
-found dimension was out of spec.
-found result of repaired was not permissible
-

CRANKSHAFT
FORGING NUMBER : 3119303 ASSEMBLY ...........................................
CUSTOMER : PT. LOTUS SG LESTARI DEALER : J210
INSPECTED BY : SIGIT G ...............................................................................................
WORK ORDER NUMBER : 8500062172 STORE : 10
DATE : 19/09/2019....................................................................................................
ENGINE MODEL : C11 SERIAL NUMBER : TXE07368
COMMENTS : (4.2520 ± .0008”) FORGING HEAT CODE (OPTIONAL) .........................................................................
MAIN JOURNAL INSPECTION MEASUREMENTS

MEASURED JURNAL DIAMETERS OUT-OF-
TAPER FILLET
HARDNESS VISUAL CHECK
MAIN Spect : ROUND RADIUS SURFACE
(Rc) PROVILE PITTED
CHECK FINISH
JURNAL CENTER 3 Spect : CHECK WATER MARK,
3.0 ± 0.2 mm CHECK
FRONT 1 REAR (2) (1) MINUS (3) (1) MINUS (2) 66-75 CRACK
90O TO (1) AND (2) 0.12 ± 0.008”
1 4.256” 4.253” 4.253” 0.003 0.003 0.120 73 NONE - OK
2 4.253 4.253” 4.253” 0 0 0.120 78 NONE - OK
3 4.254” 4.256” 4.254” 0.002 0 0.120 74 NONE - OK
4 4.254” 4.254” 4.253” 0 0.001 0.120 84 NONE - OK
5 4.254” 4.254” 4.255” 0 0.001 0.120 82 NONE - OK
6 4.253” 4.254” 4.253” .0001 0 0.120 81 NONE - OK
7 4.255” 4.253” 4.252” 0.002 0.003 0.120 80 NONE - OK
JURNAL BEND MEASUREMENTS MISCELLLANEOUS
ROD JOURNAL EASURING AFTER
BEFORE STRAIGHTENING
STRAIGHTENING
LOCATIONS POLISH MAGNETIK CRACK INSPECTION
√ 1-2 .002”
-
GRIND BEFORE GRINDING
-
1 2 CORE FOR EXCHANGE 2-3 .002” AFTER GRINDING / STRAIGHTENING
HOLD FOR -
3-4 .002” GRINDING DATA :
SCRAP
- ROD JOURNAL ..............................MAIN JOURNAL ...............................
............................................................ 4-5 -
THRUST FACE :
-
3 5-6 .002” WIDTH
DATE : -
6-7 .002” CHECK SURFACE FINISH : SCRATCH
By : -
7-8 -
Note: - -
8-9 SHOT PEENING : NOT REQUIRED
Refer to GRPTS &SEBF8041-
RODS
22for Correct Dimension & ROTATION : STANDARD-ccw cw MAINS, EXCEPT
Specification. (VIEW FROM FLYWHEEL)

CONNECTING ROD JOURNAL INSPECTION
MEASURE JURNAL DIAMETERS OUT-OF- VISUAL CHECK

TAPER FILLET HARDNESS SURFACE
ROD Spect : 3.5039 ± 0.008” ROUND PROVILE PITTED
RADIUS (Rc) FINISH
JOURNAL CENTER 3 CHECK WATER MARK,
FRONT 1 REAR 2 1 MINUS 3 1 MINUS 2 CHECK Sepect : CHECK CRACK
90O TO 1 AND 2
1 3.504” 3.505” 3.504” -0.001” 0” 0.120 81 - - OK
2 3.505” 3.505” 3.505” 0” 0” 0.120 74 - - OK
3 3.505” 3.505” 3.505” 0” 0” 0.120 80 - - OK
4 3.505” 3.504” 3.505” 0.001” 0” 0.120 82 - - OK
5 3.504” 3.504” 3.504” 0 0” 0.120 80 - - OK
6 3.504” 3.504” 3.505” 0” 0.001” 0.120 78 - - OK
7
8
9
10
11
12
13
14
15
16
ROD JOURNAL COMMENTS :
MEASURING
Crankshaft Reuse again after polish all journal
LOCATIONS

CAMSHAFT
Seg. # : - Camshaft 223-7463 Technician : Sigit G Foreman : Ending S
Opr. # : PN : Date : Date :
- 19/09/2019 19/09/2019
INTAKE LOBES EXHAUST LOBE

Cyl. Base Circle Lobe Height Lobe Lift Visual Cyl. Base Circle Lobe Height Lobe Lift Visual
Reusability Reusability
No A B C Inspection No A B C Inspection
1 2.05” 2.54” 0.4968” Ok √ 1 2.35” 2.68” 0.3708” Ok √
2 2.05” 2.52” 0.4969” Ok √ 2 2.31” 2.67” 0.3715” Ok √
3 2.05” 2.54 0.4968” Ok √ 3 2.31” 2.68” 0.3712” Ok √
4 2.05” 2.53’ 0.4968” Ok √ 4 2.31” 2.67” 0.3710” Ok √
5 2.05” 2.52” 0.4967” Ok √ 5 2.30” 2.67” 0.3715” Ok √
6 2.05” 2.54” 0.4968” Ok √ 6 2.30” 2.67” 0.3715” Ok √
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
SPECIFICATON BASE CIRCLE LOBE HEIGHT LOBE LIFT

Intake (Inch) .4963”
Exhaust (Inch) .3707”
Injector (Inch) .5.0001”

INJECTOR LOBES JOURNAL DIAMETER
Cyl. Base Circle Lobe Height Lobe Lift Visual Cyl.
Reusability RH LH VisualInspection Reusability
No A B C Inspection No
1 2.03” 2.53” 0.5006 Ok √ 1 3.066” - Ok √
2 2.03” 2.53” 0.5007” Ok √ 2 3.066” - Ok √
3 2.04” 2.53” 0.5006” Ok √ 3 3.066” - Ok √
4 2.05” 2.54” 0.5006” Ok √ 4 3.066” - Ok √
5 2.04” 2.53” 0.5007” Ok √ 5 3.066” - Ok √
6 2.03” 2.53” 0.5007” Ok √ 6 3.066” - Ok √
7 7 3.066” - Ok √
8 8
9 9
10
11
12
13 Journal Diameter (Inch) Specification (3.0650 ± .0010”)
14
15
16
Overall Reusability Reason / Comments Action Required
Good Condition Reuse again

Branch : BSD Unit No :- Engine : C11
Dealer Code : J22X Model : 966H Engine SN
Model : TXE07368
Customer ID :259
ENGINE SLIPPER & ROLLER VALVE LIFTER

Seg. # : - Valve Lifter - Technician : Sigit G Foreman : Ending S
Opr. # : PN : Date : Date :
- 19/09/2019 19/09/2019
Camshaft Failure
ROLLER LIFTER SLIPPER LIFTER Visual
No Position Depth of concave Inspection / Reuse? Reason / Comments
A B C Surface
surface
Front .007” .016” .016” - Good √ Good
1
Rear .003 .016” .016” - Good √ Good
Front .007 .012” .012” - Good √ Good
2
Rear .003 .012” .012” - Good √ Good
Front .004 .023” .023” - Good x Out spec
3
Rear .004 .023 .023” - Good x Out spec
4
Rear .004 .033” .033” - Good x Out spec
Front .003 .013” .013” - Good √ Good
5
Rear .003 .013” .013” - Good √ Good
6
Rear .003 .023” .023” - Good x Out spec
Front .003 .013” .013” - Good √ Good
7
Rear .003 .013” .013” - Good √ Good
Front .003 .015” .015” - Good √ Good
8
Rear .003 .015” .015” - Good √ Good
Front .003 .015” .015” - Good √ Good
9
Rear .003 .015” .015” - Good √ Good
Front .003 .015” .015” - Good √ Good
10
Rear .003 .020” .015” - Good √ Good
Front .003 .020 .020” - Good x Out spec
11
Rear .003 .020” .020” - Good √ Out spec
12
Rear .003 - .020” - Good √ Out spec
Maximum Allowable Total Movement for Reusability
Direction of Direction of Direction of

Engine
Movement A Movement B Movement C
- .007 .020 .020

Model : TXE07368
Customer ID :259
Maximum Allowable Depth of concave surface for Reusability 0.010 Inchi
CYLINDER LINER PROJECTION

Specification : Liner projection Max diff between high and low.
Adjacent liner must be within of each other
Piston projection
Cylinder No. 1 2 3 4 5 6 7 8
A
B
C
D
Average
Cylinder No. 9 10 11 12 13 14 15 16
A
B
C
D
Average
1. Checked by Foreman
2. Checked by Supervisor
Main Bearing Clearance Specification
1 2 3 4 5 6 7 8 9
Rod Bearing Clearance Specification
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Crankshaft End Play
Specification : Actual:
Timing Gears (Aligment & Backlash) Spec :
Timing of front gear Timing of rear gear
1. Checked by 1. Checked by
2. Checked by 2. Checked by
Foreman Supervisor
Note : Refer to Service Manual for Assembly Details & Specification
PISTON
Model : TXE07368
Customer ID :259
Seg. # : - Technician : Juliono A Foreman : Wanto

Desc. : PISTONS
Opr. # : - Date : 18/09/2019 Date : 20/09/2019
Illustration : Illustration :
Snap Heat
General Visual Entire Ring Top Ring Pin
Skirts Ring Plugs Reusable? Remarks
# Crowns Grooves Lands Bores
Condition (v/x) Grooves (if any)
(v/x) (v/x) (v/x) (v/x) (Y/N) (need polish, etc..)
(erosion, scuffing, etc..) (v/x) (v/x)
Wear step ring
1 grooves √ X √ √ √ √ - N Replace
Wear step ring
Wear step ring
Wear step ring
Wear step ring
Wear step ring
7
10
11
12
13
14
15
16
Notes : Replace all piston, wear step on ring grooves area and out New pistons required : 6 pcs.
of spec ring grooves width. -
Reusable pistons : pcs.
CONNECTING ROD & PISTON

Model : TXE07368
Customer ID :259
PIN
Seg. # : - CONNECTING ROD AS. Technician : Juliono A Foreman : Wanto
Desc.: & PISTON PINS
Opr. # : - Date : 18/09/2019 Date : 20/09/2019
Illustration :
SPECIFICATIONS VALUE
Average crankbore’s diameter :
(A B) 0.0015 in.
C
2
Crank bore’s ovalness :
A  B or (B  A) 0.0015 in.
Crank bore’s diameter :

3.6929±0.0005 in.
(A, B, & C)
Pin bore’s diameter : (D) 2.0947±0.0003 in. *
Std. 2.0927 in *
Piston pin’s diameter : (E)
Mi 2.0921 in *
A  B n.
Conrod Visual (A B) Is the rod PISTON PINS
A B C C or D
# Condition (inch) (inch) (inch) 2 B  A (inch/mm)*
reusable? Visual Condition reusable?
(bent, nicked, etc..) (Y/N) & Diameter (E) (Y/N)
Good
1 Good 3.6924 3.6934 3.6929 0 -0.001 2.0950 Y Y
2.0925
Good
2 Void 3.6934 3.6939 3.6939 -0.00025 -0.0005 2.0950 N Y
2.0925
Good
3 Good 3.6934 3.6934 3.6939 -0.0005 0 2.0950 Y Y
2.0925
Good
4 Good 3.6929 3.6929 3.6934 -0.0005 0 2.0950 Y Y
2.0925
Good
5 Good 3.6934 3.6934 3.6939 -0.0005 0 2.0950 Y Y
2.0927
Good
6 Good 3.6934 3.6934 3.6934 0 0 2.0950 Y Y
2.0927
7
10
11
12
13
14
15
16
New conrods required : 1 pcs.

Notes : Replace 1x conrod, Void on parting line.
-
New piston pins required : pcs.

Model : TXE07368
Customer ID :259
CONNECTING ROD ALIGNMENT

Seg. # : - CONNECTING ROD Technician : Juliono A Foreman : Wanto
Desc. : ALIGNMENT CHECK
Opr. # : - Date : 18/09/2019 Date : 20/09/2019
Illustration :
C – C distance tolerance : .000” + .0030”

Bore Parallel tolerance
.000” + .0045”
(Before rebuild) :
Bore Parallel tolerance
.000” + .0030”
(After rebuild) :
Twist tolerance : .000” + .0120”
Connecting rods have been checked with :
Old pin bushing in New pin bushing in
No pin bushing in
Fixture Readings C – C Tolerance Bore Parallel Is the rod

# Twist reusable? Remarks
A B # (A B) @ (A B)
(replace rod, resleeve, etc..)
(inch) (inch) 2 2 (Y/N)
1 0.002 -0.003 -0.0005 0.0025 0.004 Y Reuse
2 0.0015 -0.0025 -0.0005 0.002 0.004 N Replace rod
3 0.001 -0.001 0 0.001 0.004 Y Reuse
4 0.0005 -0.0035 -0.0015 0.002 0.004 Y Reuse
5 0.002 -0.004 -0.001 0.003 0.004 Y Reuse
6 0.001 -0.0005 0.00025 0.00075 0.004 Y Reuse
10
11
12
13
14
15
16
@ Do not apply plus minus from fixture readings# Apply plus minus from fixture readings
New conrods required : 1 pcs.
Notes : Replace 1x conrod, void on parting line,
New piston pins required : pcs.
-

Model : TXE07368
Customer ID :259
CRITICAL CHECK POINT PISTON & CONROD

Seg. # : PISTON & Technician : Foreman :
Desc.
Opr. # : CONROD Date : Date :
CHECK
PISTON (Qty: pcs) Y N
1. Posisi ring piston TOP & INTERMEDIATE tidak tertukar
2. Posisi ring retainer tidak tebalik
3. Pin piston mudah bergerak
4. Posisi spring pada Oil Ring Piston 180'
CONROD (Qty: pcs)

1. Permukaan Thrust face tidak tajam
2. Pemasangan CAP sesuai dengan nomor
3. Pastikan baut tidak ada yang rusak
4. Pastikan kekencangan baut conrod
5. Permukaan Bore Crank (Polish)
GENERAL
1. Posisi pemasangan piston & conrod seragam
2. pelumasan saat pemasangan
3. pemberian WD 40 saat packing
4. Piston, Pin, Conrod terpasang sesuai posisi semula
5. Final check meliputi semua komponen

Model : TXE07368
Customer ID :259
CYLINDER LINER
Seg. # : - Technician : Juliono A Foreman : Wanto
Desc. : CYLINDER LINERS
Opr. # : - Date : 18/09/2019 Date : 20/09/2019
Illustration :
Max. use againbore’s diameter 5.1211 in.

New bore’s diameter 5.1191 in.
Checking fixture’s set to : 5.1191 in.
# Visual Condition Upper End Bore Lower End Bore Reusable? Remarks
(pitting, wear step, etc..) (Y/N) (need hardhone, etc..)
(Comp. Name)
0oposition 90oposition 0oposition (Comp. Name)
90oposition
1 Wear step 5.1201 in. 5.1201 in. 5.1191 in. 5.1191 in. N Replace
7 in. in. in. in.
8 in. in. in. in.
9 in. in. in. in.
10 in. in. in. in.
11 in. in. in. in.
12 in. in. in. in.
13 in. in. in. in.
14 in. in. in. in.
15 in. in. in. in.
16 in. in. in. in.
Notes : Replace all cylinder wear step on inside wall. New liners required : 6 pcs.
Liners need to be hardhone : - pcs.
Reusable liners : - pcs.

Model : TXE07368
Customer ID :259
CRITICAL CHECK POINT

LINER
Seg. # : Technician : Foreman :
Desc. LINER
Opr. # : Date : Date :
CHECK
LINER (Qty: pcs) Y N
1. Pastikan kondisi Liner bersih
2. Ikut sertakan seal / fillerband (field)
3. Memberi pelumasan sebelum packing/storage
Notes :

Model : TXE07368
Customer ID :259
CYLINDER HEAD
Seg. # : - Cylinder Head Casting/s
Technician : Trio Adi P Foreman : Wanto S
Desc. :
Opr. # : - Date : 18/09/2019 Date : 20/09/2019
Ilustration : SPECIFICATIONS Value
Minimum head thickness 164.50 mm
Actual head’s thickness 165.02 mm
Description Actual Visual Reusable? Recommendation

#
(Is there any .....?) Condition (Y/N) (salvage/replace)
CASTING PHYSICAL
1.1 ... spalled/broken edges ? Good Y -
1.2 ... damaged/eroded valve cover seat ? Good Y -
1.3 ... welded casting ? Good Y -
1.4 ... damaged bolt’s seat areas ? Good Y -
1.5 ... signs of discolorations ? Good Y -
COMBUSTION & EXHAUST PORT SURFACES
2.1 ... cracked area on valve ports ? Good Y -
2.2 ... cracked nozzle/injector holes? Good Y -
2.3 ... cracked bolt holes ? Good Y -
2.4 ... cracked area between seat inserts ? Good Y -
2.5 ... deep fretting corrosion on fire ring areas ? Deep fretting corrosion on fire area Y Salvage
2.6 ... bad erosion on valve ports ? Good Y -
2.7 ... deep erosion/pitting on entire surfaces ? Good Y -
2.8 ... deep erosion on coolant/oil passages ? Good Y -
2.9 ... damaged across fire ring area ? Good Y -
2.10 ... damaged by foreign materials ? Good Y -
2.11 ... deep erosion on exhaust port surfaces ? Good Y -
WATER COMPARTMENT AREA/S
3.1 ... deep erosion on water line contact area ? Good Y -
3.2 ... deep eroded seats of nozzle/spark plug adapters ? Good Y -
3.3 ... cracked seats of nozzle/spark plug adapters ? Good Y -
THREADED HOLES
4.1 ... damaged threads on inlet & exhaust ports ? Good Y -
4.2 ... damaged threads on water line/s contact areas ? Good Y -
4.3 ... damaged threads on valve cover & lifting areas ? Good Y -
INJECTOR/NOZZLE BORES
5 ... deep grooved & eroded bores ? Good Y -
CASTING FLATNESS
6 ... unflatted/curved surfaces ? Good Y -
Notes : Deep fretting corrosion on fire ring areas, suggest to -

New cylinder head as. required : pcs.
Salvage owss for reuse again.

Model : TXE07368
Customer ID :259
ENGINE VALVES
Seg. # : - Technician : Trio Adi P Foreman : Wanto S
Desc. : ENGINE VALVES
Opr. # : - Date : 18/09/2019 Date : 22/09/2019
Illustration :
A
Measured Points INLET EXHAUST
Min. Lip Thickness (A) 2.46 mm 1.94 mm
Min. Stem’s diameter (B) 9.408 mm 9.408 mm
Inlet Valves Exhaust Valves

Cyl.
Visible Visible
# Stem’s Lip Reusable? Stem’s Lip Reusable?
Chamfer Chamfer
OD Thickness (Y/N) OD Thickness (Y/N)
(Y/N) (Y/N)
Go Wear - N Go Wear - N
1
2
3
4
5
6
10
11
12
Note : New inlet valves required : pcs.

“GO” means that actual stem/lip’s dimension is larger than min. spec. & reusable. 12
“NO GO” means that actual stem/lip’s dimension is under min. spec. & must be replaced.
New exh. valves required : 12 pcs.

Model : TXE07368
Customer ID :259
VALVE GUIDES
Seg. # : - Technician : Trio Adi p Foreman : Wanto
Desc. : VALVE GUIDES
Opr. # : - Date : 18/09/2019 Date : 22/09/2019
Ilustration :
SPECIFICATIONS INLET EXHAUST
Max. Bore’s Diametre (A) 9.441 mm 9.441 mm
Inlet Guides Exhaust Guides

Cyl. #
Visual Reusable? Visual Reusable?
Bore’s ID Bore’s ID
Condition (Y/N) Condition (Y/N)
Good No Go N Good No Go N
1
2
3
4
5
6
10
11
12
Note :
“GO” means that actual bore’s diameter is smaller than max. spec. & reusable. New inlet guides required : 12 pcs.
“NO GO” means that actual bore’s diameter is larger than max. spec.& must be replaced. New exh. guides required : pcs.
12

Model : TXE07368
Customer ID :259
VALVE SPRINGS
Seg. # : - VALVE SPRINGS Technician : Trio Adi P Foreman : Wanto
Desc. :
Opr. # : - (Outer)* Date : 18/09/2019 Date : 22/09/2019
SPECIFICATIONS
Squareness (E) 2.50 mm
Min. Load at Assembled Length (H) 182.32 lbs.
Assembled length (G) 52.95 mm
Approximated Free Length (J) 62.70 mm
Cyl. Visual Free Assembled Min. Load Reusable?
Part # Squareness
# Condition Length (J) Length (H) at (H) (Y/N)
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
1
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
2
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
3
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
4
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
5
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
6
332-2152 Notches 62.70 52.95 - 2.50 N
332-2152 Notches 62.70 52.95 - 2.50 N
Note : New valve springs required : pcs.

“GO” means that actual spring’s dimension is larger than min. spec. & reusable. 24
“NO GO” means that actual spring’s dimension is smaller than min. spec. & must be replaced.

Model : TXE07368
Customer ID :259
VALVE SPRING
Seg. # : - VALVE SPRINGS Technician : Trio Adi P Foreman : Wanto S
Desc. :
Opr. # : - (Inner)* Date : 18/09/2019 Date : 18/09/2019
SPECIFICATIONS
Square ness (E) 2.24 mm
Min. Load at Assembled Length (H) 28.89 lbs.
Assembled length (G) 50.47 mm
Approximated Free Length (J) 64.10 mm
Cyl. Visual Free Assembled Min. Load Reusable?
Part # Squareness
# Condition Length (J) Length (H) at (H) (Y/N)
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
1
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
2
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
3
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
4
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
5
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
6
224-4441 Notches 64.10 50.47 - 2.24 N
224-4441 Notches 64.10 50.47 - 2.24 N
Note : New valve springs required : pcs.

“GO” means that actual spring’s dimension is larger than min. spec. & reusable. 24
“NO GO” means that actual spring’s dimension is smaller than min. spec. & must be replaced.

Model : TXE07368
Customer ID :259
VALVE ROTATORS
Desc. : VALVE ROTATORS
Opr. # : - Date : 18/09/2019 Date : 22/09/2019
Illustration :
Inlet Rotators Exhaust Rotators

Cyl.
# Visual Reusable? Visual Reusable?
Part No. Part No.
7E-7977 Rough to turn N 7E-7977 Rough to turn N
1
2
3
4
5
6
10
11
12
New inlet rotators required : 12 pcs. New exhaust rotators required : 12 pcs

Model : TXE07368
Customer ID :259
CYLINDER HEAD CRITICAL CHECK POINTS

Desc. CYLINDER HEAD
Inlet Exhaust Valves Valve Projections Head

Cyl. Valve
Valve Seat Valv Seat Valve Vacuu
No. Guides Inserts
Vacuum Rotators Guide s m Rotators Inlet Exhaust Status
es Inserts
s
Test Test min : min :
Cod N or N or
N or R N or R √ or X N or R √ or N or R N or R √ or X N or R N or R
e R R √ or X max : max :
X
10
11
12
13
14
15
16
New Cyl. Head required : pcs.

Notes :
ReusedCyl.Headpcs.

Model : TXE07368
Customer ID :259
3500 SERIES ROCKER ARM & SHAFT

Desc. : ROCKER ARM & SHAFT
Opr. # : - Date : 18/09/2019 Date : 22/09/2019
Ilustration :
Arm Bore’s Diameter 34.075 ± 0.015 mm

Shaft’s Diameter 34.050 ± 0.015 mm
Rocker Arms Rocker Shafts

# Bore’s Shaft’s
Visual Reusable? Visual Reusable?
Desc. Diameter Remarks Diameter Remarks
(A) (B)
Inlet Good 34.066 Y Worn out 34.032 N -
1 Injector Bushing wear 34.055 Y Replace bushing On surface 34.032 N -
Exhaust Good 34.063 Y 34.032 N -
Inlet - - - - - - - -
7 Injector - - - - - - - -
Exhaust - - - - - - - -
Inlet - - - - - - - -
8 Injector - - - - - - - -
Exhaust - - - - - - - -
New valve arm required : - pcs.

Notes : wear bushing on rocker arm, suggest to replace, worn out
-
On surface rocker shaft, suggest to replace. New injector arm required : pcs.
New bushing required : 6 pcs.
New rocker shaft required : 3 pcs.

Model : TXE07368
Customer ID :259
VALVE BRIDGE & ADJUSTMENT SCREW

Seg. # : - VALVE BRIDGES & Technician : Trio Adi P Foreman : Wanto S
Desc. : ADJUSTMENT SCREWS
Opr. # : - Date : 18/09/2019 Date : 22/09/2019
Illustration :
Description Actual Visual Reusable? Recommendation

#
(Is there any .....?) Condition (Y/N) (salvage/replace)
BRIDGE’S PHYSICAL INSPECTION

1.1 ... broken valve stem’s pocket(D) ? Good Y
1.2 ... excessive wear on contact surface (C) ? Good Y
1.3 ... significant wear on valve stem pocket (D) ? Significant wear on valve pocket N Replace
1.4 ... seizure marks on contact surface (C) ? Good Y
1.5 ... damage from being out of position due to valve failure ? Good Y
1.6 ... damage on adjustment’s threaded holes*? - - -
ADJUSTMENT SCREW’S PHYSICAL INSPECTION
2.1 ... damaged tightening groove (E) ? Good Y
2.2 ... damaged/stretched threads (F) ? Stretched thread N Replace
2.3 ... excessive wear on ball pen surfaces (G) ? Good Y
2.4 ... crack on ball pen surfaces (G) ? Good Y
* for gas application only
Notes :
New bridge required : 3 pcs.
New screw required : 1 pcs.
New nut required : - pcs.

Model : TXE07368
Customer ID :259

ROCKER ARM
Seg. # : ROCKER Technician : Foreman :
Desc.
Opr. # : ARM Date : Date :
Remark
No. CHECK POINT
Y N
1 Oil supply holes dari sleeve bearing harus sejajar dengan oil supply hole rocker arm
2 Check dan ukur bore bearing
3 Sejajarkan tanda scribe pada socket dengan tanda scribe pada rocker arm
Install retaining ring, button, socket, adjustment screw dan nut secara tepat dan sesuai
4
posisinya pada rocker arm
5 Lumasi bearings dan shaft dari rocker arms dengan oli bersih
6 Install rocker arms pada shaft sesuai posisinya
Notes :

Model : TXE07368
Customer ID :259
BELT TIGHTENER
Seg. # : - Technician : Ruby M Foreman : Wanto S
Desc. : BELT TIGHTENER
Opr. # : - Date : 19/09/2019 Date : 19/09/2019
C B
E
F
REUSABILITY
ITEM DESCRIPTION VISUAL INSPECTION
REUSE REPAIR REPLACE
Part No. : -
A Cover - - -
-
Part No. : -
B Pulley - - -
-
Part No. : -
C Shaft - - -
-
Part No. : -
D Spacer - - -
-
Part No. : -
E Bracket - - -
-
Part No. : -
F Tensioner Spring - - -
-
*) Coret yang tidak perlu.
Notes : Replace belt tensioner because damage.

Model : TXE07368
Customer ID :259
OIL PUMP3400 SERIES

Desc. : OIL PUMP 3400 SERIES
Opr. # : - Date : 19/09/2019 Date : 19/09/2019
1
Illustration :
A
A Pump Body / Scavenge Pump Body
B B Pump Cover / Scavenge Pump Spacer
A
C C Drive Shaft Gear
D Driven Shaft Gear
E Scavange Gear
E F Spool Relief
D G Spring Relief
H Retainer
H
G
F
PART VISUAL INSPECTION AND REUSABILITY

ITEM DESCRIPTION
NUMBER MEASUREMENT REUSE REPAIR REPLACE
Visual Scratch
Pump Body - Thread Hole - √
A
Spool Housing -
Scavenge Pump Body *) - Visual -
B Cover / Spacer *) - Visual Scratch √
Shaft Journal -
C Drive Shaft 9Y-8076 √
Gear Pitted
Shaft Journal -
D Driven Shaft 9Y-8075 √
Gear Wear
E Scavenge Gear *) - Visual -
F Spool/Relief Valve - Visual -
Visual -
Test Force -
G Spring Relief - Forced Length -
Free Length
(after test)
-
H Retainer - Visual -
Drive Gear As.
-
(if equipped)
- Visual -
Idler Gear As.

-
(if equipped)
- Visual -
Idler Gear Shaft As.

-
(if equipped)
- Visual -
*) Coret yang tidak perlu
Notes : Replace oil pump Gp, because housing cover and shaft gear look as scratch and wear step.

Model : TXE07368
Customer ID :259

ENGINE OIL PUMP 3400 SERIES
Desc. OIL PUMP
Remark
No. CHECK POINT
Y N
1 Gear shaft sudah dilumasi oli engine.
2 Spool valve sudah dilumasi oli engine dan pastikan tidak terbalik.
3 Baut cover sudah di kencangkan dengan torsi ………. (lb.ft) dan diberi tanda.
4 Baut retainer sudah dikencangkan dengan torsi ……….(lb.ft) dan diberi tanda.
5 Baut oil pump gear sudah di beri thread lock.
6 Baut oil pump gear sudah dikencangkan dengan torsi …….(lb.ft) dan diberi tanda.
7 Pastikan putaran gear shaft smooth.
Notes :

Model : TXE07368
Customer ID :259
FRESH WATER PUMP 3400 SERIES

Desc. : FRESH WATER PUMP
Opr. # : - Date : 19/09/2019 Date : 19/09/2019
Ilustration :
3400 series water pump 1.1 & 1.2 litres series water pump
P/N &Visual Condition Reusable? Remarks

Item Description
(v/x) (Y/N) (after repair/salvage, etc…)
P/N : 228-5810
Pump Cover
A Y -
(Adapter) Good
P/N : 291-6905 Seal Gp. P/N : 349-2654

Pump Drive
B N
Shaft Scratch Replace
P/N : 223-9143
C Impeller Y -
Good
P/N : 223-9145
D Pump Housing Y -
Good
P/N : 292-1200
Pump
E Y -
Gear/Pulley* Good
*coret yang tidak perlu
Notes : repair STD GOH

Model : TXE07368
Customer ID :259
CRITICAL CHECK POINT WATER PUMP 3400 SERIES

Seg. # : WATER Technician : Foreman :
Desc.
Opr. # : PUMP Date : Date :
Remark
No. CHECK POINT
Y N
1 Lip seal terpasang menghadap ke luar.
2 Retainer terpasang.
3 Baut retainer dikencangkan dengan torsi ……….(lb.ft) dan ditandai.
4 Baut gear pump dikencangkan dengan torsi …….. (lb.ft) dan ditandai.
5 Ceramic seal terpasang dengan benar.
6 Impeller terpasang dengan benar.
7 Baut impeller dikencangkan dengan torsi ………(lb.ft) dan ditandai.
8 Test kebocoran dengan pressure ………….(psi)
9 Pasang busa filter pada lubang indicator kebocoran.
Notes :

Model : TXE07368
Customer ID :259
TURBOCHARGER
Desc. : TURBOCHARGER
Opr. # : - Date : 19/09/2019 Date : 19/09/2019
ACTUAL MEASUREMENT
COMPONENTS Specifications* FRH FLH RRH RLH
Turbine/Compressor Turbine/Compressor Turbine/Compressor Turbine/Compressor
Performance Spec.#. - Turbocharger Type* [Ex. 4HD, 4MF, C153, etc..]
As. Shipped Part # - P/N : P/N : P/N : P/N :
Serial No. - -
TIR - -
Turbine
Journal’sØ - / / / /
Wheel
Ring Groove - -
Visual GRPTS GOOD

v
Compressor Visual GRPTS GOOD
Wheel v
Out Side Ø - / / / /
Floating
In Side Ø - / / / /
Bearing
Visual -
v
Thrust
Visual -
Bearing v
Centre Visual GRPTS Good

v
Housing Bore Ø - / / / /
Back Plate Visual GRPTS Good
v
Compressor Visual GRPTS Good

v
Housing Aspect Ratio - 0.65
Turbine Visual GRPTS Good

v
Housing Aspect Ratio - 1.05
Compressor
Visual - -
End Insert s
Flinger V
Visual - -
Sleeve v
( BEFORE / AFTER )* REBUILT DATA
Critical Check Points Specification FRH FLH RRH RLH
End Play 0.003” - 0.010” .004”

Radial Play 0.003” - 0.028” .022”
Turbine Wheel Air Gap 0.003” - 0.030” .009”
Compressor Wheel Air Gap 0.003” - 0.030” .0010”
* see details on performance spec. & specification section of service manual or SIS
Notes : Replace 1x turbocharger Gp. Because radial play approach max spec and turbine housing crack.

Model : TXE07368
Customer ID :259
CRITICAL CHECK POINT TURBOCHARGER

Desc. TURBOCHARGER
CHECK
No. CHECK POINT
Y N
1 Nut shaft sudah di kencangkan dengan spec. ………………………………dan diberi tanda.
2 Shroud diberi ANTI SIZE COMPOUND.
3 Nozzle dipasang sesuai dudukannya di turbin housing.
4 Sejajarkan tanda dan hubungkan turbocharger cartridge pada turbine housing.
5 O-ring terpasang pada cartridge turbocharger.
6 Sejajarkan tanda dan hubungkan turbocharger cartridge pada compressor housing
7 Nut clamp di beri ANTI SIZE COMPOUND
8 Nut clamp di kencangkan dengan spec. ………..(lb.ft) dan diberi tanda.
9 Shaft tidak bergesekan dengan housing, dan berputar dengan smooth.
( BEFORE / AFTER )* REBULIT DATA
Critical Check New /
Spesification FRH FLH RRH RLH Remark
Points Reuse
End Play 0,003” - 0,010”
Radial Play 0,003” - 0,030”
Turbine Wheel
0,003” - 0,030”
Air Gap
Compressor
0,003” - 0,030”
Wheel Air Gap

Customer ID :259
DATA TEST INJECTOR

EUI / HEUI / 3500 / C-SERIES ENGINE
Seg. # : - Technician : Sriyono Foreman : Wanto
Injector PN : 249-0712
Opr. # : - Date : 17/09/2019 Date : 22/09/2019
Cyl. External Leaks Trim Code Serial Number

Actual Part
No Visual Inspection Comments Result
Number √ X EUI / HEUI ACERT
1. 249-0712 N/A 2341 - Normal Condition Replace

7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
New Injector Required : 6 pcs.

Notes : # All injector has can’t be test & recommended to replace at GOH.
Reusability Injector are Required : pcs.
-

Customer ID :259

INJECTOR
Injector PN :
EU HEUI MECHANIC
I AL
CHECK
No. CHECK POINT
Y N
1 All Component Clean
2 All Seal Installed
3 Rack Move Smooth
4 Spring Good
5 Tip Good
6 Body Not Crack
7 Reusability (Reuse ………… pcs) (Replace …………… pcs)
Notes :

Customer ID :259
CHECK LIST PISTON COOLING TUBE

Seg. # : - Piston Cooling Technician : Sriyono Foreman : Wanto
Tube PN :
276-7222
Opr. # : - Date : 17/09/2019 Date : 20/09/2019
Ilustration :
No Part Number Spray Test Visual Inspection Reuse Replace Repair

1 276-7222 Can’t Be Test Normal Condition √
7
8
9
10
11
12
13
14
15
16
Component Qty Part Number Visual Inspection / Remark Reuse Replace Repair
Bolt
Plate / Retainer
Bolt
New Piston Cooling Tube required : - pcs.

Notes : Replace 1 Pcs Bolt caused damage plate.
Reusability Cooling Tube Are required: 6 pcs.

Customer ID :259

PISTON COOLING TUBE
Seg. # : Fuel Priming Technician : Foreman :
Opr. # : Pump PN : Date : Date :
CHECK
No. CHECK POINT
Y N
2 All Component Installed
3 Tube Reusability (Reuse ………… pcs) (Replace …………… pcs)
4 Bolt Reusability (Reuse ………… pcs) (Replace …………… pcs)
Notes :

Customer ID :259
CHECK LIST FUEL TRANSFER PUMP

EUI/ HEUI TYPE
Seg. # : - Fuel Transfer Technician : Sriyono Foreman : Wanto
Pump GP PN :
384-8611
Opr. # : - Date : 17/09/2019 Date : 22/09/2019
Ilustration :
Fuel Transfer Pump for EUI Fuel Transfer Pump for HEUI
Item Component Part Number Visual Inspection Reuse Replace Repair

A Gear √
B Bolt √
C Housing √
D Cover
No Serviced Parts √
E Elbow √
F Connector √
G Coupling √
Notes : There is no serviced parts & recommended to replace at GOH.

Customer ID :259
DATA TEST ALTERNATOR

Seg. # : - Alternator GP 253-7133 Technician : Haeris Foreman : Ending S
Opr. # : - PN : 80A Date : 14/09/2019 Date : 14/09/2019
Static Test Part No Spec Actual Visual Check Reuse Replace Repair
Main Stator Ok Good √
Resistance T0 - T1 0.1Ω 0.1 Ω
Isolation
100KΩ 0L Ω
Resistance
Main Rotor Ok Good √
Resistance 9.3-9.5Ω 8.2 Ω
Isolation
100KΩ 0L Ω
Resistance
Diode Ok Good √
Positive 0.4-1.0VDC 0.4/0L
Negative 0.4-1.0VDC 0.4/0L
Diode Trio 0.4-1.0VDC 0.4/0L Good √
Capasitor 100KΩ Can’t Test Good √
Regulator Can’t Test Normal Replacement √
Housing Front Ok Good √
Bushing Wear Normal Replacement √
Bearing Seat Ok Good √
Housing Rear Ok Good √
Bearing Seat Ok Good √
Brush N/A Normal Replacement
Slip Ring N/A
Fan Ok Good √
Pulley 123-0790 Ok Good √
Ok Good √
Dynamic Test Spec Actual Visual Inspection Result

Voltage ( Volt ) 24 V 27.85 V Good Reuse / Recondition
Load ( Amp ) 00 A 00 A
Notes :

Customer ID :259

ALTERNATOR
Alternator PN :
CHECK
No. CHECK POINT
Y N
2 All Component Installed & has been Torque
3 Test Dynamic at ………… Volt, …………Ampere
Notes :

Customer ID :259
DATA TEST ELECTRIC STARTING MOTOR I

Seg. # : - Starting Motor 363-9839 Technician : Haeris Foreman : Ending S
Opr. # : - GP PN : 50 Mt Date : 14/09/2019 Date : 14/09/2019
Static Test Part No Spec Actual Visual Inspection Reuse Replace Repair
Armature Ok Good √
Isolation Resistance 100 K Ω 40.90 Ω
Growler Test Not vibrate Not
Shaft / groove drive Ok
Coil Ok Good √
Resistance 0,1 Ω 0.1 Ω
Isolation Resistance 100 K Ω 14.50 Ω
Solenoid Out of spect √
Pull in Winding
0,4 - 0,7 Ω 0.6 Ω
Resistance
Hold in Winding
1,3 - 3,4 Ω 3.4 Ω Burn on contact
Resistance
Contact Bad Wear at contact
Plunger Bad Low tension
Drive As Ok Good √
6N-3826
(11) 184-6964 184-6964
Gear pinion ( teeth ) 6N-3827 (13) (13)
(12)
Lever Bad Wear at contact point √
Brush Wear Normal Replacement √
Bearing / Bushing Wear Normal replacement √
Brush Holder Ok Good √
Terminal ( - ) Ok Good √
Cable Jumper Bad Broken at cable √
Cable Ground Bad Cable Hard √
Dynamic Test Spec Actual Visual Inspection Result
Volatge ( Volt ) 24 V 24 V Good Recondition / Reuse
Load ( Amp ) 120 A 120 A
Notes :

Customer ID :259

ELECTRIC STARTING MOTOR
Seg. # : Starting Motor Technician : Foreman :
Opr. # : GP. PN : Date : Date :
CHECK
No. CHECK POINT
Y N
3 Test Dynamic at ……………… Volt, ………………Ampere
4 Test Dynamic at ……………… Volt, ………………Ampere
Notes :

Customer ID :259
DATA TEST ELECTRIC SYSTEM

Seg. # : - Harness GP Technician : Haeris Foreman : Ending S
PN / SN :
328-4411
Opr. # : - Date : 14/09/2019 Date : 14/09/2019
Switch Qty Part No Spec Actual Visual Inspection Reuse Replace Repair
Oil Pressure
Water Temperature
Fuel Pressure
Water Flow
Over Speed
Water Level
Oil Level
Potentio Speed
Potentio Voltage
Relay Start
Relay Shut off
E.C.S
Emergency Stop
Lamp Switch
Harness Engine 2 Continuity Simulation test Good √
Harness Injector 1 Continuity Simulation test Good √
Cable Red 1 320-4417 Visual Broken Insulator √
Sensor Qty Part No Spec Actual Visual Inspection Reuse Replace Repair
Oil Pressure 1 274-6719 Good √
Fuel Pressure 1 274-6719 Good √
Boost Pressure
Atmospheric Press 1 274-6717 Good √
Injection Actuation
Air Inlet Pressure 1 274-6718 Good √
Crancase Pressure
Oil Temperature
Fuel Temperature 1 256-6453 Good √
Water Temperature 1 256-6453 Good √
Manifold Temp 1 256-6453 Good √
Exhaust Temp
Speed Timing 2 279-9828 Good √
279-9829
Magnetic Pick Up
ECM 1 372-2905 Good √
Solenoid Shut Off
Fuel Press diff 1 275-1253 Good √
Notes : Update flash file To 5488452 FL 2 (Old 367-7565) New Sensor required : - pcs.
CPI 362071
-
New Switch required : pcs.

Customer ID :259

ELECTRIC SYSTEM
Seg. # : Wiring PN / Technician : Foreman :
Opr. # : Type / Arr / SN Date : Date :
CHECK
No. CHECK POINT
Y N
3 Sensor MPU Adjust
4 BundleHarness With Ties & Clip
Notes :

Customer ID :259
LEAK TEST COOLING SYSTEM COMPONENT

Seg. # : - Technician : Nasrulloh Foreman : Ending S
Opr. # : - Date : 17/09/2019 Date : 17/09/2019
Part No. Qty Description Condition Picture Visual Inspection
Good Leak Yes No Good No
After Cooler Good
236-8745 1 Oil Cooler √ √ Good
Heat Exchanger
Good
Radiator Core
Good
Transmission Oil Good Leak Yes No Good No
187-3523 1 Cooler √ √ Good
Hydraulic Oil Good Leak Yes No Good No
Cooler Good
Fuel Cooler
Good
Notes : End sheet memburuk
Procedure :
1. Tutup salah satu ujung core (aftercooler atau cooler) dengan plat/plug
Close one end of core (aftercooler or cooler) tube with blanking plate.plug, etc
2. Hubungkan ujung lainnya dengan udara bertekanan
Connect the other tub with pressurized air
3. Pastikan tidak ada kebocoran dengan udara bertekanan
Make sure there`s no leak at all connections
4. Atur tekanan udara pada regulator
15 psi untuk aftercooler ( tekanan pada cooling system )
100 psi untuk oilcooler ( tekanan pada oil pressure )
Dilarang melebihi tekanan di atas, untuk menghindari kerusakan pada core
Set the air pressure regilator at :
15 psi for aftercooler ( pressure at cooling system )
100 psi for oilcooler ( pressure at oil pressure )
To avoid damage for core, do not exceed the pressure above the limit
5. Selama pemberian udara bertekanan, core direndam dalam air selama 30 menit.
Pemeriksaan apakah ada gelembung udara yang mengindikasikan adanya kebocoran
During pressurising the core, submerge the core into the water for 30 minutes
Check for air bubbles appearance that indicate leaking
6. Memberikan tekanan pada gauge 20 kpa (3 psi) lebih tinggi dari tekanan pada presseure cap
Get pressure reading on the gauge to 20 kpa (3 psi )more then pressure on the pressure cap
7. Cek kebocoran pada bagian luar radiator
Check the radiator for outside leakage
8. Cek semua sambungan dan hose dari kebocoran
Check all connections and hoses for the cooling system for outside leakage
9. Jika tidak terjadi kebocoran, dan tekanan pada gauge tetap sama selama 5 menit, maka Radiator dan cooling system tidak terjadi
kebocoran
If you do not see any outside leakage and the pressure reading on the gauge is still the same after 5 minutes, the radiator and cooling
system does not have leakage
10. Dokementasikan foto kebocoran
Take picture of leaking

Customer ID :259
CRITICAL ENGINE DISASSEMBLY CHECKLIST

SHORT BLOCK
Mechanic
No. Operation Date Checked By Remarks
Incharge
1. Cylinder Block 14/09/2019 Sigit G Ending S -
2. Spacer Plate 14/09/2019 Sigit G Ending S -
3. Camshaft & Gear 14/09/2019 Sigit G Ending S -
4. Crankshaft, Gear, Plug & Bolt Counter Weight 14/09/2019 Sigit G Ending S -
5. Main Bearing, Rod Bearing & Thrust Plate 14/09/2019 Sigit G Ending S -
6. Bolt Cylinder Head 14/09/2019 Sigit G Ending S -
7. Push Rod & Lifter 14/09/2019 Sigit G Ending S -
8. Sleeve Dowel Lub Block to Head 14/09/2019 Sigit G Ending S -
BASIC ENGINE
Mechanic
Incharge
1. Valve Cover, Base & Bolts 14/09/2019 Sigit G Ending S -
2. Side Cover & Bolts 14/09/2019 Sigit G Ending S -
3. Front Housing & Accessories (Gear, Bearing & Bolts) 14/09/2019 Sigit G Ending S -
4. Rear Housing & Accessories (Gear, Bearing & Bolts) 14/09/2019 Sigit G Ending S -
5. Flywheel, Ring Gear & Bolts 14/09/2019 Sigit G Ending S -
6. Control Rack - - - -
7. Vibration Damper, Guard & Bolts 14/09/2019 Sigit G Ending S -
8. Lifting Engine & Bolts 14/09/2019 Sigit G Ending S -
9. Guard Fan Drive & Bolt - - - -
10. Fan Blade & Bolt - - - -
11. Pulley Crankshaft 14/09/2019 Sigit G Ending S -
12. Vee Belt 14/09/2019 Sigit G Ending S -
13. Oil Pan (Bolt & Screen) 14/09/2019 Sigit G Ending S -
14. Mounting & Trunnion 14/09/2019 Sigit G Ending S -
LUBRICATION SYSTEM
Mechanic
Incharge
1. Bolt Oil Pump 14/09/2019 Sigit G Ending S -
2. Housing Oil Filter (Filter, Spring & Bolt) 14/09/2019 Sigit G Ending S -
3. Oil Lines, Clamp & retainer 14/09/2019 Sigit G Ending S -
4. Cap Oil Filter, Hose breather & Clamp 14/09/2019 Sigit G Ending S -
5. Oil Lines Turbo & Clamp 14/09/2019 Sigit G Ending S -
6. Hose Prelube Pump 14/09/2019 Sigit G Ending S -

Customer ID :259
CRITICAL ENGINE DISASSEMBLY CHECKLIST
COOLING SYSTEM
Mechanic
Incharge
1. Housing Regulator 14/09/2019 Sigit G Ending S -
2. Water Regulator 14/09/2019 Sigit G Ending S -
3. Water Lines, Tube & Elbow 14/09/2019 Sigit G Ending S -
4. Oil Cooler & Lines 14/09/2019 Sigit G Ending S -
5. Radiator, Hose, Tube & Mounting - - - -
AIR INTAKE & EXHAUST SYSTEM

Mechanic
Incharge
Air Cleaner Housing, Clamp, Hose, Air Filter & Air
1. - - - -
Indicator
2. After Cooler Housing, Flange, Bolt & Spacer - - - -
3. Air Lines to Turbo & Flange 14/09/2019 Sigit G Ending S -
4. Air Shut Off - - - -
5. Exhaust Manifold 14/09/2019 Sigit G Ending S -
6. Exhaust Elbow - - - -
7. Bolt Hight Temperature. For Turbo & Exhaust Manifold 14/09/2019 Sigit G Ending S -
FUEL SYSTEM
Mechanic
Incharge
1. Fuel Lines, Clamp, Grommet & Adapter 14/09/2019 Sigit G Ending S -
2. Fuel Filter & Housing 14/09/2019 Sigit G Ending S -
3. Adapter Actuator - - - -
4. Governor Linkage - - - -
5. Fuel Control Linkage - - - -
6. Fuel Control Rack - - - -
7. Fuel Water Separator 14/09/2019 Sigit G Ending S -
ELECTRICAL SYSTEM
Mechanic
Incharge
1. Mounting Alternator 14/09/2019 Sigit G Ending S -
2. Guard Alternator - - - -
3. Shim Generator - - - -
4. Vee Belt Alternator - - - -
5. Rubber Coupling Generator & Compound - - - -

Customer ID :259
CRITICAL ENGINE ASSEMBLY CHECKLIST

MECHANIC
NO. OPERATION DATE CHECKED BY REMARKS
INCHARGE
1 Cylinder Block Clean
2 Block Plugs check / Installation
3 Crankshaft Installation
4 Cylinder Liner Installation
5 Piston / Ring / Conrod Assemble
6 Piston / Ring / Conrod Installation
7 Cooling Jet Clean & Torqued (Spec, torque :.... )
8 Camshaft Installation
9 Gear Installation with marked
10 Front Housing Installation (include fastener check)
11 Rear Housing Installation (included Fastener Check)
12 Crankshaft Seal Front Installation
13 Crankshaft Seal Rear Installation
14 Flywheel Installation (Spect:.......)
15 Vibration damper installation (Spect:........)
16 Engine to Oil Pan Installation (include fastener check)
17 Cylinder Head Installation
18 Cylinder Head Fastener Check (Spec:.........)
19 Exhaust Manifold Installation
20 Aftercooler Installation
21 Injector Installation
22 Valve Mechanism Installation
23 Valve and Injector Timing Setting (Spec:......)
24 Oil Cooler Installation
25 Engine Oil Pump Installation
26 Fresh Water Pump Installation
27 Auxiliary Water Pump Installation
28 Install Turbocharger (include fastener check)
29 Install Air Cleaner Housing
30 Connected Generator / Gearbox
31 Engine Endplay Checking
32 Alignment check Generator / Gearbox

Customer ID :259
PREPARATION ENGINE START UP

MECHANIC CHECKED
NO OPERATION DATE REMARKS
INCHARGE BY
Check All Fluids, such as Engine Oil,
1
Coolant Level, and Fuel System
Turn the Crankshaft Twice to make sure
2
the engine free rotation.
3 Prelube the engine Oil (if equipped)
Cranking the engine for make sure the
4
engine oil pressure to build min 10 Psi
Verify and check for default setting Engine
5
Safety Device for engine Shutdown:
- Engine Low Lube Oil Pressure ( PSI )
- Engine Over speed ( RPM )
- Emergency Shutdown
After engine oil pressure build, start the
6
engine at low idle RPM (Max 900 RPM)
At low idle, make sure value of all
7 parameter; oil pressure, water temp at
specification.

Customer ID :259
COMPLETION
MECHANIC CHECKED
NO OPERATION DATE REMARKS BY
INCHARGE BY
1 Engine Test
2 Recheck Valve Lash (if required)
Download Product Status Report (ET
3
compatibility)
RE-CHECK VALVE LASH AFTER PERFORMANCE TEST
Spec ClearanceIn : Ex :
CYL. INTAKE EXHAUST

NO 1 2 1 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Note : *For valve recession measurement record data

* If only re-check valve lash give "√"
*If re-adjust valve lash give note "Nominal actual re-adjust"

PT. TRAKINDO UTAMA
ENGINE SAFETY DEVICE TEST REPORT
SAFETY DEVICE TESTS ON ALARM AND SHUTDOWN AT NO LOAD CONDITION.

OBJECTTIVE: TO ENSURE THE ALARM AND SHUTDOWN SYSTEM AT THE SPECIFIED SET POINT
READING
SAFETY DEVICE TEST FOR ALARM / SHUTDOWN SET POINT ALARM SHUTDOWN REMARK
RECORDED
Engine Low Lube Oil Pressure ( PSI )
Engine High Water Temperature ( OC )
Engine Over speed ( RPM )
Low Coolant Level
Engine Fail To Start (Second)
Emergency Shutdown (Fromm Engine Control Panel)
Engine fuel leaks (Double wall Fuel Lines)
Customer Tested By Witnessed By
Model TU Personnel Signature
S/N Date Date
SMU
Job No.

Branch : Unit No : Engine Model :
Dealer Code : Model : Engine SN :
Customer : Machine SN : Arrangement :
Customer ID : Job No. : Service Meter : Hours
ENGINE TEST RECORD

Spec. No Date
KW Conduct By
:
Test Step I II III IV V VI
:
Time
Duration
Total KW
Ampere R
S
T
Voltage R
S
T
Power Factor Lead/Lug
Percent of Load
HZ/RPM
Oil Pressure (Kpa)
Fuel Pressure (psi
Boost Pressure (psi)
Water Temperature (0C)
Fuel Consumption (Ltr/Hrs)
Exhaust Temperature (0C) 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Energi Used (KWH)
Bearing Temperature (Rear) (0C)
LH Stack Temperature (0C)
RH Stack Temperature (0C)

ATTACHMENT
Part Number -Name – Modifier Code OBSERVATION
(RH/LH/Upper/Lower etc) To Help Explain Progression/Stage of Failure,
– Notes Identify Type, Amount, Location of Use – Photos/Parts Book Illustration.
Wear, Deposits, Damage, Fractures etc.
Part Name : ENGINE GP
S/N : TXE07368
Arr : 2347848
Status : Engine received in workshop BSD
: At 14/ 09 /19
(Right side)
(Left side )

ATTACHMENT
Part Name : TUBE
P/N : 3176752
Qty : 1
Failure : DAMAGE
Possible : -
Root Cause
Part Name : Housing regulator

P/N : 2386730
Qty : 1
Failure : damage
Possible : corossion
Root Cause
Part Name : mounting

P/N : 6y9960
Qty : 2
Failure : Damage (not flexible)
Possible : LIFE TIME
Root Cause

ATTACHMENT
Part Name : LIFTER
P/N : 2511005
Qty : 5
Failure : OUT SPECT
Possible :
Root Cause
Part Name : TUBE

P/N : 2759370
Qty : 1
Failure : WELD
Possible : -
Root Cause
Part Name : REGULATOR AS VOLTAGE

P/N : 185-2648
Qty : 1
Failure : CAN,T TEST
Possible : ELECTRONIC COMPONENT
Root Cause

ATTACHMENT
Part Name : KIT-HARDWARE
P/N : 185-2658
Qty : 1
Failure : NO ORDER SEPARATE
Possible : LIFETIME
Root Cause
Part Name : WIRE AS

P/N : 3T-3422
Qty : 1
Failure : BROKEN AT INSULATOR
Possible : LIFETIME
Root Cause
Part Name : CABLE AS

P/N : 236-4269
Qty : 1
Possible : LIFETIME
Root Cause

ATTACHMENT
Part Name : LEVES AS SHIFT
P/N : 4M-1853
Qty : 1
Failure : WEAR AT CONTACT POINT
Possible : LIFETIME
Root Cause
Part Name : BRUSH AS

P/N : 3T-9524
Qty : 6
Failure : WEAR AT CONTACT POINT
Possible : LIFETIME
Root Cause
Part Name : SOLENOID AS STARTING MOTOR

P/N : 318-2082
Qty : 1
Failure : OUT OF SPECT
Possible : LIFETIME
Root Cause

ATTACHMENT
Part Name : CABLE AS
P/N : 328-4417
Qty : 1
Possible : LIFETIME
Root Cause
Part Name : CAP AS

P/N : 7E-6508
Qty : 6
Failure : STRECTHED AT THREAD
Possible : LIFETIME
Root Cause
Part Name : SWITCH GP-TOOGLE(PRIMING)

P/N : 165-5970
Qty : 1
Failure : BROKEN AT CABLE
Possible : LIFETIME
Root Cause

ATTACHMENT
Part Name : MOUNT ISOLATION
P/N : 8T-9655
Qty : 8
Failure : BRITTLE
Possible : LIFETIME
Root Cause
Part Name : PLUG AS CONNECTOR

P/N : 240-7874
Qty : 3
Failure : BROKEN AT LOCK
Possible : LIFETIME
Root Cause
Part Name : PLUG AS CONNECTOR

P/N : 240-7878
Qty : 3
Failure : BROKEN AT LOCK
Possible : LIFETIME
Root Cause

ATTACHMENT
Part Name : SHAFT LEVER

P/N : 4M-1854
Qty : 1
Failure : WEAR AT SHAFT SURFACE
Possible : LIFETIME
Root Cause
Part Name : COVER STARTING

P/N : 125-6535
Qty : 1
Failure : COMPLETING
Possible : ORDER
Root Cause
Part Name : FUEL TRANSFER PUMP

P/N : 384-8611
Qty : 1
Failure : WEAR STEPS AT SHAFT
Root Cause

ATTACHMENT
Part Name : INJECTOR

P/N : 249-0712
Qty : 6
Failure : CAN’T BE TEST
Root Cause
Part Name : BOLT

P/N : 8T-0100
Qty : 1
Failure : DAMAGE FLATS
Possible : SHOCK IMPACT
Root Cause

STATUS : AFTER PDI
Front side view

ATTACHMENT

STATUS : AFTER PDI
Left side view

STATUS : AFTER PDI
Right side view

ATTACHMENT

STATUS : AFTER PDI
Front side view

STATUS : AFTER PDI
Left side view

ATTACHMENT

STATUS : AFTER PDI
Right side view
Part Name :
P/N :
Qty :
Failure :
Possible :
Root Cause
Part Name :
P/N :
Qty :
Failure :
Possible :
Root Cause

ATTACHMENT
Part Name :
P/N :
Qty :
Failure :
Possible :
Root Cause

ATTACHMENT
-RESULT OF DYNO/LOAD BANK TEST-

ATTACHMENT
-ENGINE TEST CERTIFICATE-

Customer ID :259

Customer ID :259
Branch Address List Here

Customer ID :259

Pt. Lotus SG Lestari C11 - Txe07368 (966H - Tal02635)

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LEAK TESTheui

ENGINE REBUILD REPORT / SERVICE REPORT

Dear Bapak/Ibu ...,

Thank you very much.

ENGINEREBUILD REPORT Page 2

SUMMARY OF ENGINE REPAIR

THE CAUSE of FAILURE

ENGINE RECONDITION DESCRIPTION

2. Assembling engine components.

3. Engine performance Test.

ENGINEREBUILD REPORT Page 3

ENGINEREBUILD REPORT Page 4

ENGINEREBUILD REPORT Page 5

FUEL INJECTION PUMP & GOVERNOR ..............................................................................................................................................

ENGINEREBUILD REPORT Page 6

VISUAL INSPECTION DISASSEMBLE AREA

SELURUH COMPONENT DIBERSIHKAN, DIKERINGKAN DAN DIBERI ANTI RUST

DATA DIATAS MERUPAKAN HASIL INSPEKSI SELAMA PEMBONGKARAN

Inspected by, Supervised by,

ENGINEREBUILD REPORT Page 7

TOP DECK SURFACE

FRONT SIDE SURFACE

REAR SIDE SURFACE

R/H SIDE SURFACE

L/H SIDE SURFACE

LOWER SIDE SURFACE

INNER SIDE SURFACE

ENGINEREBUILD REPORT Page 8

MAIN BEARING BORE

VEE TYPE CYL. IN LINE CYL.

ENGINEREBUILD REPORT Page 9

MAIN JOURNAL INSPECTION MEASUREMENTS

ENGINEREBUILD REPORT Page 10

MEASURE JURNAL DIAMETERS OUT-OF- VISUAL CHECK

ENGINEREBUILD REPORT Page 11

INTAKE LOBES EXHAUST LOBE

SPECIFICATON BASE CIRCLE LOBE HEIGHT LOBE LIFT

Injector (Inch) .5.0001”

ENGINEREBUILD REPORT Page 12

Overall Reusability Reason / Comments Action Required

Good Condition Reuse again

ENGINEREBUILD REPORT Page 13

ENGINE SLIPPER & ROLLER VALVE LIFTER

Direction of Direction of Direction of

- .007 .020 .020

ENGINEREBUILD REPORT Page 14

Maximum Allowable Depth of concave surface for Reusability 0.010 Inchi

CYLINDER LINER PROJECTION

Seg. # : - Technician : Juliono A Foreman : Wanto

CONNECTING ROD & PISTON

Crank bore’s diameter :

New conrods required : 1 pcs.

ENGINEREBUILD REPORT Page 17

CONNECTING ROD ALIGNMENT

C – C distance tolerance : .000” + .0030”

Fixture Readings C – C Tolerance Bore Parallel Is the rod

1 0.002 -0.003 -0.0005 0.0025 0.004 Y Reuse

2 0.0015 -0.0025 -0.0005 0.002 0.004 N Replace rod

3 0.001 -0.001 0 0.001 0.004 Y Reuse

4 0.0005 -0.0035 -0.0015 0.002 0.004 Y Reuse

5 0.002 -0.004 -0.001 0.003 0.004 Y Reuse

6 0.001 -0.0005 0.00025 0.00075 0.004 Y Reuse

ENGINEREBUILD REPORT Page 18