by Tyo’

by Tyo’
 Sasaran Training

Setelah mengikuti training ini, peserta

dapat melakukan Preventive Maintenance
pada unit Nissan CWB520 LDN sesuai
dengan standard pabrik.

Introduction by Tyo’
 Filosofi Maintenance
Maintenance :
Suatu kegiatan service untuk mencegah
timbulnya keausan tidak normal sehingga umur
alat sesuai dengan rekomendasi pabrik.

Kegiatan service :
Pengontrolan
Penggantian
Penyetelan
Perbaikan
Pengetesan
Introduction by Tyo’
 Grafik Kerusakan akibat kesalahan Maintenance

1. Lack of Operation
Improper Adjustment
12%
28% 12%
Untimely

2. Lack of Daily 12%

tono change of
element

Inspection 13%
6% 6% 6% 5%
Insufficien
tini
lubrication and
Greasing
Improper
Water Drain 41%
From Fuel Tank
31% rina Others

Improper 3. Lack of Periodic

Cleaning of
Element Maintemance
Insufficien
Cooling Water Insufficien Lube
Oil

Introduction by Tyo’
 Klasifikasi Maintenance
Daily
Inspection
PERIODIC
INSPECTION
PERIODIC Weekly
MAINTENANCE Inspection

PERIODIC 1000 km
SERVICE

ENGINE TOP
PREVENTIVE 5000 km
OVERHAUL
MAINTENANCE
ENGINE OVERHAUL
10.000 km

CLUTCH OVERHAUL
MAINTENANCE

15.000 km

SCHEDULE TRANSMISSION Sampai 60.000 km

OVERHAUL OVERHAUL

STEERING
OVERHAUL

FINAL DRIVE
OVERHAUL
MONITORING
OTHERS
CONDITION BASED SCHEDULE INSPECTION
MAINTENANCE REPAIR PROGRAM

SERVICE
COUNTER MEASURE A
REPAIR & ADJUSTMENT NEWS
FACTORY
CORRECTIVE
MODIFICATION
MAINTENANCE MODIFICATION
BREAK DOWN
PROGRAM
MAINTENANCE
Introduction by Tyo’
 Model code Nissan CWB520 LDN
Model identification C : Heavy-duty (Cab over type)
T : Heavy-duty (Bonnet type)

Wheel and drive arrangement K W

G Z
Variant (G.V.M Class)
26.000 kg

D F
Engine model

12: FD46 series

Model changes 21: FE6 series
31: NE6 series
43: PE6 series
45: PF6 series
Wheelbase
52: RF8 series
61: RE10 series

Application Usage
D : Dump H : Cargo L : Tank M : Mixer P : Full trailer
T : Tractor

Steering and braking

system N :Right-hand steering, air brake

Introduction by Tyo’
 Machine Specification

Introduction by Tyo’
Introduction by Tyo’
by Tyo’
 Pelaksanaan Perawatan Harian (P2H)
Persiapan
1. Parkir di tempat yang rata.
2. Kunci kontak pada posisi “OFF”.
3. Transmisi lever pada posisi “Netral”.
4. Parking brake posisi “ON”.

Yang Perlu dilakukan

1. Pastikan kalau ada yang tidak normal 5. Pemeriksaan setelah engine hidup

2. Pemeriksaan bagian luar unit Air pressure gauge

Kekencangan ban, keretakan dan kerusakan Fuel gauge

Ketebalan groove pada ban Semua fungsi gauge

Engine oil level Free play brake

Brake oil level Free play steering wheel

Buang air dan endapan di fuel tank Kerja exhaust brake

Buang air dan endapan di tanki udara Lampu kerja dan indicator

3. Pemeriksaan setelah kabin dibuka Horn, wiper, dan air wiper

Kekencangan V-belt Kebocoran air, oli dan solar

Periksa jumlah air radiator dan kebocorannya 6. Pemeriksaan ketika sedang beroperasi

4. Pemeriksaan di dalam kabin setelah ditutup Kerja brake

Kunci pintu, parking brake lever, kaca spion Kerja exhaust brake
Kerja steering wheel
Daily Check by Tyo’
 Pemeriksaan Kondisi Ban

Pengecekan tekanan ban

Pengecekan keausan ban

Daily Check by Tyo’

 Pemeriksaan Pada Pintu

Pastikan semua handle

pintu dan lock knob
dapat berfungsi
dengan baik.

Daily Check by Tyo’

 Pemeriksaan level oli engine
1. Buka lid depan
2. Periksa level oli dengan
menggunakan deepstick (jumlah
oli tepat jika permukaan oli engine
berada di daerah “H” dan “L”).
3. Periksa keadaan oli dari
kontaminasi.

Daily Check by Tyo’

 Pemeriksaan level air pendingin & Level
Oli Steering

Periksa jumlah air

pendingin, jika level air
pendingin berada pada
daerah “L”, maka harus
segera ditambah

Periksa jumlah oli

steering, jika level oli
berada pada daerah
“L”, maka harus segera
ditambah
Daily Check by Tyo’
 Pembuangan air dari tanki udara

Pembuangan air pada tanki

udara :
Buka drain cock dan buang
endapan air yang terdapat pada
reservoir, setelah selesai cepat tutup
kembali drain cock.
Jika dilengkapi dengan air drier , air
akan termonitor pada indikator jika
reservoir terlalu banyak air, dan air
akan otomatis terbuang.

Daily Check by Tyo’

 Pengecekan kondisi V-belt

Pengecekan tension dan kondisi V-belt

AUTO TENSIONER
Periksa ketegangan (tension) pada V- WATER PUMP PULLEY GENERATOR
belt dengan cara menekannya pada PULLEY PULLEY
posisi tengah (diantara pulley) dengan
A
gaya penekanan +/- 10 kg (22lb).
Defleksi pada V-belt harus sesuai COOLER
B COMPRESSOR
dengan spesifikasi. PULLEY
TENSION PULLEY
V-belt Deflection

A Water pump 11 – 14 mm CRANK PULLEY

pulley-crank TENSION PULLEY
(0.43 – 0.55)
pulley

B Crank pulley- 10.5 – 13.5 mm

cooler (0.413 – 0.531)
compressor
puley

Daily Check by Tyo’

 Pemeriksaan brake pedal

1. Tekan pedal brake dengan

ringan dan periksa
besarnya play pada brake
pedal.
2. Pastikan brake pedal
dapat diinjak penuh tanpa
terjadi lengket.
3. Pastikan terdengar suara
angin keluar dari breather Standard brake pedal play :
pada saat pedal brake 12 – 18 mm (0.47 – 0.71 inchi)
diinjak

Daily Check by Tyo’

 Pemeriksaan Parking Brake

Pastikan bahwa
parking brake bekerja
jika ditarik 3 – 12
notches

Daily Check by Tyo’

 Pemeriksaan tekanan udara

Periksa kenaikan tekanan

udara pada pressure
gauge.

Air Pressure gauge

Time
Engine rpm Air pressure
(Approximate)

A.O.H
0 – 8 kg/cm2 Less than 5
brake
(0 – 785 kPa) min.
vehicle
Idling speed
0 – 8.5
Air brake Less than 7
kg/cm2 (0 –
vehicle min
834 kPa)

Daily Check by Tyo’

 Pemeriksaan Clutch Pedal

Tekan pedal clutch dengan

ringan dan periksa besarnya
play. Pastikan sudah sesuai
dengan standard

Standard Free play :

35 – 55 mm (1.38 – 2.17 in)

Daily Check by Tyo’

 Pemeriksaan Steering Wheel Free Play

Pastikan keadaan roda

depan dalam posisi lurus,
kemudian gerakkan
steering wheel searah
jarum jam dan
berlawanan jarum jam.
Ukur besarnya free play
dan pastikan sudah sesuai
dengan standard.
Standard free play :
30 – 50 mm (1.18 – 1.97 in)

Daily Check by Tyo’

 Pemeriksaan Warna Gas Buang

Laksanakan warming-up pada

engine dan periksa warna gas
buang.

Warna gas buang :

Transparant : normal
Black : pembakaran tidak
sempurna
White : ada oli ikut terbakar atau
temperatur engine terlalu rendah

Daily Check by Tyo’

 Pemeriksaan kemampuan brake

Dengan kecepatan unit

5 – 10 km/jam lakukan
pengereman, pastikan
proses pengereman
berjalan normal.

Daily Check by Tyo’

 Pemeriksaan Exhaust Brake

Pastikan accelerator dan brake

pedal tidak diinjak.
Pastikan exhaust brake bekerja
pada saat tanda pemakaian
exhaust brake menyala dan
switch dioperasikan

Daily Check by Tyo’

 Pemeriksaan Kebocoran Oli, Fluid, and
Fuel

Periksa unit dari segala macam kebocoran, baik

kebocoran Oli, Fluid, maupun fuel

Daily Check by Tyo’

 Form Pelaksanaan Perawatan Harian (P2H)

Daily Check by Tyo’

 Easy for Maintenance

Daily Check by Tyo’

by Tyo’
 Periodic Maintenance

Periodic Maintenance by Tyo’

Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
Periodic Maintenance by Tyo’
by Tyo’
 Instrument Panel (R.H.D Model)

1. Illumination control rheostat 7. Coolant temperature gauge

2. Speedometer 8. Fuel gauge
3. Warning light check switch 9. Tachometer
4. Turn signal indicator lights 10. Hour meter (optional)
5. Indicator and warning lights 11. Voltage gauge
6. Air pressure gauge 12. Indicator and warning light
13. Oil pressure gauge
Memberikan informasi kepada operator
Cabin by Tyo’
 Instruments
Km/jam Normal : 7.2 – 8.5 kg/cm2

Speedometer Air Pressure gauge

Hijau : daerah operasi

Hijau = Ekonomis
Merah : overheat
Merah = Berbahaya
C : cool
Tachometer H : Hot
Coolant temperature

E : empty
1 s.d 4 kg/cm2
F : full

Oil pressure gauge

Fuel Gauge

Engine hidup : 28 V
Engine mati : 24 V

Cabin Voltage gauge by Tyo’

 Warning Light (nama & fungsi)

Item Nama Warning Light Fungsi

Warning light ini akan menyala jika terjadi
Oil filter warning light
kebuntuan pada oil filter element

Air cleaner element warning Warning light ini akan menyala jika terjadi
light kebuntuan pada air cleaner element

Lampu ini akan menyala jika parking brake

Parking brake warning light
diaktifkan

Lampu ini akan menyala jika spring brake

Spring brake warning light
dioperasikan

Clutch disc warning light Lampu ini akan menyala jika langkah dari
clutch booster power piston melebihi standard,
hal ini mengindikasikan keausan pada clutch
disc

Cabin by Tyo’
 Item Nama Warning Light Fungsi

Oil pressure warning light Warning light ini akan menyala jika
tekanan oli di engine turun hingga 49 kPa
(0.5 kgf/cm2)

Warning light ini akan menyala jika terjadi

Charge warning light
keabnormalan pada charging system
yang menyebabkan pada tidak bisa
dicharge

Coolant level and overheat Jika coolant level turun di bawah standard
warning light atau temperaturnya naik sampai 100° C
lampu ini akan menyala disertai dengan
buzzer

Brake warning light (A.O.H
brake vehicle
Lampu ini akan menyala disertai dengan
bunyi buzzer jika brake shoe clearance
melebiihi standard atau terjadi malfungsi
pada brake system. Selain itu lampu ini
akan menyala ketika brake fluid kurang
melebihi standard

Check switch
Cabin by Tyo’
by Tyo’
 Engine Code

V Engine

Variant

8 Silinder

General by Tyo’
 Engine Numbers

RF8 - 131155

Engine serial number

Engine model

General by Tyo’
 Engine Position

RIGHT

REAR
FRONT

L3
LEFT

General by Tyo’
 Engine Specification

General by Tyo’
General by Tyo’
 Technical Term
1. Four – cycle engine

INTAKE COMPRESSION POWER EXHAUST

STROKE STROKE STROKE STROKE

Technical term by Tyo’

Technical term by Tyo’
 2. Bore/stroke

Bore : diameter dalam silinder

Stroke : jarak antara bottom dead center

(BDC) sampai dengan top dead center
(TDC) dalam gerakan piston.

Technical term by Tyo’

 3. Total displacement

Technical term by Tyo’

 4. Compression ratio

Technical term by Tyo’

 5. Horse power

1 sec
75 kg 1m

HP = Horsepower ( British Horsepower )

1 HP = 550 ft.lb/sec
1 ft = 0.3048 meter 1 HP = 76.04 Kg.m/sec
1 lb = 0.4536 Kg 1 HP = 1.014 PS

PS = PferdStrake ( metric Horsepower )

1 PS = 75 Kg.m/sec
1 PS = 735.4 Watt
100 Kw = 136 PS
Technical term by Tyo’
 6. Firing Order

F.O = 1 – 2 – 4 - 3 F.O = 1 – 5 – 3 – 6 – 2 - 4

Adalah urutan pembakaran yang terjadi pada engine dengan jumlah

silinder lebih dari satu .

Tujuannya adalah untuk meratakan hasil power, agar gaya yang

ditimbulkan oleh piston seimbang.

Technical term by Tyo’

 Upper Side of Engine
1. Water tube
2. Wire harness of heater
3. Air intake duct assembly
4. Air heater assembly (right
and left)
5. Fuel filter assembly
6. Fuel tube and others
7. Accel link
8. Injection pump assembly
9. Air compressor assembly
10. Hydraulic pump assembly
11. Injection pump support
assembly
12. Brather pipe
13. Air intake manifold
14. Nozzle holder assembly

Structure & Function by Tyo’

 Front Side of Engine

1. Cooling fan
2. Alternator drive belt
3. Water pump drive belt
4. Alternator assembly
5. Thermostat housing
6. Water duct
7. Water pump assembly
8. Cooler compressor drive belt

Structure & Function by Tyo’

 Right Side of Engine

1. Exhaust manifold
2. Oil filter assembly
3. Oil cooler assembly
4. Cylinder block shield
5. Oil cooler short valve assembly

Structure & Function by Tyo’

 Left Side of Engine

1. Oil level guide

2. Exhaust manifold
3. Oil pressure switch
4. Starting motor assembly
5. Cylinder block shield

Structure & Function by Tyo’

 Fuel System Spec.

Structure & Function by Tyo’

 Fuel System Diagram

Structure & Function by Tyo’

 Fuel Circuit

Nozzle
Injection
pump
Nozzle

Fuel Filter Feed pump Primary Fuel Filter Fuel tank

: Supply line

: Overflow line

Structure & Function by Tyo’

 Injection Pump Assembly

Structure & Function by Tyo’

 Classification of Injection System

In-line type

Distributor type

Central type
V type

Parallel type
Injection Pump

Unit injector
Separate type

Single type

Structure & Function by Tyo’

 In- Line Injection Pump

Structure & Function by Tyo’

 Plunger Operation

Structure & Function by Tyo’

 Automatic Advance Timer
(Mechanical)

Structure & Function by Tyo’

Structure & Function by Tyo’
Structure & Function by Tyo’
 Lubrication System Spec.

Structure & Function by Tyo’

 Lubrication System

Structure & Function by Tyo’

 Lubrication circuit
ROCKER SHAFT GALERY ROCKER ARM

ROCKER ARM BRACKET TENSIONER

BRACKET

PISTON PIN,
INJECTION PUMP PISTON, &
CYLINDER HEAD GALERY CYLINDER CAMSHAFT
AIR COMPRESSOR INJECTION PUMP DRIVE SUPPORT
LINER GEAR

OIL JET
CAMSHAFT CUT OFF
VALVE OIL JET
JOURNAL

IDLER GEAR INJECTION

MAIN GALERY SHAFT & PUMP IDLER
BUSH GEAR

OIL FILTER SHORT VALVE CRANKSHAFT MAIN

BEARING SHELL
REGULATOR Lubrication circuit
VALVE
OIL COOLER SHORT VALVE By-pass circuit
CRANKSHAFT OIL
GALERY
Return
OIL PUMP RELIEF VALVE
CONNECTING ROD
BEARING SHELL
OIL SCREEN

OIL PAN

Structure & Function by Tyo’

 Oil Pump

Structure & Function by Tyo’

Structure & Function by Tyo’
Structure & Function by Tyo’
 Oil Cooler

Structure & Function by Tyo’

 Cooling System

Structure & Function by Tyo’

 Cooling Circuit
Radiator

Open Close
Thermostat

Thermostat
Housing

Water subtank Cylinder head Cylinder head Car heater

Cylinder block

Oil cooler

Water Pump

Structure & Function by Tyo’

Structure & Function by Tyo’
Structure & Function by Tyo’
Structure & Function by Tyo’
 Thermostat

To water
pump
To
Radiator

From
Piston Engine
Expander Sensor

Fungsi :
Mengatur saat menutup dan membuka aliran air
pendingin ke radiator.
Opening temperatur : 74.5 – 78.5°C
Full opening temperature : 90°C
Valve Lift : Minimum 10 mm

Structure & Function by Tyo’

 Engine Maintenance, Testing & Adjusting
1. Maintenance interval

by Tyo’
by Tyo’
2. Check valve clearance

by Tyo’
by Tyo’
3. Check V-belt

by Tyo’
4. Check crank damper

by Tyo’
5. Compression pressure

by Tyo’
6. Tinghten cylinder head bolt

by Tyo’
7. Check engine for oil leaking

by Tyo’
by Tyo’
by Tyo’
by Tyo’
by Tyo’
Power Train

by Tyo’
Fungsi Clutch

by Tyo’
Structure & Pengoperasian Dry Type
Clutch

by Tyo’
Clutch Body

by Tyo’
Clutch Disc

by Tyo’
by Tyo’
Clutch Cover Ass’y

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