47-MLB_A15001.D PORT_STBD MDE REMOVE_INSTALL PROCEDURE.pdf

U.S. COAST GUARD

COMPUTERIZED MAINTENANCE SYSTEM

MLB-47

A15001.D

REV'D 01/15/21

ASSET NUMBER OPERATING ACTIVITY MAINTENANCE ACCOMPLISHED MAINTENANCE DUE

DATE ASSET HOURS DATE ASSET HOURS

MO DAY YEAR MO DAY YEAR

ZULU DATE ZULU TIME

MO DAY YEAR

ITEM 1

DUE

CMS CODE ACTION DESCRIPTION CEINUM

A15001 REM/INST DIESEL ENGINE, STBD ML-A150-001

SCHEDULED UNSCHEDULED

P A R T

O F F

STBD ENGINE SERIAL NO.

PART NO.

HOUR READING FROM ECM ECM SERIAL NUMBER

REASON REMOVED: TIME___ TROUBLE___ CANNIBALIZATION___ OTHER___ COMPONENT STATUS: RFI__ NON RFI__

TECHNICIAN'S TECHNICIAN'S QUALITY ASSURANCE

SIGNATURE ID SIGNATURE

P A R T

O N

STBD ENGINE SERIAL NO.

PART NO.

HOUR READING FROM ECM ECM SERIAL NUMBER

TECHNICIAN'S TECHNICIAN'S QUALITY ASSURANCE

SIGNATURE ID SIGNATURE

* ASTERISK INDICATES QA REQUIRED QA* QA* QA* QA* QA* QA* QA*

MAN HOURS: MK___.___DC___.___EM___.___ET___.___IT___.___GM___.___BM___.___FN___.___SN___.___ME___.___OTHER___.___

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Distribution Statement D: Distribution authorized to the DHS/CG/DoD and their contractors Administrative/Operational use, 12/18/20. Other requests shall be referred to the appropriate asset product line.

WARNING: This document contains technical data whose export is restricted by the Arms Export-Control Act (Title 22, U.S.C., Sec 2751, et. seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C. App 2401 et. seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

DESTRUCTION NOTICE: For classified documents, follow the procedures in DoD 5200.22-M, National Industrial Security Program Operating Manual, Section 5-705 or DoD 5200.1-R, Information Security Program Regulation, Chapter VI, Section 7. For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document.

PRIVACY ACT STATEMENT

Authority: 44 U.S.C. 3101; 44 U.S.C. 3534; 5 U.S.C. §552a (e)(3); and Executive Order 9397.

Purpose: To account for scheduled and unscheduled maintenance performed on CG aircraft and surface assets.

Routine Uses: Authorized CG personnel will use this information to document scheduled and unscheduled maintenance, man-hours expended, and the technician respon-sible for tasks performed on CG aircraft and surface assets. Any external disclosures of data within this record will be made in accordance with DHS/ALL-004, General Information Technology Access Account Records, 77 Federal Register 70792, November 27, 2012.

Disclosure: Furnishing your Tech ID is voluntary; however, the inability to collect this information could result in untimely or incomplete Asset Computerized Maintenance System reports or the inability for the CG to make informed decisions regarding manpower analysis.

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ASSET NUMBER OPERATING ACTIVITY MAINTENANCE ACCOMPLISHED MAINTENANCE DUE

DATE ASSET HOURS DATE ASSET HOURS

MO DAY YEAR MO DAY YEAR

REMARKS INDICATING THE REASON FOR REMOVAL ARE REQUIRED

REFERENCES:

See reference continuation on Page 5

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ASSET NUMBER OPERATING ACTIVITY MAINTENANCE ACCOMPLISHED MAINTENANCE DUE

DATE ASSET HOURS DATE ASSET HOURS

MO DAY YEAR MO DAY YEAR

ZULU DATE ZULU TIME

MO DAY YEAR

ITEM 1

DUE

CMS CODE ACTION DESCRIPTION CEINUM

A15002 REM/INST DIESEL ENGINE, PORT ML-A150-004

SCHEDULED UNSCHEDULED

P A R T

O F F

PORT ENGINE SERIAL NO.

PART NO.

HOUR READING FROM ECM ECM SERIAL NUMBER

REASON REMOVED: TIME___ TROUBLE___ CANNIBALIZATION___ OTHER___ COMPONENT STATUS: RFI__ NON RFI__

TECHNICIAN'S TECHNICIAN'S QUALITY ASSURANCE

SIGNATURE ID SIGNATURE

P A R T

O N

PORT ENGINE SERIAL NO.

PART NO.

HOUR READING FROM ECM ECM SERIAL NUMBER

TECHNICIAN'S TECHNICIAN'S QUALITY ASSURANCE

SIGNATURE ID SIGNATURE

* ASTERISK INDICATES QA REQUIRED QA* QA* QA* QA* QA* QA* QA*

MAN HOURS: MK___.___DC___.___EM___.___ET___.___IT___.___GM___.___BM___.___FN___.___SN___.___ME___.___OTHER___.___

REMARKS INDICATING THE REASON FOR REMOVAL ARE REQUIRED

REVIEWED

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LOG YN DATA

ENTRY

COMPLETED

PRIVACY ACT STATEMENT

Authority: 44 U.S.C. 3101; 44 U.S.C. 3534; 5 U.S.C. §552a (e)(3); and Executive Order 9397.

Purpose: To account for scheduled and unscheduled maintenance performed on CG aircraft and surface assets.

Routine Uses: Authorized CG personnel will use this information to document scheduled and unscheduled maintenance, man-hours expended, and the technician respon-sible for tasks performed on CG aircraft and surface assets. Any external disclosures of data within this record will be made in accordance with DHS/ALL-004, General Information Technology Access Account Records, 77 Federal Register 70792, November 27, 2012.

Disclosure: Furnishing your Tech ID is voluntary; however, the inability to collect this information could result in untimely or incomplete Asset Computerized Maintenance System reports or the inability for the CG to make informed decisions regarding manpower analysis.

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REV'D 01/15/21

ASSET NUMBER OPERATING ACTIVITY MAINTENANCE ACCOMPLISHED MAINTENANCE DUE

DATE ASSET HOURS DATE ASSET HOURS

MO DAY YEAR MO DAY YEAR

REFERENCES:

See reference continuation on Page 5 DWG 47B-MLB-300-20, 47 ft. Motor Lifeboat Electrical One Line Diagram TP 3359-259-A, Exhaust System USCG Specification 23330-AKP-0520-47MLB-Main Engine, Renew USCG Specifiation 24310-AKP-0520-47MLB-Cardan Shaft, Renew

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A15001.D

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1 ENGINE REMOVE

REFERENCES:

COMDTINST 9077.1 (series) Equipment Lockout/Tags-Plus Instruction

MPC A15005.0

MPC A15007.0

MPC A15011.0

MPC A15033.0

MPC A51012.0

MPC A52030.0

MPC A55004.0

MPC B00012.D

MPC D10001.0

MPC P20005.0

MPC S10001.0

TOOLS/TESTEQUIPMENT:

5 Gallon Closeable Container (3) (Unit supplied) Alignment Pointer Kit, P/N: 47MLB-RMF-ETRGAP, CAGE: OBRT6, NIIN: N/A Brush, Wire, Stainless Steel, P/N: 7920-00-269-1259, CAGE: 80244, NIIN: 7920-00-269-1259 Engine Bar, P/N: 47MLB-RMF-EP-6V92, CAGE: OBRT6, NIIN: N/A (Sector supplied) Engine Lifting Bracket with Shackles, P/N: 47MLB-RMF-EP-6V92, CAGE: OBRT6, NIIN: N/A (Sector supplied) Engine Mount Extra Deep Socket 1 1/2 inch, P/N 47MLB-RMF- EMSDS, CAGE: OBRT6, NIIN: N/A (Sector supplied) Engine Stand, P/N: 47MLB-RMF-ESWC-6V92, CAGE: OBRT6, NIIN: N/A (Sector supplied) Hoist, Chain, P/N: CM622, CAGE: 12128, NIIN: 008898722 (Or equivelant) Multimeter, P/N: 87V/AN, CAGE: 89536, NIIN: 015217106 (Or equivalent) Pry Bar, Lady Foot, P/N:OP1250, CAGE: 55719, NIIN: 010864224 (Or equivelant) Reduction Gear Allen Tool, P/N: 47MLB-RMF-CSVCW, CAGE: OBRT6, NIIN: N/A (Sector supplied) Sling, Nylon, P/N: EE2-0802D-7FT, CAGE: 23755, NIIN 010782080 (Or equivelant) Socket, Allen Head (9 mm), P/N:FAM9E , CAGE: 55719 , NIIN:014373663 (Or equivelant) Socket Wrench Screwdriver Attachment, P/N: SW32E, CAGE: 55719, NIIN: 013673458 Torque Multiplier, P/N: GA18A, CAGE: 55719, NIIN: 013489488 (Or equivalent) Wrench, Torque (5-100 ft-lb) Wrench, Torque (25-250 ft-lb)

EXPENDABLES:

Belts, V, Matched Set, P/N: 05134212, CAGE: 72582, NIIN: 006106007 (1 set per engine required) Belts, V, Matched Set, P/N: 5126771, CAGE: 72582, NIIN: 001796829 (1 set per engine required) Clamp Loop, P/N: T40C-75-750-S, CAGE: 14242, NIIN: 016478597 (2) Clamp V-band (Bellows), P/N: 024-005000, CAGE: 09GG9, NIIN: 015686902 (If required) Clamp V-band 8 inch (Elbow Assembly), P/N: 024-007000, CAGE: 09GG9, NIIN: 015686899 (2) (If required) Clamp V-band (Turbo), P/N: 024-001000, CAGE: 09GG9, NIIN: 015932907 (If required) Engine, Port, P/N: 6V92TA-80627K90-PORT, CAGE: 72582, NIIN: 014424541 (If required) (MTI) Engine, Stbd, P/N: 6V92TA-80627K91-STBD, CAGE: 72582, NIIN: 014424549 (If Required) (MTI) Gasket (Steering Pump), P/N: 5188755, CAGE: 72582, NIIN: 006952157 Gasket (Steering Pump Adapter), P/N: 23515145, CAGE: 72582, NIIN: 013909045

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MLB-47

A15001.D

REV'D 01/15/21

Probe, Temperature, P/N: A20T-250-8-1/2, CAGE: 03479, NIIN: 016028873 (If required) Sensor, Coolant Level, P/N: 23519175, CAGE: 72582, NIIN: 015571892 (If required) Gasket (Soft Patch Kit), P/N: 47MLB‐RMF‐SPK‐40‐NB, CAGE : OBRT6, NIIN: 016907837

(The Following Items are Contained in the Kit. DONOTORDER INDIVIDUALPARTSSEPARATELY):

40 Durometer Neoprene Gasket, P/N: 47MLB-RMF-SPGAS-NEO-40 316 SS 3/8 Nylock Nuts, P/N: 290-002579 (38) 316 SS 3/8 Flat Washer, P/N: 316FW3/8 (38) Tubes Sealant, P/N: 6510 (2)

Gasket (Vent Louver Kit), P/N: 47MLB-RMF-ERVGS-40D, CAGE:OBRT6, NIIN: 016906126 (The Following Items are Contained in the Kit. DONOTORDER INDIVIDUALPARTSSEPARATELY):

Louver Gasket, P/N: 47MLB-RMF-ERVGS-40D Sealant, P/N: 6510

CONSUMABLES:

Bag, Plastic Ziplock, P/N: 14545T19, CAGE: 3A054, NIIN: 015311979 (Or equivalent) Clamp, Hose, P/N: CT 350L, CAGE: Z0BH2, NIIN: 013299147 (4) (If required) DDC Power Cool (50/50), P/N: 23528203, CAGE: 72582, NIIN: N/A Electrical Tape, P/N: MIL-I-15126, CAGE: 81349, NIIN: 000075272 Engine Flushing De-preservative, P/N: CC2610, CAGE: 15434, NIIN: 015061738 (If required) Hose, Fuel, P/N: FC234-6-FJ-FJ-24IN, CAGE: 1FFH9, NIIN: N/A (If required) Hose, Fuel (Port), P/N: FC234-6-FJ-FJB-56IN, CAGE: 1FFH9, NIIN: N/A (If required) Hose, Fuel (Stbd), P/N: FC234-6-FJ-FJB-65IN, CAGE: 1FFH9, NIIN: N/A (If required) Insulator, Stud, Cable Cap, P/N: 4015, CAGE: 1Q449, NIIN: 015643968 Lock Wire, P/N: MS-2099-5C-32, CAGE: 96906, NIIN: 002934208 (Or equivelant) Lubricating Oil, Engine, P/N: SHELLMS92500ILC0DE54160, CAGE: 54527, NIIN: 001818229 (Or equivalent) Nuts, Nylock, 1/4 inch, P/N: 290-002598, CAGE: 4FLA5, NIIN: 015641881 Nuts, Nylock, 3/8 inch, P/N: 290-002579, CAGE: 4FLA5, NIIN: 015641879 Nuts, Nylock, 9/16 inch, P/N: 290-002590, CAGE: 4FLA5, NIIN: 015641880 Sealing Compound, P/N: 6510 CAGE: 522152, NIIN: 014514046 Sealing Compound, P/N: SICKOLENE 762, CAGE, NIIN: 992202431 Sealing Compound (Loctite 243), P/N: 1329837, CAGE: 05972, NIIN: 011329624 Sealing Compound (Loctite 565), P/N: 56531, CAGE: 05972, NIIN: 015691429 Shield, Binding Post (Terminal Boots) P/N: 4014, CAGE: 1Q449, NIIN: 015636630 Silicone Compound, P/N: G635, CAGE: 01139, NIIN 009635402 Thread Teflon Tape, 1/2 Inch, P/N: 8526053, CAGE: 1YHH8, NIIN: 015138761

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A PRELIMINARY STEPS

WARNING

VARIOUS STEPS IN THIS PROCEDURE EMPLOY ITEMS ON

THE HAZARDOUS MATERIALS LIST. BEFORE EXECUTING

THIS MPC, REFER TO THE MSDS/SDS FOR FULL SAFETY

AND HANDLING PROCEDURES.

NOTE: Commercial crane service is required to complete this main-tenance procedure. If the unit is unable to perform overhead hoisting services, the unit will need to submit a service request for 8 hours of crane service. Unit should be prepared to utilize the same 8 hour contract to remove the old engine, on load the replacement engine, and load the old engine into the engine container for shipment back to SFLC.

1. Contact the Small Boat Product Line (SBPL) prior to beginning this Maintenance Procedure Card (MPC) if provisions for haul out are not available.

2. Document the following information for the off going engine on the part off of the MPC sign-off sheet:

a. Engine hours.

b. Engine serial number.

c. Engine Control Module (ECM) serial number.

3. Haul boat out of water, (Refer to MPC B00012.D).

4. Inventory part kits.

WARNING

ENSURE EQUIPMENT IS PROPERLY TAGGED OUT. FAILURE

TO COMPLY MAY RESULT IN SERIOUS PERSONAL INJURY

OR DEATH.

5. Complete Equipment Lockout/Tags-Plus Process IAW COMDTINST 9077.1 (series).

6. Attach Red Danger Tags to the following:

a. Port engine HEATER circuit breaker PP1-1P-C in the “OFF” position.

b. Stbd engine HEATER circuit breaker PP1-1P-D in the “OFF” position.

7. Check engine temperature on the overhead Electronic Display Module (EDM) to ensure it is below 120 degrees F.

a. Ensure the following circuit breakers are in the “ON” position:

(1) Engine STARTING circuit breaker DCA-24-LL (1).

(2) Port engine DDEC/IGNITION SW circuit breaker DCA-24P-GG.

(3) Stbd engine DDEC/INGINITION SW circuit breaker DCA-24P-AA.

(4) DDEC eng rm DDEC eng rm interface MDL DCA-24P-NN (1).

(5) Port eng gear interface MDL DCA-24P-YY.

(6) Stbd eng gear interface MDL DCA-24P-ZZ.

(7) Eng interface eng rm interface MDL DCA-24P-KK (1).

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(8) Marine interface port DCA-24P-WW (1).

(9) Marine interface sbd DCA-24-PXX (1).

b. Energize IGNITION switch at the enclosed bridge console.

c. Read temperature from EDM.

(1) De-energize IGNITION switch.

(2) Proceed to step 1 A 8. if the coolant temperature is below 120 degrees F.

(3) Wait 30 minutes if coolant temperature is above 120 degrees F.

(4) Repeat Step 1 A 7.c.(2) until the coolant temperature is below 120 degrees.

WARNING

FACE SHIELD, RUBBER APRON AND RUBBER GLOVES

MUST BE WORN WHILE HANDLING JACKET WATER AND

TESTING MATERIALS. FAILURE TO ADHERE TO THIS

WARNING MAY CAUSE SERIOUS PERSONAL INJURY.

WARNING

AVOID EYE CONTACT, SKIN CONTACT, INHALATION, AND

INGESTION WITH COOLANT. KEEP AWAY FROM ALL

OXIDIZERS. WASH EXPOSED SKIN THOROUGHLY AND

IMMEDIATELY REMOVE CONTAMINATED CLOTHING AFTER

HANDLING. FAILURE TO COMPLY MAY RESULT IN SERIOUS

PERSONAL INJURY.

WARNING

DO NOT REMOVE THE EXPANSION TANK PRESSURE

CAP FROM A HOT ENGINE. WAIT UNTIL COOLANT

TEMPERATURE IS BELOW (120 DEG F) BEFORE REMOVING

THE CAP. FAILURE TO COMPLY MAY CAUSE SERIOUS

PERSONAL INJURY.

8. Drain engine coolant, (Refer to MPC A51012.0)

NOTE: Coolant level sensor may need to be installed in the new en-gine. Place coolant level sensor in a safe location to prevent damage.

9. Remove coolant level sensor from the heat exchanger, (Refer to Figure 1).

10. Remove jacketwater overflow tank, (Refer to Figure 1).

a. Remove expansion tank raw water discharge flex coupling from the outboard side of the expansion tank.

(1) Loosen four hose clamps.

(2) Rotate the flex coupling to break it free.

(3) Slide the flex coupling onto the raw water tree pipe.

b. Remove hose to the pressure cap.

(1) Loosen hose clamp on the expansion tank side of the coolant recovery bottle hose.

(2) Twist hose to break it free.

c. Remove two mounting bolts from the base of the thermostat housing.

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d. Remove coolant recovery bottle hose from the expansion tank fitting.

e. Attach the bolts and washers into their original location in the thermostat housing without attaching the bracket.

NOTE: New engines do not come with a temperature probe the re-moved temperature probe will be installed in the new engine. Place sensor in the safe location to prevent damage.

11. Remove temperature probe, (Refer to Figure 1).

a. Remove probe compression nut.

b. Remove probe from reducer adapter

c. Clean the sensor and reducer.

(1) Inspect sensor and reducer for damage.

(a) Notify EPO if damage is found.

d. Coil capillary line.

(1) Place coil in a plastic bag, P/N: 14545T19.

(2) Secure coil to bulkhead 5.

12. Drain engine lube oil, (Refer to to MPC A55004.0).

WARNING

AVOID EYE AND SKIN CONTACT WITH LUBRICATING

OIL. KEEP AWAY FROM ALL OXIDIZERS. USE IN A WELL

VENTILATED AREA. WASH EXPOSED SKIN THOROUGHLY

AFTER HANDLING. FAILURE TO COMPLY MAY RESULT IN

PERSONAL INJURY.

a. Wipe up any residual lube oil.

B REMOVE SOFT PATCH

NOTE: The lower tow reel assembly must be removed when remov-ing the port engine.

1. Remove lower spool assembly if removing the port engine, (Refer to Figure 2), (Refer to MPC P20005.0).

WARNING

FOLLOW PROPER LIFTING TECHNIQUES WHEN HANDLING

HEAVY OBJECTS. OBJECTS WEIGHING OVER 50 LBS

REQUIRE AT LEAST TWO PERSONNEL TO SAFELY MOVE

THEM. FAILURE TO COMPLY MAY RESULT IN SERIOUS

PERSONAL INJURY.

a. Lift lower spool with motor assembly installed from the aft deck.

2. Remove the aft deck ladder.

a. Remove two nuts, washers, and bolts from ladder posts.

(1) Place in plastic bag for reuse.

(2) Label bag.

b. Remove lower ladder section.

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3. Remove engine room air intake louvers.

a. Remove the following fasteners from louver flange:

(1) 20 nuts.

(2) 20 washers.

(3) 20 bolts.

(a) Place fasteners in plastic bag for reuse.

(b) Label bag.

b. Remove louver assembly.

4. Remove the soft patch.

a. Remove all soft patch bolts with a deep socket and impact rated flat screwdriver socket.

b. Remove the screw and hose hanger, holding the raw water supply exhaust hose to soft patch handle.

c. Slide gasket scraper between the soft patch and gasket ensuring the adhesive is free all the way around the sealing surface.

CAUTION

WHENREMOVING THESOFT PATCH, ENSUREYOUARENOT

CUTTING INTO THE INSULATION IN THE ENGINE ROOM.

d. Lift soft patch and remove from the aft deck.

e. Discard soft patch gasket.

f. Remove all sealant and corrosion from the soft patch gasket surfaces with a gasket scraper and stainless steel wire brush.

g. Remove all sealant and corrosion from the aft deck gasket surfaces with a gasket scraper and stain-less steel wire brush.

C REMOVE EXHAUST

WARNING

WEAR APPROPRIATE PERSONAL PROTECTION

EQUIPMENT (PPE) IAW UNIT REGULATIONS WHEN

WORKING WITH WEIGHT HANDLING EQUIPMENT SUCH AS

A CRANE, AERIAL LIFT, OVERHEAD GANTRY, OR SIMILAR

LIFTING DEVICE. FAILURE TO COMPLY MAY RESULT IN

SERIOUS PERSONAL INJURY.

1. Support silencer with an overhead crane, (Refer to Figure 3).

2. Remove raw water supply by loosening the two hose clamps.

3. Loosen hose clamps on the exhaust CROSSOVER valve.

4. Loosen hose clamps on overboard discharge hose.

5. Remove exhaust flange shielding by cutting the lock wire

NOTE: Use a small pry bar to remove the V-band clamp.

6. Remove V-band clamps from the lower horizontal exhaust piping.

7. Support piping and remove it from the engine room.

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8. Remove four bolts holding the silencer to the bulkhead mounting brackets and retain rubber bushings.

9. Lift silencer up to remove load from bulkhead brackets.

a. Remove two bulkhead silencer brackets.

(1) Remove three bolts from each bracket.

(a) Retain bolts.

(b) Discard the nylock nuts.

10. Lift silencer from engine room.

a. Lower silencer into the pier.

11. Remove V-band clamp from turbo charger.

12. Remove V-band clamp from bellows.

13. Remove bellows assembly from engine room.

D REMOVE RAW WATER PIPING

1. Remove walker air separator, (Refer to MPC A52030.0)

2. Remove raw water piping from the sea chest.

a. Loosen hose clamps from strainer.

b. Inspect hose clamps for indication of wear or stretching.

(1) Discard hose clamps if wear and stretching is apparent.

c. Loosen hose clamps to raw water pump.

d. Remove hose clamps from the heat exchanger discharge hose.

e. Inspect hose clamps for indication of wear or stretching.

(1) Discard hose clamps if wear and stretching is apparent.

3. Remove two bolts securing the raw water tree to the thermostat housing.

a. Retain bolts for installation

4. Remove raw water supply hose from the raw water tree.

a. Label hose.

5. Remove raw water return hose to the reduction gear.

a. Label hose.

6. Remove supply hose to reduction gear.

a. Label hose.

7. Remove bolts securing raw water tree to overhead.

NOTE: Stbd raw water tree will require the removal of the steering system cooler supply and return hoses. These hoses should be dis-connected from the tree and not the cooler.

8. Remove raw water tree from engine room.

9. Inspect all open surfaces for pitting, corrosion, and damage prior to installation.

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E REMOVE HYDRAULIC STEERING PUMP

CAUTION

DO NOT BREAK FITTINGS LOOSE ON THE HYDRAULIC

SYSTEM. INTRODUCTION OF AIR AND CONTAMINANTS CAN

CAUSE DAMAGE.

1. Remove two bolts securing the pump to the accessory drive, (Refer to Figure 4).

2. Pull the hydraulic pump forward, toward bulkhead 5.

3. Secure hydraulic pump to the forward bulkhead.

4. Remove sun gear from the accessory drive housing, (Refer to Figure 5).

5. Retain sun gear for installation.

6. Clean gasket surfaces of hydraulic pump with gasket scraper.

F ELECTRIC ISOLATION

1. Complete Equipment Lockout/Tags-Plus Process IAW COMDTINST 9077.1 (series).

2. Attach the Red Danger Tags to the following in the “OFF” position:

a. Engine starting circuit breaker DCA-24-LL (1).

b. Inverter/charger 1 120V AC panel PP1-1P-A.

c. Inverter/charger 2 120V AC panel PP1-1P-E.

d. Port engine DDEC/ignition SW DCA-24P-GG.

e. Stbd engine DDEC/ignition SW DCA-24P-AA.

f. Start BATTERY DISCONNECT switch.

g. Service BATTERY DISCONNECT switch.

h. Parallel BATTERY DISCONNECT switch.

3. Attach the Red Danger Tags to the following in the “CLOSED” position:

a. Port engine fuel oil CUTOUT valve.

b. Stbd engine fuel oil CUTOUT valve.

G REMOVE ALTERNATORS

1. Remove start alternator, (Refer to MPC D10001.0).

a. Verify DC power has been secured to the alternator terminals.

(1) Check alternator terminals with multimeter.

b. Remove start alternator belt guard.

(1) Remove bottom guard bolt, lock washer, and washer

(2) Remove top guard bolt, lock washer, and washer.

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c. Remove belt guard to fully expose alternators belt and pulley.

CAUTION

TOPREVENTDAMAGEDTOTHEALTERNATOR, IF DROPPED,

SUPPORT THE ALTERNATOR WHILE REMOVING.

(1) Loosen the adjusting eye bolt, (Refer to Figure 6).

(2) Remove aligning spacer.

(a) Remove the mounting bolts from the aligning spacer.

(b) Remove aligning spacer.

(3) Rotate adjusting eye bolt with alignment bracket inboard out of the way.

NOTE: Use care when lifting the alternators to protect the alternator and fan assembly from damage.

(4) Remove alternators from mounting bracket.

(a) Remove pivot bolt.

(b) Place alternator in low area of frame to prevent damage.

(5) Remove drive belts.

(a) Discard the drive belts.

2. Remove service alternator, (Refer to MPC D10001.0).

a. Verify DC power has been secured to the alternator terminals.

(1) Check alternator terminals with multimeter.

NOTE: Use care when lifting the alternator to protect the alternator and fan assembly from damage.

(2) Loosen the adjusting eye bolt, (Refer to Figure 6).

(3) Remove pivot bolt.

(4) Remove the alternator from mounting bracket.

(a) Remove pivot bolt.

(b) Place alternator in low area of frame to prevent damage.

(5) Remove the drive belt.

(a) Discard the drive belts.

H REMOVE START MOTOR TERMINALS

1. Verify DC power has been secured to the starter terminals.

a. Check starter terminals with multimeter.

2. Label starting motor wire leads, (Refer to Figure 7).

a. Remove connector insulators, P/N: 4014, and/or, P/N: 4015.

b. Disconnect the starting motor wire leads.

3. Label solenoid wiring terminal leads.

a. Disconnect solenoid terminal leads.

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4. Insulate all cable ends with electrical tape, P/N: MIL-I-15126.

I DISCONNECT BLOCK HEATER

1. Open block heater junction box, (Refer to Figure 8).

a. Remove four screws on the junction box cover.

b. Remove cover.

NOTE: Cable PP1-1P-D is for the stbd engine and cable PP1-1P-C is for the port engine.

2. Label the three wire leads in applicable cable run.

3. Disconnect leads from the terminal block.

a. Wrap leads with electrical tape.

4. Loosen and remove cord grip nut on stuffing tube.

5. Pull cable from the junction box.

a. Retain cord grip nut and stuffing tube from junction box for reuse.

J REMOVE FUEL SYSTEM

CAUTION

CAP OFF ALL FUEL LINES. FAILURE TO DO SO MAY RESULT

IN THE FUEL TANK GRAVITY DRAINING INTO THE ENGINE

ROOM.

NOTE: Variations in fuel line configurations are illustrated in Figure 9, Detail A and Detail B.

1. Disconnect fuel supply hoses to the mechanical fuel pump at the fuel primer filter housing, (Refer to Figure 9).

2. Proceed to Step 1 J 5. if asset is fitted with configuration illustrated in Detail B.

3. Disconnect fittings from the ECM

a. Remove the two bracket mount bolts, (Refer to Detail A).

b. Remove the “T” fitting and elbow.

c. Remove the elbow from the ECM.

4. Disconnect fuel return line to tank.

5. Disconnect ECM fuel return line to the pressure regulator.

K REMOVE SECONDARY COMPONENTS

NOTE: Documentation of electrical connections after labeling can as-sist during reassembly and help prevent incorrect wiring connections.

1. Disconnect air shutdown solenoid.

a. Label both wires on the solenoid.

b. Remove ring terminals from the solenoid and retain the nuts for installation.

2. Wrap connectors in electrical tape.

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3. Disconnect air shutdown manual cable.

a. Separate the set nut and jam nut on the pull cable.

(1) Retain standard nut for instillation.

(2) Discard 14 inch nylock nut.

b. Remove both screws from the hold down clamp on the solenoid frame.

c. Relax the shutdown cable against bulkhead 5 and secure.

4. Disconnect tachometer (tach) sensor from the blower housing, (Refer to Figure 10).

a. Remove the bolt from the end of the hold down clamp.

b. Slide the clamp off the tach adapter.

c. Remove the tach adapter from the blower housing.

d. Unthread the tach sensor from the tach adapter.

(1) Retain adapter for installation.

e. Route the tach sensor away from snag hazards and secure it to bulkhead 5.

5. Disconnect plugs from the bottom of the Marine Interface Module (MIM).

a. Rotate lock collar counterclockwise to disconnect round cannon plug.

b. Remove power cable from the MIM.

c. Remove Engine Room Interface Module (ERIM) cable from the MIM.

d. Use an Allen wrench to remove the retention screw on the ERIM plug.

6. Disconnect magnetic tach pickup, (Refer to Figure 11).

a. Unscrew the collar by rotating counterclockwise.

b. Route the magnetic tach pickup away from snag hazards.

7. Remove oil hose from bottom of pressure block, (Refer to Figure 8).

a. Cap hose.

b. Secure pressure block to bulkhead 5.

8. Disconnect overhead gauge panel.

a. Support gauge panel.

b. Remove the following fasteners securing gauge panel to overhead.

(1) Nylock nuts.

(a) Discard.

(2) Bolts.

(3) Washers.

c. Place bolts and washers in plastic bag.

d. Label plastic bag.

9. Reposition gauge panel to secure to bulkhead 5.

a. Secure to bulkhead 5.

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L DISCONNECT LUBE OIL PIPING

CAUTION

HOSES MUST BE MARKED FROM THE DIRECTION OF FLOW

AS INDICATED ON THE REMOTE OIL FILTER HOUSING.

FLOWREVERSAL OF THE SUPPLY AND RETURN LINESWILL

CAUSE FAILURE OF THE ELEMENT AND RESULT IN FREE

FLOW OF CONTAMINATION THROUGH THE LUBRICATION

SYSTEM.

NOTE: Hoses should be removed from the oil cooler side of the en-gine.

1. Disconnect oil filter supply line to the oil cooler, (Refer to Figure 8).

2. Disconnect oil filter return line to the oil cooler.

3. Cap hoses to reduce residual oil leaking from the lines.

a. Place the oil lines in a plastic bag.

b. Secure plastic bag with electrical tape.

4. Remove oil hose from bottom of pressure block.

a. Cap oil hose.

b. Secure pressure block to bulkhead 5.

5. Remove oil pressure sensor block from the engine.

a. Remove bottom hose from pressure sensor block.

b. Remove bolt and washer securing pressure sensor block to turbo drain cover.

(1) Retain bolt for installation.

(a) Place bolt and washer in ziplock bag.

(b) Label bag.

c. Shift the pressure sensor block toward bulkhead 5.

(1) Secure pressure sensor block to bulkhead 5.

M REMOVE CARDAN SHAFT

1. Remove Cardan shaft safety guard.

a. Remove bolts and washers from the bellhousing on the inboard half of the safety guard.

(1) Retain for install.

(a) Place bolts and washers in a plastic bag.

(b) Label bag.

b. Rotate guards down around Cardan shaft and slide out horizontally.

c. Remove bolts and washers from the bellhousing on the outboard half of the safety guard.

(1) Retain for install.

(a) Place bolts and washers in a plastic bag.

(b) Label bag.

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d. Remove the shaft guard from the reduction gear space.

2. Verify shaft alignment, (Refer to MPC A15021.D (stbd) and MPC A15022.D (port)).

a. Rotate Cardan shaft to orient reduction gear coupler U-joint in a “6 O’CLOCK/12 O’CLOCK” position.

b. Place the level across the yoke of the reduction gear coupler transversely to ensure gear side yoke is zero, (Refer to Figure 12).

c. Position digital level on top of Cardan shaft and “zero” the level, (Refer to Figure 13).

d. Place provided machined surface on top of the gear side yoke.

e. Place level longitudinally on machined spacer, (Refer to Figure 14).

f. Record Cardan shaft angle between engine coupling and gearbox coupling reading on Table 1.

g. Place level across the yoke of engine coupler, (Refer to Figure 15).

h. Record angle between Cardan shaft end reading on Table 1.

CAUTION

THE CARDAN SHAFT AND YOKE ARE A BALANCED TWO

PIECE ASSEMBLY. EXTRA CARE MUST BE TAKEN TO AVOID

SEPARATING THE FORWARD AND AFT SECTIONS DURING

MOVEMENT. USE LINE LOOPED THROUGH BOTH YOKES

TO PREVENT SEPARATION. IF SHAFT IS NOT ALIGNED

PROPERLY IT CAN CAUSE BEARING FAILURE, REDUCED

PERFORMANCE, AND VIBRATION.

3. Disconnect Cardan shaft seal.

a. Remove the following fasteners from bulkhead 5 seal housing (reduction gear side):

(1) Six nuts.

(2) Six washers.

(3) Six bolts.

b. Retain fasteners for install.

(1) Place fasteners in a plastic bag.

(2) Label bag.

CAUTION

CORROSION ON THE CARDAN SHAFT CAN DAMAGE THE

O-RING DURINGMOVEMENT. IF CORROSION IS EXCESSIVE,

CLEAN THE CARDAN SHAFT PRIOR TO MOVEMENT. SUP-

PORT THE COUPLING DURING MOVEMENT TO PREVENT

DAMAGE TO THE O-RING AND GASKETS.

c. Slide the seal assembly down the Cardan shaft, away from the bulkhead.

4. Disconnect the Cardan shaft from the Centax-V coupling.

a. Support the weight of the Cardan shaft on the gear space side of bulkhead 5.

(1) Wrap a lifting strap around the Cardan shaft.

(2) Attach a chain fall to the overhead lifting eye, (Refer to Figure 16).

(3) Attach the lifting strap to the chain fall.

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(4) Operate chain fall to provide light tension on the Cardan shaft.

(5) Remove the following from the reduction gear input shaft coupling:

(a) Ten nuts.

(b) Ten washers.

(c) Ten bolts.

b. Compress engine side yoke until the dust seal contacts the taper on the shaft.

c. Apply corresponding paint marks on both shaft pieces.

CAUTION

THE CARDAN SHAFT AND YOKE ARE A BALANCED TWO

PIECE ASSEMBLY. EXTRA CARE MUST BE TAKEN TO AVOID

SEPARATING THE FORWARD AND AFT SECTIONS DURING

MOVEMENT. USE LINE LOOPED THROUGH BOTH YOKES

TO PREVENT SEPARATION. IF SHAFT IS NOT ALIGNED

PROPERLY IT CAN CAUSE BEARING FAILURE, REDUCED

PERFORMANCE, AND VIBRATION.

NOTE: Due to clearance issues created by the universal joint Hex head bolts require the use of the reduction gear Allen tool.

5. Disconnect Cardan shaft from reduction gear coupler.

a. Remove the nuts and bolts from the reduction gear input shaft.

b. Retain fasteners for install.

(1) Place fasteners in a plastic bag.

(2) Label bag.

c. Lift the Cardan shaft out of reduction gear space.

6. Check windage alignment of the reduction gear and engine, (Refer to Figure 17).

a. Install the first needle point on the Cardan shaft mounting face of the reduction gear using Cardan shaft hardware.

(1) Install ten bolts and washers retained from the yoke.

(2) Install ten nuts retained from the yoke.

NOTE: There is no torque value require, do not over tighten.

(3) Tighten bolts.

b. Install the second needle point on the Cardan shaft mounting face of the Centax-V coupler using

Cardan shaft hardware.

(1) Install ten Allen head bolts and washers retained from the yoke.

NOTE: There is no torque value required, do not over tighten.

(2) Tighten bolts.

(3) Extend needle points.

NOTE: There is no torque value required, do not over tighten.

(4) Tighten collar nut.

c. Observe the elevation and windage of needle points, (Refer to Figure 17).

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* QA REQUIRED (1)

d. Record windage difference reading on Table 1.

7. Remove alignment needle.

a. Remove alignment needle from Centax-V coupling mount surface.

(1) Remove the following from the Centax-V coupling:

(a) Ten washers.

(b) Ten bolts.

N REMOVE MOTOR MOUNTS

NOTE: Both bolts have jam nuts to prevent movement.

1. Remove two bolts that secure the aft engine mount to the bed frame, (Refer to Figure 18), (Refer to MPC A15011.0).

2. Remove the forward bolts.

3. Remove set nut and jam nut.

O LIFTING ENGINE

1. Attach Engine lifting bracket, (Refer to Figure 19).

a. Attach 3/4 inch threaded shackle on the lift eye located on the heat exchanger.

b. Attach 5/8 inch shackles to attach the lift bracket to the two aft lift eyes located between the engine heads and turbo pedestal.

* QA REQUIRED (2)

2. Lift the engine from the engine room.

3. Set engine on engine stand.

P REMOVE SERVICABLE PARTS NOT SUPPLIED WITH REPLACEMENT ENGINE

CAUTION

THE CENTAX-V COUPLER WEIGHS APPROXIMATELY 40

POUNDS. DO NOT ALLOW IT TO FALL FREELY, THIS MAY

DAMAGE THE EQUIPMENT OR CAUSE INJURY.

1. Remove Centax-V Coupler from non-servicable engine.

a. Remove outer most Allen head bolts with a 9 mm Allen driver, (Refer to Figure 20).

b. Tap the Centax-V coupler with a soft faced dead blow hammer.

NOTE: It may be necessary to elevate the engine off the stand to gain clearance to remove the mounts.

2. Remove engine mounts.

a. Mark each mount with identifying marks, the mounts are not interchangeable.

b. Remove 6 bolts from each engine mount.

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c. Retain fasteners for install.

(1) Place fasteners in a plastic bag.

(2) Label bag.

d. Inspect mounts for cracks.

(1) Notify EO/EPO if cracks are found.

3. Remove coolant temperature sensor adapter.

a. Clean thread sealant from adapter with brush.

4. Remove steering pump adapter.

a. Remove gasket material from sealing surface with gasket scraper.

5. Remove the oil cooler fittings.

a. Clean thread sealant from cooler fittings.

6. Remove flange shielding from inboard (port) and outboard (stbd) exhaust risers.

a. Cut lock wire.

b. Unwrap shielding.

Q REMOVE ENGINE RIGGING

1. Remove engine lifting bracket.

a. Remove 3/4 inch threaded shackle on the lift eye located on the heat exchanger.

b. Remove 5/8 inch threaded shackles from the lift bracket to the two aft lift eyes located between the engine heads and turbo pedestal.

R REMOVE REPLACEMENT ENGINE FROM SHIPPING CRATE

1. Open shipping container.

a. Loosen nuts and bolts securing top cover to shipping container.

CAUTION

CONTAINER UNDER PRESSURE. RELEASE PRESSURE

PRIOR TO REMOVING THE REMAINING HARDWARE.

b. Remove hardware from shipping crate.

c. Lift cover free from shipping container with overhead hoist.

2. Attach engine lifting bracket.

a. Attach 3/4 inch threaded shackle on the lift eye located on the heat exchanger.

b. Attach 5/8 inch shackles to attach the lift bracket to the two aft lift eyes located between the engine heads and turbo pedestal.

3. Remove 5/8 inch nuts and bolts from bellhousing mounting plate.

4. Remove 5/8 inch nuts and bolts from forward engine mount.

5. Lift engine from engine crate.

6. Set engine on engine stand.

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S INSTALL SERVICEABLE PARTS NOT SUPPLIED WITH REPLACEMENT ENGINE

1. Remove oil pressure sensor block installed on replacement engine.

a. Remove bottom hose from pressure sensor block.

b. Remove 7/16 inch bolt securing pressure sensor block to turbo drain star plate cover.

2. Install the Centax-V coupler.

a. Paint removal may be necessary to ensure a clean mating surface on the engine flywheel.

b. Lift the coupler into position on the flywheel.

WARNING

AVOID EYE CONTACT, SKIN CONTACT, AND INGESTION

WITH SEALING COMPOUND. KEEP AWAY FROM ALL

SOURCES OF IGNITION AND OXIDIZERS. WASH EXPOSED

SKIN THOROUGHLY AFTER HANDLING. FAILURE TO

COMPLY MAY RESULT IN PERSONAL INJURY.

c. Apply sealing compound Loctite 243, P/N: 1329837, on the threads of Allen head bolts.

d. Install a bolt and washer into the hole at the 12 o’clock in the coupling and corresponding hold in the flywheel.

e. Thread the bolt in by hand until flush with Centax-V coupler.

f. Thread the remaining hardware into the corresponding holes of the coupler.

NOTE: There is no torque value required, do not over tighten.

g. Tighten the hardware in a star pattern to ensure equal tension and correct alignment.

h. Torque the Allen head bolts to 36 ft-lb.

* QA REQUIRED (3)

3. Install engine mounts, (Refer to Figure 18).

a. Apply a thin coat of clean engine oil to the engine mount bolts.

b. Install six mounting bolts into the engine mount to the engine block.

c. Torque to 100 ft-lb in a criss-cross pattern.

4. Install new coolant temperature sensor adapter, (Refer to Figure 1).

a. Remove the existing plug in the thermostat housing.

b. Wrap the threads of the adapter with thread sealant Teflon tape.

c. Install adapter into the thermostat housing.

5. Install steering pump adapter, (Refer to Figure 4).

a. Remove the auxiliary drive cover.

b. Clean gasket material and oil residue from the auxiliary drive mounting surface.

c. Install new adapter gasket, P/N: 23515145.

d. Install bolts in adapter.

e. Torque to 71-75 ft-lb.

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6. Install oil cooler fittings, (Refer to Figure 2).

a. Remove plugs from oil cooler.

b. Apply a thin, even coat of thread sealer, P/N: 56541, to the fittings.

c. Thread the bottom fitting in first.

CAUTION

OVER TIGHTENING OF THE OIL COOLER FITTINGS MAY RE-

SULT IN CRACKING THE CAST OIL COOLER HOUSING.

NOTE: There is no torque vale required, do not over tighten.

(1) Tighten bottom fitting.

d. Install top fitting.

NOTE: There is no torque value required, do not over tighten.

e. Tighten top fitting.

7. Install flange shielding on the inboard and outboard exhaust risers.

a. Secure with lock wire, P/N: MS-2099-5C-32.

8. Remove walker air separator, (Refer to MPC A52030.0).

T ENGINE INSTALL

1. Lift engine

a. Remove the engine, P/N: 6V92TA-80627K90-PORT, or, P/N: 6V92TA-80627K91-STBD, from the en-gine stand.

b. Lower engine into engine room.

U INSTALL ENGINE ON MOUNTS

1. Suspended engine in the engine room over engine mounts.

2. Align forward engine mounts to the frame mounted pedestals, (Refer to Figure 18).

NOTE: While lowering engine, ensure all hoses, wires, and fixtures are clear from pinch points that may result in damage.

3. Use two lady foot pry bars for alignment of the aft engine mount to mount frame.

4. Verify the aluminum cylinders in the forward mounts are seated correctly in the base of the mount prior to the engine being fully lowered into position.

5. Remove engine lifting bracket.

a. Remove 3/4 inch threaded shackle on the lift eye located on the heat exchanger.

b. Remove 5/8 inch threaded shackles from the lift bracket to the two aft lift eyes located between the engine heads and turbo pedestal.

V ALIGNMENT VERIFICATION

1. Check alignment of the reduction gear and engine, (Refer to Figure 17).

a. Verify the first needle point on the Cardan shaft mounting face of the reduction gear was not removed.

b. Install the second needle point on the Cardan shaft mounting face of the engine coupler using Cardan shaft hardware.

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c. Extend needle points.

NOTE: There is no torque value required, do not over tighten.

d. Tighten collar nut.

e. Observe the elevation and windage of needle points, (Refer to Figure 17).

* QA REQUIRED (4)

f. Record windage difference reading in Table 1.

2. Remove alignment needle.

a. Remove alignment needle from the Centax-V coupling mount surface.

(1) Remove the following from the Centax-V coupling:

(a) Ten bolts.

(b) Ten washers.

(c) Needle point.

b. Remove needle from reduction gear mounting surfaces.

(1) Remove the following from the reduction gear input shaft coupling:

(a) Ten nuts.

(b) Ten washers.

(c) Ten bolts.

(d) Needle point.

W INSTALL CARDAN SHAFT

CAUTION

THE CARDAN SHAFT AND YOKE ARE A BALANCED TWO

PIECE ASSEMBLY. EXTRA CARE MUST BE TAKEN TO AVOID

SEPARATING THE FORWARD AND AFT SECTIONS DURING

MOVEMENT. USE LINE LOOPED THROUGH BOTH YOKES

TO PREVENT SEPARATION. IF SHAFT IS NOT ALIGNED

PROPERLY IT CAN CAUSE BEARING FAILURE, REDUCED

PERFORMANCE, AND VIBRATION.

1. Lift and lower Cardan shaft into the survivor compartment, (If required).

2. Attach to overhead chain fall with strap, (Refer to Figure 16).

3. Lower Cardan shaft into reduction gear space.

a. Align yoke to input flange mating surface.

b. Install Allen bolts from the reduction gear side of the input flange.

c. Install washers and nuts.

4. Remove line from shaft yokes.

5. Extend Cardan shaft to Centax-V coupling yoke.

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6. Install Allen bolts on the Centax-V coupler flange.

a. Torque Centax-V coupler flange Allen bolts to 46-64 ft-lb.

7. Install the remaining Allen bolts, washers, and nuts on the input flange.

a. Torque gear input flange Allen bolts and nuts 46-58 ft-lb.

8. Verify Cardan shaft angle against base readings on Table 1.

a. Rotate Cardan shaft to orient reduction gear coupler U-joint in a “6 O’CLOCK/12 O’CLOCK” position.

(1) Place the level across the yoke of the reduction gear coupler transversely to ensure gear side yoke is “zero”, (Refer to Figure 12).

(2) Position digital level on top of Cardan shaft and “zero” the level, (Refer to Figure 13).

(3) Place provided machined surface on top of the gear side yoke.

(4) Place level longitudinally on machined spacer, (Refer to Figure 14).

(5) Record Cardan shaft angle between engine coupling and gearbox coupling reading on Table 1.

(6) Place level across the yoke of engine coupler, (Refer to Figure 15).

(7) Record angle between Cardan shaft end reading on Table 1.

* QA REQUIRED (5)

CAUTION

THE CARDAN SHAFT AND YOKE ARE A BALANCED TWO

PIECE ASSEMBLY. EXTRA CARE MUST BE TAKEN TO AVOID

SEPARATING THE FORWARD AND AFT SECTIONS DURING

MOVEMENT. USE LINE LOOPED THROUGH BOTH YOKES

TO PREVENT SEPARATION. IF SHAFT IS NOT ALIGNED

PROPERLY IT CAN CAUSE BEARING FAILURE, REDUCED

PERFORMANCE, AND VIBRATION.

9. Install Cardan shaft safety guard.

a. Rotate guard down around Cardan shaft with flat surface facing engine bellhousing.

b. Slide guard in horizontally towards engine.

c. Install bolts on the outboard half guard.

d. Install inboard guard with remaining hardware.

e. Install input shaft guard in the reduction gear space.

10. Install Cardan shaft seal.

a. Slide bulkhead seal, retainer rings, internal gasket, and shaft ring until contact is made with bulkhead

5.

b. Apply a drop of sealing compound Loctite 243, P/N: 1329837, to the threads of the Allen bolts.

c. Align mounting holes and install Allen head bolts.

NOTE: There is no torque value required, do not over tighten.

d. Tighten Allen head bolts.

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X TORQUE ENGINE MOUNTS

1. Torque 5/8 inch mounting bolts.

a. Attach socket to torque wrench.

b. Torque nuts to 168-178 ft-lb.

* QA REQUIRED (6)

c. Attach jam nut.

NOTE: There is no torque value required, do not over tighten.

d. Tighten jam nut.

2. Torque 1 inch mounting bolts.

a. Attach torque multiplier to torque wrench.

b. Attach 1 1/2 inch extra deep socket to torque multiplier.

c. Torque 1 inch bolts to 440-460 ft-lb using torque wrench.

* QA REQUIRED (7)

d. Install jam nut.

NOTE: There is no torque value required, do not over tighten

e. Tighten jam nut.

Y INSTALL LUBE OIL PIPING

1. Install oil filter line from “Filter In” to “Oil Out” (top fitting) supply line from oil cooler, (Refer to Figure 8).

2. Install oil filter line from “Filter Out” to “Oil In” (bottom fitting) return line to oil cooler.

CAUTION

FLOW REVERSAL SUPPLY AND RETURN LINE WILL CAUSE

FAILURE OF THE ELEMENT AND RESULT IN FREE FLOW OF

CONTAMINATION THROUGH THE LUBRICATION SYSTEM.

3. Install oil pressure sensor block.

a. Thread bolt through oil pressure sensor block in to auxiliary drive surface on the corner of the turbo drain star plate.

NOTE: There is no torque value required, do not over tighten.

b. Tighten mount bolt.

c. Install oil supply hose into the bottom of pressure sensor block.

Z INSTALL SECONDARY COMPONENTS

1. Install magnetic tach pickup, (Refer to Figure 11).

a. Ensure tach wire is free of twists.

b. Align plug with sensor.

(1) Insert connection and rotate collar quarter turn clockwise.

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2. Install plugs in MIM.

a. Push in round cannon plug into MIM.

b. Rotate the collar clockwise to secure round cannon plug.

c. Push square ERIM to MIM plug into MIM.

NOTE: There is no torque value required, do not over tighten.

d. Tighten retention setscrew on the ERIM to MIM plug.

3. Install local tach sensor on blower assembly, (Refer to Figure 10).

a. Thread tach sensor onto tach adapter.

b. Install tach adapter into blower assembly.

c. Slide hold down clamp over tach adapter ensuring the barbs engage blower housing.

NOTE: There is no torque value required, do not over tighten.

d. Tighten bolt on clamp to fully seat tach sensor adapter.

4. Attach air shutdown solenoid and manual cable.

a. Route pull cable under solenoid.

b. Slide cable through hole in air dampener trip.

NOTE: Ensure groove in cable corresponds with dimple in the clamp to prevent cable from slipping, preventing proper activation of air dampner.

c. Install cable clamp and screws.

5. Adjust air dampner.

a. Ensure air dampener is in the “OPEN” position.

b. Install adjustment nut until contact is made with air dampner latch.

c. Test manual activation from enclosed bridge.

(1) Ensure air dampner trips.

d. Reset engine emergency stops.

e. Push the engine emergency stop T-handle in by hand.

NOTE: To reset the air dampener, manually push the lever down and insert the solenoid arm.

f. Reset the engine air dampener latch.

g. Install jam nut, P/N: 290-002598, on pull cable.

NOTE: There is no torque value required, do not over tighten.

h. Tighten jam nut to lock into place.

6. Install shut down solenoid.

a. Remove nuts and lock washers on the solenoid posts.

b. Install wire ring terminals on corresponding posts.

c. Install lock washers.

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d. Install nuts.

CAUTION

OVERTIGHTENING OF THE TERMINAL NUTS MAY RESULT IN

INTERNAL DAMAGE TO THE SOLENOID

NOTE: There is no torque value required, do not over tighten.

(1) Tighten nut.

7. Install coolant level sensor, P/N: 23519175, (Refer to Figure 1).

a. Apply thread sealing tape to level sensor.

b. Thread sensor into the side of the expansion tank.

c. Connect sensor lead.

(1) Press connector firmly into sensor until fully seated.

8. Install gauge panel.

a. Remove from bulkhead 5.

b. Align holes with overhead mount.

c.…