Electro-Motive MI 1722_Maintenance Instruction.pdf

M.I. 1722

MAINTENANCE INSTRUCTION

SCHEDULED MAINTENANCE PROGRAM

MARINE PROPULSION (GM) AND

GENERATING (MG) UNITS WITH

TURBOCHARGED ENGINES

I _ Fuel oil used will meet the spt*cil‘ici~tions of Maintonancc Instr\rc’tion 1750.

2. I.ubricating oil used will meet the specifications of Maintenance Instructions I760 and 1764 and will he changed at the intervals spccilied in this M. I.

4. Izubricating oil filters will he of’ a yuality qua1 to original cyuipment and will be changccl at the intervals specified in this M.l.

5. Operating load limitations will be adhered to.

0. ‘foryuing procedures contained in this M. I. will hc I‘c.,llowcd f’or IICW engines and newly installed replacement asscmhlies.

7. Reduction gear tnaintcni~n~e ttr hc p~rli‘~rm~d in ;1CCord;tt~C~ with manul’xturcr’s rccc.)lrlrrlendati(,xls.

‘I’his Maintenance Instruction is divided ink) three sections. ‘l‘he first section ih rnainicnunce performed before and :tfter each start. the second section is performed on it “t:alendi~r period” basis, and the third section is performed on a “running time” basis. Hecausc operating rcyuirements for this cquipmeni. can vary from standby, to periodic, to continuous usage, ,the maintr:nance procedures must lx modil’ied to suit individual rcquiremcnts.

REFERENCES

Abbreviations are trked in this instruction to rcl’crcncc piihlications that contain information related to maintenance. ‘l‘hc fc.,llowing examples arc provided 1.0 aid in understanding the abbreviations used.

BEFORE EACH START

LUBE OIL SYSTEM

Check for lube oil in pan and strainer box, if so equipped. Add oil if required.

NOTE

If engine requires prelube, recheck lube oil level in pan as a quantity will transfer to external system (cooler, filter, strainer and piping). Add oil if required.

COOLING SYSTEM

Check coolant level and add coolant if required.

Do not continue to operate engine requiring perlodlc addltlon of coolant. Check for possible coolant leak and re~air if reuuired.

FUEL SYSTEM

Check fuel supply and open fuel supply valves.

Prime system.

AIR SYSTEM

Drain condensate.

Check system pressure.

Check oil supply in air line lubricator.

ENGINE

Check overspeed trip lever OST to ensure it is in the running “latched” position.

Open cylinder test valves and manually bar over engine one complete revolution, check for liquid ejected from valves, and close test valves.

On units with engine mounted lube oil strainer box (E7B, E7C, F7B & G7 models), prelube engine if unit has been shut down for over 48 hours.

On units with in-line mounted lube oil strainers (E7BA, E7CA, F7BA & G7 modified models with engine mounted raw water pump), prelube engine if unit has been shut down for over 2 hours.

Ensure exhaust stack is open.

GOVERNOR

Check lube oil level. Add oil if necessary.

EMM, M.I. 1760

EMM

EMM

EMM

EMM

EMM

EMM. If fluid discharge is observed from any cylinder, find the cause and make the necessary repairs prior to starting the engine.

EM M. Unless equipped with immersion heater system.

EMM

EMM, M.I. 1764

-3-

IMMEDIATELY AFTER EACH START 1

INSPECT FOR LEAKS

Cooling system Fuel system Lube oil system Exhaust system

LUBE OIL SYSTEM

Check lube oil level in pan with engine at idle. EMM

Check lube oil pressure at engine. EMM

COOLING SYSTEM

Check operation of external cooling system.

FUEL SYSTEM

Check for proper fuel pressure.

ENGINE

Check cylinder test valves for leakage. Tighten if EMM required.

Check handhole covers for leakage. Tighten if EMM required.

Check air box drains for proper operation and EMM. If drains are kept closed, drain every 4 clean, if necessary. hours.

Check for unusual noises or sound, or any fault indications (lights or alarm), as provided.

-4-

PERFORM THE FOLLOWING ITEMS ON CALENDAR TIME BASIS

DAILY

INSPECT FOR LEAKS

Cooling system Fuel system Lube oil system Exhuast system Air System

LUBE OIL SYSTEM

Check lube oil level in pan. EMM

COOLING SYSTEM

Check coolant level. EMM

NOTE

Do not continue to operate engine requiring periodic addition of coolant. Check for possible coolant leak and re~air as reauired.

FUEL SYSTEM

Check fuel supply.

AIR SYSTEM

Drain condensate from lines and tanks.

GOVERNOR

Check oil level and add oil if required. EMM

ENGINE AIR FILTER - PAPER OR FIBERLGASS TYPE

Monitor filter pressure indicator. If tripped, take EMM manometer readings and replace elements if neces-sary.

EVERY MONTH

LUBE OIL SYSTEM

Take sample for analysis. The services of a competent laboratory should be used to monitor the suitability of the oil for continued use according to M.I. 1760.

LUBE OIL CIRCULATING PUMP AND MOTOR (Where Used)

Check for proper operations. EMM

IMMERSION HEATER (Where Used)

Check for proper operation. EMM

-5-

EVERY TWO MONTHS

AUXILIARY TURBOCHARGER FILTER (Where Used)

Replace elements. EMM

IN-LINE LUBE OIL STRAINER (Where Used)

Clean strainer screen.

EVERY YEAR

LUBE OIL CIRCULATING PUMP AND MOTOR (Where Used)

Inspect and clean with dry air.

Replace brushes. If equipped with DC motor.

Remove and clean check valve.

ELECTRICAL CONTROL CABINET AND ASSOCIATED EQUIPMENT (Where Used)

Check operation of protective devices. Protective switches, relays, and alarm indicators.

Visually inspect and clean:

Voltage regulator. M.I. 4523 or appropriate manufacturer’s voltage regulator manual.

All relays, contractors, and circuit breakers.

Remove circuit breakers from compartments.

Clean insulators.

Lubricate linkage bearings.

Check operation.

COOLING SYSTEM

Check operation and setting of engine water temper-ature control(s).

Check torque on flexible pipe coupling bolts.

Take cooling water sample for lab analysis and M.I. 1748. Unless 2000 hour sampling has occurred corrosion test. first.

LUBE OIL FILTERS

Change filter elements. EMM. Unless the 1400 hour filter change has occurred first.

Clean lube oil strainers. EMM. Fill strainer box with oil before starting engine. (E7B, E7C, F7B & G7 models.)

TURBOCHARGER AND SOAK BACK OIL FILTERS

Replace filter elements. EMM. Unless 1400 hour falter change has occurred first.

-6-

FUEL FILTERS

Change engine

EVERY TWO YEARS

mounted filter elements.

Clean or replace suction strainer element.

ENGINE PROTECTOR

Replace or recondition and requalify.

LUBE OIL CIRCULATING PUMP AND MOTOR

Replace.

EMM. Unless 2000 hour filter change has occurred first.

EMM. Unless 2000 hour maintenance has occur-red first.

M.I. 259 or M.I. 260. Qualify on test stand after renewing spring, “O” rings, and diaphragms.

(Where Used)

Replacement can be EMD Unit Exchange.

EVERY THREE YEARS

COOLING SYSTEM THERMOSTATIC VALVE

Replace “O” rings and thermostatic elements. EMM, M.I. 581

EVERY FOUR YEARS

COOLING SYSTEM PRESSURE CAP (Where Used)

Replace. Unless 16,000 hour replacement has occurred first.

EVERY FIVE YEARS

FREQUENCY GENERATOR COUPLING SPIDER (Where Used)

Replace. Unless 16,000 hour replacement has occurred first.

EVERY SIX YEARS

ENGINE

Replace top deck cover seals and check latches.

Replace cylinder head grommets, inlet and outlet seals, and lower liner seals.

MAIN GENERATOR (MG Models)

Remove bearing cover and inspect for grease con-tamination, excessive wear, and overheating. Apply new grease.

-7-

EMM. Unless 8,000 hour replacement has occurred first.

EMM. Unless 16,000 hour cylinder assembly re-placement has occurred first.

Unless 60,000 hour lubrication has occurred first.

M.I. 3328 for EMD generator. If generator is other than EMD, refer to manufacturer’s manual.

PERFORM THE FOLLOWING ITEMS ON RUNNING TIME BASIS

~AFTER THE FIRST 350 HOURS OF OPERATION I

ENGINE NUT AND BOLT TIGHTNESS CHECK Torque to values specified in EMM.

Cylinder head crab nuts.

Exhaust manifold flange bolts.

Cylinder liner water inlet line nuts and bolts.

Head frame to crankcase bolts.

Turbocharger to air duct bolts, aftercooler to air duct bolts, and air duct to crankcase bolts, and turbine inlet link bolts.

Engine mounting bolts.

Miscellaneous nuts and bolts, and all piping con-nections.

ENGINE

Inspect air box.

Inspect crankcase.

Inspect crankshaft and connecting rods.

Inspect pistons and piston rings.

Inspect cylinder liners.

Inspect cylinder head mechanism with engine idling and at operating temperature.

Inspect engine fuel lines and connections for leaks.

Inspect engine water system for leaks.

All except those equipped with plate type crabs.

EMM

EMM

EMM

EMM

EMM

EMM

EMM

EMM

EVERY 350 HOURS

FUEL FILTER

Check fuel pressure gauge with engine at rated RPM. On units where gauge is connected to filter input side, change filter elements if pressure is greater than 345 kPa (50 psi).

On units where gauge is connected on filter output side, change filter elements if pressure is less than 83 kPa ( 12 psi).

-8-

LUBE OIL FILTER

Check lube oil filter pressure gauges with engine at On units with rack mounted oil filter, change filter rated RPM. elements if input pressure is greater than 172 kPa

(25 psi).

On units where filter is not rack mounted, and has external 138 kPa (20 psi) bypass valve, change falter elements if pressure differential between input and output exceeds 103 kPa (15 psi).

On units where filter is not rack mounted and has external 207 kPa (30 psi) bypass valve, change filter elements if pressure differential between input and output exceeds 138 kPa (20 psi).

RAW WATER PUMP - BELT DRIVEN

Inspect drive belt for signs of slipping or chafing. EMM

EVERY 700 HOURS

ENGINE PROTECTOR

Check operation. EMM, M.I. 259 or M.I. 260

SOAK BACK PUMP AND MOTOR

Check operation. With the engine shut down and soak back pump motor running, remove left rear handhole cover and check oil flow through gear train.

Observe camshaft bearings. If lube oil flows from camshaft bearings with soak back pump running and engine shut down, inspect turbo filter outlet check valve for proper operation.

ENGINE AIR FILTER - REMOTE MOUNT OIL BATH (Where Used)

Check oil level. M.I. 442

ENGINE AIR FILTER - PANEL TYPE OIL BATH (Where Used)

Check oil level. M.I. 440

ENGINE AIR FILTER - PAPER OR FIBERGLASS TYPE (Where Used)

Check indicator. If tripped, take manometer readings, and replace elements if necessary.

HEAT EXHANGER

Inspect corrosion zinc electrodes. EMM

RAW WATER PUMP - BELT DRIVEN

Lubricate shaft bearings. EMM

Check drive belt tension. EMM

-9-

EVERY 1400 HOURS 1

LUBE OIL FILTERS

Change filter elements.

Clean lube oil strainers. Fill strainer box with oil before starting engine.

(E7B, E7C, F7B & G7 models.)

TURBOCHARGER AND SOAK BACK OIL FILTERS

Replace elements. Filter elements must be of a quality equal to original equipment. The interval of change for turbocharger and soak back filter elements is influenced by load factor, kind of lubricating oil, type of operation, climatic conditions, and main-tenance of main lube oil filters.

PROTECTIVE DEVICES

Check operation. EMM

EVERY 2000 HOURS 1

FUEL FILTERS

Clean or replace suction strainer element. EMM

Change engine mounted filter elements. EMM. Use only elements equal to original equip-ment.

COOLING SYSTEM

Take cooling water sample for lab analysis and cor- M.L 1748. Unless the yearly sampling has occurred rosion test. first.

ENGINE AIR FILTER - REMOTE MOUNT OIL BATH (Where Used)

Change oil. Drain and fill only. M:I. 442

ENGINE AIR FILTER - PANEL TYPE OIL BATH (Where Used)

Change oil. Drain and fill only. M.I. 440

ENGINE AIR FILTER - PAPER TYPE (Where Used)

Take manometer readings. Replace elements if necessary.

ENGINE AIR FILTER - FIBERGLASS TYPE (Where Used)

Replace elements.

-1o-

ENGINE

Inspect air box.

Inspect crankcase.

Inspect crankshaft and connecting rods.

Inspect pistons and piston rings.

Inspect cylinder liners.

Inspect cylinder head mechanism with engine idling and at operating temperature.

Inspect engine fuel lines and connections for leaks.

Inspect engine water system for leaks.

EMM

EMM

EMM

EMM

EMM

EMM

EMM

EMM

EVERY 4000 HOURS

EXHAUST SYSTEM

Remove exhaust manifold-to-turbocharger adapter assembly.

TURBOCHARGER EXHAUST DIFFUSER

Visually inspect for evidence of warpage or damage.

EDUCTOR TUBE (Exhaust Stack Mounted)

Inspect for carbon deposits and clean, if necessary.

LUBE OIL SYSTEM

Change engine oil.

Clean oil suction screens.

Clean scavenging oil screens.

Clean oil pan.

Clean falter housing.

ENGINE

Check pressure drop across aftercoolers; oil bath falter equipped engines only.

Check exhaust manifold base flange bolts for proper tightness.

GOVERNOR

Change oil.

Lubricate linkage moving parts.

Lubricate governor synchronizing motor, motor bearings. (Where used.)

EMM. Clean screen and trap box. Observe recom-mendations found in EM M concerning checking for cracks.

EMM

EMM

EMM. Evaluation of engine and oil condition should dictate the frequency of this item. Type of service, type of oil, quality of filter elements, and condition of engine will influence the frequency of oil change.

EMM

Fill strainer box with oil before starting engine.

(E7B, E7C, F7B & G7 models.)

EMM

EMM

EMM. Clean air passages if necessary.

EMM

EMM, M.I. 1764

EMM

EMM

-11-

EVERY 8000 HOURS

ENGINE NUT AND BOLT RETORQUING

Cylinder head crab nuts.

Main lube oil and piston cooling oil pump shaft nut.

Head frame to crankcase bolts.

Turbocharger to air duct bolts, aftercooler to air duct bolts, air duct to crankcase bolts, and turbine inlet link bolts.

Engine mounting bolts.

Miscellaneous nuts and bolts, and all piping con-nections.

ENGINE

Replace top deck cover seals and check latches.

Quality injectors.

Check injector timing and injector rack length.

Check engine speed.

Check overspeed trip.

Remove and clean oil separator element.

Check pressure drop across aftercooler; paper and fiberglass filter equipped engines only.

Inspect crankshaft damping device.

Remove, clean, and inspect; replace if necessary:

Soak back check valve in the turbo filter inlet.

Soak back oil pressure relief valve in the soak back filter head.

Soak back filter bypass valve in the soak back filter head.

Turbo oil filter check valve in the turbo filter head.

EXHAUST SYSTEM

Inspect manifold sections for possible cracked leg baffles or expansion joints and replace, if necessary.

MAIN GENERATORS (MG Models)

Visually inspect and clean.

Torque to values specified in EMM.

All except those equipped with plate type crabs.

EMM

EMM

EMM

EMM

EMM

EMM

EMM. Clean air passages if necessary.

EMM

EMM

EMM

M.I. 3328

ENGINE AIR FILTER - REMOTE MOUNT OIL BATH (Where Used)

Change oil. Clean sump and filter media. M.I. 442

ENGINE AIR FILTER - PANEL TYPE OIL BATH (Where Used)

Change oil. Clean sump and filter media. M.I. 440

-12-

SOAK BACK PUMP MOTOR

Inspect and clean with dry air. M.I. 4101

Replace brushes. M.]. 4101

COOLING SYSTEM (Pressurized System Only)

Inspect and perform pressure test.

Replace pressure cap if defective.

LUBE OIL COOLER (Tube Bundle Type)

Replace floating header seal.

MAIN LUBE OIL PUMP BYPASS VALVE (Where Used)

Remove, clean, inspect, and test. EMM

LUBE OIL FILTER

Remove internal oil filter bypass valve; clean, inspect, M.I. 926 and test. (Where used.)

LUBE OIL FILTER AND OIL COOLER BYPASS VALVES (Where Used)

Remove, clean, inspect, and test. EMM

STARTING MOTORS

Disassemble, clean, inspect

Renew parts if necessary.

I and lubricate.

EMM

EVERY 16.000 HOURS

I , FUEL PUMP

Replace coupling spider.

SOAK BACK PUMP

Replace coupling spider.

COOLING SYSTEM

Replace pressure cap. (Where used.)

Inspect filler neck for damage. Replace if damaged.

(Where used.)

ENGINE

Replace cylinder assemblies.

Replace injectors.

Inspect and qualify connecting rod bearings.

Inspect and qualify piston cooling tubes.

Check rocker arms, rocker arm bushings, and cam followers.

Check lash adjusters.

Check exhaust valve timing.

Inspect lower liner inserts, and replace if required.

EMM. Except where Premium Power Packs are used.

EMM. Replacement should be EMD Unit Ex-change or equivalent.

EMM

EMM

EMM

EMM

EMM

-13-

EVERY 30,000 HOURS

ENGINE

Replace cylinder assemblies

Install new thrust collars.

Replace injectors.

Install new lower main bearings.

Install new upper corm. rod bearings.

Replace water pump seals and all worn parts.

Replace lash adjusters.

Inspect lower liner inserts and replace -8 required.

Inspect injector control linkage. Replace links, seals, and bearings where required.

TURBOCHARGER

Unit Exchange.

EMM. Provided Premium Power assemblies are used.

EMM

EMM

Inspect and qualify lower corm. rod bearing for reuse.

EMM

EMM

EMM

EMM

EM M. Average individual operating conditions will determine frequency.

TURBOCHARGER-TO-FILTER AIR DUCT (Where Used)

Replace.

COOLING SYSTEM

Replace flexible coupling seals.

LUBE OIL COOLER

Inspect, clean, and test.

HEAT EXCHANGER

Inspect, clean, and test.

RAW WATER PUMP

Replace ball bearings and bearing seals.

Replace pump seal and gaskets.

Replace drive belt (where used).

GOVERNOR

Replace.

GOVERNOR BOOSTER SERVO (Where Used)

Disassemble, clean, inspect, and replace O-ring seals.

-14-

M.I. 927

EMM

EMM

EM M

EMM

Replacement should be EMD Unit Exchange or equivalent.

FUEL PUMP

Replace or recondition. M.I. 4110. Replacement can be EM D Unit Exchange.

SOAK BACK PUMP AND MOTOR

Replace or recondition. Ml. 4101, M.I. 4110. Replacement can be EMD Unit Exchange.

EVERY 60.000 HOURS 1

ENGINE

Replace or recondition oil pumps. EMM. Replacement can be EMD Unit Exchange.

Remove oil pressure relief valve; clean, inspect, and EMM test.

PEDESTAL BEARING ASSEMBLY (Belt Driven Raw Water Pump)

Replace bearing

MAIN GENERATOR (MG Models)

Remove bearing cover and inspect for grease con- M.I. 3328 for EMD generator. If generator is lamination, excessive wear, and overheating. Apply other than EMD, refer to manufacturer’s manual.

new grease.

ENGINE

Replace crankshaft damping device. EMM. Recondition and requalify.

EVERY 120,000 HOURS

ENGINE

Unit Exchange or completely rebuild.

MAIN GENERATOR (MG Models)

Unit Exchange or completely rebuild.

-15-

— Document Number MMOO1O9O

Electro-Motive Division Of General Motors Corporation La Grange, Illinois 60525 USA Telex: 270041 McCook, Illinois USA Cable: ELMO DIV LaGrange, Illinois USA Telephone: 708-387-6000

@Copyright 1990 Electro-Motive Division, General Motors Corporation. All rights reserved. Neither this document, nor any part thereof, may be reprinted without the expressed written consent of the General Motors Locomotive Group. Contact EMD Customer Publications Office.

TITLE