3905_233_A_Diesel_Eng_Insp_Alco_Model_251.pdf

TP: 3905

(HM&E MANUAL)

TECHNICAL MANUALS

DIESEL ENGINE INSPECTION

PROCEDURE – ALCO MODEL 251

ALCO OWNERS GROUP

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PUBLISHED UNDER AUTHORITY OF THE U.S. COAST GUARD

SWBS 233

SECTION: A

Department of Homeland Security

UNITED STATES

COAST GUARD

Individual Manual Application Sheet

Technical Publications Number

Section Applicability

SWBS Number 233 SWBS Element Title

PROPULSION INTERNAL COMBUSTION

ENGINES

Section Identifier A

Equipment Functional Description

DIESEL ENGINE INSPECTION

PROCEDURE - ALCO MODEL 251

CI Functional Description ESWBS Code Remarks

Planset Hulls

400-WAGB 10, 11

618-WMEC 615, 616, 617, 618, 619

627-WMEC 620, 621, 623, 624, 625, 626, 627, 629, 630

901-WMEC 901, 902, 903, 904

905-WMEC 905, 906, 907, 908, 909, 910, 911, 912, 913

UNITED STATES COAST GUARD

ALCO DIESEL ENGINE

INSPECTION PROCEDURE

TP 3905

ADMINISTRATIVE PHASE

INSPECTION WORKSHEET

NOTE

Discrepancies Only, No Grade Assigned

USCGC

Date:

1. Engine APL and APL Date (Check for Configuration).

Comments:

2. Engine Technical Manuals.

3. Operating Logs.

Any reading out of specification must be circled in red and corrective action documented.

4. Engine Hour Logs.

5. Machinery History.

TP 3905 2

6. Jacket Water Treatment Records/NSTM 220, VOL 3.

7. Lube Oil Quality Management Program/NSTM 262.

8. Diesel Engines/NSTM Chapter 233.

9. Last Diesel Inspection Report.

10. DEMPS/Full Power.

11. Engine Data:

Engine No. Serial No. Model No. Hrs Since Ovhl. Hrs Since Comm.

If total hours since overhaul are unknown, estimate hours based on yearly usage and enter that figure for a five-year period. Also, total engine hours since commissioning are unknown, estimate based on yearly usage and enter that figure times the years the engine has been in commission.

TP 3905 3

ALCO SECURED PHASE

WORK SHEETS

TP 3905 4

ALCO ENGINES

SECURED-PHASE INSPECTION WORKSHEETS

USCGC

DATE

ENGINE NO.

A. INSPECT THE FOLLOWING SPECIAL TOOLS:

1. Appropriate size micrometers inside and outside (O to 10 inch).

2. Depth Micrometer (O to 3 inch).

Comments:

3. Torque wrench (1/2-inch drive) ( ft/lb.).

Comments:

4. Torque wrench (3/4-inch drive) ( ft/lb.).

Comments:

5. Crankshaft deflection gage.

Comments:

6. Dial indicator.

Comments:

7. Magnetic base for dial indicator.

Comments:

8. Feeler gages (short and long) two sets.

Comments:

9. Hand or strobe tachometer.

Comments:

10. Cylinder pressure gage (Keine indicator).

Comments:

11. Valve spring compressor.

TP 3905 5

12. Ring compressor.

13. Liner puller.

Comments:

14. Cylinder head/cylinder liner lapping tool.

Comments:

15. Cylinder head/cylinder liner lapping check tool.

Comments:

16. Cylinder head torque converter (Sweeny).

Comments:

17. Main bearing torque converter (Sweeny).

Comments:

18. Main bearing removal tool.

Comments:

19. Main bearing bolt stretch gage.

Comments:

20. Connecting rod bolt stretch gage.

Comments:

21. Governor tail rod jack.

Comments:

22. Governor power piston spacers.

a. 0.220 inch Full fuel and 0.640 inch Midrange and 0.860 Low range.

Comments:

23. Jacket water test kit.

Comments:

24. Lube oil test kit.

Comments:

25. Timing trammel.

Comments:

26. Hand tools (see PMS).

TP 3905 6

B. VISUAL INSPECTION

1. Crankcase and block. Isolate expansion tank and hydrostatically test jacket water system according to PMS if any of the following conditions exist; rust, excessive water and chemical makeup, water streaks, obvious external/internal leaks, and NOAP results.

a. Inspect engine foundation bolts and chock blocks for correct installation.

Comments:

b. Inspect for loose or missing bolts securing block to base.

Comments:

c. Inspect for cracks in base, block, and camshaft bearing supports.

Comments:

d. Inspect engine internals for unusual discoloration or signs of overheating.

Comments:

e. Check for foreign material in crankcase.

Comments:

f. Verify correct installation of connecting-rod bolts.

Bolts must be installed with flat side of each head butted together.

g. Verify that there are no broken or missing cotter pins on connecting rod bolts.

NOTE

Cotter pins are required on bolts with 0.015-inch stretch only, not on bolts with 0.026-inch stretch. Caps and rods are marked for 0.026-inch stretch.

h. Verify that matching “O”marks on each connecting rod and cap, face outward for each bank.

TP 3905 7

Crankcase and block (continued).

i. Verify that there are no broken or missing cotter pins on main bearing castellated nuts (upper) and that washers have been installed with main bearing nuts (lower).

Comments:

j. Check main bearing and connecting-rod bearing edges for proper installation or looseness of bearing shell.

Comments:

k. Perform main bearing press-ups (four, every inspection, starting at the 18,000 hour point) and connecting rod bearing visual inspections (one, every inspection starting at the 12,000 hour point). Record on the data sheet.

Comments:

l. Check for signs of water dripping at liner-to-block sealing surfaces.

Comments:

m. Verify correct installation of internal lube oil lines.

Comments:

n. Inspect for damage to and ensure correct installation of sump screens.

Comments:

o. Barring engine over, with pistons near TDC, inspect liners from beneath for signs of scoring, galling, and dull spots.

Honeycombed (dimpled) liner surfaces are normal.

2. Crankshaft.

a. Check vibration damper for freedom of movement (10 degrees either direction, which is approximately l-1/2 to 2 inches total movement).

Comments:

b. Measure crankshaft deflection at crankweb closest to the drive end according to PMS. Record on data sheet.

Comments:

c. Measure crankshaft thrust according to PMS. Record on data sheet.

TP 3905 8

Crankshaft (continued).

d. Verify that No. 1R is at TDC to check accuracy of the flywheel pointer. (Use timing trammel).

Comments:

e. Inspect flywheel ring gear teeth and air starter motor pinion for cracking and excessive wear.

f. Inspect rear crankshaft oil seal for indication of leaking.

If there is indication of leaking at the crankshaft oil seal, inspect the oil seal drain line for leakage and obstructions

g. Check crankshaft plugs for correct installation.

Comments:

h. Inspect accessory drive and crankshaft gears for broken teeth, unusual wear pattern, excessive wear, proper lockwiring, and proper lubrication.

CAUTION

Use extreme care, as engine must be barred over several revolutions to inspect all gears.

i. Run prelube pump and check for oil leaks and adequate lubrication of running gear assemblies and power pack assemblies.

Comments:

3. Camshafts (From crankcase, either use inspection mirror or feel surfaces with hand ). Flame hardening on camshafts is normal.

a. Inspect camshaft lobes for excessive pitting, flat spots, and galling.

TP 3905 9

Camshafts (continued).

b. Inspect camshaft drive gears for broken teeth and excessive wear.

Perform thrust check every 6,000 hours (starting at 12,000 hours).

Record on data sheet.

Comments:

c. Inspect camshaft coupling bolt-locking devices.

Comments:

d. Verify that the camshaft gear nut locking screw has been lockwired.

Comments:

4. Balance shafts (8-251 Cyl engines, Icebreaker Class).

a. Inspect bushings for signs of spinning or movement in or out of the bushing bore. For further detail see ALCO MI 11249.

Comments:

b. Inspect drive gears for broken teeth, unusual wear pattern, and excessive wear.

Comments:

5. Fuel injection pump crosshead assembly (from crankcase, use inspection mirror or feel surfaces with hand).

Comments:

a. Inspect fuel cam roller for excessive wear or flat spots.

Comments:

b. Inspect fulcrum-to-support locking-plate bolts and ensure that the lockwire is in place.

Comments:

c. Inspect pushrod lifters.

Comments:

d. Check valve pushrod cam rollers for excessive wear or flat spots.

Comments:

e. If any problems are evident during inspections 5a through 5e, remove the fuel pump crosshead assembly and check for excessive looseness and wear.

TP 3905 10

6. Running gear assemblies.

a. Inspect valve levers and pushrods.

Comments:

b. Check for excessive wear in the rocker arm assemblies.

Comments:

c. Spot-check valve clearances (minimum four on each bank). (Intake and exhaust should be according to PMS. Record on data sheet.

d. Inspect for broken springs on valves and valve bridges.

Valve bridge springs are not to be installed on cylinder heads with valve rotator cups.

7. Cylinder heads.

a. Inspect for broken or damaged cylinder head nuts and for correct installation.

The two inside nuts require seal caps.

b. Inspect the nozzle strongback for correct installation and the retaining nuts for proper torque.

With both nuts hand tightened, torque only inboard nut to 50 ft-lb.

c. Inspect for evidence of water or fuel leakage around cylinder heads.

TP 3905 11

Cylinder heads (continued).

d. Borescope cylinder, piston crown, valves and nozzle tip by removing the thermocouple and jacking engine over until the exhaust valves are open.

Insert flexible scope through open valves. Remove one head and disassemble to check valve, guide and stem wear at 12,000 hours. Record on data sheet.

Comments:

e. Run prelube pump and check for oil leaks and adequate lubrication of running gear assemblies and power pack assemblies. (Verify that there is no oil flow to the cylinder heads on the 270’ class 18-251 engines).

Comments:

8. Fuel control linkage and governor assembly.

a. Check uniformity of rack settings. (Use governor tail rod jack to position rack to full load gap).

Comments:

b. Check freedom of movement of all racks, linkage, and control shafts.

(Disconnect governor linkage and /or accelerator linkage).

Comments:

c. Check fuel injection pump pointer setscrew tightness and be sure that the pointer reading meets current PMS requirements.

Comments:

d. Check all linkage for lost motion with clevis pin nuts securely tightened against shoulders and all cotter keys in place.

Comments:

e. Work each spring lever and ensure that it returns to its original position with no evidence of binding.

Comments:

f. Check governor oil level and for oil leakage around base of governor.

Comments:

g. Visually check governor drive gear for excessive wear. Record readings on data sheet for 16-251 series engines only.

Comments:

h. Ensure that fuel rack limiter stop bolt is adjusted correctly, lockwired, and that the governor top (lid) is lockwired.

TP 3905 12

Fuel control linkage and governor assembly (continued).

i. Ensure that fuel injection pump control rack latches and retainers have been installed to position rack at zero.

Comments:

j. Spot-check fuel injection pump timing (minimum two pumps on each bank), record, satisfactory/unsatisfactory (SAT/UNSAT) on the data sheet.

Comments:

9. Jacket and Raw water pumps.

a. Check for any leakage observed out of the telltale hole and miscellaneous piping (leakage from telltale holes indicates defective mechanical seals).

Check telltale holes for blockage.

Comments:

b. Check all vent valves for proper operation.

Comments:

10. Lube oil system.

a. Check for any leakage of oil out of pipe connections and flanges (to be observed during operational test).

Comments:

b. Check for signs of overheating of lube oil pump housing.

Comments:

b. Remove and open one lube oil filter element per engine (lower one if installed) and inspect for types of contamination.

d. Inspect filter elements for correct type and installation.

No sock-type filters.

Comments:

e. Ensure that filter spring retainers have been installed.

Comments:

f. Check lube oil sampling valves for proper location, handwheels, and caps.

TP 3905 13

Lube oil system (continued).

g. Check lube oil strainer baskets for damage/contaminants.

Comments:

h. Shift lube oil strainer to check shifting chain for freedom of movement and material condition.

Comments:

i. Inspect lube oil strainer packing nut for excessive leakage.

Comments:

j. Check for completed PMS on testing of lube oil system relief, bypass, and pressure-regulating valves.

Comments:

11. Turbocharger.

a. Inspect turbocharger compressor rotating assembly for damage and/or oil seal leakage.

Comments:

b. Ensure that turbocharger rotor is not binding.

Comments:

c. Inspect external surface of the turbocharger for evidence of exhaust gas and jacket water leaks.

Comments:

d. Remove cover or plugs and inspect turbocharger aftercooler for dirt, fin damage, oil contamination, and jacket water leaks.

Comments:

e. Verify that the 1/16-inch shims have been installed for proper adjustment of turbocharger to exhaust manifold height.

Comments:

f. Measure bearing and thrust collar clearance. Record on data sheet.

Comments:

g. Measure inducer and blower casing clearance. Record on data sheet.

TP 3905 14

12. Fuel oil system.

a. Inspect flexible coupling for uneven or excessive wear.

Comments:

b. Inspect fuel oil booster pump drive shaft oil seal for evidence of leakage.

Comments:

c. Ensure that strainer T-handle turns freely.

Comments:

d. Check internal condition of strainers/coalescers.

Comments:

e. Inspect filter and strainer drain valves for proper operation.

Comments:

f. Ensure that fuel filter shifting device operates properly.

Comments:

g. Test fuel nozzles every 6,000 hours.

Comments:

13. Flexible hoses, piping, and fittings.

a. Inspect flexible hoses for cracks, fraying, rubbing, swelling, and deterioration.

Comments:

Fuel and lube oil systems are not permitted to have galvanized fittings.

14. Air intake system.

a. Inspect filter element for cleanliness and completeness; ensure that filter element is firmly seated in housing.

Comments:

b. Inspect air filter cover gasket for proper fit or deterioration.

Comments:

c. Inspect air ducting from filter-to-turbocharger air inlet for cracks, missing sections, loose or missing nuts, bolts, and rivets.

TP 3905 15

15. Safety devices.

a. Ensure that label plates for remotely operated safety devices identify correct engine and function.

Comments:

b. Remotely operate the emergency trip (inspect for frayed wire and improper connection. ) Comments:

c. Check manual trip stop lever capscrew for tightness and retainers for wear.

Comments:

16. Exhaust system.

a. Visually inspect engine exhaust system in space for leaks during operational test.

Comments:

b. Inspect hangers for material condition, and indications of movement.

Comments:

c. Check exhaust pipe/silencer drain valves for freedom of movement and clogging.

Comments:

17. Intake and exhaust manifolds.

a. Inspect air and exhaust elbows for proper securing devices, installation, and leaks.

Comments:

18. Heat exchangers and temperature regulation valves.

a. Inspect heat exchangers for external leaks.

Comments:

b. Inspect jacket water Amot valve manual/automatic levers for proper operation.

Comments:

c. Inspect lube oil Amot valve manual/automatic levers for proper operation (applies only to SSDG).

TP 3905 16

Heat exchangers and temperature regulation valves (continued).

d. Check condition of temperature regulating valve.

Comments:

e. Check for correct level of water in the expansion tank.

Comments:

f. Ensure that zinc maintenance is being performed on the jacket water cooler and generator air cooler according to current PMS requirements.

Comments:

19. Gages and instruments.

a. Check for proper operation, installation, and calibration during operational test.

Comments:

20. Crankcase exhauster system.

a. Check baffle plates for correct installation and cleanliness.

Comments:

b. Check all fittings for tightness.

Comments:

C. Check exhauster fan for proper operation during operational test.

TP 3905 17

TOLERANCE MEASUREMENT DATA SHEET

USCGC

DATE

ENGINE NO.

All measurements are to be obtained in accordance with current PMS requirements and current printed instructions.

SPEC ACTUAL

1. Crankshaft measurements:

a. Crankshaft thrust readings

b. Crankshaft deflection readings (TIR)

Show direction of rotation.

c. Main bearing “Press-ups” (four at 6,000 hour intervals at 18,000 hours).

Cyl No. 1 2 3 4 5 6 7 8 9 10

Clearance

d. Rod bearing inspection chart (one at 6,000 hour intervals 12,000 hours and beyond).

Cyl No. 1L 2L 3L 4L 5L 6L 7L 8L 9L Condition Cyl No. 1R 2R 3R 4R 5R 6R 7R 8R 9R Condition

TP 3905 18

TOLERANCE MEASUREMENT DATA SHEET (continued).

2. Turbocharger measurements: SPEC ACTUAL

a. Bearing thrust clearance

b. Inducer and blower casing clearance

3. Pump timing measurements:

a. Sat/Unsat

Cylinder 1 2 3 4 5 6 7 8 9 Left Right

4. Valve clearances as found, Spec is 0.034 inch (hot or cold).

a. Clearances as found:

Cylinder 1 2 3 4 5 6 7 8 9

b. Clearances reset to 0.034 inch: Hot , Cold (check one).

If there are any unusual wear patterns in the gear trains, take the following measurements:

5. Jacket water, Raw water and Lube oil pump backlash measurements:

a. Jacket water

b. Salt water

c. Oil pump backlash measurement

Pump Spec Min Max 0 90 180 270 AVG.

J/W S/W Oil Pump

TP 3905 19

TOLERANCE MEASUREMENT DATA SHEET (continued).

6. Governor backlash measurement MIN. MAX. AVG.

a. Bevel and pinion gears

b. Governor drive and camshaft gear

MIN. MAX. AVG.

7. Camshaft measurement (6,000hours)

a. Camshaft thrust

8. Borescope results:

Cylinder 1L 2L 3L 4L 5L 6L 7L 8L 9L

Piston Crown

Liner

Nozzle

Valves

Cylinder 1R 2R 3R 4R 5R 6R 7R 8R 9R

Piston Crown

Liner

Nozzle

Valves

TP 3905 20

9. Cylinder head disassembly (one)

a. Cylinder number

b. Record data in 0.000 inch.

Guides Valves Intake (inboard) Intake (inboard) Intake Intake Exhaust (inboard) Exhaust (inboard) Exhaust Exhaust

TP 3905 21

OPERATIONAL TEST

DATA SHEET

Ship name: Engine rpm:

Engine No: KW:

Date: Amps:

Hrs. since overhaul: Volts:

Hrs. since last trend: Governor position:

Sea state (MPDE only): Control air psi:

Ships draft (MPDE only): Shaft rpm (MPDE only):

% of pitch (MPE only):

Exhaust Temperature

Cyl No. 1L 2L 3L 4L 5L 6L 7L 8L 9L Ex. Temp Fi. Pres.* Com Pres.

Rack Pos*

Cyl No. 1R 2R 3R 4R 5R 6R 7R 8R 9R Ex. Temp Fi. Pres.* Com Pres.

Rack Pos*

*Record at the same time.

Pressures: Temperatures:

Crankcase vacuum: J.W. to engine:

Fuel header/pump press: J.W. from engine:

L.O. pump disch: L.O. to engine:

J.W. pump disch: L.O. from engine:

S.W. pump disch: Salt Water in:

Generator brg—fwd: Salt Water Ovbd:

TP 3905 22

Generator brg—aft: Generator brg—fwd:

L.O. strainer DP: Generator brg—aft:

TP 3905 23

L.O. filter DP:

Air box press/turbo: Overspeed Trip Setting:

HIGH LOW DIFFERENCE

Cylinder Firing Pressures:

Cylinder compression pressures:

Cylinder exhaust temperatures:

ACTUAL

Left bank combined exhaust temp:

Right bank combined exhaust temp:

Difference between left and right banks:

ALCO ENGINES OPERATIONAL TEST DATA SHEET

Front Matter: