S9311-A1-MMM-010(SHIP SERVICE GENERATOR).pdf

TECHNICAL MANUAL

FOR

[SGML VERSION; SEE CHANGE

RECORD ]

SHIP SERVICE GENERATOR

CHAPTERS 1 THROUGH 6

OPERATION, MAINTENANCE, AND REPAIR

INSTRUCTIONS WITH PARTS LIST

ORGANIZATIONAL, INTERMEDIATE, AND

DEPOT MAINTENANCE LEVELS

DISTRIBUTION STATEMENT B: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT

AGENCIES ONLY; THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR FOR

ADMINISTRATIVE OR OPERATIONAL PURPOSES: (15 OCTOBER 1986). OTHER

REQUESTS FOR THIS DOCUMENT MUST BE REFERRED TO THE NAVAL SEA SYS-

TEMS COMMAND (SEA-09T).

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(D).

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO-

SURE OF CONTENTS OR RECONSTRUCTION OF THIS DOCUMENT.

S9311-A1-MMM-010

0910-LP-094-3600 VOLUME 1

Change C TITLE-1 / (TITLE-2 Blank)@@FIpgtype@@TITLE@@!FIpgtype@@ @@FIpgtype@@TITLE@@!FIpgtype@@

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

15 OCT 1986

CHANGE C 15 JAN 2005

CHANGE RECORD

CHANGE NO. DATE TITLE AND/OR BRIEF DESCRIPTION/PREPARING ACTIVITY

A NI

B 1 MARCH 1999 INCORPORATED TMDERS P40498. R27848, R31930-90-0000,

R36764-92-0000, R47589-96-0000, R48725-96-0000, T15831-97-0001

TO CHANGE TABLE 2-1, ENGINE SHUTDOWN LOW LUBE OIL

PRESSURE, LOW SPEED/HIGH SPEED TO READ 20± 5 /30 ± 5

PSIG; TO CHANGE MINIMUM OIL PRESSURES, PARAGRAPH

3-9.5.1; AND TO REVISE CRANKSHAFT THRUST CLEARANCE

IN PARAGRAPH 4-2.37.3.2.C AND CRANKSHAFT END PLAY

CLEARANCE ON TABLE 6-4.

C 15 JANUARY 2005 INCORPORATED TMDER N65540-02-SC24 TO CORRECT JACKET

WATER MAXIMUM TEMPERATURE. CHANGE AUTHORIZED BY

NSWCCD-SSES CODES 9442 AND 9325. THE FOLLOWING WAS

CHANGED:

PARAGRAPH(S) AND 2-3.3.2.2

FIGURE(S) 2-8.

NOTE

THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONIC

SOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NO LOEP.

ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOT MATCH THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE CONTENT IS EXACTLY THE SAME.

ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TMWILL ONLY FIT IN THIS PAGINATED VERSION.

S9311-A1-MMM-010

Change C CHANGE RECORD-1 / (CHANGE RECORD-2 Blank)

FOREWORD

This technical manual contains operation, maintenance, and repair instructions for the Ship Service Gen-erator. The manual is applicable to ships identifie in the Approval and Procurement Record Page.

This technical manual consists of two volumes. Volume I contains the following chapters:

Chapter Title

1 General Information and Safety Precautions 2 Operation 3 Functional Description 4 Scheduled Maintenance 5 Troubleshooting 6 Corrective Maintenance

Volume II contains the remaining chapters:

7 Parts List

8 Installation

Ships, training activities, supply points, depots, Naval Shipyards and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors, omissions, discrepancies and suggestions for improvement to NAVSEA technical manuals shall be forwarded to:

COMMANDER,

CODE 310 TMDER, BLDG 1389

NAVSURFWARCENDIV NSDSA

4363 MISSILE WAY

PORT HUENEME CA 93043-4307

on NAVSEA/SPAWAR Technical Manual Deficiency/Evaluatio Report (TMDER), NAVSEA form 4160/1. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting therefrom.

One copy of NAVSEA form 4160/1 is at the end of each separately bound technical manual 8-1/2 x 11 inches or larger. Copies of NAVSEA form 4160/1 may be requisitioned from the Naval Systems Data Support Activity Code 310 at the above address. Users are encouraged to transmit deficienc submittals via the Naval Systems Data Support Activity web site located at:

https://nsdsa.nmci.navy.mil/tmder/tmder.asp?lvl=1

Individual electronic TMs do not contain NAVSEA form 4160/1 but are linked to an electronic version on the resident CD-ROM. Therefore, we encourage the user to transmit deficienc submittals via the Naval Systems Data Support Activity web site located above.

Change C FOREWORD-1 / (FOREWORD-2 Blank)

TABLE OF CONTENTS

Chapter/Paragraph Page

1 GENERAL INFORMATION AND SAFETY PRECAUTIONS . . . . . . . . . . . 1-1

1-1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1.1 PROTECTIVE CLOTHING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1.2 KEEP AWAY FROM LIVE CIRCUITS. . . . . . . . . . . . . . . . . . . . . 1-1

1-1.3 DO NOT SERVICE OR ADJUST ALONE. . . . . . . . . . . . . . . . . . . 1-1

1-1.4 RESUSCITATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1.5 FUEL MIST HAZARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1.6 EXHAUST STACK FIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1.7 ENGINE IDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1.8 DO NOT OPERATE THE ENGINE WITH LOOSE CRANKCASE

COVERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1.9 PRESSURIZED HOT FLUIDS. . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1.10 OIL ACCUMULATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-1.11 MOVING PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-2 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-3 EQUIPMENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-3.1 CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-3.1.1 THE ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-3.1.2 COUPLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-3.1.3 THE GENERATOR. . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-3.1.4 THE EXCITERS. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1-3.2 PRINCIPLE OF ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . 1-22

1-3.2.1 INTAKE STROKE. . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

1-3.2.2 COMPRESSION STROKE. . . . . . . . . . . . . . . . . . . . . 1-23

1-3.2.3 POWER STROKE. . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

1-3.2.4 EXHAUST STROKE. . . . . . . . . . . . . . . . . . . . . . . . . 1-23

1-3.2.5 FIRING ORDER. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

1-3.3 PRINCIPLE OF GENERATOR OPERATION. . . . . . . . . . . . . . . . . . 1-23

1-3-3.1 THEORY OF GENERATION. . . . . . . . . . . . . . . . . . . . 1-23

1-3.3.2 ARMATURE REACTION. . . . . . . . . . . . . . . . . . . . . . 1-23

1-3.3.3 OUTPUT FREQUENCY AND PHASE. . . . . . . . . . . . . . . 1-26

1-3.4 PRINCIPLE OF EXCITATION SYSTEM OPERATION. . . . . . . . . . . . 1-26

1-3.4.1 SHUNT STATIC EXCITERS. . . . . . . . . . . . . . . . . . . . 1-26

1-3.4.2 EXCITATION SUPPORT SYSTEM. . . . . . . . . . . . . . . . . 1-26

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2 CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2.1 ENGINE CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . 2-2

2-2.1.1 INSTRUMENT PANEL (Figure 3-26). . . . . . . . . . . . . . . 2-2 2-2.1.2 FUEL OIL DRAIN SWITCH (Figure 1-3 Sheet 2). . . . . . . . 2-2

Change C i

TABLE OF CONTENTS - Continued

2-2.1.3 LUBE OIL FILTER SERVICE INDICATOR (14, figur 2-6). . . 2-2 2-2.1.4 CRANKCASE DIPSTICK (Figure 1-3 Sheet 3). . . . . . . . . . 2-2 2-2.1.5 EXPANSION TANK WATER LEVEL SWITCH (Figure 1-3

Sheet 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-2.1.6 CRANKCASE PRESSURE MANOMETER (Figure 1-3 Sheet

3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2-2.1.7 AIR CLEANER SERVICE INDICATOR (Figure 1-3 Sheet 4). . 2-3 2-2.1.8 MANUAL AIR START VALVE (Figure 1-3 Sheet 3). . . . . . . 2-3 2-2.1.9 AIR START SOLENOID VALVE (Figure 1-3 Sheet 3). . . . . . 2-3

2-2.1.10 GOVERNOR/ACTUATOR. . . . . . . . . . . . . . . . . . . . . . 2-3

2-2.1.11 HYDRA-MECHANICAL SHUT-DOWN. . . . . . . . . . . . . . 2-3

2-2.1.12 MECHANICAL SHUT-OFF. . . . . . . . . . . . . . . . . . . . . 2-3

2-2.1.13 MECHANICAL SHUT-OFF RESET LEVER. . . . . . . . . . . 2-3

2-2.1.14 EMERGENCY MANUAL SHUTOFF. . . . . . . . . . . . . . . 2-3

2-2.2 GENERATOR CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . 2-4

2-2.2.1 STATOR TEMPERATURE DETECTORS. . . . . . . . . . . . . 2-4

2-2.2.2 BEARING TEMPERATURE DETECTORS. . . . . . . . . . . . 2-4

2-2.2.3 GENERATOR AIR TEMPERATURE DETECTOR. . . . . . . . 2-4

2-2.3 EXCITATION SYSTEM CONTROLS AND INDICATORS (See figur 2-1 and figur 2-2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-2.3.1 VOLTAGE REGULATOR AUTO/MANUAL SWITCH AND

MANUAL VOLTAGE ADJUST. . . . . . . . . . . . . . . . . 2-9

2-2.3.2 VOLTAGE REGULATOR AUTOMATIC ADJUST. . . . . . . . 2-9

2-2.3.3 MANUAL FIELD FLASHING SWITCH. . . . . . . . . . . . . . 2-9

2-2.3.4 EXCITATION CIRCUIT BREAKER. . . . . . . . . . . . . . . . 2-9

2-3 OPERATING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-3.1 PRE-START CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-3.2 STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-3.2.1 NORMAL STARTING FROM THE REMOTE STATION. . . . 2-10

2-3.2.2 STARTING FROM THE LOCAL (SWITCHBOARD)

STATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2-3.2.3 STARTING FROM THE LOCAL (ENGINE) STATION. . . . . 2-11

2-3.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2-3.3.1 NORMAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . 2-12

2-3.3.2 ABNORMAL AND EMERGENCY OPERATION. . . . . . . . . 2-12

2-3.3.2.1 LOSS OF ELECTRIC GOVERNOR CONTROL. . 2-12

2-3.3.2.2 LOSS OF SEA WATER COOLING. . . . . . . . . . 2-13

2-3.4 SHUTTING DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-3.4.1 NORMAL STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-3.4.2 EMERGENCY STOP. . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-4 OPERATOR MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . 2-13 2-4.1 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-4.1.1 FUEL OIL STRAINER. . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-4.1.2 PRIMING THE FUEL SYSTEM. . . . . . . . . . . . . . . . . . 2-16

2-4.1.3 CLEANING THE FUEL OIL DUPLEX FILTER. . . . . . . . . 2-16

ii Change C

2-4.1.4 LUBE OIL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-4.1.4.1 MAIN LUBE OIL FILTER. . . . . . . . . . . . . . . 2-18

2-4.1.4.2 AUXILIARY LUBE OIL FILTER (Figure 2-6). . . . 2-21

2-4.1.5 JACKET WATER COOLING SYSTEM. . . . . . . . . . . . . . 2-21

2-4.1.6 SEAWATER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 2-22

2-4.1.7 INDUCTION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 2-22

2-4.2 GENERATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 2-4.3 EXCITATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2-5 STANDARD LOG FORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 2-5.1 PURPOSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 2-5.2 TRAINING SUMMARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2-5.2.1 SIGNIFIGANCE OF MONITORING POINTS. . . . . . . . . . 2-25

2-5.2.2 SIGNIFICANCE OF READINGS. . . . . . . . . . . . . . . . . . 2-25

2-5.2.3 USING THE FORM. . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2-5.2.4 ACTION FOR READINGS OUT OF TOLERANCE. . . . . . . 2-25

3 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2 THE ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2.1 ENGINE BLOCK (Figure 7-1). . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2.1.1 COVERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2.1.2 CYLINDER LINER. . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2.1.3 LIFTING EYES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2.2 OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2.3 CRANKSHAFT (Figure 7-3). . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2.3.1 MAIN AND THRUST BEARINGS. . . . . . . . . . . . . . . . . 3-2

3-2.3.2 TORSIONAL VIBRATION DAMPER. . . . . . . . . . . . . . . 3-2

3-2.3.3 FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2.4 DRIVE COUPLING (Figure 3-1). . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-2.5 CAMSHAFT (Figure 7-6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-2.6 PISTONS AND CONNECTING RODS (Figure 7-7). . . . . . . . . . . . . . 3-2 3-2.7 CYLINDER HEAD (Figure 3-2). . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-2.7.1 INTAKE AND EXHAUST VALVES. . . . . . . . . . . . . . . . 3-4

3-2.7.2 LIFTERS, PUSHRODS, AND ROCKER ARMS. . . . . . . . . 3-4

3-2.7.3 PRECOMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . 3-4

3-2.8 FRONT ACCESSORY DRIVE (Figure 3-3). . . . . . . . . . . . . . . . . . . 3-4 3-2.9 FUEL PUMP AND GOVERNOR DRIVE (Figure 6-21). . . . . . . . . . . . 3-4 3-2.10 EMISSION CONTROL FILTER (Figure 1-3, sheet 3). . . . . . . . . . . . . 3-7

3-3 FUEL SYSTEM (Figure 3-4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3-3.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3-3.2 FUEL TRANSFER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3-3.3 FUEL INJECTION PUMP (Figure 3-5). . . . . . . . . . . . . . . . . . . . . 3-7 3-3.4 FUEL INJECTION VALVE, (Figure 3-6). . . . . . . . . . . . . . . . . . . . 3-7

Change C iii

3-3.5 FUEL OIL PRIMING PUMP (Figure 3-7). . . . . . . . . . . . . . . . . . . . 3-7 3-3.6 FUEL OIL REGULATOR VALVE. . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-3.7 FUEL OIL DUPLEX FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-3.8 PRIMARY FUEL OIL STRAINERS. . . . . . . . . . . . . . . . . . . . . . . 3-12

3-4 LUBE OIL SYSTEM (Figure 3-8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-4.2 LUBE OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-4.3 OIL COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-4.4 MAIN LUBE OIL FILTER (Figure 3-9). . . . . . . . . . . . . . . . . . . . . 3-14 3-4.5 AUXILIARY LUBE OIL FILTER. . . . . . . . . . . . . . . . . . . . . . . . 3-14 3-4.6 VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-4.6.1 LUBE OIL DIVERTER VALVE (Figure 3-10). . . . . . . . . . . 3-14

3-4.6.2 LUBE OIL FILTER VENT VALVE. . . . . . . . . . . . . . . . . 3-14

3-4.7 GAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3-4.8 SUMP PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-5 JACKET WATER SYSTEM (Figure 3-11). . . . . . . . . . . . . . . . . . . . . . . . 3-17 3-5.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 3-5.2 JACKET WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 3-5.3 HEAT EXCHANGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-5.4 JACKET WATER (KEEP-WARM) HEATER. . . . . . . . . . . . . . . . . . 3-17

3-5.5 WATER TEMPERATURE REGULATORS. . . . . . . . . . . . . . . . . . . 3-19

3-5.6 EXPANSION TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3-5.6.1 PRESSURE RELIEF CAP. . . . . . . . . . . . . . . . . . . . . . 3-19

3-5.6.2 LIQUID LEVEL SWITCH. . . . . . . . . . . . . . . . . . . . . . 3-19

3-6 SEAWATER SYSTEM (Figure 3-12). . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 3-6.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 3-6.2 SEAWATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3-7 INDUCTION AND EXHAUST SYSTEMS (Figure 3-13). . . . . . . . . . . . . . . . 3-19 3-7.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 3-7.2 TURBOCHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 3-7.3 AFTERCOOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 3-7.4 AIR CLEANER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 3-7.5 INTAKE MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-7.5.1 AIR SHUT-OFF VALVE (Figure 3-16). . . . . . . . . . . . . . . 3-22

3-7.5.2 AIR INLET TEMPERATURE SENSOR. . . . . . . . . . . . . . 3-22

3-7.6 EXHAUST MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 3-7.7 EXHAUST ELBOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3-8 AIR START SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 3-8.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 3-8.2 AIR START MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 3-8.3 PRELUBE PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 3-8.4 MANUAL AIR START VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 iv Change C

3-8.5 ELECTRIC SOLENOID VALVE. . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-8.6 OIL PRESSURE LOCKOUT VALVE. . . . . . . . . . . . . . . . . . . . . . 3-31

3-8.7 AIR PILOTED RELAY VALVE. . . . . . . . . . . . . . . . . . . . . . . . . 3-31 3-8.8 OIL PILOTED RELAY VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 3-8.9 QUICK-RELEASE VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 3-8.10 LUBRICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-9 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 3-9.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 3-9.2 GOVERNOR/ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-9.2.1 ELECTRO-HYDRAULIC CONTROL (Figure 3-21). . . . . . . 3-31 3-9.2.2 MECHANICAL-HYDRAULIC CONTROL (Figure 3-21). . . . 3-32

3-9.2.3 ELECTRICAL-MECHANICAL CONTROL INTERACTION

(Figure 3-21). . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 3-9.2.4 SHUT-DOWN SOLENOID (Figure 3-21). . . . . . . . . . . . . 3-32

3-9.2.5 GOVERNOR ADJUSTMENTS. . . . . . . . . . . . . . . . . . . 3-32

3-9.2.5.1 SPEED DROOP (Figure 3-21). . . . . . . . . . . . . 3-32

3-9.2.5.2 LOAD CONTROL. . . . . . . . . . . . . . . . . . . 3-38

3-9.2.5.3 SPEED CONTROL. . . . . . . . . . . . . . . . . . . 3-38

3-9.3 EMERGENCY MANUAL SHUT-OFF. . . . . . . . . . . . . . . . . . . . . . 3-38

3-9.4 MECHANICAL FUEL RACK SHUT-OFF. . . . . . . . . . . . . . . . . . . . 3-38

3-9.4.1 LOW OIL PRESSURE SHUT-OFF (Figure 3-23). . . . . . . . . 3-38

3-9.4.2 OVERSPEED SHUT-OFF. . . . . . . . . . . . . . . . . . . . . . 3-40

3-9.4.3 EMERGENCY MANUAL SHUTOFF BUTTON (Figure 3-23b).

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-9.4.4 RESETTING THE MECHANICAL FUEL RACK SHUT-OFF. . 3-40

3-9.5 HYDRA-MECHANICAL SHUT-DOWN (Figure 3-24 and Figure 3-25). . . 3-40

3-9.5.1 LOW OIL PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-9.5.2 HIGH JACKET WATER TEMPERATURE. . . . . . . . . . . . . 3-43

3-9.5.3 OVERSPEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3-9.5.4 MANUAL SHUTDOWN (Figure 3-25). . . . . . . . . . . . . . . 3-43

3-10 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 3-10.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 3-10.2 INSTRUMENT PANEL (Figure 3-26). . . . . . . . . . . . . . . . . . . . . . 3-43

3-10.2.1 PRESSURE GAGES. . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-10.2.2 TEMPERATURE GAGES. . . . . . . . . . . . . . . . . . . . . . 3-45

3-10.2.3 TACHOMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-10.3 MAGNETIC PICK-UP DEVICE. . . . . . . . . . . . . . . . . . . . . . . . . 3-45 3-10.4 SERVICE METER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-11 THE GENERATOR (Figure 1-5 and Figure 7-66). . . . . . . . . . . . . . . . . . . . 3-45 3-11.1 AIR COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 3-11.2 GENERATOR ROTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-11.2.1 ROTOR SPIDER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-11.2.2 POLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-11.3 STATOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

Change C v

3-11.3.1 STATOR FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-11.3.2 STATOR CORE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-11.3.3 STATOR COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-11.3.4 FINAL INSULATION. . . . . . . . . . . . . . . . . . . . . . . . 3-47

3-11.4 FANS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 3-11.5 RESISTANCE TEMPERATURE DETECTORS (RTDs). . . . . . . . . . . . 3-47 3-11.6 COLLECTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 3-11.7 EXCITER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3-11.7.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3-11.7.2 SSE FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3-11.7.2.1 EXCITATION POWER. . . . . . . . . . . . . . . . . 3-48

3-11.7.2.2 AUTOMATIC EXCITATION CONTROL. . . . . . . 3-48

3-11.7.2.3 UNDERFREQUENCY LIMITER. . . . . . . . . . . 3-48

3-11.7.2.4 VOLTAGE DROOP. . . . . . . . . . . . . . . . . . . 3-51

3-11.7.3 ESS FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

3-11.7.3.1 ESS POWER. . . . . . . . . . . . . . . . . . . . . . 3-51

3-11.7.3.2 EXCITATION CONTROL. . . . . . . . . . . . . . . 3-51

3-11.7.3.3 ESS FEATURES. . . . . . . . . . . . . . . . . . . . . 3-51

3-11.7.3.4 ESS DISABLE. . . . . . . . . . . . . . . . . . . . . 3-51

3-11.7.3.5 SSE DISABLE. . . . . . . . . . . . . . . . . . . . . 3-51

3-11.7.3.6 EXCITATION SHUTDOWN. . . . . . . . . . . . . . 3-51

3-11.7.4 OPERATIONAL SEQUENCE. . . . . . . . . . . . . . . . . . . . 3-51

4 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1.1 CONTENT AND PRESENTATION. . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1.2 PLANNED MAINTENANCE SYSTEM. . . . . . . . . . . . . . . . . . . . . 4-1

4-2 SCHEDULED MAINTENANCE ACTIONS. . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2.1 INSPECT TURBOCHARGER AIR INTAKE FILTER INDICATORS. . . . . 4-4

4-2.1.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-4

4-2.1.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-4

4-2.1.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-2.2 TEST ENGINE LUBRICATING OIL FOR VISCOSITY. . . . . . . . . . . . 4-5

4-2.2.1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . 4-5

4-2.2.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-5

4-2.2.3 SAMPLING PROCEDURE. . . . . . . . . . . . . . . . . . . . . 4-5

4-2.2.4 TESTING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 4-6

4-2.3 CLEAN AND INSPECT BRUSHES AND COLLECTOR RINGS. . . . . . . 4-6

4-2.3.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-6

4-2.3.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-6

4-2.3.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-2.4 TEST COOLING SYSTEM SODIUM CHROMATE-DISODIUM

PHOSPHATE MIXTURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-2.4.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-9

4-2.4.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-11

vi Change C

4-2.4.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-2.5 RUN SECURED SHIP SERVICE GENERATORS (WEEKLY). . . . . . . . 4-13

4-2.5.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-13

4-2.5.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-13

4-2.5.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-2.6 CHECK INSULATION RESISTANCE OF GENERATOR. . . . . . . . . . . 4-13

4-2.6.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-13

4-2.6.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-13

4-2.6.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-2.6.3.1 MEASURING STATOR INSULATION

RESISTANCE. . . . . . . . . . . . . . . . . . . . 4-13

4-2.6.3.2 MEASURING ROTOR INSULATION

RESISTANCE. . . . . . . . . . . . . . . . . . . . 4-14

4-2.7 TEST ENGINE LUBRICATING OIL FOR ACIDITY. . . . . . . . . . . . . 4-14

4-2.7.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-14

4-2.7.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-14

4-2.7.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-2.8 CLEAN AIR-START MOTOR LUBRICATOR. . . . . . . . . . . . . . . . . 4-15

4-2.8.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-15

4-2.8.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-15

4-2.8.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-2.9 LUBRICATE ENGINE COMPONENTS. . . . . . . . . . . . . . . . . . . . . 4-16

4-2.9.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-16

4-2.9.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-16

4-2.9.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-2.10 RUN SECURED SHIP SERVICE GENERATORS (MONTHLY). . . . . . . 4-16

4-2.10.1 SAFETY PRECAUTION. . . . . . . . . . . . . . . . . . . . . . . 4-16

4-2.10.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-16

4-2.10.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-2.11 INSPECT ZINC RODS IN AIR COOLERS. . . . . . . . . . . . . . . . . . . 4-17

4-2.11.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-17

4-2.11.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-17

4-2-11.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-2.12 WATER tEMPERATURE REGULATOR TESTING. . . . . . . . . . . . . . 4-17

4-2.12.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-17

4-2.12.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-18

4-2.12.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-2.13 TEST REMOTE MANUAL SHUTDOWN (HYDRA-MECHANICAL

SHUTDOWN DEVICE). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-2.13.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-18

4-2.13.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-18

4-2.13.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-2.14 THERMOSTATIC PILOT VALVE TESTING. . . . . . . . . . . . . . . . . . 4-19

4-2.14.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-19

4-2.14.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-19

4-2.14.3 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Change C vii

4-2.15 TEST ENGINE OVERSPEED DEVICE (HYDRA-MECHANICAL). . . . . 4-20

4-2.15.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-20

4-2.15.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-20

4-2.15.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-2.16 SPECTROGRAPHIC, PHYSICAL, AND CHEMICAL ANALYSIS OF

LUBRICATING OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-2.16.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-22

4-2.16.2 TOOLS/MATERIAL. . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-2.16.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-2.17 CHECK AND ADJUST BRUSH PRESSURE. . . . . . . . . . . . . . . . . . 4-23

4-2.17.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-23

4-2.17.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-23

4-2.17.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4-2.18 MEASURE TURBOCHARGER CLEARANCE. . . . . . . . . . . . . . . . . 4-23

4-2.18.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-23

4-2.18.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-23

4-2.18.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-2.19 INSPECT FOUNDATION BOLTS, SCREWS, AND RESILIENT

MOUNTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-2.19.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-24

4-2.19.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-24

4-2.19.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-2.20 CHANGE OIL IN GOVERNOR. . . . . . . . . . . . . . . . . . . . . . . . . 4-27

4-2.20.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-27

4-2.20.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-27

4-2.20.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

4-2.21 CLEAN CRANKCASE BREATHER AND CHANGE EMISSION

CONTROL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

4-2.21.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-27

4-2.21.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-27

4-2.21.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

4-2.22 TEST COOLING SYSTEM SOLUBLE OIL MIXTURE. . . . . . . . . . . . 4-28

4-2.22.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-28

4-2.22.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-28

4-2.22.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

4-2.23 TEST COOLING SYSTEM ANTIFREEZE MIXTURE. . . . . . . . . . . . 4-29

4-2.23.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-29

4-2.23.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-29

4-2.23.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4-2.24 INSPECT ZINC RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4-2.24.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-31

4-2.24.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-31

4-2.24.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4-2.25 LUBRICATE GENERATOR BALL BEARINGS. . . . . . . . . . . . . . . . 4-31

4-2.25.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-31

4-2.25.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-31

viii Change C

4-2.25.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

4-2.26 INSPECT AND TIGHTEN ELECTRICAL EQUIPMENT. . . . . . . . . . . 4-32

4-2.26.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-32

4-2.26.2 TOOLS/MATERIALS REQUIRED . . . . . . . . . . . . . . . . 4-32

4-2.26.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

4-2.27 THOROUGHLY CLEAN THE GENERATOR. . . . . . . . . . . . . . . . . . 4-33

4-2.27.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-33

4-2.27.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-33

4-2.27.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

4-2.28 INSPECT FANS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

4.2.28.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-34

4-2.28.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-34

4-2.28.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

4-2.29 INSPECT CYLINDER HEAD ASSEMBLIES. . . . . . . . . . . . . . . . . . 4-34

4-2.29.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-34

4-2.29.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-34

4-2.29.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

4-2.30 TEST FUEL INJECTION VALVES. . . . . . . . . . . . . . . . . . . . . . . 4-35

4-2.30.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-35

4-2-30.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-35

4-2.30.3 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

4-2.31 GAGE AND SENSOR MAINTENANCE. . . . . . . . . . . . . . . . . . . . 4-38

4-2.31.1 TEST TACHOMETER. . . . . . . . . . . . . . . . . . . . . . . . 4-38

4-2.31.2 CLEAN AND INSPECT THERMOCOUPLES. . . . . . . . . . . 4-38

4-2.31.2.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . 4-38

4-2.31.2.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . 4-38

4-2.31.2.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . 4-38

4-2.31.3 TEST AIR TEMPERATURE GAGES. . . . . . . . . . . . . . . . 4-39

4-2.31.3.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . 4-39

4-2.31.3.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . 4-39

4-2.31.3.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . 4-39

4-2.31.4 TEST OIL AND WATER TEMPERATURE GAGES. . . . . . . 4-39

4-2.31.5 TEST FUEL PRESSURE GAGE. . . . . . . . . . . . . . . . . . 4-39

4-2.31.5.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . 4-39

4-2.31.5.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . 4-39

4-2.31.5.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . 4-39

4-2.31.6 TEST OIL PRESSURE GAGE. . . . . . . . . . . . . . . . . . . 4-39

4-2.32 INSPECT DRIVE COUPLING RUBBER BLOCKS. . . . . . . . . . . . . . 4-39

4-2.32.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-39

4-2.32.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-40

4-3.32.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

4-2.33 INSPECT AND CLEAN WINDINGS AND INSULATION. . . . . . . . . . 4-40

4-2.33.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-40

4-2.33.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-40

4-2.33.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

4-2.34 INSPECT AND CLEAN GENERATOR AIR COOLERS. . . . . . . . . . . . 4-41

Change C ix

4-2.34.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-41

4-2.34.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-41

4-2.34.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

4-2.35 INSPECT AND CLEAN GENERATOR EXCITATION SYSTEM. . . . . . . 4-42

4-2.35.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-42

4-2.35.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-42

4-2.35.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

4-2.36 TEST GENERATOR RESISTANCE TEMPERATURE DETECTORS

(RTD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

4-2.36.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-42

4-2.36.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-43

4-2.36.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

4-2.37 CRANKSHAFT MEASUREMENTS. . . . . . . . . . . . . . . . . . . . . . . 4-43

4-2.37.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-43

4-2.37.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-43

4-2.37.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

4-2.37.3.1 MEASURE CRANKSHAFT DEFLECTION. . . . . 4-44

4-2.37.3.2 MEASURE CRANKSHAFT THRUST

CLEARANCE. . . . . . . . . . . . . . . . . . . . 4-44

4-2.38 INSPECT SEAWATER PUMP INTERNAL PARTS. . . . . . . . . . . . . . . 4-47

4-2.38.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-47

4-2.38.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-47

4-2.38.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

4-2.39 INSPECT STARTER PINION DRIVE. . . . . . . . . . . . . . . . . . . . . . 4-48

4-2.39.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-48

4-2.39.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-48

4-2.39.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

4-2.40 INSPECT FLYWHEEL RING GEAR. . . . . . . . . . . . . . . . . . . . . . 4-48

4-2.40.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-48

4-2.40.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-49

4-2.40.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

4-2.41 INSPECT CYLINDER HEADS. . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

4-2.41.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-49

4-2.41.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-49

4-2.41.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

4-2.42 REPLACE SERVICE METER. . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

4-2.42.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-53

4-2.42.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-53

4-2.42.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

4-2.43 REPLACE VIBRATION DAMPER. . . . . . . . . . . . . . . . . . . . . . . 4-53

4-2.43.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-53

4-2.43.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-53

4-2.43.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

4-2.44 INSPECT INTERNAL PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

4-2.44.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-54

4-2.44.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-55

x Change C

4-2.44.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

4-2.45 CLEAN JACKET WATER HEAT EXCHANGER. . . . . . . . . . . . . . . . 4-60

4-2-45.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-60

4-2.45.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-60

4-2.45.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

4-2.46 CLEAN AND INSPECT LUBE OIL PUMP SUCTION STRAINER. . . . . 4-61

4-2.46.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-61

4-2.46.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-61

4-2.46.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61

4-2.47 CLEAN AND INSPECT AFTERCOOLER, (Figure 6-44). . . . . . . . . . . 4-62

4-2.47.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-62

4-2.47.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-62

4-2.47.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

4-2.48 CLEAN AND INSPECT CRANKCASE EXPLOSION RELIEF VALVES. . 4-63

4-2.48.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-63

4-2.48.2 TOOLS/MATERIALS REQUIRED. . . . . . . . . . . . . . . . . 4-63

4-2.48.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

4-2.49 REBUILD FUEL INJECTION SYSTEM. . . . . . . . . . . . . . . . . . . . 4-64

4-2.49.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-64

4-2.49.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-64

4-2.49.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

4-2.50 REPLACE RESILIENT SHAFT COUPLING RUBBER BLOCKS. . . . . . 4-65

4-2.50.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-65

4-2.50.2 TOOLS/MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . 4-65

4-2.50.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

4-2.51 CHANGE ENGINE LUBE OIL. . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

4-2.51.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-66

4-2.51.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-66

4-2.51.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

4-2.52 TEST ENGINE JACKET WATER SYSTEM. . . . . . . . . . . . . . . . . . 4-67

4-2.52.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-67

4-2.52.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-67

4-2.52.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

4-2.53 INSPECT FUEL OIL TRANSFER PUMP AND LUBE OIL PUMP

INTERNAL PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

4-2.53.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-68

4-2.53.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-68

4-2.53.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

4-2.54 INSPECT JACKET WATER PUMP INTERNAL PARTS; REPLACE

MECHANICAL SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

4-2.54.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-70

4-2.54.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-70

4-2.54.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70

4-2.55 TESTING LEVEL SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

4-2.55.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-71

4-2.55.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-71

Change C xi

4-2.55.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

4-2.55.3.1 JACKET WATER EXPANSION TANK. . . . . . . . 4-71

4-2.55.3.2 FUEL OIL DRAIN LEVEL SWITCH (8, figur

7-24). . . . . . . . . . . . . . . . . . . . . . . . . . 4-71

4-2.56 JACKET WATER HEATER THERMOSTAT CALIBRATION. . . . . . . . . 4-72

4-2.56.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-72

4-2.56.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-72

4-2.56.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72

4-2.57 JACKET WATER HEATER THERMAL CUTOUT CALIBRATION. . . . . 4-73

4-2.57.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-73

4-2.57.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-73

4-2.57.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73

4-2.58 INSPECT THE JACKET WATER HEATER. . . . . . . . . . . . . . . . . . . 4-74

4-2.58.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-74

4-2.58.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-74

4-2.58.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

4-2.59 PREPARE ENGINE FOR LAY-UP. . . . . . . . . . . . . . . . . . . . . . . . 4-75

4-2.59.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-75

4-2.59.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-75

4-3.59.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

4-2.60 PREPARE ENGINE FOR START-UP. . . . . . . . . . . . . . . . . . . . . . 4-76

4-2.60.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-76

4-2.60.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-76

4-2.60.3 PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

4-2.61 LAY-UP MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

4-2.61.1 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . 4-77

4-2.61.2 TOOLS/MATERIAL REQUIRED. . . . . . . . . . . . . . . . . . 4-77

4-2.61.3. PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

4-2.61.3.1 INSPECT WATER LEVEL IN EXPANSION TANK

(For engines layed-up less than 6 months). . . . . 4-77

4-2.61.3.2 TURN ENGINE OVER 1-1/4 TURNS. . . . . . . . 4-77

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2 TROUBLESHOOTING CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

SECTION I. ADJUSTMENT AND ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-2.1 VALVE LASH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-2.2 FUEL INJECTION PUMP TIMING. . . . . . . . . . . . . . . . . . . . . . . 6-3 xii Change C

6-2.2.1 TIMING THE FUEL INJECTION PUMP TO THE

FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-2.2.2 FUEL INJECTION PUMP TIMING (ON ENGINE). . . . . . . . 6-6

6-2.2.3. FUEL INJECTION PUMP TIMING (OFF ENGINE). . . . . . . 6-8

6-2.3 FUEL RACK AND GOVERNOR LINKAGE ADJUSTMENT. . . . . . . . . 6-10

6-2.3.1 FUEL RACK ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 6-10

6-2.3.2 GOVERNOR LINKAGE ADJUSTMENT (Figure 6-6). . . . . . 6-11

6-2.4 MECHANICAL FUEL RACK SHUT-OFF OVERSPEED CONTROL

ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-2.5 GOVERNOR/ACTUATOR ADJUSTMENT (Figure 6-8). . . . . . . . . . . . 6-17

6-3 ALIGNMENT OF THE GENERATOR SET. . . . . . . . . . . . . . . . . . . . . . . 6-19 6-3.1 CHECKING ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-3.2 ALIGNING THE GENERATOR TO THE ENGINE. . . . . . . . . . . . . . 6-22

6-4 EXCITATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

SECTION II. REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

6-5 ENGINE REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 6-5.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

6-5.1.1 AREA PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . 6-23

6-5.1.2 DRAINING OF ENGINE SYSTEMS. . . . . . . . . . . . . . . . 6-23

6-5.1.3 MARKING OF ENGINE PARTS. . . . . . . . . . . . . . . . . . 6-23

6-5.1.4 ENGINE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6-5.2 CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6-5.2.1 CYLINDER HEAD REMOVAL. . . . . . . . . . . . . . . . . . . 6-30

6-5.2.2 INTAKE VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6-5.2.2.1 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . 6-34

6-5.2.2.2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . 6-34

6-5.2.2.3 REASSEMBLY AND INSTALLATION. . . . . . . . 6-34

6-5.2.3 EXHAUST VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6-5.2.3.1 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . 6-34

6-5.2.3.2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . 6-35

6-5.2.3.3 REASSEMBLY AND INSTALLATION. . . . . . . . 6-35

6-5.2.4 VALVE SEAT INSERT. . . . . . . . . . . . . . . . . . . . . . . . 6-35

6-5.2.4.1 INSPECTION. . . . . . . . . . . . . . . . . . . . . . 6-35

6-5.2.4.2 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 6-36

6-5.2.4.3 INSTALLATION. . . . . . . . . . . . . . . . . . . . 6-36

6-5.2.5 VALVE GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6-5.2.5.1 INSPECTION. . . . . . . . . . . . . . . . . . . . . . 6-36

6-5.2.5.2 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 6-36

6-5.2.5.3 INSTALLATION. . . . . . . . . . . . . . . . . . . . 6-36

6-5.2.6 PRECOMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . 6-36

6-5.2.6.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 6-36

6-5.2.6.2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . 6-37

6-5.2.6.3 INSTALLATION. . . . . . . . . . . . . . . . . . . . 6-37

Change C xiii

6-5.2.7 VALVE ROCKER ARM. . . . . . . . . . . . . . . . . . . . . . . 6-37

6-5.2.7.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . 6-37

6-5.2.7.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . 6-37

6-5.2.7.3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . 6-37

6-5.2.7.4 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . 6-38

6-5.2.7.5 INSTALLATION. . . . . . . . . . . . . . . . . . . . 6-38

6-5.2.8 CYLINDER HEAD INSPECTION. . . . . . . . . . . . . . . . . 6-38

6-5.2.9 CYLINDER HEAD INSTALLATION. . . . . . . . . . . . . . . 6-38

6-5.3 PISTON AND CONNECTING ROD. . . . . . . . . . . . . . . . . . . . . . . 6-39

6-5.3.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

6-5.3.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

6-5.3.3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

6-5.3.4 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

6-5.3.5 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

6-5.4 CYLINDER LINER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

6-5.4.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

6-5.4.2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

6-5.4.3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

6-5.5 VIBRATION DAMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

6-5.5.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

6-5.5.2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

6-5.5.3 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

6-5.6 FRONT ACCESSORY DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

6-5.6.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

6-5.6.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

6-5.6.3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

6-5.6.4 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

6-5.6.5 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

6-5.7 FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

6-5.7.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

6-5.7.2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

6-5.7.3 INSTALLATION. . . . . . . . . . . . . . .