S9311-A1-MMM-020_0_A (2).pdf

TECHNICAL MANUAL

FOR

[SGML VERSION; SEE CHANGE

RECORD ]

SHIP SERVICE GENERATOR

CHAPTER 7 PARTS LIST

CHAPTER 8 INSTALLATION

DISTRIBUTION STATEMENT E: DISTRIBUTION AUTHORIZED TO DOD COMPONENTS

ONLY; CRITICAL TECHNOLOGY; (15 OCTOBER 1986). OTHER REQUESTS FOR THIS

DOCUMENT SHALL BE REFERRED TO THE NAVAL SEA SYSTEMS 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-020

0910-LP-094-3700 VOLUME 2

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PUBLISHED BY THE DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

15 OCT 1986

CHANGE A 15 JAN 2008

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A 15 JANUARY 2008 INCORPORATEDTMDER R38960-93-0000 CORRECTING PART

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TER 7 TABLES. CHANGE AUTHORIZED BY NSWCCD-SSES

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TABLE(S) AND 7-37.

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 TM WILL ONLY FIT IN THIS PAGINATED VERSION.

S9311-A1-MMM-020

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CHANGE RECORD-2 Change A

FOREWORD

This technical manual contains operation, maintenance, and repair instructions for the Ship Service Gen-erator. This technical manual is intended for guidance of and use by personnel operating and maintaining the equipment described herein.

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 1388

NAVSURFWARCENDIV NSDSA

4363 MISSILE WAY

PORT HUENEME CA 93043-4307

on NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation 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 deficiency submittals via the Naval Systems Data Support Activity web site located at:

http://nsdsa.phdnswc.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 deficiency submittals via the Naval Systems Data Support Activity web site located above.

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FOREWORD-2 Change A

TABLE OF CONTENTS

Chapter/Paragraph Page

7 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2 LIST OF MAJOR COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-3 PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-3.1 FIGURE AND INDEX NUMBER. . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-3.2 NAME AND DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-3.3 QUANTITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-3.4 CAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-3.5 MANUFACTURER’S PART NUMBER. . . . . . . . . . . . . . . . . . . . . 7-2

8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-2 TOOLS AND MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3 UNPACKING, STORAGE, AND REPACKING. . . . . . . . . . . . . . . . . . . . . 8-1 8-3.1 UNPACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3.1.1 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3.1.2 EXCITER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3.2 STORAGE AND REPACKING. . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3.2.1 SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3.2.2 PROTECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3.2.3 PRESERVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8-4 PREPARATION OF FOUNDATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8-5 INTERFACE REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8-6 INSTALLATION PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8-6.1 INSTALLING THE GENERATOR SET ON THE SHIP’S FOUNDATION.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

8-6.2 EXTERNAL SYSTEMS CONNECTIONS. . . . . . . . . . . . . . . . . . . . 8-25

8-6.2.1 PIPING SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

8-6.2.2 ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

8-7 INSTALLATION CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

8-7.1 INSTALLATION INSPECTION AND PRE-START PROCEDURES. . . . . 8-26

8-7.2 INITIAL START AND PRELIMINARY TEST. . . . . . . . . . . . . . . . . 8-41

8-7.3 INSTALLATION VERIFICATION TESTS. . . . . . . . . . . . . . . . . . . 8-42

Change A i

LIST OF TABLES

Table Title Page

7-1. List of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2. Engine Block and Cover Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . 7-5

7-3. Crankcase Explosion Relief Valves Parts List . . . . . . . . . . . . . . . . . . . . . . 7-8

7-4. Crankshaft Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-5. Torsional Vibration Damper Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-6. Flywheel Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-7. Camshaft Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

7-8. Connecting Rod and Piston Assembly Parts List . . . . . . . . . . . . . . . . . . . . 7-17

7-9. Cylinder Head and Valve Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . 7-19

7-10. Oil Pan Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7-11. Engine Support Rails Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7-12. Front Accessory Drive Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

7-13. Fuel Pump and Governor Drive Assembly Parts List . . . . . . . . . . . . . . . . . . 7-31

7-14. Lifting Eye Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

7-15. Breather Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

7-16. Emission Control Filter Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

7-17. Resilient Shaft Coupling Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

7-18. Fuel Oil Transfer Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45

7-19. Fuel Injection Pump Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-49

7-20. Fuel Lines Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55

7-21. Fuel Injection Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

7-22. Fuel Oil Priming Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59

7-23. Fuel Oil Duplex Filter Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61

7-24. Fuel Oil Strainer Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63

7-25. Fuel Oil Drain Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65

7-26. Lube Oil Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69 ii Change A

LIST OF TABLES - Continued

7-27. Sump Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72

7-28. Oil Cooler Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74

7-29. Main Lube Oil Filter Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79

7-30. Auxiliary Lube Oil Filter Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82

7-31. Lube Oil Diverter Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84

7-32. Lube Oil Filter Gage Panel Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86

7-33. Lube Oil Distribution Gallery Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-89

7-34. Jacket Water Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-91

7-35. Jacket Water Heat Exchanger Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-93

7-36. Jacket Water Heater Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95

7-37. Expansion Tank Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99

7-38. Thermostatic Pilot Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101

7-39. Seawater Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-105

7-40. Turbocharger Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108

7-41. Turbocharger Shield Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-111

7-42. Aftercooler Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-113

7-43. Air Cleaner Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-117

7-44. Intake Manifold Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-119

7-45. Air Shut Off Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121

7-46. Exhaust Piping Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-123

7-47. Exhaust Manifold Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125

7-48. Air Start Motor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-129

7-49. Prelube Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-132

7-50. Prelube Pump Discharge Check Valve Parts List . . . . . . . . . . . . . . . . . . . . 7-133

7-51. Air Start Control Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-135

7-52. Oil Pressure Lockout and Manual Air Start Valves Parts List . . . . . . . . . . . . . 7-137

Change A iii

7-53. Air Piloted Relay Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-138

7-54. Oil Piloted Relay Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-140

7-55. Quick Release Valve Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-142

7-56. Air Start Solenoid Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-144

7-57. Air Motor Lubricator Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-145

7-58. Governor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-147

7-59. 2500 Speed Control Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-149

7-60. 2500 Load Sensor Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 7-151

7-61. Motor Operated Potentiometer Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-155

7-62. Digital Reference Unit Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-158

7-63. Emergency Manual Shut-Off Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 7-160

7-64. Mechanical Fuel Rack Shut-Off Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-163

7-65. Hydra-Mechanical Shutdown Assembly Parts List . . . . . . . . . . . . . . . . . . . 7-175

7-66. Hydraulic Fuel Rack Shut-Off Assembly Parts List . . . . . . . . . . . . . . . . . . . 7-179

7-67. Diverter Valve Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-180

7-68. Instrument Panel Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-182

7-69. Service Meter and Tachometer Drive Parts List . . . . . . . . . . . . . . . . . . . . . 7-185

7-70. Magnetic Pickup Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-187

7-71. Generator Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-191

7-72. Air Cooler Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-195

7-73. ESS (Excitation Support System) Chassis, 125-17 Parts List . . . . . . . . . . . . . . 7-197

7-74. Capacitor Chassis Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-198

7-75. SSE (Shunt Static Exciters) 125-17 Rectifier Parts List . . . . . . . . . . . . . . . . . 7-199

7-76. SSE (Shunt Static Exciters) 125-17 Control Chassis Parts List . . . . . . . . . . . . 7-201

7-77. Field Flashing Chassis Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-202

7-78. Push Plate Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-203 iv Change A

7-79. Lifting Hook Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-205

7-80. Camshaft Removal and Installation Tools Parts List . . . . . . . . . . . . . . . . . . 7-209

7-81. Workbench Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-213

7-82. Flywheel Lifting Bracket Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-214

7-83. Driver Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-216

7-84. Puller Plate Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-218

7-85. Valve Guide Removal and Installation Tools Parts List . . . . . . . . . . . . . . . . . 7-220

7-86. Bearing Removal Tools Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . 7-221

7-87. Liner Installer Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-223

7-88. Puller Plate Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-223

7-89. Seal Installer Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-224

7-90. Adapter Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-225

7-91. Precombustion Chamber Wrench Parts List . . . . . . . . . . . . . . . . . . . . . . . 7-225

7-92. Piston Ring Expander Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-227

7-93. Step Plate Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-227

7-94. Spacer Tube Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-228

7-95. Wear Sleeve and Seal Installer Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-229

7-96. Piston Ring Groove Gage Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-231

7-97. Piston Ring Compressor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-232

7-98. Valve Guide Gage Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-233

7-99. Fuel Injection Nozzle Tester Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 7-235

7-100. Engine Turning Tool Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-237

7-101. Liner Puller Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-239

7-102. Piston Cooling Jet Alignment Tools Parts List . . . . . . . . . . . . . . . . . . . . . . 7-240

7-103. Valve Spring Compressor Assembly Parts List . . . . . . . . . . . . . . . . . . . . . 7-242

7-104. Multitach Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-244

Change A v

7-105. Pressure Tester Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-246

7-106. Lifter Setting Tools Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-248

7-107. Valve Seat Extractor Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-250

7-108. Rack Position Tools Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-252

7-109. Engine Tilting Tools Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-254

7-110. Crankshaft Main Bearing Wrench Parts List . . . . . . . . . . . . . . . . . . . . . . . 7-255

7-111. Camshaft Bearing Installation and Removal Tools Parts List . . . . . . . . . . . . . . 7-257

7-112. Spring Tester Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-258

7-113. Turbocharger Fixture Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . 7-259

7-114. Turbocharger Housing Fixture Parts List . . . . . . . . . . . . . . . . . . . . . . . . . 7-260

7-115. Liner Projection Tool Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-261

8-1. Interface Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-2. Wire Gage for Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25 vi Change A

LIST OF ILLUSTRATIONS

Figure Title Page

7-1. Engine Block and Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-2. Crankcase Explosion Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-3. Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-4. Torsional Vibration Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-5. Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7-6. Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-7. Connecting Rod and Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7-8. Cylinder Head and Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-9. Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7-10. Engine Support Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7-11. Front Accessory Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7-12. Fuel Pump and Governor Drive Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . 7-29

7-12. Fuel Pump and Governor Drive Assembly (Sheet 2 of 2) . . . . . . . . . . . . . . . 7-30

7-13. Lifting Eye Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

7-14. Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

7-15. Emission Control Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

7-16. Resilient Shaft Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

7-17. Fuel Oil Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

7-18. Fuel Injection Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47

7-19. Fuel Lines Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51

7-19. Fuel Lines Assembly (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53

7-20. Fuel Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

7-21. Fuel Oil Priming Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

7-22. Fuel Oil Duplex Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

7-23. Fuel Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62

7-24. Fuel Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64

Change A vii

LIST OF ILLUSTRATIONS - Continued

7-25. Lube Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67

7-26. Sump Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71

7-27. Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73

7-28. Main Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77

7-29. Auxiliary Lube Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81

7-30. Lube Oil Diverter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83

7-31. Lube Oil Filter Gage Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86

7-32. Lube Oil Distribution Gallery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87

7-33. Jacket Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90

7-34. Jacket Water Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92

7-35. Jacket Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94

7-36. Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97

7-37. Thermostatic Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101

7-38. Seawater Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103

7-39. Turbocharger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107

7-40. Turbocharger Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110

7-41. Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112

7-42. Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115

7-43. Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-118

7-44. Air Shut Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-120

7-45. Exhaust Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122

7-46. Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-124

7-47. Air Start Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127

7-48. Prelube Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131

7-49. Prelube Pump Discharge Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 7-133

7-50. Air Start Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-134 viii Change A

7-51. Oil Pressure Lockout and Manual Air Start Valves . . . . . . . . . . . . . . . . . . . 7-136

7-52. Air Piloted Relay Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-138

7-53. Oil Piloted Relay Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-139

7-54. Quick Release Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-141

7-55. Air Start Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-143

7-56. Air Motor Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-145

7-57. Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-147

7-57A. 2500 Speed Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-148

7-57B. 2500 Load Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-150

7-57C. Motor Operated Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-153

7-57D. Digital Reference Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-157

7-58. Emergency Manual Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-159

7-59. Mechanical Fuel Rack Shut-Off (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 7-161

7-59. Mechanical Fuel Rack Shut-Off (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . 7-162

7-60. Hydra-Mechanical Shutdown Assembly (Sheet 1 of 4) . . . . . . . . . . . . . . . . . 7-167

7-60. Hydra-Mechanical Shutdown Assembly (Sheet 2 of 4) . . . . . . . . . . . . . . . . . 7-169

7-60. Hydra-Mechanical Shutdown Assembly (Sheet 3 of 4) . . . . . . . . . . . . . . . . . 7-171

7-60. Hydra-Mechanical Shutdown Assembly (Sheet 4 of 4) . . . . . . . . . . . . . . . . . 7-173

7-61. Hydraulic Fuel Rack Shut-Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7-178

7-62. Diverter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-180

7-63. Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-181

7-64. Service Meter and Tachometer Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-184

7-65. Magnetic Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-186

7-66. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-189

7-67. Air Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-193

7-68. ESS (Excitation Support System) Chassis, 125-17 . . . . . . . . . . . . . . . . . . . 7-196

Change A ix

7-68A. Capacitor Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-198

7-69. SSE (Shunt Static Exciters) 125-17 Rectifier . . . . . . . . . . . . . . . . . . . . . . 7-199

7-70. SSE (Shunt Static Exciters) 125-17 Control Chassis . . . . . . . . . . . . . . . . . . 7-200

7-71. Field Flashing Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-202

7-72. Push Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-203

7-73. Lifting Hook Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-204

7-74. Camshaft Removal and Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . 7-207

7-75. Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-211

7-76. Flywheel Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-214

7-77. Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-215

7-78. Puller Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-218

7-79. Valve Guide Removal and Installation Tools . . . . . . . . . . . . . . . . . . . . . . . 7-219

7-80. Bearing Removal Tools Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-221

7-81. Liner Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-222

7-82. Puller Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-223

7-83. Seal Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-224

7-84. Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-225

7-85. Precombustion Chamber Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-225

7-86. Piston Ring Expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-226

7-87. Step Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-227

7-88. Spacer Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-228

7-89. Wear Sleeve and Seal Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-229

7-90. Piston Ring Groove Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-230

7-91. Piston Ring Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-232

7-92. Valve Guide Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-233

7-93. Fuel Injection Nozzle Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-234 x Change A

7-94. Engine Turning Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-236

7-95. Liner Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-238

7-96. Piston Cooling Jet Alignment Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-240

7-97. Valve Spring Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-241

7-98. Multitach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-243

7-99. Pressure Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-245

7-100. Lifter Setting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-247

7-101. Valve Seat Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-249

7-102. Rack Position Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-251

7-103. Engine Tilting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-253

7-104. Crankshaft Main Bearing Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-255

7-105. Camshaft Bearing Installation and Removal Tools . . . . . . . . . . . . . . . . . . . 7-256

7-106. Spring Tester Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-258

7-107. Turbocharger Fixture Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-259

7-108. Turbocharger Housing Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-260

7-109. Liner Projection Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-261

8-1. Control Chassis Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8-2. Rectifier Chassis Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8-3. ESS Mounting Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8-4. Diesel Generator Set Foundation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 8-11

8-4. Diesel Generator Set Foundation (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . 8-13

8-5. Diesel Generator Set Dimensions and Interconnection Diagram (Sheet 1 of 5) . . . . 8-15

8-5. Diesel Generator Set Dimensions and Interconnection Diagram (Sheet 2 of 5) . . . . 8-17

8-5. Diesel Generator Set Dimensions and Interconnection Diagram (Sheet 3 of 5) . . . . 8-19

8-5. Diesel Generator Set Dimension and Interconnection Diagram (Sheet 4 of 5) . . . . 8-21

8-5. Diesel Generator Set Dimensions and Interconnection Diagram (Sheet 5 of 5) . . . . 8-23

Change A xi

8-6. Wiring Diagram (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

8-6. Wiring Diagram (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31

8-6. Wiring Diagram (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

8-7. Resistance Temperature Detectors and Heater Connections . . . . . . . . . . . . . . . 8-34

8-8. Connection of Generator Stator RTD Leads . . . . . . . . . . . . . . . . . . . . . . . 8-35

8-9. SSE and ESS Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37

8-10. Bearing and Generator Airstream RTDs . . . . . . . . . . . . . . . . . . . . . . . . . 8-39 xii Change A

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. Should situations arise that are not covered in the general or spe-cific safety precautions, the commanding officer or other authority will issue orders as deemed necessary to cover the situation. No work shall be undertaken on energized equipment or circuits until approval of the commanding officer is obtained, and then only in accordance with Naval Ships Technical Manual (NSTM) S9086-KC-STM- 010/Chapter 300.

DO NOT REPAIR OR ADJUST ALONE

Under no circumstances shall repair or adjustment of energized equipment be attempted alone. The imme-diate presence of someone capable of rendering first aid is required. Before making adjustments, be sure to pro-tect against grounding. If possible, adjustments should be made with one hand, with the other hand free and clear of equipment. Even when power has been removed from equipment circuits, dangerous potentials may still exist due to retention of charges by capacitors. Circuits must be grounded and all capacitors discharged prior to attempting repairs.

TEST EQUIPMENT

Make certain test equipment is in good condition. If a metal-cased test meter must be held, ground the case of the meter before starting measurement. Do not touch live equipment or personnel working on live equipment while holding a test meter. Some types of measuring devices should not be grounded; these devices should not be held when taking measurements.

INTERLOCKS

Interlocks are provided for safety of personnel and equipment and should be used only for the purpose intended. They should not be battle shorted or otherwise modified except by authorized maintenance personnel.

Do not depend solely upon interlocks for protection. Whenever possible, disconnect power at the power distri-bution source.

MOVING EQUIPMENT

Personnel shall remain clear of moving equipment. If equipment requires adjustment while in motion, a safety watch shall be posted. The safety watch shall have a full view of the operations being performed, and immediate access to controls capable of stopping equipment motion.

FIRST AID

An injury, no matter how slight, shall never go unattended. Always obtain first aid or medical attention immediately, and file an injury report in accordance with OPNAVINST 5102.1 series, subj: Mishap Investigation and Reporting.

Change A xiii

SAFETY SUMMARY - Continued

RESUSCITATION

Personnel working with or near high voltage shall be familiar with approved methods of resuscitation.

Should someone be injured and stop breathing, begin resuscitation immediately. A delay could cost the victim’s life. Resuscitation procedures shall be posted in all electrically hazardous areas.

GENERAL PRECAUTIONS

The following general precautions are to be observed at all times.

1. Install and ground all electrical components associated with this system/equipment in accordance with applicable Navy regulations and approved shipboard practices.

2. Ensure that all maintenance operations comply with Navy Occupational Safety and Health (NAVOSH) Program Manual for Forces Afloat, OPNAVINST 5100.19 series.

3. Observe precautions set forth in NSTM S9086-KC-STM-010/Chapter 300 with respect to electrical equipment and circuits.

4. Ensure that protective guards and shutdown devices are properly installed and maintained around rotating parts of machinery and high voltage sources.

5. Do not wear loose clothing while working around rotating parts of machinery.

6. Ensure that special precautionary measures are employed to prevent applying power to the system/ equipment any time maintenance work is in progress.

7. Do not make any unauthorized alterations to equipment or components.

8. Before working on electrical system/equipment, check with voltmeter to ensure that system is not energized.

9. Consider all circuits not known to be ″dead,″ ″ live″ and dangerous at all times.

10. When working near electricity, do not use metal rules, flashlights, metallic pencils, or any other objects having exposed conducting material.

11. Deenergize all equipment before connecting or disconnecting meters or test leads.

12. When connecting a meter to terminals for measurement, use range higher than expected voltage.

13. Before operating equipment or performing any tests or measurements, ensure that frames of all motors and starter panels are securely grounded.

14. Ensure that area is well-ventilated when using cleaning compound or solvent. Avoid prolonged breathing of fumes and compound or solvent contact with skin or eyes.

WARNINGS AND CAUTIONS Specific warnings and cautions applying to the system/equipment cov-ered by this manual are summarized below. These warnings and cautions appear elsewhere in the manual follow-ing paragraph headings and immediately preceding the text to which they apply. They are repeated here for emphasis.

xiv Change A

WARNING

Make sure that power to the jacket water heater controllers and the genera-tor space heater is turned off and that the main generator circuit breaker is open. Tag all applicable switches and circuit breakers DANGER in accor-dance with NSTM, Chapter 300. Life-threatening voltages may otherwise be present in some junction boxes. (Page 8-27)

WARNING

The following procedure may expose personnel to life-threatening voltages.

Deenergize circuits and tag switches DANGER as required by NSTM Chap-ter 300. (Page 8-41)

Change A xv / (xvi Blank) xvi Change A

CHAPTER 7

PARTS LIST

7-1. INTRODUCTION.

This chapter lists the major components of the Ship Service Generator Set, includes the replaceable parts for all configurations, and provides a list of manufacturers. Table 7-1 shows the major components included as parts of the engine, and generator. Tables 7-2 through 7-115 identify the engine parts that can be replaced, indicating those which change for rotation and mounting. A symbol (*) is located next to items that require special atten-tion, and a footnote follows for explanation.

7-2. LIST OF MAJOR COMPONENTS.

Table 7-1 lists the major components of the Ship Service Generator Set, the quantity installed on or for each engine, and is linked to the parts list for each component.

Table 7-1. List of Major Components

RIC Number Qty Name Figure No.

701110508 1 Governor 7-57 664810093 1 Hydra-Mechanical Shutdown 7-60

1 Mechanical Fuel Rack Shut-off 7-59 053990015 2 Turbocharger 7-39 019990151 16 Fuel Injection Pump 7-18

1 Instrument Panel 7-63 1 Coupling, Resilient Shaft 7-16

162500422 1 Generator 7-66 1 SSE (Shunt Static Exciters) Rectifier Chassis 7-69 1 ESS (Excitation Support System) Chassis 7-68

032180073 1 Air Cooler 7-67 1 Field Flashing Chassis 7-71

7-3. PARTS LIST.

Tables 7-2 through 7-115 are broken into five columns for ease of component identification and breakdown information.

7-3.1 FIGURE AND INDEX NUMBER. The first column gives the component illustration number and the index number of the individual parts on that figure.

7-3.2 NAME AND DESCRIPTION. This column lists the assemblies, subassemblies and parts by name. The principal assembly is located at the top of the page as the figure title. The parts that follow are part of the top level assembly unless otherwise indicated. The subassemblies and parts listed under the principal assembly are arranged for a level hierarchy. Parts under subassemblies show that those items are included in the preceding assembly, and come as one assembly or separately depending on the part number.

7-3.3 QUANTITY. The number listed in the quantity column after the principal assembly or figure title repre-sents the total number used per engine. All numbers that follow in this column are for quantity per assembly.

Change A 7-1

7-3.4 CAGE. The Commercial and Government Entity (CAGE) identifies the original maker of the part or assembly by a five digit code. The CAGE is shown only when it changes; therefore, each CAGE applies to the part in its line and to parts listed below it down to the next CAGE.

7-3.5 MANUFACTURER’S PART NUMBER. This is the number assigned to the part by the original manu-facturer. Each principal assembly has a number identifying the major component. In some cases the mounting hardware or other miscellaneous parts may be included as part of the assembly, but are indicated as being sepa-rate. Where rotation or mounting changes, and a different part number is required, both are listed with the part and an explanation is at the end of the list.

7-2 Change A

1.

Figure 7-1. Engine Block and Cover Assembly

Change A 7-3 / (7-4 Blank)

7-4 Change A

Table 7-2. Engine Block and Cover Assembly Parts List

FIGURE 7-1 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-1 ENGINE BLOCK AND COVER

ASSEMBLY

1 11083 3N2679

1 BOLT, 3/8-16 x 7/8 4 L1351 2 WASHER, Lock 3/8 71 3B4506

3 COVER 1 7F7670

4 GASKET 1 7F7669

5 GASKET 1 5N3275

6 HOUSING, Flywheel 1 6L2787 7 WASHER, Lock 1/2 10 3B4508 8 BOLT, 1/2-13 x 2-1/2 2 9S1366 9 BOLT, 1/2-13 x 7-1/2 6 1A0168

10 PLUG, 1-11 1/2 NPT 1 3B0551

11 BOLT, 1/2-13 x 6-3/4 2 9M7269 12 WASHER, Lock 5/8 14 3B4510 13 BOLT, 5/8-11 x 2-3/4 8 1A8537 14 BOLT, 5/8-11 x 2-1/4 6 8S9092 15 BOLT, 1/2-13 x 1 8 S1621 16 WASHER, Flat 1/2 8 5P8245 17 BOLT, 3/8-16 x 3 6 S1619

18 PLUG, 1/2-14 NPT 1 3J5389

19 ELBOW 1 4L6215

20 GASKET 1 4L6216

21 SEAL 1 L1124

22 PLUG, 2-12 1 L0827

23 STUD 18 2N5120

24 DOWEL 8 1A9759

25 NUT, 1-1/8-12 18 3S1356

26 CAP ASSEMBLY 1 2N7224

27 PIN 2 L2061

28 WASHER, Thrust 2 4L4653

29 DOWEL 2 2B2994

30 GASKET 8 1F4419

31 COVER, Cylinder Block 7 8L4857 32 BOLT, 3/8-16 x 3/4 60 S0509

33 GASKET 6 1F9223

34 PLATE, Cover 6 1F4418

35 PLUG, 3/4-14 NPT 1 1B5174

36 BOLT, 3/8-16 x 1-1/4 12 S1588

37 FLANGE 1 8F8145

38 GASKET 3 1F3131

39 BLOCK, Cylinder 1 5N8686 40 CAP, Pillow Block 1 2N7194

41 PIN 2 4L3395

42 BEARING, Sleeve 9 5L2894

43 GASKET 1 4L7586

Change A 7-5

Table 7-2. Engine Block and Cover Assembly Parts List - Continued

FIGURE 7-1 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

44 LOCK 2 2A4462

45 SCREW, 5/8-11 x 2 4 1A1135

PLATE ASSEMBLY 1 2N4518

46 ADAPTER 1 2N4516

47 PLATE 1 2N4517

48 COVER, Cylinder Block 1 6L8989

49 PIN 8 6B6863

50 PIN 32 2A3348

51 SEAL 48 6L7815

52 LINER, Cylinder 16 8N9174 53 BAND, Filler 16 8N4708

54 COVER 2 5F9303

55 DOWEL 32 1A2223

7-6 Change A

Figure 7-2. Crankcase Explosion Relief Valves

Change A 7-7

Table 7-3. Crankcase Explosion Relief Valves Parts List

FIGURE 7-2 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-2 CRANKCASE EXPLOSION RELIEF

VALVES

2 11083 3N6399

1 GASKET 2 1F9223

2 VALVE ASSEMBLY (Single) 1 2N8813 3 VALVE ASSEMBLY (Double) 1 2N8814 4 WASHER, Lock 3/8 32 3B4506 5 BOLT, 3/8-16 x 7/8 32 L1351

VALVE, Relief 1 54188 3374-634

6 COVER 1 3374-2A-23

7 PLATE, Valve 1 3374-10B-254 8 SPRING, Valve 1 3374-9-184

9 LOCKNUT, 1/2-13 1 3374-66-344

10 SPINDLE, Valve 1 3374-8C-44

11 CAP 2 3374-69-284

12 SEAL 1 3374-624

13 RETAINER 1 3374-68-274

14 SEAL 1 3374-594

15 GAUZE ASSEMBLY 1 3374-6A-124

16 SPIDER 1 3374-1B-113

17 SHELF, Support 1 3374-70-294

18 CARRIER 1 3374-1C-264

7-8 Change A

Figure 7-3. Crankshaft

Change A 7-9

Table 7-4. Crankshaft Parts List

FIGURE 7-3 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-3 CRANKSHAFT 1 11083 6L8357

1 BOLT, 3/8-16 x 1 6 S1594 2 WASHER, Lock 3/8 24 3B4506

3 BAFFLE 2 8L3972

4 GASKET 2 5L2093

5 RING 2 3N9160

6 THROWER 1 3N7326

7 RING 2 3N3234

8 BEARING 9 8N7764

9 BOLT, 7/16-14 x 3/4 8 5P3476

10 CRANKSHAFT 1 6L7500

11 COUNTERWEIGHT 8 5L2662

12 DOWEL 24 7B0537

13 BOLT, 5/8-18 x 5-1/4 16 5L2683 14 BOLT, 5/8-18 x 4-1/2 4 T0857

15 COUNTERWEIGHT 4 6L8201

16 THROWER 1 3N7327

7-10 Change A

Figure 7-4. Torsional Vibration Damper

Change A 7-11

Table 7-5. Torsional Vibration Damper Parts List

FIGURE 7-4 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-4 TORSIONAL VIBRATION DAMPER 1 11083 3N6356

1 GUARD ASSEMBLY 1 5N9077

2 BOLT, 3/8-16 x 1-1/8 9 1A2029 3 WASHER, Lock 3/8 9 3B4506

4 NUT, 1/2-20 10 1B4205

5 WASHER, Lock 1/2 10 3B4508 6 WASHER, Flat 1/2 10 3H7654

7 SPACER 10 L1002

8 DAMPER ASSEMBLY 2 2P1793

ADAPTER ASSEMBLY 1 3N6614

9 STUD, 1/2-20 & 1/2-13 x 2-3/4 10 T0167

10 ADAPTER 1 3N6613

11 WASHER, Flat 1 in. 10 5F6562 12 BOLT, 1-14 x 6 10 3F6645

13 BRACKET 6 5N1622

14 WASHER, Lock 7/16 12 3B4507 15 BOLT, 7/16-14 x 1 12 T0318

16 COVER 1 5N1621

7-12 Change A

Table 7-6. Flywheel Parts List

FIGURE 7-5 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-5 FLYWHEEL 1 11083 6L9646

1 POINTER, Timing 1 5L6745 2 WASHER, Flat 1 in. 10 5F6562 3 BOLT, 1-14 x 2-3/4 10 2H3745

FLYWHEEL ASSEMBLY 1 1N5757

4 FLYWHEEL 1 5N2828

5 GEAR, Spur 1 1N5742

Figure 7-5. Flywheel

Change A 7-13

Figure 7-6. Camshaft

7-14 Change A

Table 7-7. Camshaft Parts List

FIGURE 7-6 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-6 CAMSHAFT 1 11083 6L8396

WASHER ASSEMBLY 1 6L2195

1 WASHER, Thrust 1 6L2146 2 SCREW, Truss Head 1 4B4158 3 PLATE, Locking 2 4L6182 4 BOLT, 3/8-16 x 1-1/8 4 1A2029

GEAR ASSEMBLY 1 4L6753

5 GEAR 1 8N1356

6 PIN 1 8B1312

7 GEAR 1 8N1355

8 PLATE, Locking 4 4L6183

9 PLATE 1 5L2101

10 PLATE, Locking 1 4L6184 11 BOLT, 1/2-13 x 1-1/2 2 S1585 12 BOLT, 1/2-13 x 1-1/4 8 6H1717 13 KEY, Woodruff 1 1B8741

14 CAMSHAFT ASSEMBLY 1 1W1858

Change A 7-15

Figure 7-7. Connecting Rod and Piston Assembly

7-16 Change A

Table 7-8. Connecting Rod and Piston Assembly Parts List

FIGURE 7-7 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-7 CONNECTING ROD AND PISTON

ASSEMBLY

16 11083 6L2868

1 RING, Top 1 9S7507 2 RING, Piston 1 3S4059

3 RING 1 1W5061

BODY ASSEMBLY 1 7N4515

4 PLUG 1 8S2659

5 BODY 1 7N4514

6 WASHER 1 1P1210

7 NUT ASSEMBLY 1 1P7928

8 BEARING, Connecting Rod 1 8N7769

CONNECTING ROD ASSEMBLY 1 1P0009

9 BOLT 2 1P1758

10 ROD, Connecting 1 1P0008 11 BEARING, Sleeve 1 8N2275 12 RETAINER, Piston Pin 2 7M4926

13 PIN 1 7N9810

Change A 7-17

Figure 7-8. Cylinder Head and Valve Assembly

7-18 Change A

Table 7-9. Cylinder Head and Valve Assembly Parts List

FIGURE 7-8 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-8 CYLINDER HEAD AND VALVE ASSEMBLY 8 11083 3N2682

1 NUT, Self-locking 2 2M2570 2 WASHER, Cylinder Head Cover 2 3F9780

3 O-RING 2 8F4994

4 COVER 1 2N3598

5 SEAL, Valve Cover 1 2N3597

INTAKE VALVE ARM ASSEMBLY 2 4L3855

6 ARM 1 4L3854

7 BEARING 1 3F7445

8 SOCKET 1 9F8254

9 RING, Retaining 4 9F7707 10 BUTTON, Poppet 4 8F8858 11 WASHER, Flat, 1-5/16 6 4H6716

12 SPRING 2 1B9917

13 PIN, Cotter 2 3B4621

14 RETAINER 2 2N9297

15 LOCK 8 2A4429

RETAINER ASSEMBLY 2 1W3062

16 RETAINER 1 1W3063

17 SHIELD, Oil 1 8N7780 18 SPRING, Outer Valve 4 9M5350 19 SPRING, Inner Valve 4 9M5349 20 ROTATOR, Valve 4 7N7639

21 SPACER 4 3N1414

22 O-RING 2 6L7816

23 PRECOMBUSTION CHAMBER ASSEMBLY 2 7S5787

24 GASKET, Precombustion Chamber 2 1P8005 25 BOLT, 3/4-10 x 8-1/2 16 1D4623 26 WASHER, Flat, 3/4 16 5H1504 27 GASKET, Cylinder Head 1 3N3220

SEAL ASSEMBLY 8 3N9631

28 SEAL, Ferrule 1 6L7813 29 FERRULE, Water Director 1 6B6224

CYLINDER HEAD ASSEMBLY 1 5N8705

30 DIRECTOR, Water 8 5H7071 31 GUIDE, Intake Valve 2 2N9298 32 HEAD, Cylinder 1 5N8701 33 GUIDE, Exhaust Valve 2 2N9299 34 PLUG, Cup 8 3B0645 35 INSERT, Intake Valve Seat 2 5S1757 36 INSERT, Exhaust Valve Seat 2 8M4014 37 VALVE, Intake 2 1W8606 38 VALVE, Exhaust 2 1W1822

39 LIFTER 4 5L5486

40 PUSH ROD ASSEMBLY 4 4L7820

SEAL ASSEMBLY 6 3N9632

Change A 7-19

Table 7-9. Cylinder Head and Valve Assembly Parts List - Continued

FIGURE 7-8 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

41 FERRULE, Water Director 1 7B2420 42 SEAL, Water Director 1 6L7814 43 GASKET, Push Rod Chamber 1 6L4497

VALVE ROCKER SHAFT ASSEMBLY 1 6H3217

44 PLUG, Core 2 4F4585 45 SHAFT, Valve Rocker 1 6H3216 46 SPRING, Shaft 1 6F5034

47 NUT, 7/16-20 4 1B4204

48 STUD 2 4L8188

49 SCREW, Valve Rocker Adjusting 4 1A0744

EXHAUST VALVE ARM ASSEMBLY 2 4H9811

50 ARM, Exhaust 1 4H9810 51 STUD, Plain 2 4L8189

52 NUT, 1/2-20 4 1B4205

53 BRACKET, Valve Rocker Shaft 2 4L3803 54 WASHER, Lock 3/8 3 3B4506 55 BOLT, 3/8-16 x 7/8 4 L1351

7-20 Change A

Figure 7-9. Oil Pan

Change A 7-21

Table 7-10. Oil Pan Parts List

FIGURE 7-9 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-9 OIL PAN 1 11803 7L2500

1 GASKET 1 7L2905

2 TUBE ASSEMBLY 1 7L2341

3 BOLT, 3/8-24 x 7/8 2 T0703

4 LOCK 1 L0796

5 LOCK 2 S2415

6 NUT, 3/8-24 2 1L9061

7 PLATE 1 5B2888

8 BRACKET 1 7L2338

9 GASKET 2 7M4353

10 SCREEN ASSEMBLY 1 7L2334

11 BELL, Oil Pump 1 6N4488

12 GASKET 1 8L5457

13 WASHER, Lock 3/8 20 3B4506 14 BOLT, 3/8-16 x 1 20 S1594 15 WASHER, Flat 3/8 12 4B4278

16 PLATE 2 1N8486

17 BOLT, 3/4-10 x 4-1/2 1 2N9841 18 WASHER, Flat 7/8 1 4M6953

19 BASE ASSEMBLY 1 5N8469

20 PLUG, 2-11 1/2 NPT 1 6V1897

21 GASKET 2 7L3111

22 TUBE ASSEMBLY 1 8L8418

23 CAP ASSEMBLY 1 7L4447

24 DIPSTICK 2 7L2507

25 COVER 1 4H5440

26 BOLT, 3/4-10 x 4- 1/2 17 S1627 27 WASHER, Flat 3/4 17 5P8248 28 BOLT, 1/4-20 x 1-1/4 6 9F6580 29 PLATE, Locking 2 8F8682

30 LOCK 1 8F8683

31 U-BOLT, 3/8-24 x 3-3/4 1 4B0383 32 BOLT, 3/8-16 x 1-1/8 1 1A2029

33 LOCK 2 7L2906

34 BOLT 2 S1594

35 WASHER 2 5M2894

36 COVER 1 5N7858

37 SEAL 1 3P0656

7-22 Change A

Figure 7-10. Engine Support Rails

Change A 7-23

Table 7-11. Engine Support Rails Parts List

FIGURE 7-10 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-10 ENGINE SUPPORT RAILS 1 11083 8L6303

1 BOLT, 3/4-10 x 2-1/2 16 1A8063 2 WASHER, Flat 3/4 40 5P8248 3 SCREW, Leveling 4 4L6665

4 NUT, 1-14 4 1B4209

5 BOLT, 1/2-10 x 2 24 L1178

6 SUPPORT ASSEMBLY 1 8L6301

7 SUPPORT ASSEMBLY 1 8L6302

7-24 Change A

Figure 7-11. Front Accessory Drive

Change A 7-25 / (7-26 Blank)

7-26 Change A

Table 7-12. Front Accessory Drive Parts List

FIGURE 7-11 &

INDEX NUMBER NAME & DESCRIPTION QTY CAGE MFG PART NO

7-11 FRONT ACCESSORY DRIVE 1 11083 3N2683

1 GASKET 2 5N4688

2 TUBE…