TJ-233-01 Detroit Diesel 6V92.pdf

T9223-A T -MMC-O 1 0

T9223-AT-MMC-OIA CHANGE A

• 0910-LP-496-0101 Change A

~I"

OPERATION AND MAINTENANCE MANUAL

FOR

AUXILIARY PROPULSION

ENGINE

MODEL NO. 8062-7000

6V92

HALTER MARINE INC.

T-AOS 51/52 CLASS

NOOO24-89-2079

MANUFACTIJRED BY

DETROIT DIESEL ALLISON

13400 OUTER DRIVE, WEST

DETROIT, MICHIGAN 48239-4001

DISTRIBUTION STATEMENT ·C·. DISTRIBUTION AUTHORIZED TO U.S.

GOVERNMENT AGENCIES AND THEIR CONTRACTORS; ADMINISTRA

TIVElOPERATIONAL USE: (01-AUG-1991). OTHER REQUESTS FOR TIllS

TIllS DOCUMENT SHALL BE REFERRED TO THE COMMANDER. MILITARY

SEALIFT COMMAND, CODE N74, WASHINGTON, DC. 20398-5541.

WARNING: TIllS DOCUMENT CONTAINS TECHNICAL DATA WHOSE

EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT

(TITLE 22, U.S.C. SEC 2751 ET. SEC.) OR EXECUTIVE ORDER 12470.

VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE

CRIMINAL PENALTIES.

DESTRUCTION NOTICE: DESTROY BY ANY ME1HOD THAT Wll.L

PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF

THE DOCUMENT.

Mll..ITARY SEALIFT COMMAND

FOR OFFlCIAL USE ONLY

CHANGE A

01 JUNE 1993

EiGID lOIILUIlY PBOPDLSIOI

A

~ ~ -- .;l U '~J

T9233-AT-MMC~O

INSERT LATeST CHANGeD PAGES· DESTROV

NOTE: The portion of the text affected by the changes Is Indicated by a venlcal line In the outer margins of the page. Changes to Illustrations are Indicated by miniature polntlng hands. Changes to wiring diagrams are indicated by shaded aress.

D8Ie(s) Of Original And Change Pages Are:

Change ... A ... 01 JUNE 1993 ;

Total Number Of Pages In This Pubncatfon Is 6llZ Consisting Of The Following:

Page No. . •••. Chg No!

A •......••.. 0 Record of Change . . 0 APR Page Validation Cen . • . . 0 Foreword ...•... 0 Warranty I·xlll .•.•• 1·1·1·2 2·1 ·2·1 e .. 0 3-1 ·3-15 .. A 4-1 .4-8 5-1 - 5·23 6-1 - e-402 ••••.. 0 7-1·7-ee 6-1 • e·2 .•••••• 0

Page No. . . . . . Chg No!

• ZERO IN THIS COLUMN INDICATES AN ORIGINAL PAGE.

Page No. . .. Chg No!

":0:. :';.

T9233-AT-MMC-01O

• RECORD OF CHANGES

Change No. Date ntle Or Brief Description Entered By

T9233-AT-MMC-OIO

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: T9233-AT-MMC-010

nTLE OF MANUAL: AUXILIARY PROPULSION ENGINE MODEL 8062-7000 6V-92

APPROVAL AUTHORITY:

CONTRACT NO. APPLICABILITY QTY BUILDING YARD

N00024-89-C-2079 T-AGS 51/52 2 PER HULL HALTER MARINE INC ..

REMARKS:

CERTIFICAnON DATE: 8/1h,/'lf

IT IS HEREBY CERTIFIED THAT T9233-AT -MMC-01 0 TO BE PROVIDED UNDER CONTRACT

NUMBER N00024-87-C-2079 HAS BEEN APPROVED BY THE APPROVAL AUTHORITY

SHOWN ABOVE. ~

11J.~r-

(., HALTER MARINE INC.

T9233-AT-MMC-OIO

TECHNICAL MANUAL VALIDATION CERTIFICATE

NA VSEA 4160/3 (4-82)

TECHNICAL MANUAL TITLE: AUXILIARY PROPULSION ENGINE

EQUIPMENT NAME AND MODEL NUMBER 8062-7000 6V-92

NAVSEA TECHNICAL MANUAL NUMBER:

T9233-AT-MMC-010

CONTRACTfTMCR NO. :

N00024-89-C-2079

I· VALIDATION

DATE:

01 AUG 1991

Except as stated In II, the technical manual Identlfled above has been satisfactorily validated In accordance with all requirements of the ap plicable TMCR and the approved Validation Plan. The technical manual Is hereby certified to be accurate and complete, and the Information, Instructions, text, and Illustrations conform In all respects to the applicable general and detailed specifications.

II· EXCEPTIONS

EXCEPTIONS

SIGNATURE OF ,~,~~:l('t.~ ~~ ASSURANCE OFFICER:

c

AUTHORIZED BY

DATE:

T9233-AT-MMC-OJO

FOREWORD

This technical manual includes installation, operation, maintenance, and repair instructions, with a parts list for the Auxiliary Propulsion Engine 8062-7000. The manual covers the following:

Chp.

No. Title

1. General Information and Safety Precautions

2. Operation

3. Functional Description

4. Scheduled Maintenance

5. Troubleshooting

6. Corrective Maintenance

7. Parts List

8. Installation

Ships, training activities, supply points, depots, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of MSC technical manuals. All errors, omissions, discrepancies, and suggestions for improvement to MSC technical manuals shall be reported to the Commander, Military Sealift Command, Code M-4E, Washington, DC 20390.

T9233·AT·MMC-01O

WARRANTY

The Manufacturer will warranty this equipment against any defects or deficiencies in workmanship and/or material through the period of time that the vessel this equipment Is Installed on is completed, finally accepted by the Navy, and subsequently performs nine (9) months continuous service or nine (9) months of cumulative service In the event the vessel Is disabled because of any equipment failure.

T9233-AT-MMC-OlO

• TABLE OF CONTENTS

CHAPTER/PARAGRAPH PAGE

TABLE OF CONTENTS ....................... i LISt OF ILLUSTRATIONS ..................... v LIST OF TABLES .................. ....... xxi SAFETY SUMMARY ...................... xxiii

1 GENERAL INFORMATION .................. 1-1

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

1-2 EQUIPMENT DESCRIPTION .............. 1-1

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

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

2-2 ENGINE OPERATING INSTRUCTIONS . . . . . . . .2-1

2-3 STARTING ...................... :. 2-3

2-4 On.. PRESSURE ............ ......... 2-3

2-5 • STOPPING . . . . . . . . . . . . . . . ... " . . . . .2-4

• 2-6 ENGINE RUN-IN INSTRUCTIONS .......... 2-5

2-7 DYNAMOMETER TEST AND RUN-IN

PROCEDURES . . . . . . . . . . . . . . . ....... 2-6

2-8 RUN-IN PROCEDURE ............ ..... 2-9

2-9 LUBRlCA TING OIL. FUEL On.. AND Fll.. TER .,. 2-12 2-10 FUELOn.. ....................... 2-15

2-11 ENGINE COOLANTS ., ............... 2-15

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

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

3-2 GENERAL DESCRIPTION (6 CYLINDER) ... ... 3-1

3-3 SYSTEMS ........................ 3-1

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

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

4-2 MAINTENANCE PLAN ................. 4-1

4-3 COOLINGSYSTEM ................... 4-5

4-4 TACHOMETERDRNE ................. 4-5

4-5 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . .4-6

TABLE OF CONTENTS (Cont'd) •

CHAPTER/PARAGRAPH PAGE

4-6 THROTTLE AND CLUTCH CONTROLS .......4-6

4-7 LUBRICATINGOn..FTI..TER .............. 4-6

4-8 FUEL STRAINER AND FTI..TER ............ 4-6

4-9 EXHAUST SYSTEM . . . . . . . . . . ......... 4-6

4-10 EMERGENCY SHUIDOWN .............. 4-6

4-11 On.. PRESSURE ..................... 4-6

4-12 GOVERNOR ....................... 4-7

4-13 FUEL INJECTORS AND VALVE CLEARANCE ... 4-7

4-14 THROTTLE DELAY FUEL MODULATOR ......4-7

4-15 ENGINE AND TRANSMISSION ............ 4-7

4-16 CRANKCASE PRESSURE ............... 4-7

4-17 TIIERMOSTAT AND SEALS . . . . . . . . . . . . . . 4-7

4-18 BLOWER SCREEN ................... 4-8

4-19 CRANKCASE BREA TIIER . . . . . . . . . . . . . . . 4-8

- 4-20 ENGINE TUNE-UP .......... ......... 4-8

4-21 HEAT EXCHANGER ELECTRODES AND CORE .. 4-8 • 4-22 RAW WATER PUMP ............. ..... 4-8

5 TROUBLESHOOTlNG..................... 5-1

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

5-2 TROUBLESHOOTING PROCEDURES ........ 5-1

6 CORRECTIYEMA1NTENANCE ............... 6-1

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

6-2 TOOL AND EQUIPMENT ..... ~ ........... 6-1

SECTION 1 ADJUSTMENT AND ALIGNMENT . . . . . . . .6-5

6-3 INTRODUCTION .................... 6-5

6-4 EXHAUST VALVE BRIDGE ADJUSTMENT ..... 6-5

6-5 EXHAUST VALVE CLEARANCE ADJUSTMENT .. 6-6

6-6 FUEL INJECTOR TIMlNG ............ ... 6-8

6-7 SG VARIABLE SPEED HYDRAULIC GOVERNOR 6-10

SECTION 2 REPAIR ............. ; ........ 6-19 •

iI

T9233-AT-MMC-OlO

TABLE OF CONTENTS (Cont'd)

CHAPTE~ARAGRAPH PAGE

6-8 INTRODUCITON ................... 6-19

6-9 CLEANING AND INSPECITON ........... 6-19

6-10 PREUMINARYREPAIR/REPLACEMENT ..... 6-21

6-11 AIR START SYSTEM ................. 6-22

6-12 FUEL SYSTEM .................... 6-22

6-13 AIR INTAKE SYSTEM ............... 6-125

6-14 BLOWER ....................... 6-133

6-15 LUBRICATIONSYSTEMMAINTENANCE .... 6-167

6-16 LUBRICATING OIL COOLER (PLATE-TYPE) .. 6-174

6-17 LUBRICATING OIL COOLER BYPASS VALVE. 6-181

6-18 OILLEVELDIPSTICK ............... 6-182

6-19 OILPAN ....................... 6-184

6-20 VENTILATING SYSTEM .............. 6-185

6-21 EXHAUSTMANIFOLD(WATER-COOLED) ... 6-187

6-22 CYLINDER BLOCK . . . . . . . . . . . . . . . . . 6-189

6-23 CRANKSHAFT ................... 6-260

6-24 FLYWHEEL HOUSING . . . . . . . . . . . . . . . 6-293

6-25 PISTON AND PISTON RINGS ........... 6-299

6-26 CONNECTING ROD . . . . . . . . . . . . . . . . . 6-320

6-27 CONNECTING ROD BEARINGS . . . . . . . . . . 6-325

6-28 CYLINDER LINER ................. 6-329

6-29 GEAR TRAIN AND ENGINE TIMING . . . . . . . 6-340

6-30 ENGINE TIMING .................. 6-342

6-31 CAMSHAFTS AND BEARINGS .......... 6-344

6-32 CAMSHAFT GEARS ................ 6-356

6-33 IDLER GEAR AND BEARING ASSEMBLY . . . . 6-358

6-34 CRANKSHAFT TIMING GEAR .......... 6-367

6-35 BLOWER DRIVE GEAR AND SUPPORT

ASSEMBLY ..................... 6-369

6-36 BALANCE WEIGHT ................ 6-375

6-37 CHECKING BEARING CLEARANCES ...... 6-376

6-38 ENGINE COOLING SYSTEM MAINTENANCE . 6-376

6-39 WATERPUMP .................... 6-381

6-40 THERMOSTAT ................... 6-392

6-41 HEAT EXCHANGER ................ 6-395

iii

TABLE OF CONTENTS (Cont'd)

CHAPTER/PARAGRAPH

6-42 RAW WATER PUMP (JABS CO)

PAGE

6-397

7 PARTS LISTS _""""""""""",,7·1

7-1 INTRODUCTION """"""""",,7-1

7-2 PARTS LIST "'" , , , , , , , , , , , , , , , , , ,7-1

8 INSTALLATION , , , , , , , , , , , , , , , , , , , , , , , ,8-1

8-1 GENERAL """""",',',""," 8-1

8-2 INSTALLATION/REINSTALLATION , , , , " , , , ,8-1

8-3 START-UP AND CHECK-OUT , , , , . , , , , , , , ,8·2

iv

T9233-AT-MMC-OJO

LIST OF ILLUSTRATIONS

FIGURE DESCRlPTION PAGE

1-1

2-1

3-1

3-2 3-3 3-4 3-5 3-6 3-7

3-8

3-9 3-10 3-11 3-12

3-13

3-14

3-15

5-1 5-2 5-3

5-4 5-5 5-5 5-6 5-6 5-7

5-7

CROSS SECTION OF TYPICALAUXILIARY

DIESEL MARINE PROPUL SION ENGINE _ ... 1-2

COLLANT FREEZING AND BOILING TEMPERA

TURES VS. ANTIFREEZE CONCENTRATION

(SEA LEVEL) . . . . . . . . . . . . . . . . . . . . .2-16

TYPICAL WATER-COOLED EXHAUST MANI-

FOLD INSTALLATION ............... 3-2

RAW WATER PUMP MOUNTING . . . . ..... 3-2

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . .3-3

FUEL PUMP ASSEMBLY . . . . . . . . . . . . . .3-4

FUEL INJECTOR ASSEMBLY. . . . ....... 3-5

CUT A WA Y VIEW OF FUEL INJECTOR ...... 3-6

FUEL METERING FROM NO LOAD TO FULL

LOAD ......................... 3-6

PHASES OF INJECTOR OPERATION TIiROUGH

VERTICAL TRAVEL OF PLUNGER . . . . . . . .3-7

FUEL INJECTOR MOUNTING ...........3-8

FUEL COOLER MOUNTING ........ . ... 3-9

HYDRAULIC GOVERNOR ASSEMBLY ...... 3-10

POSmON OF GOVERNOR MECHANISM WHEN

LOAD IS CONSTANT ................ 3-11

POSmON OF GOVERNOR MECHANISM AS

LOAD INCREASE AND ENGINE SPEED TENDS

TO DECREASE . . . . . . . . . . . . . . . . . . . .3-12

POSmON OF GOVERNOR MECHANISM AS

LOAD DECREASES AND ENGINE SPEED TENDS

TOINCREASE ............ -........ 3-13

SCHEMA TIC DIAGRAM OF LUBRICATION

SYSTEM ....................... 3-14

CHECKING COMPRESSION PRESSURE ..... 5-2

INSPECTING PISTON RINGS ........... 5-3

COMPARISON OF COLUMN HEIGHT FOR

MERCURY AND WATER MANOMETERS ....5-6

EXCESSIVE CRANKCASE PRESSURE ... ... 5-8

EXHAUST SMOKE ANALYSIS (SHEET 1 OF 2) .5-9

EXHAUST SMOKE ANALYSIS (SHEET 2 OF 2) .5-10

HARD STARTING (SHEET 1 OF 2) ........5-11

HARD STARTING (SHEET 2 OF 2) ........ 5-12

ABNORMAL ENGINE OPERATION

(SHEET 1 OF 3) ................... 5-13

ABNORMAL ENGINE OPERATION

(SHEET 2 OF 3) ...................5-14

v

T9233-AT-MMC-010

LIST OF ILLUSTRATIONS (Cont'd)

FIGURE DESCRIPTION PAGE

S-7

S-8

S-8

5-9

5-9

S-lO 5-10 S-11

5-12 6-1 6-2 6-3 6-4 6-5

6-6

6-7 6-8 6-9 6-10 6-11 6-12

6-13

6-14

6-15 6-16

6-17 6-18 6-19 6-20

ABNORMAL ENGINE OPERATION

(SHEET 3 OF 3) ................... 5-15

NO FUEL OR INsumCIENT FUEL

(SHEET 1 OF 2) ................... 5-16

NO FUEL OR INSumCIENT FUEL

(SHEET 2 OF 2) ................... 5-17

mGH LUBRICATING OIL CONSUMPTION

(SHEET 1 OF 2) ................... S-18

mGH LUBRICATING OIL CONSUMPTION

(SHEET 2 OF 2) ................... 5-19

LOW OIL PRESSURE (SHEET 1 OF 2) . . . . ... S-20

LOW OIL PRESSURE (SHEET 2 OF 2) . . . . ... 5-21

ABNORMAL ENGINE COOLANT OPERATING

TEMPERATURE ................... 5-22

EXHAUSTVALVE ................. 5-23

VALVE BRIDGE ADJUSTMENT ......... . 6-S

ADJUSTING VALVE CLEARANCE ........ 6-7

PISTON FIRING ORDER ..... ......... 6-8

TIMING FUEL INmcroR .. ........... 6-9

HYDRAULIC GOVERNOR MOUNTED ON

ENGINE ........................ 6-10

POsmONING NUMBER 1R INJEcrOR RACK

CONTROL LEVER . . . . . . . ........... 6-11

CHECKING INJEcroR RACK "SPRING" . . . . .6-12 POsmONING GOVERNOR OPERATING LEVER 6-13

ADJUSTING VERTICAL LINK . . . . . . . . . . .6-14

ADJUSTING LOAD LIMIT SCREW ........ 6-1S

ADJUSTING SPEED DROOP ........ . . . .6-15

EX1ERNAL DROOP CONTROL ON PSG

ISOCHRONOUS GOVERNOR ...... ..... 6-17

ADJUSTING MAXIMUM NO-LOAD ENGINE

SPEED ..... : .................. 6-18

SCHEMA TIC DIAGRAM OF TYPICAL FUEL

SYSTEM .............. ......... 6-23

REMOVING INJEcrOR FROM CYLINDER HEAD 6-25

CHECKING RACK FOR FREENESS IN TESTER

J29S84 . . . . . . . . . . . . . . . . . . . . . . ... 6-27

REMOVING FILTER CAP .............. 6-28

LOCATIONOFFILTERININmcroRBODY .. 6-28 REMOVING INmcroR FOLLOWER STOP PIN .6-29

REMOVING OR INSTALLING PLUNGER

FOLLOWER, PLUNGER AND SPRING ...... 6-29

vi

LIST OF ILLUSTRATIONS (Cont'd)

FIGURE

6-21

6-22

6-23

6-24

6-25

6-26

6-27

6-28 6-29

6-30 6-31

6-32

6-33

6-34

6-35

6-36 6-37 6-38

6-39 6-40 6-41

6-42 6-43

DESCRIPTION PAGE

REMOVING INJECI'OR NUT USING TOOL

J4983-01 ........................ 6-30

REMOVING SPRAY TIP FROM INJECI'OR NUT

USING TOOL 11291-02 ............... 6-31

INJECI'OR RACK, GEAR, SPRAY TIP AND

VALVE ASSEMBLY DETAILS AND RELATIVE .

LOCATIONOFPARTS ............... 6-31

CLEANING INJECI'OR SPRAY TIP WITII TOOL

J24838 . . . . . . . . . . . . . . . . . . . . . . ... 6-32

CLEANING SPRAY TIP ORIFICES WITII TOOL

J4298-1 ..... ................... 6-32

CLEANING INJECTOR BODY RING WITII TOOL

J21098 . . . . . . . . . . . . . . . . . . . . . . . . .6-33

CLEANING INJECTOR NUT LOWER END WITII

TooLJ9418-5 .................... 6-34

INJECI'OR FOLLOWER . . . . . . ......... 6-35

EXAMINING SEALING SURFACE WITII A

MAGNIFYING GLASS ... ; ... ;.... ... 6-37

UNUSABLE INJECI'OR PLUNGERS ........ 6-37

omCKING NEEDLE VALVE LIFT WITII TOOL J9462-02 . . . . . . . . . . . . . . . . . . . . . . . . 6-39

SPRAY TIP SEALING SURFACE IDENTIFICA-

TION ......................... 6-42

SEALING SURFACE WHICH MAY REQUIRE

LAPPING . . . . . . . . . . . . . . . . . . . . ... 6-42

LAPPING SPRAY TIP ON LAPPING BLOCKS

J22090 . . . . . . . . . . . . . . . . . . . . . . . . .6-43

DETAILS OF INJECI'OR FILTERS AND CAPS .

AND THEIR RELATIVE LOCATION .... ... 6-44

LOCATION OF FILTER IN INJECI'OR BODY .. 6-44

INSTALLING FILTER CAP . . . . . . . . . . . . .6-45

INJECI'OR RACK, GEAR, SPRAY TIP AND

VALVE ASSEMBLY DETAILS AND RELATIVE

LOCATIONOFPARTS ............... 6-46

CUT A WA Y VIEW OF FUEL INJECI'OR . . . . . .6-47

TIGHTENING INJECTOR NUT BY HAND .... 6-47

TIGHTENING INJECI'OR NUT WITII TORQUE

WRENCH USING TOOL J4983-01 .... ..... 6-48

Il:'ISTALLING INJECTOR FOLLOWER STOP PIN 6-48

INJECI'OR PLUNGER, FOLLOWER AND

RELATIVE LOCATION OF PARTS ........ 6-49

vII

T9233-AT-MMC-OIO

i

FIGURE DESCRIPTION PAGE

6-44

6-45

6-46

6-47

6-48

6-49

6-50 6-51 6-52 6-53 6-54 6-55 6-56 6-57

6-58 6-59 6-60 6-61 6-62 6-63 6-64

6-65

6-66

6-67

6-68

6-69

INJEcrOR IN POsmON FOR TESTING WITIi

TESTER J23010-A ..... ............. 6-50

CHECKING RACK FOR FREENESS IN TESTER

J29584 . . . . . . . . . . . . . . . . . . . . . . . . .6-51 INJEcrOR TESTER J23010-A a..AMPING

HEADS ........................ 6-54

INJEcrOR INSTAl J .ED IN TESTER J23010-A WITIi a..AMPING HEADS .............6-55 INJEcrOR IN POsmON FOR TESTING WITIf J2301O-A ....................... 6-56 POsmON OF ROCKER ARM ENGAGEMENT

LEVER ........................ 6-57

INSTALUNG INJECTOR NUT ........... 6-59

TESTER J 22640-A WITIi SHIELD INSTAll ED .6-59 INJEcrOR IN CALmRATORJ22410-A ...... 6-61 POSmON OF CALmRA TOR FUEL FLOW PIPES 6-61 SETTING CALmRA TOR STROKE COUNTER .. 6-62

CHECKING FUEL OUTPUT ..... ....... 6-64

TYPES OF INJECTOR PLUNGERS ......... 6-65

PLUNGER/BUSHING AND TIP FLOW GAGE

J25600-A .......... ............. 6-66 ADJUSTING THE CALmRA TING VALVE .... 6-67

SPRAY TIP INSTALLED IN TESTER ....... 6-68

CRADLE MOUNTED ON FIXTURE ..•..... 6-69

END OF PLUNGER SHOWN IN PORT ....... 6-69

REFINISHING LAPPING BLOCKS . . . . . . . . .6-71

INJEcrORRACK-TO-GEAR-TIMING ....... 6-72 REMOVING INJECTOR TUBE WITIi TOOLS

J5286-4C AND J5286-5 ...............6-82

INST ALUNG INJEcrOR TUBE WITIi TOOLS

J5286-4C AND J5286-5 ........ ....... 6-83

UPSETTING INJEcrOR TUBE WITIi TOOLS

J5284-4C AND J5286-5 ........ ....... 6-84

REAMING INJEcrOR TUBE FOR INJEcrOR BODY NUT AND SPRAY TIP WITIi TOOL J22525-1 . . . . . . . . . . . . . . . . . . . . . . . . 6-85 REAMING INJEcrOR TUBE FOR INJEcrOR NUT WITIi TOOL J5286-9 . . . . ............. 6-85

MEASURING RELATIONSHIP OF BEVEL SEAT

OF INJEcrOR TUBE TO FIRE DECK OF CYUNDER HEAD WITIf TOOL J25521 AND GAGE J22273 .. 6-86 viii

T9233·AT·MMC-01O

LIST OF ILLUSTRATIONS (Cont'd)

FIGURE

6-70

6-71 6-72 6-73 6-74 6·75 6·76 6-77

6-78

6-79

6-80

6-81 6-82 6-83 .

6·84

6-85 6·86 6-87 6-88

6-89

6-90

6·91

6-92

6-93

6·94

DESCRIPTION PAGE

MEASURING RELA nONSHIP OF GAGE TO

FIRE DECK OF CYLINDER HEAD WITH TOOL

J25521 . . . . . . . . . . . . . . . . . . . . . . . . .6-87

TYPICAL FUEL PUMP ASSEMBLY . . . . . . . .6-88

TYPICAL FUEL PUMP MOUNTING AND DRIVE 6-88

FUEL PUMP VAL VING AND ROTA nON .... 6-89

FUEL PUMP OIL SEAL ARRANGEMPNTS .... 6-90

REMOVING FUEL PUMP COVER . . . . . . . . .6-92

REMOVING OIL SEALS USING TOOL J1508·13 .6·92

FUEL PUMP DETAILS AND RELATIVE

LOCA nON OF PARTS ............... 6-93

INSTALLING INNER OIL SEAL USING TOOL

J1508-8 ........... ............. 6-94

INSTALLING OUTER OIL SEAL USING TOOLS

J1508·8 AND J1508-9 ................6-95

INSTALLING FUEL PUMP DRIVE SHAFT AND

GEAR ASSEMBLY .. ............... 6-96

TYPICAL MOUNTING OF FUEL FILTER . . ... 6-100

FUELFILTERASSEMBLY ............. 6-100

TYPICAL FUEL STRAINER DETAILS . . . . ... 6-101

FUEL FILTER DETAILS AND RELATIVE

LOCATIONOFPARTS ............... 6-102

TYPICAL SPIN-ON FILTER MOUNTING . . ... 6-105

HYDRAULIC GOVERNOR ASSEMBLY . . . ... 6-106

HYDRAULIC GOVERNOR DRIVE ......... 6·107

POSITION OF GOVERNOR MECHANISM WHEN

LOAD IS CONSTANT . . . ............. 6-108

POSITION OF GOVERNOR MECHANISM AS

LOAD INCREASES AND ENGINE SPEED TENDS

TO DECREASE . . . . . . . . . . . . . . . . . . . . 6-108

POSITION OF GOVERNOR MECHANISM AS

LOAD DECREASES AND ENGINE SPEED TENDS

TO INCREASE ... . . . . . . . . . . . . . . . . . 6-109

TYPICAL HYDRAULIC GOVERNOR

MOUNTING ..................... 6-110

TOP VIEW OF GOVERNOR WITH COVER

REMOVED ...................... 6-111

TOP VIEW OF GOVERNOR WITH SUBCAP

REMOVED ...................... 6-112

REMOVING SPEED ADJUSTING LEVER ROLL

PIN .......................... 6-113

Ix

FIGURE DESCRIPTION PAGE

6-95

6-96

6-97

6-98

6-99

6-100

6-101

6-102

6-103 6-104 6-105 6-106

6-107

6-108

6-108

6-109 6-110

6-111

6-112

REMOVING SPEED ADJUSTING LEVER,

SPRING FORK, SPEEDER SPRING AND PILOT

VALVE PLUNGER ASSEMBLY .......... 6-113

REMOVING CUP PLUG FROM GOVERNOR

HOUSING ....................... 6-115

HYDRAULIC GOVERNOR DETAILS AND

RELATIVE LOCATION OF PARTS ........ 6-117

LOCATION OF SPEED ADJUSTING LEVER AND

TERMINAL LEVER SHAFT BUSHINGS IN

GOVERNOR HOUSING . . . . . . . . . . . . . . .6-119

LOCATION OF OIL RELIEF VALVE PLUNGER,

PLUNGER SLEEVE, SPRINGS, OIL INLET PLUG

AND DUMMY PLUG ................ 6-120

INSTALLING TERMINAL LEVER SHAFT

IN GOVERNOR HOUSING AND TERMINAL

LEVER ................. ....... 6-121

INSTALLING SPEED ADJUSTING LEVER,

FLOATING LEVER, SPEEDER SPRING AND

PILOT VALVE PLUNGER ASSEMBLY ...... 6-122

INSTALLING SPEED ADJUSTING LEVER SHAFT

IN GOVERNOR HOUSING AND ADJUSTING

LEVER ........................ 6-123

AIR FLOW THROUGH BLOWER AND ENGINE .6-126

DRY TYPE AIR CLEANER ............. 6-127

DRY TYPE AIR CLEANER (REA VY DUTY) ... 6-128

AIR SHUTDOWN HOUSING DETAILS AND

RELATIVE LOCATION OF PARTS ........ 6-130

INSTALLING AIR SHUTDOWN VALVE SPRING

ANDVALVE ..................... 6-131

BLOWER AND DRIVE ASSEMBLY AND

ACCESSORIES ATTACHED TO BLOWER

(SHEET 1 OF 2) ................... 6-134

BLOWER AND DRIVE ASSEMBLY AND

ACCESSORIES ATTACHED TO BLOWER

(SHEET 2 OF 2) ................... 6-135

BLOWER LUBRICATION . . . . . . . . . . . . . .6-136

TYPICAL BLOWER MOUNTING

(SINGLE BLOWER) ... . . . . . . . ....... 6-138

REMOVING BLOWER GEARS WITH TOOL

J6270-31 ........................ 6-140

BLOWER DETAILS AND RELATIVE LOCATION

OF PARTS ...................... 6-141

x

T9233-AT-MMC-OIO

LIST OF ILLUSTRATIONS (Cont'd)

FIGURE DESCRIPTION PAGE

6-113

6-114

6-115 6-116

6-117

6-118 6-119

6-120

6-121

6-122

6-123

6-124

6-125 6-126

6-127 6-128

6-129

6-130

6-131 6-132 6-133

REMOVING BLOWER END PLATE AND

BEARINGS FROM HOUSING AND ROTORS

WITH TOOL J6270-31 ................ 6-142

REMOVING On.. SEAL (OR On.. SEAL RING

COLLAR) AND BEARING FROM END PLATE

WITH TOOLJ6270-3 ................. 6-143

REMOVING On.. SEAL RING FROM CARRIER .6-144 REMOVING On.. SEAL RING CARRIER FROM

BLOWER ROTOR SHAFT USING TOOLS

J6270-2 AND J6270-3 ................ 6-144

INSTALLING On.. SEAL (OR On.. SEAL RING

COLLAR) IN END PLATE USING TOOL J6270-3 .6-148

LOCATION OF On.. SEALS IN END PLATE ... 6-148 INSTALLING On.. SEAL RING CARRIER ON

BLOWER ROTOR SHAFT WITH TOOL J6270-4 .6-149

ASSEMBLING BLOWER ROTORS IN HOUSING

AND FRONT END PLATE WITH On.. SEAL Pn..OTS (16270-5) .................. 6-151

INSTALLING BLOWER ROTOR IN FRONT END

PLATE (V-92T BLOWERS) ............. 6-154

INSTALUNG REAR END PLATE ON BLOWER

ROTORS AND HOUSING . . . . . . . . . . . . . .6-156

INSTALLING BALL BEARINGS ON ROTOR

SHAFT AND IN REAR END PLATE WITH TOOL

J6270-13 ........................ 6-157

INSTALLING ROLLER BEARINGS ON ROTOR

SHAFTS AND IN FRONT END PLATE WITH

TooLJ6270-13 .................... 6-158

INSTALLING BLOWER ROTOR TIMING GEARS 6-159

MEASURING "CC" AND "C" CLEARANCE

BETWEEN BLOWER ROTOR LOBES . . . . . . .6-160

END VIEW OF BLOWER ROTOR CLEARANCES 6-161

DIAGRAM SHOWING PROPER LOCATION OF

SHIMS FOR CORRECT LOBE CLEARANCE ... 6-161

MEASURING END CLEARANCE BETWEEN

BLOWER ROTORS AND END PLATE ....... 6-162

FRONT HUB ASSEMBLY - LARGE BEARING

BLOWERS ...................... 6-163

ALIGNING BLOWER WITH TOOL J33OO1 .... 6-164

TYPICAL LUBRICATING OIL PUMP MOUNTING 6-168

LUBRICATING OIL PUMP DETAILS AND

RELATIVE LOCATIONS OF PARTS ........ 6-168

xi

T9233·AT·MMC-01O

FIGURE DESCRIPTION PAGE

6-134

6-135

6·136 6·137

6-138

6-139

6-140

6-141

6-142

6-143

6-144 6-145 6-146

6-147

6-148

6-149

6-150 6-151 6·152 6-153 6-154

6-155

6-156 6-157 6-158 6-159

OIL PRESSURE REGULA TOR VALVE AND

RELIEF VALVE MOUNTING . . . . . . . . . . . .6-171

OIL PRESSURE REGULA TOR VALVE AND

RELIEF VALVE AND RELA TIVE LOCATION

OF PARTS ...................... 6-171

TYPICAL OIL COOLER MOUNTING ....... 6-174

FORMER AND CURRENT OIL COOLER

CONFIGURATION .................. 6-175

OIL COOLER ADAPTOR AND BYPASS VALVE

MOUNTING ..................... 6-175

LOCATION OF CYLINDER BLOCK OIL

GALLERY CUP PLUG ................ 6-177

OIL COOLER CORE PREPARED FOR PRESSURE

CHECK ........................ 6-178

OIL COOLER DETAILS AND RELATIVE

LOCATIONOFPARTS ............... 6-179

TWIN PLATE OIL COOLER DETAILS AND

RELATIVE LOCATION OF PARTS ........ 6-180

OIL COOLER ADAPTORS WITH BYPASS VALVE

ASSEMBLY COMPONENTS ............ 6-182

TYPICAL DIPSTICK MOUNTING ......... 6-183

TYPICAL ONE·PIECE OIL PAN .......... 6-184

CYLINDER BLOCK TO CYLINDER HEAD

BREATHER SYSTEMS ............... 6-186

TYPICAL MOUNTING OF BREATHER

ASSEMBLY ON VALVE ROCKER COVER .... 6-186

CORRECT INSTALLATION OF BREATHER

CLAMP . . . . . . . . . . . . . . . . . . . . . . . .6-187

TYPICAL WATER· COOLED EXHAUST

MANIFOLD INSTALLATION ........... 6-188

CYLINDER BLOCK . . . . . . . . . . . . . . . . .6-190

ENGINE MOUNTED ON OVERHAUL STAND .. 6-191

LIFTING ENGINE WITH SPREADER AND SLING 6-193

INSTALLING AFTER COOLER WATER PLUG .. 6-194

CYLINDER BLOCK BORE MEASUREMENT

DIAGRAM ...................... 6·197

CHECKING TOP SURFACE OF CYLINDER

BLOCK ........................ 6-198

CHECKING DEPTIl OF COUNTERBORE ..... 6-199

CYLINDER BLOCK MARKINGS .......... 6-199

CYLINDER BLOCK REAR END PLATE . . . ... 6-202

INSTALLING FRONT END PLATE ........ 6-203

xII

T9233-AT-MhlC-OIO '

LIST OF ILLUSTRATIONS (Cont'd)

FIGURE DESCRIPTION PAGE

6·160 6-161

6-162

6-163

6-164 6-165 6-166

6-167

6-168

6-169

6-170

6-171

6-172

6·173 6-174

6-175

6-176

6-177

6-178 6-179 6-180

6·181

6-182

6-183

EARLY AIR BOX DRAIN TUBE .. . . . . . . . .6-204

OPEN AIR BOX DRAIN TUBE AND CHECK

VALVBSYSTEM .................. 6-205

CURRENT OPEN AIR BOX DRAIN TUBE AND

CHECK VAL VB SYSTEM . . . . . . . . . ..... 6-205

FORMER CLOSED AIR BOX DRAIN TUBE AND

CHECK VAL VB SYSTEM . .. . . . . . . . . . . .6-206

TYPICAL CYLINDER HEAD ASSEMBLY .... 6-207

CYLINDER HEAD MOUNTING .......... 6-207

COOLANT PASSAGES AROUND EXHAUST

VALVES AND FUEL INJECTORS ......... 6-208

LOCATION AND POSITION OF WATER

NOZZLES IN CYLINDER HEAD .......... 6-208

REMOVING OR INSTALLING CYLINDER HEAD

USING TOOL J22062-01 ............... 6-211

CYLINDER HEAD PREPARED FOR PRESSURE

TESTING USING TOOL J28454 ........... 6-212

CHECKING BOTTOM FACE OF CYLINDER

HEAD ............ " ............ 6-214

MINIMUM DISTANCE BETWEEN TOP AND

BOTTOM FACES OF CYLINDER HEAD ..... 6-215

COMPRESSION GASKET MOUNTING IN

CYLINDER BLOCK ................. 6-218

CYLINDER HEAD SUPPORT SHIMS IN PLACE .6-218

CYLINDER HEAD BOLT TIGHTENING

SEQUENCE . . . . . . . . . ............. 6-220

VAL VB AND INJECTOR OPERATING

MECHANISM ....................6-223

LUBRICATION OF VAL VB OPERATING

MECHANISM ................. ... 6·224

REMOVING PUSH ROD FROM UPPER SIDE OF

CYLINDER HEAD USING TOOL J3092-01 ....6-227

CAM FOLLOWERS AND GUIDE .........6-227

CAM ROLLER CLEARANCES . . . . . . . . ... 6·228

TESTING CAM FOLLOWER SPRING wrrn

TOOL J22738·02 ... . . . . . . . . . . . . . . . .6-229

REMOVING OR INSTALLING CAM FOLLOWER

ROLLER USING TOOL 133421 ........... 6-230

VAL VB AND INJECTOR OPERATING

MECHANISM AND RELATIVE LOCATION

OF PARTS ...................... 6-232

INSTALLATION OF CAM FOLLOWERS ..... 6-233

xIII

FIGURE DESCRIPTION PAGE

6-184

6-185 6-186 6-187

6-188

6-189

6-190

6-191

6-192

6-193

6-194

6-195

6-196 6-197 6-198

6-199

6-200

6-201

6-202

6-203 6-204 6-205

CHECKING CAM FOLLOWER TO GUIDE

CLEARANCE . . . . . . . . . . . . . . . . . . . . .6-233

ADJUSTING CAM FOLLOWER GUIDE ...... 6-234

LOCATION OF EXHAUST VAL YES . . . ..... 6-238

ASSEMBLY OF EXHAUST VAL YES AND

GUIDES . . . . . . . . . . . . . ........... 6-238

REMOVING EXHAUST VAL YE SPRING WITIi

TOOL 17455 ................ ..... 6-240

TESTING EXHAUST VAL YE SPRING USING

TOOL 122738-02 ............ ....... 6-242

CLEANING EXHAUST VALVE GUIDE WITIi

TOOL 15437 ..................... 6-243

REMOVING EXHAUST VAL YE GUIDE WITIi

TOOL J6569 .............. ....... 6-244

INSTALLING VALYE GUIDE WITIi TOOL J21520 ......................... 6-244

REMOVING PRESS-FIT EXHAUST VAL YE

BRIDGE GUIDE ................... 6-~5

REMOVING BROKEN EXHAUST VAL YE

BRIDGE GUIDE WITIi TOOL 17453 AND SLIDE

HAMMER J2619-01 ................. 6-246

INSTALLING VAL YE SEAT INSERT WITIi

TOOL J 24357 ....................6-247

REFACING EXHAUST V ALYE .......... 6-247

GRINDING VAL YE SEAT INSERT ........ 6-248

EXHAUST VAL YE PROTRUSION BEYOND

CYLINDER HEAD . . . . . . . . . . . ....... 6-249

GRINDING WHEEL DRESSING TOOL OF SET

J24566 . . . . . . . . . . . . . . . . . . ....... 6-249

CHECKING RELATIYE CONCENTRICITY OF

VAL YE SEAT INSERT WITIi RELATION TO

VALYEGUIDE .................... 6-250

EXHAUST VAL YE. SPRING AND SEAL

CONFIGURATION .................. 6-251

CHECKING PRESSURE REQUIRED TO OPEN THE

EXHAUST VAL YE IN CYLINDER HEAD WITIi

TOOL J25076-01 ................... 6-252

VAL YE BRIDGE ADJUSTMENT . . . . . . . . . .6-253

ADJUSTING VAL YE CLEARANCE ........ 6-255

TYPICAL VAL YE ROCKER COVER ASSEMBLY

(CURRENT) .....................6-257

xlv

T9233·AT·MMC·OIO

LIST OF ILLUSTRATIONS (Cont'd)

FIGURE

6·206

6-207 6-208

6-209

6·210 6·211 6-212

6-213 6-214 6-215

6-216 6-217

6·218

6-219 6-220

6-221 6-222

6·223

6·224

6-225 6·226 6·227 6-228 6-229

6-230 6-231 6-232

DESCRIPTION PAGE

TYPICAL VALVE ROCKER COVER ASSEMBLY

(FORMER) ................. ..... 6-258

TYPICAL CRANKSHAFT ..... " ......... 6-259

CROSS·SECTIONAL VIEW OF CRANKSHAFT

SHOWING OFFSET, RELOCATED MAIN

BEARING JOURNAL OIL HOLES .........6-260

ROLL PIN INSTALLED IN END OF

CRANKSHAFT . . . . . ................ 6-261

REMOVING OR INST ALUNG CRANKSHAFT .. 6-262

DIMENSIONS OF CRANKSHAFT JOURNALS .. 6-264

STANDARD DIMENSION AT REAR MAIN

BEARING THRUST WASHERS ..... ..... 6-264

CRITICAL CRANKSHAFT LOADING ZONES .. 6-266

CRANKSHAFT FATIGUE CRACKS ........6-267

TYPICAL CRANKSHAFT FRONT.OIL SEAL

MOUNTING ... ~ . . . . . . . . . . . . . . . . .6-270

CRANKSHAFT REAR OIL SEAL MOUNTING .. 6-270

INSTALLING CRANKSHAFT REAR SEAL WITH

INSTALLER SET J21112·B AND HANDLE

13154-1 ........................ 6-273

CHECKING CRANKSHAFT REAR SEAL

SQUARENESS .... . . . . . . . . . . . . . ... 6-274

CRANKSHAFT CAP MOUNTING ......... 6-276

MAIN BEARING SHELLS, BEARING CAPS AND

CRANKSHAFT THRUST WASHERS .......6-277

REMOVING MAIN BEARING CAP ........6-278

REMOVING UPPER MAIN BEARING SHELL

(EXCEPT REAR MAIN) . . . . . . . . . . . . ... 6-279

REMOVING UPPER REAR MAIN BEARING

SHELL ..................... ... 6·279

COMPARISON OF LOWER MAIN BEARING

SHELLS . . . . . . . . . . . . . . .. . . . . ..... 6·280

MAIN BEARING MEASUREMENTS ......... 6-281

MEASURING THICKNESS OF BEARING SHELL 6-281

STABILIZERS MOUNTED ON BLOCK ...... 6·282

ENGINE FRONT COVER MOUNTING ...... 6-285

FRONT COVER DETAILS AND RELATIVE

LOCATIONOFPARTS ............... 6-287

TYPICAL FLYWHEEL ASSEMBLY ...... . .6-288

PILOT BEARING RETAINER ............ 6-289

TORQUE· TURN LIMITS . . . . . . . . . . . . . .6-291

FIGURE DESCRIPTION PAGE

6-233

6-234

6-235 6-236

6-237

6-238

6-239

6-240

6-241

6-242 6-243

6-244

6-245 6-246 6-247

6-248

6-249

6-250

6-251 6-252

6-253 6-254 6-255

6-256 6-257

INSTALLING FLYWHEEL HOUSING, USING

OIL SEAL EXPANDER AUGNING STUDS _ ... 6-293

FLYWHEEL HOUSING COVER A IT ACHING

STUDS (NATURALLY ASPIRATED ENGINES) .6-295

IDLER GEAR HOLE SPACER SHIM . . . . . . . .6-295

FLYWHEEL HOUSING BOLT TIGHTENING

SEQUENCE (OPERATION 1) . . . . . . . . . . . .6-296

FLYWHEEL HOUSING BOLT TIGHTENING

SEQUENCE (OPERATION 2) . . . ......... 6-297

CHECKING FLYWHEEL HOUSING

CONCENTRICITY .................. 6-298

CROSS-HEAD PISTON AND CONNECTING ROD

ASSEMBLY .....................6-299

CROSS-HEAD PISTON AND CONNECTING ROD

COMPONENTS ...................6-300

IDENTIFICATION OF PISTON USING GAGE

125397 . . . . . . . . . . . . . . . . . . . . . . ... 6-301

PLASMA-FACED FIRE RING : ........... 6-301

REMOVING OR INSTALLING PISTON RINGS

USINGTOOLJ8128 ................. 6-302

CHECKING FIRE RING GROOVE IN PISTON

CROWN WITH TOOL J24599 . . . . . . . . . ... 6-305

INSTALLING SEAL RING ............. 6-305

INSTALLING PISTON PIN ............. 6-306

TIGHTENING CONNECTING ROD TO PISTON

PINBOLTS ...................... 6-313

INSTALLING PISTON PIN RETAINER WITH

TOOL 123762-A ...................6-314

CHECKING PISTON PIN RETAINER FOR PROPER

SEAUNG WITH TOOL J23987-01 ......... 6-314

MEASURING PISTON-TO-LINER CLEARANCE

WITH GAGE 15438-01 . . . ............. 6-315

PISTON RING LOCATION ............. 6-316

COMPARISON OF PRE-STRESSED

COMPRESSION RINGS ............... 6-316

MEASURING PISTON RING GAP ......... 6-317

MEASURING PISTON RING SIDE CLEARANCE 6-318

PERIPHERAL ABUTMENT TYPE OIL CONTROL

RINGEXPANDER .................. 6-319

PISTON RING INSTALLATION INSTRUCTIONS 6-319

CONNECTING ROO DETAILS . . . . . . . . . . .6-320

xvi

T9233-AT-MMC,-010

LIST OF ILLUSTRATIONS (Cont'd)

FIGURE

6-258

6-259

6-260 6-261

6-262 6-263

6-264 6-265 6-266 6-267 6-268 6-269 6-270

6-271

6-272

6-273

6-274 6-275 6-276

6-277

6-278 6-279

6-280

6-281

6-282

DESCRIPTION PAGE

MAGNETIC PARTICLE INSPECTION LIMITS

FOR CONNECTING ROD . . . . . . . ....... 6-322

DIMENSIONAL INSPECTION OF CROSS-HEAD

PISTON CONNECTING RODS ........ ... 6-323

COMPARISON OF CONNECTING RODS ..... 6-324

BEARING FACES (10.) OF FORMER AND NEW

PISTON PIN BUSHINGS ... ........... 6-325

CONNECTING ROD AND BEARING SHELLS .. 6-325

COMPARISON OF CONNECTING ROD

BEARING SHELLS .................6-327

TYPICAL CYLINDER UNER . . . . . . . . . . . .6-329

REMOVING CYLINDER UNER ..........6-330

GLAZED SURFACE OF CYLINDER UNER .... 6-332

CYLINDER UNER RIDGE DUE TO WEAR .... 6-332

CYLINDER LINER MEASUREMENT DIAGRAM 6-333

CYLINDER UNER MOUNTING IN BLOCK ...6-334

CHECKING DISTANCE OF LINER FLANGE

BELOW TOP FACE OF BLOCK USING CLAMP

124565-02 AND GAGE 124898 ...........6-335

INSTALLING PISTON AND CONNECTING ROD

ASSEMBLY IN RING COMPRESSOR AND

CYLINDER UNER. . . . . . . . . . . . . ..... 6-336

INSTALLING PISTON, CONNECTING ROD

AND LINER ASSEMBLY IN CYLINDER BLOCK 6-338

TYPICAL FRONT BALANCE WEIGHT

MOUNTING .....................6-339

GEAR TRAIN .................... 6-340

GEAR TRAIN AND TIMING MARKS ....... 6-341

CAMSHAFT INTERMEDIATE BEARING

(LOWER HALF) ................ ... 6-345

LOOSENING CAMSHAFT GEAR RETAINING

NUT ....... , ........ ; ......... 6-346

REMOVING CAMSHAFT PULLEY ........ 6-346

REMOVING OR INSTALLING CAMSHAFT END

BEARING RETAINING BOLTS .......... 6-347

REMOVING OR INSTALLING CAMSHAFT

ASSEMBLY ..,..................6-347

REMOVING CAMSHAFT WITH CAMSHAFT

GEAR PULLER 11902-01 AND ADAPTOR PLATE

SET16202 ....................... 6-348

REMOVING GEAR (CAMSHAFT GEAR PULLER

11902-01) ....................... 6-349 xvii

FIGURE DESCRIPTION PAGE

6-283 6-284 6-285

6-286 6-287 6-288 6-289 6-290 6-291 6-292 6-293

6-294 6-295 6-296 6-297 6-298

6-299 6-300

6-301

6-302

6-303 6-304

6-305 6-306

6-307

6-308

6-309

6-310

CHECKING CAM LOBE WEAR ..........6-350

CAMSHAFT JOURNAL FD...LET .......... 6-351

CAMSHAFT DETAILS AND RELA TlVE

LOCATION OF PARTS ............... 6-352

CAMSHAFT PLUG INSTALLATION .. ..... 6-353

CAMSHAFT GEARS MOUNTED ON ENGINE .. 6-356

REMOVING CAMSHAFT GEAR . . . . . . . ... 6-357

INSTALLING CAMSHAFT GEAR ......... 6-358

IDLER GEAR MOUNTING ............. 6-359

IDLER GEAR SPACER ............... 6-359

PRESSING HUB OUT OF IDLER GEAR BEARING 6-360

IDLER GEAR DET AD...S AND RELA TlVE

LOCATION OF PARTS ............... 6-361

PRESSING HUB INTO IDLER GEAR BEARING .6-363

FIXTURE FOR TESTING BEARING PRE-LOAD .6-365

PLATES FOR BEARING TEST FIXTURE . . . . .6-366

CHECKING IDLER GEAR BEARING PRE-LOAD 6-366

INSTALLING IDLER GEAR, HUB AND BEARING

ASSEMBLY. . . . . . . . . . ........... 6-367

CRANKSHAFT TIMING GEAR MOUNTING ... 6-368

BLOWERDIDVEGEARMOUNTING

(NON-TURBOCHARGED ENGINE) ..... ... 6-370

REAR HUB ASSEMBLY (NON-TIJRBOCHARGED

ENGINE) ....................... 6-371

REAR HUB, BLOWER DruVE GEAR. SUPPORT

ASSEMBLY AND RELATIVE LOCATION OF

PARTS ........................ 6-372

BLOWER DIDVE COMPONENTS ......... 6-373

CHECKING CLEARANCE BETWEEN BLOWER

DIDVE GEAR SUPPORT THRUST WASHER AND

TIiRUST BEARING ................. 6-374

BALANCE WEIGHT COVER MOUNTING .... 6-375

USING PLASTIC STruP TO MEASURE BEARING-

TO-CRANKSHAFT CLEARANCE ......... 6-377

WATER PUMP MOUNTING (FORMER COVER

WITIi SPIROLOX RING) .............. 6-381 WATER PUMP DET AD...S AND RELA TlVE

LOCATIONOFPARTS ............... 6-382

DIVIDED INLET HIGH CAPACITY WATER

PUMP ......................... 6-382

WATER PUMP SEALS ...............6-383

xviii

LIST OF ILLUSTRATIONS (Cont'd)

FIGURE DESCRIPTION PAGE

6-311

6-312

6-313

6-314 6-315

6-316

6-317

6-318

6-319 6-320 6-321

7-1 7-2 7-3 7-4 7-5 7-6 7-7

. 7-8 7-9 7-10 7-11 7-12 7-13

7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21 7-22

INSERT, ADHESIVE WASHER, IMPELLER

STACK-UP ., .................... 6-385

CHECKING IMPELLER AND GEAR SLIP

TORQUE WIlli TOOL J33765 ...........6-386

REMOVING RETAINING RING USING TOOL

J4646 ...................... ... 6-388 PRESSING SHAFf OUT OF GEAR . . . . ..... 6-389 PRESSING BEARING ON PUMP SHAFf USING

TOOL J25257 . . . . . . . . ... . . . ... . ..... 6-390

PRESSING GEAR ON PUMP SHAFf USING

TOOL J25257 ..................... 6-391

THERMOSTAT HOUSING AND RELATIVE

LOCATIONOFPARTS ............... 6-393

METIiOD OF CHECKING THERMOSTAT

OPERATION ..................... 6-394

TYPICAL HEAT EXCHANGER MOUNTING ... 6-396

RA W WATER PUMP MOUNTING . . . . . . . . .6-398

RAW WATER PUMP DETAILS AND RELATIVE

LOCATIONOFPARTS ............... 6-400

CYLINDER BLOCK ................. 7-3

AIR BOX DRAIN ................... 7-5

CYLINDER HEAD .................. 7-7

ENGINE LIFIER BRACKET ............ 7-9

CRANKSHAFf .................... 7-11

SEAL. CRANKSHAFT OIL-FRONT ........ 7-12

FLYWHEEL AND FLYWHEEL HOUSING .... 7-15

BEARING CAP STABILIZER ............ 7-16

GEAR TRAIN .................... 7-18

CONNECTING ROD AND PISTON ......... 7-19

CAMSHAFT AND GEAR .............. 7-19

BLOWER DRIVE GEAR ............... 7-22

VALVE AND INJECTOR OPERATING

MECHANISM ....................7"25

ROCKER COVER ..... ; ............ 7-27

ROCKER COVER OIL FILLER ........... 7-28

FUEL INJECTOR ................... 7-31

FUEL PUMP ..................... 7-33

FUEL FILTER .................... 7-35

FUEL SYSTEM, TYPICAL ............. 7-38

INJECTOR CONTROLS ............... 7-40

AIR INLET HOUSING ................ 7-42

BLOWER ....................... 7-45

xix

FIGURE DESCRIPTION PAGE

7-23 7-24 7-25 7-26 7-27 7-28 7-29 7-30 7-31 7-32 7-33 7-34

7-35 7-36 7-37 7-38 7-39 7-40 on.. PUMP ...................... 7-47 On.. DISTRIBUTION SYSTEM ........... 7-49 On.. PRESSURE REGULATOR ... . . . . . ... 7-51 On.. Fll..TER ..................... 7-53 On.. COOLER ..................... 7-55 On.. Fll..LER ..................... 7-57

DIPSTICK ....................... 7-59

On.. PAN ....................... 7-61 VENTll..ATING SYSTEM .............. 7-63

FRESH WATER PUMP ............ ... 7-65

TIlERMOSTAT AND WATER BYPASS TUBE .. 7-68

EXHAUST MANIFOLD (CENTER OUTLET,

FLANGE) ....................... 7-70

RAW WATER PUMP ................ 7-73

HEAT EXCHANGER ................ 7-76

ENGINE MOUNTS AND BASE . . . . . . . . ... 7-78

HYDRAULIC GOVERNOR ............. 7-81

INSTRUMENTS ................... 7-83

STARTER MOTOR ................. 7-86

xx

TABLE

1-1 2-1 2-2 2-3 3-1 4-1 4-2 5-1 5-2 5-3 5-4 6-1 6-2 6-3 6-4 6-5 6-6 6-7

6-8 6-9

6-10 6-11 6-12

6-13 6-14 6-15 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9

7-10 7-11 7-12

T9233-AT-MMC-01O

LIST OF TABLES

DESCRIPTION PAGE

PRINCIPALCHARAcrERISTICS ......... 1-1

FINAL ENGINE RUN-IN SCHEDULE ....... 2-7

ENGINE OPERATING SPECIFICATIONS ..... 2-8

BASIC ENGINE RUN-IN SCHEDULE .......2-8

ENGINE SPECIFICATIONS . . . . . . . . . . . . .3-1

PREVENTIVE MAINTENANCE SCHEDULE . . .4-2

FUEL OIL SPECIFICATION CHART .. : . . . . .4-3

COMPRESSION PRESSURE ............5-2

CYLINDER COMPRESSION PRESSURE .. ... 5-3

MANOMETER CRANKCASE PRESSURE . . ... 5-5

PRESSURECONVERSION.TABLE ........ 5-7

SERVICE TOOLS ..................6-1

INJECTOR TIMING ................. 6-10

MINIMUM THICKNESS (USED PARTS) ..... 6-39

INJECTOR OUTPUT SPECIFICATIONS . . . . . .6-63

CYLINDER HEAD WARPAGE SPECIFICATIONS 6-215

FUEL PIPE TORQUE VALVES .......... 6-221

EXCEPTIONS TO STANDARD BOLT AND NUT

TORQUE SPECIFICATIONS ............ 6-236

CRANKSHAFT MEASUREMENTS ..... ... 6-264

CRANKsHAFT DIMENSIONAL .

SPECIFICATIONS ................. ·.6-267

THRUST WASHER SIZES ........ ..... 6-268

BEARING SPECIFICATIONS ............ 6-281

SPECIFICATIONS, NEW CLEARANCES AND

WEAR LIMITS . . . . . . . . . . . . . . ... . . . .6-308

STANDARD BEARING SHELL ........... 6-327

LINER INSERT SPECIFICATIONS ......... 6-335

TIMING CHECKS ..................6-344

CYLINDER BLOCK ................. 7-2

AIR BOX DRAIN .................. 7-4

CYLINDER HEAD .................. 7-6

ENGINE LIFTER BRACKET ............ 7-8

CRANKSHAFT, OIL SEAL AND STABILIZERS· .7-10

FLYWHEEL AND FLYWHEEL HOUSING .... 7-13

CONNECTING ROD AND PISTON ......... 7-17

CAMSHAFT AND GEAR TRAIN ......... 7-20

VALVE AND INJECTOR OPERATING

MECHANISM .................... 7-23

ROCKER COVER .................. 7-26

FUEL INJECTOR ................... 7-29

FUEL PUMP ..................... 7-32

xxi

TABLE

7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21 7-22 7-23 7-24 7-25 7-26 7-27 7-28 7-29

7-30 7-31 7-32 7-33 7-34 7-35

T9233-AT-MMC-010

LIST OF TABLES (Cont'd)

DESCRIPTION PAGE

FUEL FILTER AND STRAINER .......... 7-34

FUEL LINES .....................7-36

INJECTOR CONTROLS ............... 7-39

AIR INLET HOUSING ................ 7-41

BLOWER AND DRIVE ............... 7-43

On. PUMP ........... ........... 7-46 On. DISTRIBUTION SYSTEM ........... 7-48 On. PRESSURE REGULATOR ........... 7-50 On. FILTER ..................... 7-52 On. COOLER ..................... 7-54 On. FILLER ..................... 7-56

DIPSTICK ....................... 7-58

On. PAN ........................ 7-60 VENTll..A TING SYSTEM .............. 7-62

FRESH WATER PUMP ...............7-64

THERMOSTAT AND WATER BY PASS TUBE .. 7-66

EXHAUST MANIFOLD (CENTER OUTLET,

~GE) . . . . . . . . . . . . . . . . . . . . . . . 7-~

RAWWATERPUMP ................ 7-71

HEAT EXCHANGER AND RAW WATER PIPING 7-74

ENGINE MOUNTS AND BASE ........... 7-77

HYDRAULIC GOVERNOR ............. 7-79

INSTRUMENTS ................... 7-82

STARTER MOTOR ................. 7-84

xxii

T9233-AT-MMC-OIO

SAFETY SUMMARY

The following are general safety precautions that are not related to any specific pro cedures and therefore do not appear elsewhere In this publication. These are recom mended precautions that personnel must understand ~nd apply during many phases of operation and malntenance.

WARNING notices are used to warn personnel about procedures which must be fol lowed for the protection of personnel. Failure to comply may result In Injury or death to personnel.

CAUTION notices are used to warn personnel about procedures which must be fol lowed for protection of equipment. Fallure to comply may result in damage to equip ment.

KEEP AWAY FROM LIVE CIRCUITS

Operating personnel must at all times observe all safety regulations. Do not replace components or make adjustments inside the equipment with the high voltage supply energized. Under certaln conditions, dangerous potentials due to the charges retalned by the capacitors may exist when power Is off. To avoid casualties, always disconnect the power and discharge the circuit before touching It.

DO NOT SERVICE OR ADJUST ALONE

Under no circumstance should any person reach Into an enclosure for the purpose of servicing or adjusting the equipment when not In the company of someone who Is capable of rendering aid In the event of accidental shock.

REDUCE RISK OF ACCIDENTAL SHOCK

Personnel working with or near high voltage should remove watches, rings or any jewelry that could accidentally make physical contact with circuits.

RESUSCITATION

Personnel working with high or near high voltage should be familiar with modem methods of resuscitation. Such Information may be obtalned from the Bureau of Medicine and Surgery.

xxiii

WARNING AND CAUTIONS

The following warnings and cautions appear In this technical manual, and are repeated here for emphasis:

·IWARNINgl Start fluid used In capsules Is highly Inflam mable, toxic and posseses sleep Inducing properties. (Page 2-3).

IWARNINgl Contact with hot coolants can result In serious bums. Do no bleed hot pressurized coolant from a closed cooling system. (Page 2-4).

ICAUnOf\1 The emergency shutdown system should never be used except In an emergency. Use of the emergency shutdown can cause oil to be sucked past the 011 seals and Into the blower housing. (Page 2-4).

ICAunoij To avoid damaging the phenolic bypass valve, the bolt should be finger-tightened only and then secured In place with the lock nut. On fll ter adapters with more than one bypass valve, Install modified valve plugs In all valve open Ings before starting or dynamometer testing the engine. (Page 2-9).

ICAUTION!

Soluble ollis not recommended as a corrosive Inhibitor. (Page 2-15).

IWARNINgl Sodium chromates and potassium dlchromates are toxic. Care should be exer cised when handling these chemicals.

(Page 2-15) xxiv

T9233-AT-MMC-OlO

ICAUTIOij Prior to adding chromates to the coolant sys tem, antifreeze should be dralned and the cool Ing system chemically cleaned. Failure to clean the system will cause chromium hydroxide to form which will collect on the cool Ing system passage, reduce heat transfer and cause engine over heating. (Page 2-16).

ICAUTIOij Do not use the all gallery on the upper front left bank of the cylinder block (Figure 3-15) for an oil supply or pressure take-off. This gallery In tersects the cylinder head oil supply gallery. If used, it will reduce 011 pressure to the rocker arm assemblies. (Page 3-15).

ICAUTlOij 011 may be blown out through the crankcase breather If the crankcase if overfilled.

(Page 4-1).

IWARNINGII

Personal injury and/or property damage may result from fire due to the leakage of flam mable fluids such as fuel or lube 011.

(Page 4-4).

IWARNINGII

Do not remove the pressure control cap from the heat exchanger or attempt to drain the coolant until the engine has cooled. Once the engine has cooled, use extreme care when removing the cap. The sudden release of pres sure from a heated cooling system can result In a loss of coolant and possible personal in jury (Scalding) from the hot liquid. (Page 4-5).

!CAUTiON!

Loosening or tightening the locknut with the bridge In place may result in a bent bridge guide or bent rear valve stem. (Page 6-5).

xxv

IWARNINGII

To reduce the risk of personal Injury when bar ring over or "bumping" the starter while per forming an engine tune-up, personnel should keep their hands and clothing away from the engine as there is a remote possibility the en gine could start. (Pages 6-7,6-9,6-225,6-240, 6-255,6-277,6-292).

ICAUTIOij Care should be taken to avoid setting the racks too tlgh1 causing the fuel rod to bend.

(Page 6-11).

ICAUTION!

Overtightening of the Injector rack control tube lever adjusting screws during Installation or ad justment can result In damage to the Injector control tube. The recommended torque of the adjusting screws is 24-36In-lbs. (Page 6-12).

IWARNINGII

Use of cleaning solvent In a confined area can result In Injury or death. Avoid prolonged breathing of fumes and solvent contact with skin or eyes. Avoid use near heat or open flame. (Page 6-19).

IWARNINGII

Never tum a stream of compressed air on anyone. Severe Injury or death could result.

(Page 6-19).

ICAUTION!

Do not use harsh abrasives that might scratch, score or otherwise mar surface finishes. (Page 6-19).

!CAUTION!

Do not allow machined or lapped mating sur faces to contact any surfaces without protec tion against nicks, scratches, burrs, etc. (Page 6-19).

xxvi

ICAUTION)

Avoid scratching and nicking critical surfaces of balls and rollers In bearings; Take care to protect surfaces of shaft/bearing fit. (Page 6- 19).

ICAUTION)

Do not clean bearings ultrasonically; This method can pit bearing surfaces. Do not agitate any other parts longer than 5 minutes at a time. (Page 6-20).

ICAUTION!

Ensure that low-pressure air used to dry com ponents is clean and dry. Moisture in the air line can cause rust. (Page 6-20).

ICAUTIOij If polishing Is required, avoid leaving deposit of metal dust in and around bearings. (Page 6- 20).

IPNARNINgl

Rotating machinery can cause Injury or death.

Ensure the engine Is shut down and the alr start shut off valve Is tumed off and tagged out. Tag starter switch on control panel out-of service. (Page 6-21).

ICAUTIOij Make sure that new filters have been Installed In a reconditioned Injector which Is to be placed in stock. This precaution will prevent dirt particles from entering the Injector due to a possible reversal of fuel flow when Installing the injector In an engine other than the original unit. (Page 6-24).

xxvII

ICAUTION!

Immediately after removal of the fuel pipes from an injector, cover the filter caps with ship ping caps to prevent dirt from entering the In jector. Also, protect the fuel pipes and fuel connectors from entry of dirt or foreign material. (Page 6-25).

IWARNINGI

To prevent possible personal injury, wear ade quate eye protection and do not exceed 40 psi air pressure. (Pages 6-26, 6-30, 6-33, 6-34, 6- 43,6-86,6-92,6-103,6-109,6-115,6-131, 6- 145,6-169,6-172,6-181,6-185,6-187,6-194, 6-196, 6-197, 6-201, 6-211, 6-213, 6-214, 6- 225, 6-228, 6-242, 6-259, 6-263, 6-268, 6-292, 6-303, 6-320, 6-333, 6-350, 6-357, 6-361, 6- 362, 6-369, 6-372, 6-389).

ICAunoij Care must be exercised when Inserting the carbon remover J24838 In the spray tip to avoid contacting the needle valve seat In the tip. (Page 6-32).

ICAUTION!

Do not buff the spray tip area excessively. Do not use a steel wire buffing wheel or the spray tip holes may be distorted. (Page 6-33).

ICAUTIOij Do not damage the Injector body ring during this operation. This spiral ring forms part of the Injector body and is not serviced. If the ring is damaged, the injector body must be replaced. (Page 6-34).

xxvIII

T9233-AT-MMC-OIO

ICAUTION!

Do not attempt to install the plunger of one P & B into the bushing of another P & B, and vise versa. Since components of P & B assemblies are supplied as matched sets, any attempt to mix them can result In P & B seizure and serious Injector damage. (Page 6-36).

ICAUTION!

Check the injector control rack for free move ment. Excess torque can cause the control rack to stick or bind. (Page 6-52).

ICAUTlOij New flared end fuel pipes should be Installed.

When Installing flared end fuel pipes, use fuel pipe nut wrench J8932-01 and "clicker" type torque wrench J24405 (calibrated In Inch pounds) to apply proper torque and avoid damaging the fuel pipes. Aefer to the chart for torque specifications. Fuel leakage from damaged or Improperly installed fuel pipes can cause lube oil dilution, which may result In ~erlous engine damage. (Page 6-53).

ICAUTION!

Because of their low friction surface, Endurion

(A) - coated nuts on fuel jumper lines must be tightened to 130 In-Ib torque, Instead of the 160 In-Ib required with uncoated nuts. To avoid possible confusion when tightening Jumper line nuts, do not mix lines with un coated and Endurlon (A) - coated nuts on the same cylinder head. (Page 6-53).

tAUTIOij Do not bend the fuel pipes and do not exceed the specified torque. Excessive tightening will twist or fracture the flared end of diluted by fuel oil can cause serious damage to the engine bearings. (Page 6-53).

xxix

The fuel spray from an Injector can penetrate the skin. Fuel oil which enters the blood stream can cause a serious infection. There fore, follow Instructions and use the proper equipment to test an Injector. (Page 6-54).

I WARNINGI I

Do not operate the tester without !he shield.

The fuel spray can penetrate the skin. Fuel 011 which enters the blood stream can cause a serious infection. Therefore, follow Instruc tions and use the proper equipment to test an Injector. (Page 6-59).

ICAUTlOij DO NOT use this valve as an air shutoff. Tight closing of this valve may result In valve seat damage. (Page 6-66).

ICAUTlOij With the engine at rest, as In Method 2 allinjec tors will leak to some extent when pressurized.

The leakage occurs because there Is no place else for the pressurized fuel to go. When the low and high pressure cavltltes In the Injector are subjected to the high test pressure, fuel Is forced past the plunger Into the rack and gear cavity. Result: Droplets of fuel form at the rack and drip off. (Page 6-74).

xxx

T9233-AT-MMC-OIO

!CAUTiON!

The manufacturer recommends that the original fuel pipes not be reused. New'flared end fuel pipes should be Installed.