TJ-233-03 EMD Engine 12-645F7B.pdf

T9233-AS-MMO-010

OPERATION AND MAINTENANCE MANUAL

FOR I

ENGINE, MAlN PROPULSION l

DIESEL EMD 121645F7B I

Halter Marine, Inc. l l T-AGS 51 /52 l

MANUFACTURED BY

GENERAL MOTORS CORPORATION

LA GRANGE, IL 60525

Contract No. N00024-894-2079

ELECTRO-MOTIVE DlVlSlON

DlSTRlBUTlON STATEMENT "C": DlSTRlBUTlON AUTHORIZED TO

MINISTRATIVUOPERATIONAL USE: 1 MAY 1990. OTHER REQUESTS

FOR THlS DOCUMENT MUST BE REFERRED TO THE COMMANDER, WARNING: THlS DOCUMENT CONTAINS TECHNICAL DATA WHOSE

EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT

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

VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE

CRlMlNAL PENALTIES.

U.S. GOVERNMENT AGENCIES AND THElR CONTRACTORS; AD-

MlLlTARY SEALlFT COMMAND, CODE M-4E WASHINGTON, DC 20390.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WlLL

PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF

THE DOCUMENT.

MlLlTARY SEACIFT COMMAND a U 9

"9233-AS-MMO-010

a l

Date,. 01 01 .J.. ia

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer rnargins of the page. Chranges to illustrations are indicated by rniniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.

And Change Pages Are:

Original ... 0 .... 1 MAY 1991

Total Number Ol Pages In This Publication 1s €&i- Consisting 01 The Following:

Page No. . . . . . Chg h0.O Page No. . . . . Chg No." Page No. . . . . . Chg No."

TitlePage a . . . . . . . . . . . o RecordofChanges . 0 APRPage ValiiationCerP Foreword Warranty i -xmi i i 1-1 -1-13 2-1 -2-19 3-1-3-64 4 1 - 4 - 1 3 5-1 . 5-56 6-1-6-228 7-1 - 7 - 1 6 8-1 -8-3

A-1 . A-75

* E R O IW T#IS W W M i I W D l C k S AN ORIGINAL PAGE.

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: T9233-AS-MMO-010

TITLE OF MANUAL: ENGINE, MAlN PROPULSION DIESEL EMD 12-645F7B APPROVAL AUTHORITY: Supervisor of Shipbuilding, Pascagoula, M S 39567

CONTRACT NO. APPLlCABlLlTY QTY BUlLDlNG YARD

N00024-89-C-2079 T-AGS 5 1/52 2 PER HULL HALTER MARINE, INC.

A CERTl FlCATlON tq/

IT IS HEREBY CERTlFlED THAT T92$3-AS-hllMO-010 1 0 BE PROVIDED UNDER CONTRACT

NUMBER N00024-89-C-2079 HAS BEEN APPROVED BY THE APPROVAL AUTHORITY

SHOWN ABOVE.

HALTER MARINE, INC.

TECHNICAL MANUAL VALIDATION CERTIFICATE

NAVSEA 41 60/3 (4-82)

TECHNICAL MANUAL TITLE: OPERATION AND MAINTENANCE MANUAL FOR

ENGINE, MAlN PROPULSION DIESEL EMD 12-645F7B

NAVSEA TECHNICAL MANUAL NUMBER:

T9233-AS-MMO-010

DATE:

1 MAY 1991

CONTRACTflMCR NO. :

N00024-89-C-2079

I - VALIDATION

Except as stated in II, the technical manual identified 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.

11- EXCEPTIONS

EXCEPTIONS AUTHORIZED BY

SIGNATURE OF PUBLICATIONS Q DATE:

79233-AS-MMO-010

FOREWORD

This technical manual includes installation, operation, maintenance, andrepairinstructions, with a parts list for the Engine, Main Propulsion Diesel EMD 12-645F7B . The manual covers the foiiowing:

Chp.

No.

1.

2.

3.

4.

5.

6.

7.

8.

Title

General Information and Safety Precautions Operation Functional Description Scheduled Maintenance Trou bles hooting Corrective Maintenance Parts List Installation

Ships, training activities, supply points, depots, naval shipyards, and Supervisors of Shipbuild-ing are requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors, omissions, discrepancies, and suggestions for irnprovement to NAVSEA technical manuals shall be reported to the Naval Sea Data Support Activity (NSDSA), Naval Ship Weapon Systems Engineering Station (Code 5H21.5), Port Hueneme, CA 93043 on NAVSEA Technical Manual Deficiency/Evaluation Report, NAVSEA Fom 9086/10. To facilitate such reporting, three (3) copies of NAVSEA Form 9086/10 are included at the end of the bound part of each newly published unclassified technical manual. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting therefrom.

Extra copies of NAVSEA Form 9086/10 may be requisitioned ffom the Naval Publications and Forms Center (NPFC), Philadelphia, PA 19120.

T9233-AS -MMO-0 10

WARRANTY

The Manufacturer will warranty this equipment against any defects or deficiencies in workmanship and/or material through the period of time that the vesse l 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 vesse l i s disabled because of any equipment failure.

Table of Contents l

ChapterParag aph Page 1 l

1 GENERALINFORMATIONAND

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 1.1

1-1 INTRODUCTION . . . . . . . . . . . . . . . . . . 1.1

1-2 GENERAL ENGINE INFORMATION . . . . . . . 1.1

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2- 1 INTRODUCTION . . . . . . . . . . . . . . . . . . 2.1

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

2-3 PRESTART PROCEDURE . . . . . . . . . . . . 2.5

2-4 OPERATION . . . . . . . . . . . . . . . . . . . 2.13

3 FUNCTIONALDESCRIPTION . . . . . . . . . . . . . . . . 3.5

3- 1 INTRODUCIlON . . . . . . . . . . . . . . . . . . 3.5

3-2 SERIAL NUMBERS . . . . . . . . . . . . . . . . 3.6

3-3 DESCRIPTION OF MAJOR ASSEMBLIES . . . . 3.7

4 SCHEDULEDMAINTENANCE . . . . . . . . . . . . . . . . 4-1

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

4-2 MAINTENANCEPLAN . . . . . . . . . . . . . . 4 - 1

5 TROUBLESHOOTING ..................... 5.1

5- 1 5-2 5-3 5-4 5-5

5-6 5-7 5-8

INTRODUCTION . . . . . . . . . . . . . . . . . . 5.1

GENERAL ..................... 5.1

EXPLANATION OF TABLES . . . . . . . . . . . 5.1

USING THE TABLES . . . . . . . . . . . . . . . 5.1

TROUBLESHOOTJNG ENGINE WITH

FAILED TURBOCHARGER . . . . . . . . . . . . 5.1

"ONE REVOLUTION" INSPECTION . . . . . . . 5.7

LINER/PISTON VISUAL INSPECTION GUIDE . 5.8

PROPULSION SYSTEM TROUBLESHOOTING .

GENERAL ..................... 5.9

I

"9233-AS-MIM0-010

Chapkr/Paragaph Page

6 CORREClWE MAlNTENAEdCE . . . . . . . . . . . . . . . 6-1

6-1 6-2 6-2.1

6-2.1.1 6-2.1.2 6-2.1.3 6-2.2 6-2.3 6-3 6-3.1 6-3.2 6-3.2.1 6-3.3 6-3.3.1 6-3.3.2 6-3.4 6-3.5 6-3.5.1

6-3.6 6-3.6.1 6-3.7 6-3.8 6-3.9 6-3.9.1

6-3.10 6-3.10.1 6-3.10.2 6-3.10.3 6-3.10.4 6-3.10.5

INTRODUCTIQN . . . . . . . . . . . . . . . . . . 6-1

ADJUS-SMALIGNMWS . . . . . . 6-4

EXHAUST VALVE TlMIN6 EQUIPI"

REQUIRED ..................... 6-4

LOcaTIEdG TOP DEaD CEEdTER . . . . . . . . 6-4 CHECKINGEIMAUSTVALVETIIWIEdG . . . . 6-7 TlIWNG EXMUST V A W S . . . . . . . . . . . 6-8

ADJUSTIN6 HYDRBULIC LASH ADJUSTERS 6-10

TIMNGTHEINJECTOR . . . . . . . . . . . . 6-13 .

REPAIR ...................... 6-14

PAINTlN6 .................... 6-14 CRBEdP(LCASE . . . . . . . . . . . . . . . . . . . 6-15 IPaSPECTION . . . . . . . . . . . . . . . . . . . 6-15 LOWER L W R BQRE IPaSERT . . . . . . . . . 6-15

INSERT APPLICATIQN . . . . . . . . . . . . . 6-16

IPaSERT REMQVAL . . . . . . . . . . . . . . . 6-17 CRaB BOLTS . . . . . . . . . . . . . . . . . . 6-17 MAIEd B E M 6 STUD BOLTS M CAPS . . 6-18 CHECKING AMIN BEARIPaGS STEEL BORE

DWNSIQNS . . . . . . . . . . . . . . . . . . 6-19

OIL PaEd ..................... 6-20 IPaSPECTIQN . . . . . . . . . . . . . . . . . . . 6-21

CRMKCASE TO OIL PAN SEAL . . . . . . . 6-21

A R BQX DRMNS . . . . . . . . . . . . . . . . . 6-21

TOP DECKHEaD FRAME AEdD COVER . . . 6-22 HEaD FRawIE TO CRANKCASE

APPLICATIQN . . . . . . . . . . . . . . . . . . 6-23

CYLINTIER HEAD AWD ACCESSQRIES . . . 6-24

EXHAUST VALVE AND SPRING REMQVAL 6-24

VALVE GUIDES . . . . . . . . . . . . . . . . . 6-26

CLEAMNG CYLIpaDER HEAD . . . . . . . . . '6-26

CYLINDER HEAD LEAK 'IEST . . . . . . . . . 6-28

INSPECTIQN . . . . . . . . . . . . . . . . . . . 6-28

ii

-233-AS-MMO-010

Table of Contents . Cont'd

Chapterparagaph Page

6-3.10.6 CYLINDER HEAD REBUILD . . . . . . . . . . 6-28

6-3.10.7 EXHAUST VALVES . . . . . . . . . . . . . . . 6-37

6-3.10.8 VALVE SPRING. SEAT AND LOCK . . . . . . 6-40

6-3.10.9 EXHAUST VALVE INSTALLATION . . . . . . 6-41

6-3.10.10 VALVE STEM IiEIGHT CHECK . . . . . . . . 6-41

6-3.10.11 VALVE SEAT SEAL TEST . . . . . . . . . . . 6-41

6-3.10.12 EXHAUST VALVE BRIDGE ASSEMBLY . . . 6-42

6-3.10.13 LASH ADJUSTER . . . . . . . . . . . . . . . . 6-45

6-3.10.14 ROCKER ARM ASSEMBLY . . . . . . . . . . 6-49

6-3.10.15 ROCKERARMSUPPORTASSEMBLY . . . . 6-50

6-3.10.17 CYLINDER HEAD SEAT RING . . . . . . . . . 6-53

6-3.10.16 CYLINDER TEST V L V E . . . . . . . . . . . . 6-51

6-3.11.1 6-3.11.2 6-3.11.3 6-3.11.4 6-3.11.5 6-3.11.6 6-3.11.7 6-3.12 6-3.12.1 6-3.12.2 6-3.12.3 6-3.12.4

6-3.12.5 6-3.13 6-3.13.1 6-3.13.2 6-3.13.3 6-3.13.4 6-3.13.5

6-3.14

PISTON AND ROD INSPECTION . . . . . . . . 6-53

PISTONANDRODDISASSEMBLY . . . . . . 6-57

CLEANING .................... 6-58

PISTON INSPECTION . . . . . . . . . . . . . . 6-61

CARRIER INSPECTION . . . . . . . . . . . . . 6.64

PISTON INSPECTION . . . . . . . . . . . . . . 6-65

OIL PAN INSPECTION . . . . . . . . . . . . . 6.56

CONNECTLNG ROD ASSEMBLY . . . . . . . 6-66

CLEANING .................... 6.66

FORK ROD INSPECTION . . . . . . . . . . . . 6.67

BLADE ROD INSPECTION . . . . . . . . . . . 6-69

CHECKING ROD LENGTH. TWIST. AND

BORE PARALLELISM . . . . . . . . . . . . . . 6.70

CHECKING CONNECTING ROD BEARINGS . 6-72

CYLINDER LINER . . . . . . . . . . . . . . . . 6.72

INSPECTION IN ENGINE . . . . . . . . . . . . 6.72

CLEANING .................... 6-73

MEASURING LINERS FOR WEAR . . . . . . . 6.73

OVERSIZEiD LINERS . . . . . . . . . . . . . . 6-75

MARKZNG USED LINERS AND PISTONS

IN STOCK ..................... 6.76

CYLINDER POWER ASSEMBLY . . . . . . . . 6-76

iii

Chapter/IParagaph Page

6-3.14.1 6-3.14.2 6-3.14.3

6-3.14.4 6-3.14.5 6-3.15

6-3.15.1 6-3.15.2 6-3.15.3 6-3.15.4 6-3.15.5 6-3.15.6 6-3.16

6-3.16.1 6-3.17

6-3.18

6-3.18.1 6-3.19

6-3.20 6-3.20.1 6-3.21

6-3.2 1.1 6-3.21.2 6-3.21.3 6-3.21.4

6-3.21.6 I 6-3.21.7

6-3.21.5

COMPONENT BY COprlLpoNENT REMOVAL . 6-77

UNI" REMOVAL . . . . . . . . . . . . . . . . . 6.83

COMPONENTBY COMPONENT

I N S T U T I Q N . . . . . . . . . . . . . . . . . 6-87 .

UEdIT INSTALUTIQN . . . . . . . . . . . . 6-100

POWERASSEMBLY PACKAGING . . . . . 6-109

CRANKSHAFT ASSEABLY AEdD ACCESSORY

DRIVEGEARTRAIN . . . . . . . . . . . . . 6-110

CRANKSHAFT . . . . . . . . . . . . . . . . . 6-110

AUINBEARINGS . . . . . . . . . . . . . . . 6-111

THRUST COUAR . . . . . . . . . . . . . . . 6-115

GEARTWETQRSIQNALDAAdPER . . . . . 6-115 ACCESSORY DRWE 6EARTRAIEd . . . . . 6-117

ACCESSQFZY D W GEAR . . . . . . . . . 6-1 17

GOVERNQRDRIWGEARAPaDSTUBSHaFT D E S C m Q N . . . . . . . . . . . . . . . . . 6-120 I N S T U T I Q N . . . . . . . . . . . . . . . . 6-120

ACCESSORY D W HOUSING

BPPLICATIQNapaDALIGNMENT . . . . . 6-122

RING GEAR AND COUPLING DISC

(FJLYWHEEL) . . . . . . . . . . . . . . . . . . 6-124

MMNTENANQE . . . . . . . . . . . . . . . . 6-124

DIGlTAL TACHQMETER WGNETIC

PICKUP ..................... 6-125

ACCESSORYDRIVECOUPLING . . . . . . 6-126

COUPLING APPLICATION . . . . . . . . . . 6-126

CAIWSHAFT GEAR TRAIN. AUXLIARY

DRIVE. AWD CAMSHAF" ASSEMBLIES . . 6-127

CAWISHAFT GEAR TRAIEd . . . . . . . . . . 6-121

CAIWSHAFT DRNE GEARS . . . . . . . . . 6-128

SPRINGDRIVEGEARASSEMBLY . . . . . 6-131

NQ . 1 IDLERGEAR . . . . . . . . . . . . . . 6-133

IDLER GEAR STUBSHAFT ASSEMBLY . . 6-134

CRANKSHAFTGEAR . . . . . . . . . . . . . 6-136

CAIWSHAFI'GEAR TIuupd ASSEMBLY . . . 6-136

19233-AS-MMO-010

Table of Contents . Cont'd

Chapter/Parag aph Page

6-3.21.8 PISTON COOLING FLANGES AND LUBE

OIL MANIFOLD APPLICATION . . . . . . . 6-141

6-3.21.9 CAMSHAFT DRIVE HOUSING

6-3.21.10 AUXKLIARY DRIVE ASSEMBLY . . . . . . 6-145

6-3.21.1 1 CAMSHAFT ASSEMBLIES . . . . . . . . . . 6-146

6-3.21.12 CAMSHAFI' COUNTERWEIGHT

APPLICATION . . . . . . . . . . . . . . . . . 6-150

6-3.22 AIRINTAKEANDEXHAUSTSYSTEMS . . 6-150

APPLICATION . . . . . . . . . . . . . . . . . 6-142

6-3.22.1 TURBOCHARGER . . . . . . . . . . . . . . . 6-150

6-3.22.2 AIRINTAKEmTER . . . . . . . . . . . . . 6-159

6-3.22.3 EXHAUSTMANIFOLD . . . . . . . . . . . . 6-159

6-3.23.2 PISTON COOLING OIL PRESSURE . . . . . 6-162

6-3.23.1 MAINLUBRICATINGOILPRESSURE . . . 6-161

6-3.23.3 LUBEOILPRESSURERELIESVALVE . . . 6-162

6-3.23.4 PISTON COOLING OIL PIPE . . . . . . . . . 6-164

6-3.23.5 CHECKING OIL VISCOSITY . . . . . . . . . 6-165

6-3.23.6 CHANGINGOIL . . . . . . . . . . . . . . . . 6-165

6-3.23.7 OIL STRAINERHOUSING . . . . . . . . . . 6-166

6-3.23.8 LUBE OIL SEPARATOR . . . . . . . . . . . . 6-167

6-3.23.9 MAIN LUBE 0% AND PISTON COOLING

OILPUMPS . . . . . . . . . . . . . . . . . . . 6-167

6-3.23.10 SCAVENGING OIL PUMP . . . . . . . . . . . 6-175

6-3.23.1 1 TURBOCHARGER OIL FILTER . . . . . . . 6- 179

6-3.23.12 SOAK BACK OIL FILTER . . . . . . . . . . . 6-180

6-3.23.13 IN-LINE LUBE OIL STRAINER . . . . . . . . 6-180

6-3.23.14 ACCESSORY RACK COMPONENTS . . . . 6-180

6-3.24.1 PIPING INSTALLATION . . . . . . . . . . . 6-1 8 1

6-3.24.2 WATERLEAKS . . . . . . . . . . . . . . . . 6-181

6-3.24.3 AFI'ERCOOLER . . . . . . . . . . . . . . . . 6-183

6-3.24.4 FRESH WATER PUMPS . . . . . . . . . . . . 6-186

6-3.24.5 ACCESSORY RACKCOMPONENTS . . . . 6-194

6-3.24.6 UNA'ITACHED ACCESSORIES . . . . . . . 6-200

6-3.25 FUELSYSTEM . . . . . . . . . . . . . . . . . 6-200

6-3.25.1 FUELINJECI'ORS . . . . . . . . . . . . . . . 6-200

T9233-AS-MM0-010

ChapterParag aph Page

6-3.25.2 6-3.25.3 6-3.25.4 6- 3.25.5 6-3.26 6-3.26.1 6-3.26.2 6-3.26.3 6-3.26.4 6-3.26.5 6-3.26.6 6-3.26.7 6-3.27 6-3.27.1 6-3.27.2

6-3.27.3 6-3.27.4 6-3.27.5 6-3.28 l 6-3.28.1 6-3.28.2 1

INJECTQR LINKAGE . . . . . . . . . . . . . 6-206

FUEL P W . . . . . . . . . . . . . . . . . . 6-208

FUEL FILTER ASSEMBLY . . . . . . . . . . 6-208

ACCESSORY MCKCOIWPONENTS . . . . 6-209

GOVERWOR . . . . . . . . . . . . . . . . . . 6-211

GOVERWQR REMQVAL . . . . . . . . . . . 6-21 1

GOVERWOR INSTALLATION . . . . . . . . 6-212

GOVERPJQRDRWEASSEMBLY . . . . . . 6-212

FLUSHIPdG GQVERPJOR . . . . . . . . . . . 6-212

QILSUPPLY . . . . . . . . . . . . . . . . . . 6-213

STQRAGE .................... 6-213

MMiVTENANa . . . . . . . . . . . . . . . . . 6-213 PROTIEcTI\IE D E W a S AND ALARMS . . 6-218 QWRSPEED TRIP ALaRpdp . . . . . . . . . . 6-218

CRANKCASE PRESSURE DETECTOR

ASSEMBLY . . . . . . . . . . . . . . . . . . 6-220

LOW O L LEVEL IWDICATOR . . . . . . . . . 6-220

TURBQOJLPRESSURESWITCH . . . . . . 6-220

ENGINE OILPRESSURE S W C H . . . . . . 6-220

AIR STARTDJG SYSTEM . . . . . . . . . . . 6-221

AIR STARTING MQTOR . . . . . . . . . . . 6-221

WATI'ACHED ACCESSQIPIES . . . . . . . 6-225

7 ILLUSTXATED PARTS LISTS . . . . . . . . . . . . . . . ' . 7.1

7- 1 7-2

7-3 7-4 7-5 7-6 7-7 7-8 7-9

IEdTRODUCTION . . . . . . . . . . . . . . . . . . 7.1

EXPLANATIQN OF C O L W S LISTED IN

T€E PARTS LISTS . . . . . . . . . . . . . . . . . 7. 1

REFiERENCE MJMBER COLupu1[Ed . . . . . . . . 7. 1

DESCRIPTION COLUMN . . . . . . . . . . . . . 7. 1

PART MJMBER C O L W . . . . . . . . . . . . 7.1 .

FSCM C0LUM.N . . . . . . . . . . . . . . . . . . 7.1

QUMTITY REQUIRED C0LUM.N . . . . . . . . 7.1

LIST OF IWWUFACTURER CODES (FSCM) . . 7.2

ORDERIWGUWIDEM'IFIEDPARTS . . . . . . -7-4

vi

Table of Contents - Cont'd

ChapterParagaph Page

8 INSTAUATION . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1

8- 1 GENEFUL . . . . . . . . . . . . . . . . . . . . . 8 - 1

8-2 ENGINE INSTALLATION . . . . . . . . . . . . .8 - 1

8-3 ALIGNMENT . . . . . . . . . . . . . . . . . . . . 8 - 1

APPENDIXA

EMD MAINTENANCE INSTRUCI'IONS

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . A - 1

vii

"9233-As-MMO-010 t . Page

1-1

1-2

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

2-4

2-5 2-6 2-7 2-8 2-9 2- 10 2-11 2-12 2- 13A 2-13B 2- 14 2-15

3- 1

3-2

3-3

3-4

3-5 3-6 3-7 3-8 3-9 3- 10

Injector Rack Position/Brake HP at Various

Fuel Consumption and Horsepower at Varioush' Engine Speeds . . . . . . . . . . . . . . . . . . . . . 1.8

Engine Speeds ..................... . 1-9 Engine Arrangement . . . . . . . . . . . . . . . . .1.1 0.

Three-Quarter Right Rear View of Engine Three-Qua~ter Left Front View of Engine 645 Series Diesel Marine Engine . . . . . . . . . . . 1.'13 Engine Instrument Panel . . . . . . . . . . . . . . . 2.2 Engine Control Panel . . . . . . . . . . . . . . . . . 2.3 Qptional Crankover TooI956 1844 and Electric Drive Unit 9543867 ..................... 2.5 Optional Air Drive Kit 9560333 And Remote Control9560338 . . . . . . . . . . . . . . . . . . . 2.5 Air Starting System . . . . . . . . . . . . . . . . . . 2.6 Solenoid Valve Ovemde . . . . . . . . . . . . . . . 2.7 Test Valve Wrench . . . . . . . . . . . . . . . . . . 2.8 Oil Level Gauge ..................... 2.9 FGA Govemor, 3/4 Front View . . . . . . . . . . . . 2-10 Reset And Shutdown Lever Positions . . . . . . . . . 2.10 P A Governor 3/4 Rear View . . . . . . . . . . . . 2. 1 1 AkBoxDrain ..................... 2.12 Booster Servomotor . . . . . . . . . . . . . . . . . . Z-13 Injector Control Lever . . . . . . . . . . . . . . . . . 2.14 Model645FIB Engine W/Engine FWM Curves . . . 2.18

Engine Speeds . . . . . . . . . . . . . . . . . . . . . 2. 19

Motors M&l16-64!%7B Engine . . . . . . . . . . 3.1 Mdel16-645WB Engine . . . . . . . . . . . . . . . 3.2

. . . . . . 1.11

. . . . . . l-12

Injector Rack Position/Brake HP at Various

Front-Left Three-Quarter View Typical General

Rear-Right Three-Qyarter View Typical GM

Right Side View M d e l GIWB2QE7C/F7B Marine Propulsion Unit . . . . . . . . . . . . . . . . 3.3 Typical Model GWPB8E7C/F7B, GWPB12E7C/F7B, GIWB16E7C/F7B And GIWB20E7C/F7B General Arrangement . . . . . . . . . . . . . . . . . 3.3 645 Series Diesel Marine Engine . . . . . . . . . . . 3.4 SchematicIllustrationQfEngineQperation . . . . . 3.5 Crankcase . . . . . . . . . . . . . . . . . . . . . . . 3.8 Lower Liner Bore Insert . . . . . . . . . . . . . . . . 3.9 Crab Bolt Installation . . . . . . . . . . . . . . . . . 3.9 Main Bearing Shell And Cap . . . . . . . . . . . . . 3.10

.11 viii

List of Illustrations . Cont'd

Figure/Title Page ~

3-1 1 3-12 3-13 3-14 3-15 3-16 3- 17 3-18 3- 19 3-20 3-21 3-22 3-23 3-24 3-25 3-26 3-27 3-28 3-29 3-30 3-3 1 3-32

3-33 3-34 3-35 3-36 3-37 3-38 3-39 3-40 3-41 3-42 3-43 3-44 3-45 3-46 3-47 3-48 3-49 3-50

Main Bearing Stud Bolts . . . . . . . . . . . . . . . 3.11 TypicalOilPan .................... 3.11 Handhole Cover .................... 3. 12 Explosion Type Handhole Cover . . . . . . . . . . . 3. 1 Crankcase To Oil Pan Seal . . . . . . . . . . . . . . 3. 13 Engine Crankshaft . . . . . . . . . . . . . . . . . . . 3.14 Crankshaft Thrust Collar~ . . . . . . . . . . . . . . . 3.14 Gear Type Damper . . . . . . . . . . . . . . . . . . 3.15 Gear Type Damper. Exploded View . . . . . . . . . 3. 15 Accessory Drive Gear Train . . . . . . . . . . . . . . 3. 17 Typical Accessory Drive Gear. Exploded View . . . 3. 17 Connecting Rod Assembly . . . . . . . . . . . . . . 3. 18 Crankshaft Oil Passages . . . . . . . . . . . . . . . . 3.18 Piston Assembly .................... 3.19 Piston Carrier Assembly . . . . . . . . . . . . . . . 3. 19 Cylinder Liner ..................... 3.20 Cylinder Head With Valves . . . . . . . . . . . . . . 3.21 C-haft . . . . . . . . . . . . . . . . . . . . . . . 3.22 Camshaft Gear Train . . . . . . . . . . . . . . . . . 3.22 Turbocharger Assembly . . . . . . . . . . . . . . . . 3.23 Turbocharger Drive . . . . . . . . . . . . . . . . . . 3.24 Typical Disposable Fiberglass Bag Element.

Air Filter Assembly . . . . . . . . . . . . . . . . . . 3.25 Exhaust Manifold . . . . . . . . . . . . . . . . . . . 3.25 Lubricating Oil system . . . . . . . . . . . . . . . . 3.26 Oil Strainer Housing . . . . . . . . . . . . . . . . . 3.29 Main Piston Cooling Oil Pump Strainers . . . . . . . 3.29 Lube Oil Separator . . . . . . . . . . . . . . . . . . 3.30 Turbocharger Oil Filter . . . . . . . . . . . . . . . . 3.30 Soak Back Oil Motor, Pump. And Filter Installation . 3.31 Lubricating Oil Filter. Cross-Section . . . . . . . . . 3.32 Fin-Tube Core Type Oil Cooler . . . . . . . . . . . . 3.33 Cooler Core And Header Assembly . . . . . . . . . . 3.33 Cooling System Schematic . . . . . . . . . . . . . . 3.35 Cooling System Piping . . . . . . . . . . . . . . . . 3.35 Aftercooler Installation . . . . . . . . . . . . . . . . 3.36 Water Pump Installation . . . . . . . . . . . . . . . . 3.36 Thermostatic Valve . . . . . . . . . . . . . . . . . . 3.37 Thermostatic Element . . . . . . . . . . . . . . . . . 3.37 Fresh Water Cooler . . . . . . . . . . . . . . . . . . 3.39

Lubricating Oil Filter . . . . . . . . . . . . . . . . . 3.32 l ix

3-75 3-76 3-77 3-78 3-80 5- 1 5-2 5-3 5-4 5-5

5-6 5-7 5-8 5-9 5-10

3-5 1 3-52 3-53 3-54 3-55 3-56 3-57 3-58 3-59 3-60 3-61 3-62 3-63 3-64 3-65 3-66 3-67 3-68 3-69

3-70 3-7 1 3-72 3-73

Page .

Typical Fuel System . . . . . . . . . . . . . . . . . . 3.40 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . 3.41 Fuel Injector. Cross Section . . . . . . . . . . . . . . 3.42 Injector Fuel Flow . . . . . . . . . . . . . . . . . . . 3.42 Plunger Fuel Control . . . . . . . . . . . . . . . . . 3.43 Injector Linkage .................... 3.43 Fuel Pump Installation . . . . . . . . . . . . . . . . 3.44 Fuel Pump Operation . . . . . . . . . . . . . . . . . 3.44 Fuel Filter Assembly . . . . . . . . . . . . . . . . . 3.45 Accessory Rack Fuel System Components . . . . . . 3.46 Fuel Suction Strainer (Explded View) . . . . . . . . 3.47 Typical Governor Drive Application . . . . . . . . . 3.48 M&l FGA Governor, 3/4 Front View . . . . . . . . 3.49 Model PGA Governor, 3/4 Rear View . . . . . . . . 3.50 PGA Governor Schematic Diagram . . . . . . . . . . 3.5 1 Pneumatic SpeedSetting, Schematic Diagram . . . . 3.52 Rotary Terminal Shaft and Scale . . . . . . . . . . . 3.54 Qverspeed Trip .................... 3.55 Overspeed Trip Reset and Shutdown Lever Position ..................... 3.56 Crankcase Pressure Detector Assembly . . . . . . . . 3.57 Low Qil Level Indicator Application . . . . . . . . . 3.57 Shutdown Solenoid . . . . . . . . . . . . . . . . . . 3.58 119anud Shutdown Button . . . . . . . . . . . . . . . 3.59 Dual Air Starting System . . . . . . . . . . . . . . . . 3.60 Air Line Lubricator . . . . . . . . . . . . . . . . . . . 3.61 Air Start Valve .................... 3.62 Shutoff Valve ..................... 3.62 Solenoid Valve . . . . . . . . . . . . . . . . . . . . 3.63 Air Strainer . . . . . . . . . . . . . . . . . . . . . . 3.63 Impeller Damaged By Foreign Material . . . . . . . 5.2 Nicked Blades ..................... 5.3 Stretched Blades That Have Rubbed The Shroud . . . 5.4 View Down The Exhaust Stack . Warped Diffuser . . 5.5 View Down The Exhaust Stack Of A' Warped Diffuser And Damage From Broken Blades . . . . . . 5.5 Scuffing Liner ..................... 5.10 Normal Wear (Piston) . . . . . . . . . . . . . . . . . 5.11 Scuffing (Piston) . . . . . . . . . . . . . . . . . . . 5.12 Excessive Scuffing (Piston) . . . . . . . . . . . . . . 5.13 Port Streaking . . . . . . . . . . . . . . . . . . . . -5-14

Twbo Qil h s s ~ r e Switch . . . . . . . . . . . . . . . 3.60

X

T9233-AS-MM0-O 10

List of Illustrations . Cont'd

Figure/Title Page

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

6-8 6-9 6-10 6-1 1 6-12 6-13 6-14 6- 15 6-16 6- 17 6-18 6-19 6-20 6-2 1 6-22 6-23 6-24 6-25 6-26 6-27 6-28 6-29 6-30 6-3 1A 6-31B 6-32 6-33 6-34 6-35 6-36 6-37 6-38 6-39

Carbon Drag (Liner) . . . . . . . . . . . . . . . . . . 5.15 "Stop-Bar" Inserted Through Cylinder Ports . . . . . 6.5 Piston Travel Limited By "Stop-Bar" . . . . . . . . . 6.6 LimitOfPistonTravelMarkedOnFlywheel . . . . . 6.6 Second Limit Of Piston Travel Market On Flywheel . 6-7 Sample Calculation . . . . . . . . . . . . . . . . . . 6.7 Timing Exhaust Valves . . . . . . . . . . . . . . . . 6.8 Camshaft Gear Train Marking (Left-Hand Rotation Engine) . . . . . . . . . . . . . . . . . . . 6. 1 1 Exhaust Valve Timing . . . . . . . . . . . . . . . . 6.12 Checking Lash Adjuster To Valve Clearance . . . . . 6.13 Timing Injector .................... 6.14 Liner Bore Insert Application and Removal Tool . . . 6. 16 Crab Bolt Installation . . . . . . . . . . . . . . . . . 6.18 Main Bearing Stud Bolts . . . . . . . . . . . . . . . 6-19 Main Bearing Bore Measurement . . . . . . . . . . . 6.20 Crankcase to Oil Pan Seal . . . . . . . . . . . . . . . 6-21 Snake Modification . . . . . . . . . . . . . . . . . . 6-22 Cover Seal Application . . . . . . . . . . . . . . . . 6.23 Complete Cylinder Head Assembly, Exploded View . 6.25 Compressing Valve Springs . . . . . . . . . . . . . . 6.26 Cleaning Stud Holes . . . . . . . . . . . . . . . . . . 6.27 Cleaning Valve Guides . . . . . . . . . . . . . . . . 6.27 InjectorHoleReworkandReworkLimits . . . . . . 6-29 Fkface and Flange Ref~shing . . . . . . . . . . . 6.3 1 Fillet Rolling ..................... 6.32 Valve Seat GIinding Wheels and Holders . . . . . . 6.33 Dressing Valve Seat Grinding Wheel . . . . . . . . . 6.33 T a p e d Pilot Installation . . . . . . . . . . . . . . . 6.34 Tapered Pilot Checking Fixture . . . . . . . . . . . . 6-34 Lifting Spring Application . . . . . . . . . . . . . . 6.34 Grinding Valve Seat . . . . . . . . . . . . . . . . . . 6.35 Valve Measurement Points . . . . . . . . . . . . . . 6.36 Checking Valve Seat Roundness . . . . . . . . . . . 6.36 Exhaust Valve . . . . . . . . . . . . . . . . . . . . . 6.37 Cup Defects ...................... 6.39 Face and Rim Defects . . . . . . . . . . . . . . . . . 6.39 Valve Spring Seat Lock . . . . . . . . . . . . . . . . 6.40 Checking Height of Valve Stems . . . . . . . . . . . 6.41 Testing Valve Seat Seal . . . . . . . . . . . . . . . . 6.42 Valve Bridge Assembly . . . . . . . . . . . . . . . . 6.42 Removing Hydraulic Lash Adjuster . . . . . . . . . . 6-44 xi

. . . . . l

79233-As-MM0-010

. FigUreEitle Page

6-40 6-41 6-42 6-43 6-44 6-45 6-46 6-47 6-48 6-49 6-50 6-5 1

6-52 6-53 6-54 6-55 6-56 6-57 '

6-58 6-59 6-60 6-6 1

6-63 6-64

6-62

6-65 6-66 6-67

6-69 , 6-7 1 6-72 6-73 6-74 6-75 6-76 6-77 6-78 6-79

6-68

6-70

6-80

Compressing Valve Bridge Spring

Installing Lash Adjuster . . . . . . . . . . . . . . . . 6-48

. . . . . . . . . . 6.44 Valve Bridge Measurement Points . . . . . . . . . . 6.45 Lash Adjuster Test Stand . . . . . . . . . . . . . . . 6.46 Rocker h . . . . . . . . . . . . . . . . : . . . . 6-49 Injector Rocker Arm. Exploded View . . . . . . . . 6.50 Rocker Arm Support Assembly . . . . . . . . . . . . 6.50 Cyhder Test Valve . . . . . . . . . . . . . . . . . . . 6.5 1 Test Valve Wnxch . . . . . . . . . . . . . . . : . . 6.51 Reaming Test Valve Seat . . . . . . . . . . . . . . . 6.52 Test Valve Reconditioning Limits . . . . . . . . . . 6-53 Piston and Connecting R d Assembly, Cross-Section ..................... 6-54 Chrome Ring Wear Classifkation . . . . . . . . . . 6.55 Removing Piston Snap Ring . . . . . . . . . . . . . 6-57 Typical Carrier Holding Fixture . . . . . . . . . . . . 6-58 Removing Piston Rings- . . . . . . . . . . . . . . . . 6-59 Piston Measurement Pohts . . . . . . . . . . . . . . 6-62 Typical Piston Ring Groove Wear Step . . . . . . . . 6-62 Piston Ring 6roove Gauge . . . . . . . . . . . . . . 6.63 Flash Tin Plated Piston S b Sections . . . . . . . . 6-64 Piston Pin, Insert Bearing and Carrier . . . . . . . . . . 6-65 Connecting Rods, Bearing Shells, and Basket . . . . 6.66 Checking Fork R d Bolt Threads . . . . . . . . . . . 6.67 Checking Fork Rod Bore . . . . . . . . . . . . . . . 6-68 Rod Checlcing Fixture . . . . . . . . . . . . . . . . . 6.71 Checking Rod Upper Bearing Shell . . . . . . . . . . 6.72 Liner Bore Gauge .................... 6.75 Liner Measurement Points . . . . . . . . . . . . . . . 6-76 Rocker Arm Oil Line Removal . . . . . . . . . . . -6-78 ' Rocker Arm Assembly Removal . . . . . . . . . . . 6-78 Fuel Line Assembly Removal . . . . . . . . . . . . . 6.79 Removing Injector With Pry Bar . . . . . . . . . . . . 6-79 Piston Holding Tool . . . . . . . . . . . . . . . . . . 6-80 Cylinder Head Removing Fixture . . . . . . . . . . . 6-81 Basket Bolt Wrench Application . . . . . . . . . . . 6.82 Connecting Rod Positioning Clamp Application . . . 6.82 Fork Rod Support . . . . . . . . . . . . . . . . . . . 6-82 Lifting Clamp Application . . . . . . . . . . . . . . 6-86 Piston Holding Tool Application . . . . . . . . . . . 6-86 Power Assembly Removal With Lifting Clamp and Hoist . . . . . . . . . . . . . . . . . . . 6-87 Installation of Top Compression Ring . . . . . . . . 6.89 xii

79233-AS-MMO-0 10

List of Illustrations . Cont’d

Figureflitle Page

6-81 6-82 6-83 6-84 6-85 6-86 6-87 6-88 6-89 6-90 6-9 1 6-92 6-93 6-94 6-95 6-96 6-97 6-98

6-99 6-10 6-101 6-102 6-103 6-104 6- 105 6- 106 6- 107 6- 108 6-109 6-1 10 6-111

6-112 6-1 13

6-114 6-115 6-1 16 6-1 17 6-118

Piston Pin and Insert Bearing Installation . . . . . . . 6.90 Carrier in Typical Holding Fixture . . . . . . . . . . 6.90 Installing Piston Snap Ring . . . . . . . . . . . . . . 6.92 Liner Installation Using Liner Lifter . . . . . . . . . 6.92 Rod and Basket Identification . . . . . . . . . . . . . 6.93 Head-To-Liner Gasket . . . . . . . . . . . . . . . . 6.94 Cylinder Head Seat Ring . . . . . . . . . . . . . . . 6.95 Water Discharge Elbow Alignment . . . . . . . . . . 6-95 Head-To-Liner Nut Tightening Sequence . . . . . . . 6.96 Applying Seal to Water Inlet Tube Piston Cooling Oil Pipe Alignment Lead Wire Measurement . . . . . . . . . . . . . . . 6-100 Power Assembly and Container . . . . . . . . . . . . 6.101 Lifting Clamp Application . . . . . . . . . . . . . . 6- 102 Piston Holding Tool Application . . . . . . . . . . . 6- 102 Rod and Basket Identification . . . . . . . . . . . . . 6-103 Power Assembly Installation with Lifting Clamp andHoist . . . . . . . . . . . . . . . . . . . 6-103 Seat Ring Installation . . . . . . . . . . . . . . . . . 6-104 Water Discharge Elbow Alignment . . . . . . . . . . 6-105 Basket Bolt Wrench Application . . . . . . . . . . . 6-106 Lead Wire Measurement . . i . . . . . . . . . . . . 6-108 Applying Thrust Collar . . . . . . . . . . . . . . . . 6.111 Crankshaft ....................... 6-114 Gear Type Damper, Exploded View . . . . . . . . . 6. 116 Typical Accessory Drive Gear, Exploded View . . . 6. 1 18 Governor Drive Gear and Stubshaft . . . . . . . . . . 6. 121 Accessory Drive Housing Positioning . . . . . . . . 6. 123 Accessory Drive Housing Alignment . . . . . . . . . 6.123 Ring Gear and Coupling Disc Installations . . . . . . 6-125

Flywheel Indicator . . . . . . . . . . . . . . . . . . 6-125 Accessory Drive Coupling . . . . . . . . . . . . . . 6. 126 Camshaft Gear Train Markhg (Left-hand Rotation Engine) . . . . . . . . . . . . . . . . . . . 6-129 Camshaft Gear Train, Cross-Section . . . . . . . . . 6-130 Spring Drive Gear Assembly . . . . . . . . . . . . . 6. 133 Application of Parts for Checking Bearing Clearance 6-136 Idler Stubshaft Bracket Application . . . . . . . . . . 6.139 Checking No . 1 Idler Gear to Crankshaft Gear Backlash ..................... 6.140

Rocker Arm Shaft Installation . . . . . . . . . . . . 6.97 . . . . . . . . . . 6-98 . . . . . . . . . . 6.99

Mounting Of Digital Tachometer Pickup with xiii

Figuxe/Title Page

6-119 6-120 6-121 6-122 6-123 6- 124 6- 125 6-126 6-127

6-128

6- 129 6-130

6-132 6-133 6-134 6-135

6-131

6-136

6-138 6- 137

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- 152 6-151

6-153 6-154 6- 155 6-156

Idler Gear Stubshaft Bracket Alignment . . . . . . . 6-141 Checking Parallelism of No . 1 and No . 2 Stubshafts . 6-143 Lube Oil Manifold Application . . . . . . . . . . . . 6. 144 Camshaft Drive Housing Alignment . . . . . . . . . 6. 144 Checking Auxiliary Drive Gear Backlash . . . . . . . 6.146 Camshaft Application . . . . . . . . . . . . . . . . . 6.149 Camshaft Counterweight Timing . . . . . . . . . . . 6. 151 Lifting Device Applied to Turbocharger . . . . . . . 6.153 Exhaust Manifold-To-Turboharger Adapter Assembly . . . . . . . . . . . . . . . . . . . . . . . 6. 155 Fiberglass Bag . Type Elements For Engine Air

Manifold Gasket Torquing . . . . . . . . . . . . . . 6- 160 Lube Oil Manifold and Relief Valve . . . . . . . . . 6.162 Lube 0il ptessure Relief Valve . . . . . . . . . . . . 6- 163 Piston Cooling Oil Pipe Mgnment . . . . . . . . . . 6-164 Strainer Housing Drain Valves . . . . . . . . . . . . 6.166 Scavenging Oil Pump Strainm . . . . . . . . . . . . 6-168 Main Lube Oil and Piston Cooling Oil Pumps, Cross-Section ..................... 6. 169 oil Pump Body Bushing Tools . . . . . . . . . . . . . 6-173 Oil Pump Driven Gear Bushing Tool . . . . . . . . . 6-174 Checking Pump Drive Gear End Thrust . . . . . . . . 6-176 Scavenging Oil Pump, Cross-Section . . . . . . . . . 6. 176 Helix h g l e Position of Oil Pump Gears . . . . . . . 6.178 Cooling System Piping . . . . . . . . . . . . . . . . 6-182 Reading Differential Pressure Across aftercooler . . 6. 183 aftercooler Lifting Tml . . . . . . . . . . . . . . . . 6.184 Support Pad to Dowel Installation . . . . . . . . . . 6- 185 air Duct Support Pad Application . . . . . . . . . -6- 187 Drive Gear Removal . . . . . . . . . . . . . . . . . 6-188 Water Pump. Cross-Section . . . . . . . . . . . . . . 6. 188 Disassembly Tool Application . . . . . . . . . . . . 6. 189 Removing Shaft Assembly . . . . . . . . . . . . . . 6. 189

. . . . . . . . . . . . . . 6.189

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 6.159

Spring and Seal Assembly Installing Pump Impeller . . . . . . . . . . . . . . . 6-191 Pump Housing Positioning (Left-Hand Rotation Engine Shown) . . . . . . . . . . . . . . . 6.192 Checking Drive Belt Tension . . . . . . . . . . . . . 6. 195 Typical Raw Water Pump Cross-Section . . . . . . . 6.199 Raw Water Pump Seal . . . . . . . . . . . . . . . : 6-200 Thermostatic Valve, Cutaway View . . . . . . . . . . 6-201 xiw l9233-AS-MMO-010

List of Illustrations . Cont’d

FigueiTitle Page

6-157 6-158

6- 160 6-159

6-161 6-162 6-163 6-164 6-165 6- 166

6-168 6- 167

6-169 6- 170

6- 172 6- 173

6-171

6- 174 7- 1

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

7-6 7-7 7-8 7-9

7- 10

7-1 1

7-12

7-13 7-14

7-15

7-16

Injector Tester ..................... 6.203 Injector Holding Rack . . . . . . . . . . . . . . . . . 6.206 Injector Rack Positioning . . . . . . . . . . . . . . . 6-207 Injector Rack Gauge . . . . . . . . . . . . . . . . . . 6.207 Injector Rack Gauge Application . . . . . . . . . . . 6.208 Injector Linkage . . . . . . . . . . . . . . . . . . . . 6.209 Fuel Filter Assembly . . . . . . . . . . . . . . . . . 6.210 Accessory Rack Fuel System Components . . . . . . 6.210 Fuel Suction Strainer Exploded View . . . . . . . . . 6.211 Model PGA Governor, 3/4 Front View . . . . . . . . 6.2 16 Model FGA Governor, 3/4 Rear View . . . . . . . . 6-217 Overspeed Trip Adjustment . . . . . . . . . . . . . . 6-218 Dowel Hole and Air Port Alignment . . . . . . . . . 6-224 Typical Air Starting Motor . . . . . . . . . . . . . . 6.226 Air Start Valve .................... 6-227 Shutoff Valve ..................... 6.227 Solenoid Valve .................... 6.228 Air Strainer ...................... 6.228 Engine Equipped And Crankcase &

Handhole Cover .................... 7.9 Oil Pan Assembly .................... 7.5

Crankcase and Oil Pan Assembly . . . . . . . . . . . 7. 10 Cylinder Test Valve . . . . . . . . . . . . . . . . . . 7.11

Crankcase Pressure Detector Application . . . . . . . 7.12 Crankcase Pressure Detector Assembly . . . . . . . . 7.13

Crankcase Pressure Detector Assembly

Crankshaft, Main Bearings, And Main Bearing Caps . 7. 15 Connecting Rod, Bearings, Carrier, And Piston Pin . 7.17 Crankshaft Couplings, Coupling Discs and Flywheels ..................... 7. 19 Crankshaft Couplings Engine Coupling

. . . . . . . . . . . . 7.20 Crankshaft Couplings Front End Accessory Drive .................... 7.21 Harmonic Balancer And Gear Damper Assemblies

Disc and Flywheel Application

Gear Damper ..................... 7.22 Cyhder Head And Liner

Piston Assembly Reference Chart . . . . . . . . . . . 7.26

Plate -Type Crabs . . . . . . . . . . . . . . . . . . . 7.27

. . . . . . . . . . . . . . . 7.23 Pistons And Rings

Cylinder Head Crabs

Exhaust Valve Bridge, Rocker Arms, And Oil Lhes . 7.28

7- 17

7-18 7-19 l l9233-M-MM0-010

7-20 7-21

7-22

7-23 7-24 7-25 7-26

7-27

7-28

7-29 7-30 7-3 1

*7-32

7-33

7-34

7-35

7-36

7-37

7-38 7-39 7-40

Exhaust Valve Bridge Arms, And Oil Lines Exhaust Valve Bridge and Lash Adjuster, . . . . . . .7-30 Cyhder Head And Suppoq Frame . . . . . . . . . . .7-31 Cyhder Head Cover And Support Frame Cover Latches and Support Assembly . . . . . . . .7-34 Cylinder Head Cover . . . . . . . . . . . . . . . . .7-36 Exhaust Chamber Assembly Exhaust Chamber and Heat Shield Application . . . .7-37 Exhaust Chamber Assembly Themocouple Application with Ungrounded Hot Junction and Flexible Conduit . . . . . . . . . .7-39 Exhaust Stack Adapter Assembly . . . . . . . . . . . .7-40 Paper And Fiberglass Engine & Intake Filters . . . .7-41 Camshaft Drive Gear Train . . . . . . . . . . . . . . . .7-43 Camshaft Drive Gear Train Idler Gear Stubshaft Assemblies and Mounting . ; .7-45 Camshaft Drive Gear Train Upper Idler and Turbocharger Drive Gear Assembly .7-46 Camshafts And Camshaft Counterweights Camshaft Assembly . . . . . . . . . . . . . . . . . .7-47 Camshaft Be&g Brackets . . . . . . . . . . . . . .7-49

Camshaft Overspeed Trip Linkage Trip Linkage Application . . . . . . . . . . . . . . . . 7-53 Camshaft Overspeed Trip Linkage Overspeed Pawl Camshaft and Trip Assemblies . . .7-55 Camshaft Overspeed Trip Lhkage Overspeed Trip Lever, Reset Lever, and

Camshaft Overspeed Trip M a g e Overspeed Trip Pawl Bracket Assembly . ;' . . . . .7-58 Camshaft Overspeed Trip Linkage Overspeed Trip Assembly . . . . . . . . . . . . . . .7-59 Trip Assembly Counterweights and Overspeed Trip . . . . . . . . .7-60 Camshaft Overspeed Trip Linkage Trip Linkage Housing . . . . . . . . . . . . . . . . .7-62 Trip Housing Cover . . . . . . . . . . . . . . . . . .7-63 Accessory Drive Gear Assembly . . . . . . . . . . .7-64 Auxiliary Generator Drive Assembly . . . . . . . . .7-65

* . Camshaft Drive Housing . . . . . . . . . . . . . . .7-51

L i d t Switch ...................... .7-56

List of Illustrations - Cont'd

Fip/Title Page

7-41

7-42 7-43 7-44

7-45

7-46

7-47

7-48 7-49

7-50

7-5 1

7-52 7-53

7-54 7-55 7-56

7-57

7-58

7-59

' 7-60

7-61

7-62

Accessory Drive Housing Assembly Applied to Engines with Rear Drain Overspeed

Governor Drive And Governor Drive Gear . . . . . .7-69 GovernorDrive AndGovernorDriveGear . . . . . .7-70 Injector Control Linkage Control Shaft, Support Bracket, and Bearings . . . .7-71 Injector Control Linkage Spring -Loaded Adjusting Link . . . . . . . . . . . .7-73 Injector Control Linkage Current PGA Governor Lever and Control Rod Applied With Two Layshaft Hand Control Levers . .7-75 Lube Oil System Lube Oil Pumps and "Box" Type Lube Oil Strainer .7-76 Lube Oil Separator . . . . . . . . . . . . . . . . . .7-80 Lube Oil System Piston Cooling, Camshaft Stubshaft, Rocker Arm Lubricating Oil Lines and Turbocharger Filter . . . .7-83 Lube Oil System Soak Back Lube Oil System -with Flanged Connections . . . . . . . . . . . . . .7-86 Lube Oil System ManZold Relief Valve . . . . . . . . . . . . . . . .7-89 Lube Oil Level Switch . . . . . . . . . . . . . . . .7-90 Fuel Oil Piping Fuel Manifold and Valve Assembly . . . . . . . . .7-91 Fuel Oil Piping . . . . . . . . . . . . . . . . . . . .7-92 Duplex Fuel Filter Piping . . . . . . . . . . . . . . .7-94 Fuel Oil Piping Fuel Oil Manifold and Injector Fuel Oil Lmes . . . .7-96 Cooling System Water Manifold Application . . . . . . . . . . . . .7-97 Cooling System Water Inlet, Outlet and Drain Piping . . . . . . . . .7-99 Cooling System Water Drain Piping . . . . . . . . . . . . . . . . . .7-100 Cooling System AfteIcooler Piping . . . . . . . . . . . . . . . . . .7-101 Starter Motor And Mounting DualAirStartMotorMountingRightBank . . . . .7-103 Turbocharger . . . . . . . . . . . . . . . . . . . . .7-104

Trip Housings . . . . . . . . . . . . . . . . . . . . .7-67 xvii

FiptTitle Page

7-63 7-64 7-65

7-66 7-67 7-68 7-69 7-70 7-7 1 7-72

7-73 7-74 7-75 7-76 8- 1

Fuel Oil Strainer . . . . . . . . . . . . . . . . . . . .7-108 Radiator Type Core Lube Oil Cooler . . . . . . . . .7- 109 Lube Oil Filter Seven Element Filter . . . . . . . . . . . . . . . . .7- 1 12 Accessory Rack Equipment Left Hand . . . . . . . .7- 114 Dual Starter Motor Arrangement . . . . . . . . . . .7-121 Air Start Valve . . . . . . . . . . . . . . . . . . . .7-123 Automatic Air Line Lubricator . . . . . . . . . . . .7-125 Raw Water Pump Assembly . . . . . . . . . . . . .7-126 Belt Driven Raw Water Pump Assembly . . . . . . .7-130 Lube Oil Soak Back Pump With Flanged Connections . . . . . . . . . . . . . .7- 133 Immersion Heater Mounting And Equipment . . . . .7- 135 Electric Immersion Heater Water Circulating Pump .7- 137 Servo Booster Pump Assembly . . . . . . . . . . . .7- 139 Servo Booster Pump Application . . . . . . . . . . .7- 140 Schematic - prime and Post Lube Pump Control . . .8-3 wiii

List of Tables

Table 1-1 1-2 1-3 1-4 1-5 2- 1

4-1

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 6-1 1 6-12 6-13 6- 14 6-15 6-16 6- 17

6-18 6-19 6-20 6-21 6-22

Description Page

Engine Specfications . . . . . . . . . . . . . . . . . 1-2 Engine System Capacities . . . . . . . . . . . . . . . 1-2 EngineAssemblyandComponentWeights . . . . . . 1.3 Engine System Specifications . . . . . . . . . . . . . 1-4 Maximum AllowableEngine Inclinations . . . . . . 1-7 Systems Pressures and Temperams (at rated load and speed) Suggested Engine Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . 4.2 "One Revolution" Inspection Sequence . . . . . . . . 5.8 Engine Troubleshooting . . . . . . . . . . . . . . . 5.17

. . . . . . . . . . . . . . . 2. 16

Firing Order and Top Dead Center For 645 Engines . 5.9 Troubleshooting Running Turbocharger . . . . . . . 5.50 Torque Valves ..................... 6.1 Left-Hand Rotation Engine . . . . . . . . . . . . . . 6.5 Cylinder Head Valve Seat Dimensions . . . . . . . . 6-36 Exhaust Valve Dimensional Limits . . . . . . . . . . 6-38 Valve Springs Dimensional Limits . . . . . . . . . . 6-40 Valve Bridge Dimensional Limits . . . . . . . . . . 6-43 Leak Down Time . . . . . . . . . . . . . . . . . . . 6-48 Cylinder Head Seat Ring Dimensional Limits . . . . 6.53 Piston Dimension Wear Limits . . . . . . . . . . . . 6-59 Piston Carrier Dimensional Limits . . . . . . . . . . 6-65 Connecting Rod Dimensional Limits . . . . . . . . . 6.70 Liner Bore Dimensional Limits . . . . . . . . . . . . 6.74 Camshaft Gear Train Backlash Clearance Limits . . . 6.131 Camshaft Gear Train Clearance Limits . . . . . . . . 6. 137 Auxiliary Drive Dimensional Limits . . . . . . . . . 6-147 Camshaft Assembly Dimensional Limits . . . . . . . 6-149 Aftercooler to Turbocharger Air Duct Bolt Application . . . . . . . . . . . . . . . . . . . . . . 6.158 Oil System Component Dimensional Limits . . . . . 6.171 Water Pump Dimensional Limit . . . . . . . . . . . 6.194 Governor Drive Assembly Dimensional Limits . . . . 6-214 Overspeed Trip Setting Limits . . . . . . . . . . . . 6-219 Air Starting Motor Clearance Limits . . . . . . . . . 6.226

. LEGEND FOR FIGURE 7-1 . . . . . . . . . . . . . 7.6

LEGEND FOR FIGURE 7-2 . . . . . . . . . . . . . 7.9

LEGEND FOR EGURE 7-3 . . . . . . . . . . . . . 7.10

LEGENDFORFIGURE7-4 . . . . . . . . . . . . . 7.11

LEGEND FOR FIGURE 7-5 . . . . . . . . . . . . . 7.12

xix

T9233-AS-M1MO-010

Table Bescniption Page

LEGEND FQR FIGURE 7-6 . . . . . . . . . . . . . 7.13

LEGEND FQR FIGURE 7-7 . . . . . . . . . . . . . 7.1

LEGEND FQR FIGURE 7-8 . . . . . . . . . . . . . 7.17

LEGEND FQR FI6URE 7-9 . . . . . . . . . . . . . 7.19

LEGEND FOR FIGURE 7-10 . . . . . . . . . . . . 7.20

LEGEND FQR FI6URE 7-11 . . . . . . . . . . . . 7.21

LEGEND FQR FI6URE 7-12 . . . . . . . . . . . . 7.22

LEGEPJD FOR FIGURE 7-13 . . . . . . . . . . . . 7.24

LEGEND FQR FIGURE 7-14 . . . . . . . . . . . . 7.26

LEGEND FQR FI6URE 7-15 . . . . . . . . . . . . 7.27

LEGEND FQR FIGURE 7-16 . . . . . . . . . . . . 7.29

LEGEPJD FQR FI6URE 7-17 . . . . . . . . . . . . 7.30

LE6END FQR FIGURE 7-18 . . . . . . . . . . . . 7.32

LE6END FQR FIGURE 7-19 . . . . . . . . . . . . 7.34

LE6END FQR FIGURE 7-20 . . . . . . . . . . . . 7.36

. LEGEND FQR FI6URE 7-21 . . . . . . . . . . . . 7.37

LEGEND FOR FIGURE 7-22 . . . . . . . . . . . . 7.39

LE6EPJD FOR FTGURE 7-23 . . . . . . . . . . . . 7.40

LE6EPJD FQR FI6URE! 7-24 . . . . . . . . . . . . 7.41

LE6END FQR FIWRE 7-25 . . . . . . . . . . . . 7.44

LEGEND FQR FIGURE 7-26 . . . . . . . . . . . . 7.45

LEGEND FQR FI6URE 7-27 . . . . . . . . . . . . 7.46

LEGEND FQR FIGURE 7-28 . . . . . . . . . . . . 7.47

LEGEND FQR FIGURE 7-29 . . . . . . . . . . . . 7.49

LEGEND FQR FI6URE 7-30 . . . . . . . . . . . . 7.51

LEGEND FQR FIGURE 7-31 . . . . . . . . . . . . 7.53

LEGEND FQR FIGURE 7-32 . . . . . . . . . . . . 7.55

LEGEND FQR FIGURE 7-33 . . . . . . . . . . . . 7.56

LEGEND FQR FIGURE 7-34 . . . . . . . . . . . . 7.58

LEGEND FQR FIGURE 7-35 . . . . . . . . . . . . 7.59

LEGEND FQR FIGURE 7-36 . . . . . . . . . . . . 7.60

LEGEND FQR FIGURE 7-37 . . . . . . . . . . . . 7.62

LEGEND FQR FIGURE 7-38 . . . . . . . . . . . . 7.63

LEGEND FOR FIGURE 7-39 . . . . . . . . . . . . 7.64

LEGEPJD FQR FIGURE 7-40 . . . . . . . . . . . . 7.65

LEGEND FOR FIGURE 7-41 . . . . . . . . . . . . 7.67

LEGEND FQR FIGURE 7-42 . . . . . . . . . . . . 7.69

LEGEND FQR FIGURE 7-43 . . . . . . . . . . . . 7.70

LEGEND FQR FIGURE 7-44 . . . . . . . . . . . . 7.7 1

LEGEND FQR FIGURE 7-45 . . . . . . . . . . . . 7.73

LEGEND FOR FIGURE 7-46 . . . . . . . . . . . -7-75

LEGEND FQR FIGURE 7-47 . . . . . . . . . . . . 7.77

xx

. I

List of Tables . (Cont'd)

Table Description Page

LEGEND FOR FIGURE 7-48

LEGEND FOR FIGURE 7-49

LEGEND FOR FIGURE 7-50

LEGEND FOR FIGURE 7-51

LEGEND FOR FIGURE 7-52

LEGEND FOR FIGURE 7-53

LEGEND FOR FIGURE 7-54

LEGEND FOR FIGURE 7-55

LEGEND FOR FIGURE 7-56

LEGEND FOR FIGURE 7-57

LEGEND FOR FIGURE 7-58

LEGEND FOR FIGURE 7-59

LEGEND FOR FIGURE 7-60

LEGEND FOR FIGURE 7-61

LEGEND FOR FIGURE 7-62

LEGEND FOR FIGURE 7-63

LEGEND FOR FIGURE 7-64

LEGEND FOR FIGURE 7-65

LEGEND FOR FIGURE 7-66

LEGEND FOR FIGURE 7-67

LEGEND FOR FIGURE 7-68

LEGEND FOR FIGURE 7-69

LEGEND FOR FIGURE 7-70

LEGEND FOR FIGURE 7-7 1

LEGEND FOR FIGURE 7-72

LEGEND FOR FIGURE 7-73

LEGEND FOR FIGURE 7-74

LEGEND FOR FIGURE 7-75

LEGEND FOR FIGURE 7-76

. . . . . . . . . . . . 7.81

. . . . . . . . . . . . 7.84

. . . . . . . . . . . . 7.87

. . . . . . . . . . . . 7.89

. . . . . . . . . . . . 7.90

. . . . . . . . . . . . 7.91

. . . . . . . . . . . . 7.93

. . . . . . . . . . . . 7.95

. . . . . . . . . . . . 7.96

. . . . . . . . . . . . 7.98

. . . . . . . . . . . . 7.99

. . . . . . . . . . . . 7.100

. . . . . . . . . . . . 7.101

. . . . . . . . . . . . 7.103

. . . . . . . . . . . . 7.104

. . . . . . . . . . . . 7. 108

. . . . . . . . . . . . 7.109

. . . . . . . . . . . . 7. 112

. . . . . . . . . . . . 7. 118

. . . . . . . . . . . . 7.121

. . . . . . . . . . . . 7.123

. . . . . . . . . . . . 7. 125

. . . . . . . . . . . . 7. 127

. . . . . . . . . . . . 7.130

. . . . . . . . . . . . 7.133

. . . . . . . . . . . . 7.135

. . . . . . . . . . . . 7. 137

. . . . . . . . . . . . 7.139

. . . . . . . . . . . . 7. 140

7- 1 SPECIAL TOOLS AND EQUIPMENT LIST . . . . 7.141

xxi

T9233-AS-ME0-O 10

xxii

Any attempt to disassemble the spring without the proper tools can be extremely hazardous and is not recommended.

Provide an additional support at the center of the pump untll the front body and bushing and pis-ton cooling pump gears are removed.

Provide additional support until the rear body is removed.

DO NOT remove hoses with engine at hlgh speed. DO NOT apply or remove hoses singly to prevent high pressure water discharge from manometer.

Before performing any maintenance on the solenoid valve, make sure the electrlcal power and air pressure have been turned off.

I CAUTION 1

Ensure the override valve is closed when the turning operation i s completed or the engine will crank when the main air line shutoff is opened.

t CAUTION 1 Do not continue to operate an engine requiring periodic addltion of coolant. Locate and repair leak.

I CAUTION 1

Ensure the lube oil strainer housing is full before starting the engine. If strainer housing is empty, serious engine damage can occur.

xxi i i

T9233-AS-MM0-O 10

r CAUTION 1 To prevent damage to crab bolts having UNR (rolled threads), only the proper thread file should be used, a s listed in the Equipment List.

r CAUTION 1 Use of the hardened washer under the main bearing cap nut 1s mandatory to ensure proper bolt stretch and to retaln nut torque. Damaged nut seat areas on the caps must be cleaned by spot-facing or by taking a cut (1116 maximum depth) parallel to the serration surface.

I CAUTION 1

Do not pull or stretch the end! 5 of seal cord.

I CAUTION 1

Do not use any form of blast cleaning (glass, sand, or shot) on the fireface of the head a s blasting tends to remove sharp edges of the phonograph grooves of the gasket surface, reducing its sealing effectiveness.

I CAUTION 1

Abrasive material, including steel wool, should not be used to clean piston pins or insert bear-ings.

I CAUTION 1

Abrasive material, including steel wool, should not be used to clean connecting rods or bearings shells.

l CAUTION 1 Be sure the spring 0s fully seated in its groove in the back of the ring. Attempting to install the piston and ring assembly into the llner with the spring not fully seated, or with a loop of spring protruding between the ring groove and ring will result in a badly klnked spring or broken ring.

i xxvi

T9233-AS-MMO-0 10

r CAUTION 1 If shaft is pressed down too far, the piston cool-ing pump gear key will shear the collar in the spacer plate.

I CAUTION 1

Do not use a caustic cleaner, as aluminum core flns will be damaged.

I CAUTION 1

The seal surface of the stationary bushing must be absolutely smooth and flat to prevent wear of the carbon washer. A statlonary bushing that has a rough surface must be replaced with a new bushing.

I CAUTION 1

Durlng removal of the seal, take extreme care not to drop or damage any part of the seal. Take particular care not to scratch the lapped faces on the washers or the sealing seat.

I CAUTION 1

Do not hammer rings into place. Use a press, or clamp the parts in a bench vise, using wooden blocks to protect the rings.