TJ-233-03 EMD Engine_Maintenance Instruction_1722 Rev I.pdf

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ELECTRO-MOTIVE

M.I. 1722

MAINTENANCE INSTRUCTION

SCHEDULED MAINTENANCE PROGRAM

MARINE PROPULSION (GM) AND

GENERATING (MG) UNITS WITH

TURBOCHARGED ENGINES

*This bulletin is revised and supersedes previous issues of this number.

DE-M891 October 1991

M.I. 1722

INTRODUCTION

This Maintenance Instruction provides average recommendations which should ensure satisfactory engine operation and economical maintenance cost where average load factors and average climatic conditions are encountered. It is intended to serve as a guide when establishing maintenance schedules that will meet the particular requirements of individual operations, and planned economic life of the engine and associated equipment.

These recommendations are based on the following conditions:

1. Fuel oil used will meet the specifications of Maintenance Instruction 1750.

2. Lubricating oil used will meet the specifications of Maintenance Instructions 1760 and 1764 and will be changed at the intervals specified in this M.I.

3. Engine coolant used will meet the specifications in Maintenance Instruction 1748.

4. Lubricating oil filters will be of a quality equal to original equipment and will be changed at the intervals specified in this M.I.

5. Operating load limitations will be adhered to.

6. Torquing procedures contained in this M.I. will be followed for new engines and newly installed replacement assemblies.

7. Reduction gear maintenance to be performed in accordance with manufacturer's recommendations.

This Maintenance Instruction is divided into three sections. The first section is maintenance performed before and after each start, the second section is performed on a "calendar period" basis, and the third section is performed on a "running time" basis. Because operating requirements for this equipment can vary from standby, to periodic, to continuous usage, the maintenance procedures must be modified to suit individual requirements.

REFERENCES

Abbreviations are used in this instruction to reference publications that contain information related to maintenance. The following examples are provided to aid in understanding the abbreviations used.

EMM means Engine Maintenance Manual

M.I. means Maintenance Instruction

- 2 -

BEFORE EACH START

LUBE OIL SYSTEM

Check for lube oil in pan and strainer box, if so equipped. Add oil if required.

NOTE

If engine requires prelube, recheck lube oil level in pan as a quantity will transfer to external system (cooler, filter, strainer and piping). Add oil if required.

COOLING SYSTEM

Check coolant level and add coolant if required.

NOTE

Do not continue to operate engine requiring periodic addition of coolant. Check for possible coolant leak and repair if required.

FUEL SYSTEM

Check fuel supply and open fuel supply valves.

Prime system.

AIR SYSTEM

Drain condensate.

Check system pressure.

Check oil supply in air line lubricator.

ENGINE

Check overspeed trip lever OST to ensure it is in the running "latched" position.

Open cylinder test valves and manually bar over engine one complete revolution, check for liquid ejected from valves, and close test valves.

On units with engine mounted lube oil strainer box (E7B, E7C, F7B & G7 models), prelube engine if unit has been shut down for over 48 hours.

On units with in-line mounted lube oil strainers (E7BA, E7CA, F7BA & G7 modified models with engine mounted raw water pump), prelube engine if unit has been shut down for over 2 hours.

Ensure exhaust stack is open.

GOVERNOR

Check lube oil level. Add oil if necessary.

- 3 -

EMM, M.I. 1760

EMM

EMM

EMM

EMM

EMM

EMM. If fluid discharge is observed from any cylinder, find the cause and make the necessary repairs prior to starting the engine.

EMM. Unless equipped with immersion heater system.

EMM

EMM, M.I. 1764

IMMEDIATELY AFTER EACH START

INSPECT FOR LEAKS

Cooling system Fuel system Lube oil system Exhaust system

LUBE OIL SYSTEM

Check lube oil level in pan with engine at idle.

Check lube oil pressure at engine.

COOLING SYSTEM

Check operation of external cooling system.

FUEL SYSTEM

Check for proper fuel pressure.

ENGINE

Check cylinder test valves for leakage. Tighten if required.

Check handhole covers for leakage. Tighten if required.

Check air box drains for proper operation and clean, if necessary.

Check for unusual noises or sound, or any fault indications (lights or alarm), as provided.

-4-

EMM

EMM

EMM

EMM

EMM. If drains are kept closed, drain every 4 hours.

PERFORM THE FOLLOWING ITEMS ON CALENDAR TIME BASIS

INSPECT FOR LEAKS

Cooling system Fuel system Lube oil system Exhuast system Air System

LUBE OIL SYSTEM

Check lube oil level m pan.

COOLING SYSTEM

Check coolant level.

NOTE

DAILY

Do not continue to operate engine requiring periodic addition of coolant. Check for possible coolant leak and repair as required.

FUEL SYSTEM

Check fuel supply.

AIR SYSTEM

Drain condensate from lines and tanks.

GOVERNOR

EMM

EMM

Check oil level and add oil if required. EMM

ENGINE AIR FILTER - PAPER OR FIBERLGASS TYPE

Monitor filter pressure indicator. If tripped, take EMM manometer readings and replace elements if neces-sary.

EVERY MONTH

LUBE OIL SYSTEM

M.l. 1722

Take sample for analysis. The services of a competent laboratory should be used to monitor the suitability of the oil for continued use according to M.I. 1760.

LUBE OIL CIRCULATING PUMP AND MOTOR (Where Used)

Check for proper operations. EMM

(_; IMMERSION HEATER (Where Used)

Check for proper operation. EMM

- 5 -

EVERY TWO MONTHS

AUXILIARY TURBOCHARGER FILTER {Where Used)

Replace elements. EMM

IN-LINE LUBE OIL STRAINER (Where Used)

Clean strainer screen.

EVERY YEAR

LUBE OIL CIRCULATING PUMP AND MOTOR {Where Used)

Inspect and clean with dry air.

Replace brushes. If equipped with DC motor.

Remove and clean check valve.

ELECTRICAL CONTROL CABINET AND ASSOCIATED EQUIPMENT {Where Used)

Check operation of protective devices.

Visually inspect and clean:

Voltage regulator.

All relays, contactors, and circuit breakers.

Remove circuit breakers from compartments.

Clean insulators.

Lubricate linkage bearings.

Check operation.

COOLING SYSTEM

Check operation and setting of engine water temper ature control(s).

Check torque on flexible pipe coupling bolts.

Take cooling water sample for lab analysis and corrosion test.

LUBE OIL FILTERS

Change filter elements.

Clean lube oil strainers.

Protective switches, relays, and alarm indicators.

M.I. 4523 or appropriate manufacturer's voltage regulator manual.

M.I. 1748. Unless 2000 hour sampling has occurred first.

EMM. Unless the 1400 hour filter change has occurred first.

EMM. Fill strainer box with oil before starting engine. (E7B, E7C, F7B & G7 models.)

TURBOCHARGER AND SOAK BACK OIL FILTERS

Replace filter elements.

-6-

EMM. Unless 1400 hour filter change has occurred first.

EVERY TWO YEARS

FUEL FILTERS

Change engme mounted filter elements.

Clean or replace suction strainer element.

ENGINE PROTECTOR

Replace or recondition and requalify.

EMM. Unless 2000 hour filter change has occurred first.

EMM. Unless 2000 hour maintenance has occur red first.

M.I. 259 or M.I. 260. Qualify on test stand after renewing spring, "O" rings, and diaphragms.

LUBE OIL CIRCULATING PUMP AND MOTOR (Where Used)

Replace. Replacement can be EMD Unit Exchange.

EVERY THREE YEARS

COOLING SYSTEM THERMOSTATIC VALVE

Replace "O" rings and thermostatic elements. EMM, M.I. 581

EVERY FOUR YEARS

COOLING SYSTEM PRESSURE CAP (Where Used)

Replace. Unless 16,000 hour replacement has occurred first.

EVERY FIVE YEARS

FREQUENCY GENERATOR COUPLING SPIDER (Where Used)

Replace. Unless 16,000 hour replacement has occurred first.

EVERY SIX YEARS

ENGINE

Replace top deck cover seals and check latches.

Replace cylinder head grommets, inlet and outlet seals, and lower liner seals.

MAIN GENERATOR (MG Models)

Remove bearing cover and inspect for grease con tamination, excessive wear, and overheating. Apply new grease.

- 7 -

EMM. Unless 8,000 hour replacement has occurred first.

EMM. Unless 16,000 hour cylinder assembly re placement has occurred first.

Unless 60,000 hour lubrication has occurred first.

M.I. 3328 for EMD generator. If generator is other than EMD, refer to manufacturer's manual.

1-"

PERFORM THE FOLLOWING ITEMS ON RUNNING TIME BASIS

I AFTER THE FIRST 350 HOURS OF OPERATION I

ENGINE NUT AND BOLT TIGHTNESS CHECK Torque to values specified in EMM.

Cylinder head crab nuts.

Exhaust manifold flange bolts.

Cylinder liner water inlet line nuts and bolts.

Head frame to crankcase bolts.

Turbocharger to air duct bolts, aftercooler to air duct bolts, and air duct to crankcase bolts, and turbine inlet link bolts.

Engine mounting bolts.

Miscellaneous nuts and bolts, and all piping con nections.

ENGINE

Inspect air box.

Inspect crankcase.

Inspect crankshaft and connecting rods.

Inspect pistons and piston rings.

Inspect cylinder liners.

Inspect cylinder head mechanism with engine idling and at operating temperature.

Inspect engine fuel lines and connections for leaks.

Inspect engine water system for leaks.

All except those equipped with plate type crabs.

EMM

EMM

EMM

EMM

EMM

EMM

EMM

EMM

EVERY 350 HOURS

FUEL FILTER

Check fuel pressure gauge with engine at rated RPM.

- 8 -

On units where gauge is connected to filter input side, change filter elements if pressure is greater than 345 kPa (50 psi).

On units where gauge is connected on filter output side, change filter elements if pressure is less than 83 kPa (12 psi).

u

LUBE OIL FILTER

Check lube oil filter pressure gauges with engine at rated RPM.

RAW WATER PUMP - BELT DRIVEN

Inspect drive belt for signs of slipping or chafing.

M.I. 1722

On units with rack mounted oil filter, change filter elements if input pressure is greater than 172 kPa (25 psi).

On units where filter is not rack mounted, and has external 138 kPa (20 psi) bypass valve, change filter elements if pressure differential between input and output exceeds 103 kPa (15 psi).

On units where filter is not rack mounted and has external 207 kPa (30 psi) bypass valve, change filter elements if pressure differential between input and output exceeds 138 kPa (20 psi).

EMM

EVERY 700 HOURS

ENGINE PROTECTOR

Check operation.

SOAK BACK PUMP AND MOTOR

Check operation.

EMM, M.I. 259 or M.I. 260

With the engine shut down and soak back pump motor running, remove left rear handhole cover and check oil flow through gear train.

Observe camshaft bearings. If lube oil flows from camshaft bearings with soak. back pump running and engine shut down, inspect turbo filter outlet check valve for proper operation.

ENGINE AIR FILTER- REMOTE MOUNT OIL BATH {Where Used)

Check oil level. M.I. 442

ENGINE AIR FILTER - PANEL TYPE OIL BATH (Where Used)

Check oil level. M.I. 440

ENGINE AIR FILTER - PAPER OR FIBERGLASS TYPE (Where Used)

Check indicator. If tripped, take manometer readings, and replace elements if necessary.

HEAT EXHANGER

Inspect corrosion zinc electrodes. EMM

RAW WATER PUMP - BELT DRIVEN

Lubricate shaft bearings. EMM

Check drive belt tension. EMM

-9-

EVERY 1400 HOURS

LUBE OIL FILTERS

Change filter elements.

Clean lube oil strainers. Fill strainer box with oil before starting engine.

(E7B, E7C, F7B & G7 models.)

TURBOCHARGER AND SOAK BACK OIL FILTERS

Replace elements.

PROTECTIVE DEVICES

Check operation.

Filter elements must be of a quality equal to original equipment. The interval of change for turbocharger and soak back filter elements is influenced by load factor, kind of lubricating oil, type of operation, climatic conditions, and main tenance of main lube oil filters.

EMM

EVERY 2000 HOURS

FUEL FILTERS

Clean or replace suction strainer element.

Change engine mounted filter elements.

COOLING SYSTEM

Take cooling water sample for lab analysis and cor rosion test.

EMM

EMM. Use only elements equal to original equip ment.

M.I. 1748. Unless the yearly sampling has occurred first. ·

ENGINE AIR FILTER- REMOTE MOUNT OIL BATH (Where Used)

Change oil. Drain and fill only. M.I. 442

ENGINE AIR FILTER - PANEL TYPE OIL BATH (Where Used)

Change oil. Drain and fill only. M.I. 440

ENGINE AIR FILTER - PAPER TYPE (Where Used)

Take manometer readings. Replace elements if necessary.

ENGINE AIR FILTER - FIBERGLASS TYPE (Where Used)

Replace elements.

- 10-

ENGINE

Inspect air box.

Inspect crankcase.

Inspect crankshaft and connecting rods.

Inspect pistons and piston rings.

Inspect cylinder liners.

Inspect cylinder head mechanism with engine idling and at operating temperature.

Inspect engine fuel lines and connections for leaks.

Inspect engine water system for leaks.

EMM

EMM

EMM

EMM

EMM

EMM

EMM

EMM

M.I. 1722

EVERY 4000 HOURS

EXHAUST SYSTEM

Remove exhaust manifold-to-turbocharger adapter assembly.

TURBOCHARGER EXHAUST DIFFUSER

Visually inspect for evidence of warpage or damage.

E DUCTOR TUBE (Exhaust Stack Mounted)

Inspect for carbon deposits and clean, if necessary.

LUBE OIL SYSTEM

Change engine oil.

Clean oil suction screens.

Clean scavenging oil screens.

Clean oil pan.

Clean filter housing.

ENGINE

Check pressure drop across af tercoolers; oil bath filter equipped engines only.

Check exhaust manifold base flange bolts for proper tightness.

GOVERNOR

Change oil.

Lubricate linkage moving parts.

Lubricate governor synchronizing motor, motor bearings. (Where used.)

- 11 -

EMM. Clean screen and trap box. Observe recom mendations found in EMM concerning checking for cracks.

EMM

EMM

EMM. Evaluation of engine and oil condition should dictate the frequency of this item. Type of service, type of oil, quality of filter elements, and condition of engine will influence the frequency of oil change.

EMM

Fill strainer box with oil before starting engine.

(E7B, E7C, F7B & G7 models.)

EMM

EMM

EMM. Clean air passages if necessary.

EMM

EMM, M.I. 1764

1-···

EVERY 8000 HOURS

ENGINE NUT AND BOLT RETORQUING

Cylinder head crab nuts.

Main lube oil and piston cooling oil pump shaft nut.

Head frame to crankcase bolts.

Turbocharger to air duct bolts, aftercooler to air duct bolts, air duct to crankcase bolts, and turbine inlet link bolts.

Engine mounting bolts.

Miscellaneous nuts and bolts, and all piping con nections.

ENGINE

Replace top deck cover seals and check latches.

Quality injectors.

Check injector timing and injector rack length.

Check engine speed.

Check overspeed trip.

Remove and clean oil separator element.

Check pressure drop across aftercooler; paper and fiberglass filter equipped engines only.

Inspect crankshaft damping device.

Remove, clean, and inspect; replace if necessary:

Soak back check valve in the turbo filter inlet.

Soak back oil pressure relief valve in the soak back filter head.

Soak back filter bypass valve in the soak back filter head.

Turbo oil filter check valve in the turbo filter head.

EXHAUST SYSTEM

Inspect manifold sections for possible cracked leg baffles or expansion joints and replace, if necessary.

MAIN GENERATORS (MG Models)

Visually inspect and clean.

Torque to values specified in EMM.

All except those equipped with plate type crabs.

EMM

EMM

EMM

EMM

EMM

EMM

EMM. Clean air passages if necessary.

EMM

EMM

EMM

M.I. 3328

ENGINE AIR FILTER- REMOTE MOUNT OIL BATH (Where Used)

Change oil. Clean sump and filter media. M.I. 442

ENGINE AIR FILTER - PANEL TYPE OIL BATH (Where Used)

Change oil. Clean sump and filter media. M.I. 440

- 12 -

SOAK BACK PUMP MOTOR

Inspect and clean with dry air.

Replace brushes.

COOLING SYSTEM (Pressurized System Only)

Inspect and perform pressure test.

Replace pressure cap if defective.

LUBE OIL COOLER (Tube Bundle Type)

Replace floating header seal.

M.I. 4101

M.I. 4101

MAIN LUBE OIL PUMP BYPASS VALVE (Where Used)

Remove, clean, inspect, and test. EMM

LUBE OIL FILTER

Remove internal oil filter bypass valve; clean, inspect, M.I. 926 and test. (Where used.)

M.I. 1722

LUBE OIL FILTER AND OIL COOLER BYPASS VALVES (Where Used)

Remove, clean, inspect, and test.

STARTING MOTORS

Disassemble, clean, inspect and lubricate.

Renew parts if necessary.

EMM

EMM

EVERY 16,000 HOURS

FUEL PUMP

Replace coupling spider.

SOAK BACK PUMP

Replace coupling spider.

COOLING SYSTEM

Replace pressure cap. (Where used.)

Inspect filler neck for damage. Replace if damaged.

(Where used.)

ENGINE

Replace cylinder assemblies.

Replace injectors.

Inspect and qualify connecting rod bearings.

Inspect and qualify piston cooling tubes.

Check rocker arms, rocker arm bushings, and cam followers.

Check lash adjusters.

Check exhaust valve timing.

Inspect lower liner inserts, and replace if required.

- 13 -

EMM. Except where Premium Power Packs are used.

EMM. Replacement should be EMD Unit Ex change or equivalent.

EMM

EMM

EMM

EMM

EVERY 30,000 HOURS

ENGINE

Replace cylinder assemblies

Install new thrust collars.

Replace injectors.

Install new lower main bearings.

Install new upper conn. rod bearings.

Replace water pump seals and all worn parts.

Replace lash adjusters.

Inspect lower liner inserts and replace - 8 required.

Inspect injector control linkage. Replace links, seals, and bearings where required.

TURBOCHARGER

Unit Exchange.

EMM. Provided Premium Power assemblies are used.

EMM

EMM

Inspect and qualify lower conn. rod bearing for reuse.

EMM

EMM

EMM

EMM

EMM. Average individual operating conditions will determine frequency.

TURBOCHARGER-TO-FILTER AIR DUCT (Where Used)

Replace.

COOLING SYSTEM

Replace flexible coupling seals.

LUBE OIL COOLER

Inspect, clean, and test. M.I. 927

HEAT EXCHANGER

Inspect, clean, and test. EMM

RAW WATER PUMP

Replace ball bearings and bearing seals. EMM

Replace pump seal and gaskets. EMM

Replace drive belt (where used). EMM

GOVERNOR

Replace. Replacement should be EMD Unit Exchange or equivalent.

J

GOVERNOR BOOSTER SERVO (Where Used) V Disassemble, clean, inspect, and replace 0-ring seals. EMM

- 14 -

FUEL PUMP

Replace or recondition.

SOAK BACK PUMP AND MOTOR

Replace or recondition.

M.I. 1722

M.l. 4110. Replacement can be EMO Unit Exchange.

M.I. 4101, M.I. 4110. Replacement can be EMO Unit Exchange.

EVERY 60,000 HOURS

ENGINE

Replace or recondition oil pumps.

Remove oil pressure relief valve; clean, inspect, and test.

EMM. Replacement can be EMD Unit Exchange.

EMM

PEDESTAL BEARING ASSEMBLY (Belt Driven Raw Water Pump)

Replace bearing

MAIN GENERATOR (MG Models)

Remove bearing cover and inspect for grease con tamination, excessive wear, and overheating. Apply G new grease.

ENGINE

Replace crankshaft damping device.

M.I. 3328 for EMO generator. If generator is other than EMO, ref er to manufacturer's manual.

EMM. Recondition and requalify.

EVERY 120,000 HOURS

ENGINE

Unit Exchange or completely rebuild.

MAIN GENERATOR (MG Models)

Unit Exchange or completely rebuild.

- 15 -

Document Number MM001090 --------------------..

Electro-Motive Division Of General Motors Corporation La Grange, Illinois 60525 USA Telex: 270041 McCook, Illinois USA Cable: ELMO DIV LaGrange, Illinois USA Telephone: 708-387-6000

®Copyright 1990 Electro-Motive Division, General Motors Corporation. All rights reserved. Neither this document, nor any part thereof, may be reprinted without the expressed written consent of the General Motors Locomotiv~ Group. Contact EMD Customer Publications Office.