TJ-311-01 EDG Engine.pdf

1'48 091 O-LP-513-7800

OPERATION AND MAINTENANCE MANUAL

FOR

ENGINE, EMERGENCY GENERATOR

MODEL 8062-7000

6V92

HALTER MARINE INC.

T-AGS 51/52 CLASS

N00024-89-C-2079

I

MANUFACTURED BY

DETROIT DIESEL ALLISON

13400 OUTER DRIVE, WEST

DETROIT, MICHIGAN 48239-4001

DISTRIBUTION STATEMENT "CY: DISTRIBUTION AUTHORIZED TO

US. GOVERNMENT AGENCIES AND THEIR CONTRACTORS; AD-

MlNlSTRATlVUOPERATlONAL USE: (01 AUG 91). OTHER REQUESTS

FOR THIS DOCUMENTSHALL BE REFERRED TO THE COMMANDER,

MILITARY SEALIFT COMMAND, CODE M-4E WASHINGTON, DC 20390.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE

I EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT

fTlTLE 22. U.S.C. SEC 2751 ET. SECJ OR EXECUTIVE ORDER 12470.

VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE

CRIMINAL PENALTIES.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL

PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF

THE DOCUMENT.

MILITARY SEALIFT COMMAND

I

I

01 AUG 1991

ICIAL USE ONLY

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

Date@) Of Origin&, ,nd Change Pages Are:

Original. . . 0 . . . 01 AUGUST 1991

Total Number Of Pages In This Publication Is ZZS Consisting Of The Following:

Page No. . . . . . Chg No.'

4 . . * . * * . , * . . o Record of Change . . 0 APRPage ValidationCert Foreword Warranty i -xlviii 1-1 - 1-17 2-1 -2-4 3-1 -3-13 4-1 -4-9 5-1 -5-25 6-1-6-397 7-1 . 7-96 8-1 -8-2

Page No. . . . . Chg No." Page No. . . . . . Chg No.'

* ZERO IN THIS COLUMN INDICATES AN ORIGINAL PAGE.

A

Change No.

ECO RD OF C HAN G

Date Title Or Brief Description

ES

Entered By

APPROVALANDPROCUREMENTRECORDPAGE

APPROVAL DATA FOR:

TITLE OF MANUAL:

T9311 -BD-MMO-01 0

EMERGENCY GENERATOR 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 SHIPYARD

REMARKS:

I A CERTl FlCATlON DATE: M / k t 4/*3fl

IT IS HEREBY CERTIFIED THAT T9311-BD-MMO-010 TO BE PROVIDED UNDER CONTRACT

NUMBER N00024-894-2079 HAS BEEN APPROVED BY THE APPROVAL AUTHORITY

SHOWN ABOVE.

HALTER MARINE

0 TECHNICAL MANUAL VALIDATION CERTIFICATE

NAVSEA 41 60/3 (4-82)

TECHNICAL MANUAL TITLE: EMERGENCY GENERATOR ENGINE

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

NAVSEA TECHNICAL MANUAL NUMBER:

T9311 -BD-MMO-010

DATE:

01 AUG 91

CONTRACTflMCR NO. :

N00024-894-2079

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.

II- EXCEPTIONS

EXCEPTIONS AUTHORIZED BY

SIGNATURE OF PUBLICATIONS QUALITY DATE:

G

T9311-BD-MMO-010

FOREWORD

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

Chp.

No. Title

1.

2.

3.

4.

5.

6.

7.

8.

General Information and Safety Precautions Operation Functional Description Scheduled Maintenance Troubles hooting Corrective Maintenance Parts List 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 MAE, Washington, DC 20390.

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.

7331 1-BD-MMO-010

TABLE OF CONTENTS 0

Chapter Title Page i .

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . i LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . xii LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . xxii SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . xxv

1 GENERAL INFORMATION AND SAFETY PRECAUTIONS . . 1.1

1- 1 1-1.1 1-1.2 1-2 1-3

1-3.1 1-3.2 1-3.3 1-3.4 1-4 1-4.1 1-4.2 1-5 1-5.1 1-5.2

INTRODUCTION . . . . . . . . . . . . . . . . . . . 1-11

General Information . . . . . . . . . . . . . . . . . . . 1. 1 Safety Precautions . . . . . . . . . . . . . . . . . . . . 1.1

EQUIPMENT DESCRIPTION . . . . . . . . . . . . . 1.1

LUBRICATING OIL, FUEL OIL AND FILTER

RECOMMENDATIONS . . . . . . . . . . . . . . . -1-4

Lubricating Oil Lubricant Recommendation . . . . . . . . . . . . . . . 1-4

. . . . . . . . . . . . 1-5 Oil Change Intervals . . . . . . . . . . . . . . . . . . . 1-6

FUEL OIL . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Selection . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Refueling . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Coolant Requirements . . . . . . . . . . . . . . . . . . 1-7 Corrosion Inhibitors . . . . . . . . . . . . . . . . . . . 1-7

Lubricating Oil Selection Criteria

ENGINE COOLANTS . . . . . . . . . . . . . . . . . . 1-6

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

2- 1 2-2 2-2.1 2-3 2-3.1 2-3.2 2-4 2-4.1 2-4.2 2-4.3 2-5 2-5.1 2-5.2 2-5.3

INTRODUCTION . . . . . . . . . . . . . . . . . . . . 2.1

Engine Operating Instructions . . . . . . . . . . . . . . 2. 1 Preparation for Starting Engine First Time . . . . . . . 2. 1

Manual Start (Selector Switch in Manual) . . . . . . . . 2.3 Automatic Start (Selector Switch in Auto) . . . . . . . . 2.3

RUNNING . . . . . . . . . . . . . . . . . . . . . . . . 2.3

Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . 2.3

STARTING . . . . . . . . . . . . . . . . . . . . . . . 2.2

Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.3

Normal Stop . . . . . . . . . . . . . . . . . . . . . . . 2.3 Emergency Stopping . . . . . . . . . . . . . . . . . . . 2.3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . 2.3

STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

i

TABLE OF CONTENTS (Cont'd)

Chapter Title Page

2-5.4 Cooling System . . . . . . . . . . . . . . . . . . . . . 2.4 2-5.5 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . 2.4 2-5.6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.4 2-5.7 Clean Engine . . . . . . . . . . . . . . . . . . . . . . . 2.4

3 FUNCTIONALDESCRIPTION . . . . . . . . . . . . . . . . . . 3.1

3- 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . 3.1

3-2 GENERAL DESCRIPTION (6 CYLINDER) . . . . . . 3.1

3-2.1 Exhaust System . . . . . . . . . . . . . . . . . . . . . 3.1 3-2.2 Radiator Cooling System . . . . . . . . . . . . . . . . 3.2 3-2.3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . 3.2 3-2.4 Hydraulic Governor . . . . . . . . . . . . . . . . . . . 3.8 3-2.5 Lubrication System . . . . . . . . . . . . . . . . . . 3-11

4 SCHEDULWMAINTENANCE . . . . . . . . . . . . . . . . . . 4.1

4- 1 4-2 4-2.1 4-2.2 4-2.3 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4- 10 4-11 4- 12 4-12.1 4-13 4- 14 4- 15 4-16 4- 17 4-18 4- 19

INTRODUCTION . . . . . . . . . . . . . . . . . . . . 4.1

Maintenance Plan . . . . . . . . . . . . . . . . . . . . 4.1 Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . 4. 1 FuelTanks . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Fuel Lines and Flexible Hoses . . . . . . . . . . . . . . 4.4

COOLING SYSTEM . . . . . . . . . . . . . . . . . . 4.5

TACHOMETER DRIVE . . . . . . . . . . . . . . . . 4.5

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . 4.5

THROTTLE CONTROLS . . . . . . . . . . . . . . . . 4.6

LUBRICATING OIL FILTER . . . . . . . . . . . . . . 4.6

FUEL STRAINER AND FTLTER . . . . . . . . . . . . 4.6

EXHAUST SYSTEM . . . . . . . . . . . . , . . . . . . 4.6

EMERGENCY SHUTDOWN . . . . . . . . . . . . . . 4.6

OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . 4.6

GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . 4.6

Overspeed Governor . . . . . . . . . . . . . . . . . . . 4.7

FUEL INJECTORS AND VALVE CLEARANCE . . . 4.7

ENGINE AND MOUNTS . . . . . . . . . . . . . . . . 4.7

CRANKCASE PRESSURE . . . . . . . . . . . . . . . 4.7

THERMOSTAT AND SEALS . . . . . . . . . . . . . 4.7

BLOWER SCREEN . . . . . . . . . . . . . . . . . . . 4.7

CRANKCASE BREATHER . . . . . . . . . . . . . . 4.7

ENGINE TUNE-UP . . . . . . . . . . . . . . . . . . . 4-7

ci i i

Chapter Title Page

4-20 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . 4.8

4-2 1 DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . 4.8

4-22 STARTING MOTOR . . . . . . . . . . . . . . . . . . 4.8

4-23 AIR BOX DRAIN TUBE . . . . . . . . . . . . . . . . 4.9

4-24 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . 4.9

4-25 AIR BOX CHECK VALVES . . . . . . . . . . . . . . 4-9

4-26 FAN HUB . . . . . . . . . . . . . . . . . . . . . . . . 4.9

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

' e

5- 1 5-2 5-2.1 5-2.2 5-2.3 5-2.4 5-2.5 5-2.6 5-2.7 5-2.8

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

TROUBLESHOOTING PROCEDURES . . . . . . . . 5.1

Locating a Misfiring Cylinder . . . . . . . . . . . . . . 5. 1 Checking Compression Pressure . . . . . . . . . . . . . 5.2 Engine Out Of Fuel . . . . . . . . . . . . . . . . . . . 5.4 Crankcase Pressure . . . . . . . . . . . . . . . . . . . . 5.4 Exhaust Back Pressure . . . . . . . . . . . . . . . . . . 5.5 Air Box Pressure . . . . . . . . . . . . . . . . . . . . . 5.5 Air Inlet Restriction . . . . . . . . . . . . . . . . . . . 5.6 Proper Use of Manometer . . . . . . . . . . . . . . . . 5.6

6 CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . 6.1

6- 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . 6.1

6-2 TOOLS AND EQUIMENT . . . . . . . . . . . . . . . 6. 1

Section I ADJUSTMENT AND ALIGNMENT . . . . . . . . . . . . 6.5 6-3 6-4 6-4.1 6-5 6-5.1 6-5.2 6-5.3 6-6 6-6.1 6-7 6-7.1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . 6.5

ENGINE TUNE-UP PROCEDURES . . . . . . . . . . 6.5

Tune-up Sequence For Hydraulic Governor . . . . . . 6.5

Valve Clearance Adjustment (Cold Engine) . . . . . . . 6.6 Valve Clearance Adjustment (Hot engine) . . . . . . . 6.7 Check Exhaust Valve Clearance Adjustment . . . . . . 6.8

FUEL INJECTOR TIMING . . . . . . . . . . . . . . . 6.8

Time Fuel Injector . . . . . . . . . . . . . . . . . . . . 6.8

SG HYDRAULIC GOVERNOR

Injector Rack Control Adjustment . . . . . . . . . . . 6-10

EXHUAST VALVE CLEARANCE ADJUSTMENT . 6.6

iii

TABLE OF CONTENTS (Cont’d) Chapter

6-7.2

6-7.3 6-7.4

Section II

6- 8 6-9 6-9.1 6-9.2 6- 10 6-10.1 6- 10.2 6-1 1 6-11.1 6-11.2 6-12 6- 12.1 6-12.2 6-12.3 6- 12.4 6- 12.5 6- 12.6 6- 12.7 6-12.8 6-13 6-13.1 6- 13.2 6- 14 6-14.1 6- 14.2 6-14.3 6- 14.4 6-14.5 6- 14.6 6- 14.7 6-14.8

Title Page

Position Injector Rack Control Levers and Adjust Governor Linkage . . . . . . . . . . . . . . . . . . . 6-10 Adjust Load Limit . . . . . . . . . . . . . . . . . . . 6-14 Adjust Governor Speed Droop . . . . . . . . . . . . . 6-15

INTRODUCTION . . . . . . . . . . . . . . . . . . . 6-17

CLEANING AND INSPECTION . . . . . . . . . . . 6-17

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-18

General . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Preliminary Procedures and Safety Precautions . . . . 6-19

Remove Starting Motor . . . . . . . . . . . . . . . . 6-20 ..

Install Starting Motor . . . . . . . . . . . . . . . . . 6-21

Fuel Injector Maintenance . . . . . . . . . . . . . . . 6-22 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . 6-71 Detecting Internal Fuel Leaks . . . . . . . . . . . . . 6-71 Fuel Jumper Line Maintenance and Reuse . . . . . . . 6-73 Fuel Injector Tube . . . . . . . . . . . . . . . . . . . 6-77 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . 6-83 Fuel Strainer and Fuel Filter (Spin-On Type) . . . . . 6-93 SG Hydrualic Governor . . . . . . . . . . . . . . . . 6-94

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . 6-1 16 Air Shutdown Housing . . . . . . . . . . . . . . . . 6-1 17

Lubrication . . . . . . . . . . . . . . . . . . . . . . . 6-122 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-123 Remove Blower From Engine . . . . . . . . . . . . 6- 124 Remove Blower Rear End Plate Cover . . . . . . . 6-126 Disassemble Blower . . . . . . . . . . . . . . . . . 6-126 Inspection . . . . . . . . . . . . . . . . . . . . . . 6- 130 Assemble Blower . . . . . . . . . . . . . . . . . . 6- 13 1 Assemble Rotors and End Plates (Blower with Lip Type Oil Seals) . . . . . . . . . . 6-136

PRELIMINARY REPAIR/REPLACEMENT . . . . . 6-19

STARTING MOTOR . . . . . . . . . . . . . . . . . 6-20

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . 6-21

AIRINTAKESYSTEM . . . . . . . . . . . . . . . 6-115

BLOWER . . . . . . . . . . . . . . . . . . . . . . 6-1 19

iv

7331 1-BD-MMO-010

I 0

Chapter

6- 14.9 6- 14.10 6-14.11 6- 14.12 6-15 6-15.1 6-15.2 6-15.3 6-16 6-16.1 6- 16.2 6- 16.3 6- 16.4 6-17 6- 17.1 6- 17.2 6-17.3 6-18 6- 19 6- 19.1 6-20 6-20.1 6-2 1 6-21.1 6-2 1.2 6-21.3 6-22 6-22.1 6-22.2 6-22.3 6-22.4 6-22.5 6-22.6 6-22.7 6-22.8 6-22.9 6-22.10 6-22.1 1 6-22.12

TABLE OF CONTENTS (Cont’d)

Title Page

Install Blower Rotor Shaft Bearings and Gears . . . 6-134 Timing Blower Rotors . . . . . . . . . . . . . . . . 6- 139 Assemble Blower . . . . . . . . . . . . . . . . . . 6- 142 Install Blower On Engine . . . . . . . . . . . . . . 6-144

LUBRICATIONSYSTEMMAINTENANCE . . . 6-147

Lubricating Oil Pump . . . . . . . . . . . . . . . . 6- 147 Lubricating Oil Pressure Regulator . . . . . . . . . 6- 150 Oil Pressure Relief Valve . . . . . . . . . . . . . . 6-153

LUBRICATING OIL COOER (PLATE-TYPE) . . 6-154

Remove Oil Cooler Assembly . . . . . . . . . . . . 6- 156 Clean Oil Cooler Core . . . . . . . . . . . . . . . . 6- 156 Pressure Check Oil Cooler Core . . . . . . . . . . . 6-158 Install Oil Cooler Assembly . . . . . . . . . . . . . 6- 159

Remove Oil Cooler Bypass Valve . . . . . . . . . . 6- 160

Install Oil Cooler Bypass Valve . . . . . . . . . . . 6-161

OIL LEVEL DIPSTICK . . . . . . . . . . . . . . . 6-162

OIL PLAN . . . . . . . . . . . . . . . . . . . . . . 6-163

Remove and Install Oil Plan . . . . . . . . . . . . . 6- 163

VENTILATING SYSTEM . . . . . . . . . . . . . 6-164

Service . . . . . . . . . . . . . . . . . . . . . . . . 6-165

EXHAUST MANIFOLD (WATER COOLED) . . . 6-166

Remove Exhaust Manifold . . . . . . . . . . . . . . 6-166

Install Exhaust Manifold . . . . . . . . . . . . . . . 6-167

CYLINDER BLOCK . . . . . . . . . . . . . . . . 6- 168

Remove and Disassemble Engine . . . . . . . . . . 6- 170 Clean Cylinder Block . . . . . . . . . . . . . . . . 6- 17 1 Pressure Test Cylinder Block . . . . . . . . . . . . 6- 173 Inspect Cylinder Block . . . . . . . . . . . . . . . . 6- 175 Assemble and Install Engine . . . . . . . . . . . . . 6-179 Cylinder Block End Plates . . . . . . . . . . . . . . 6-179 Air Box Drains . . . . . . . . . . . . . . . . . . . . 6- 182 Cylinder Head . . . . . . . . . . . . . . . . . . . . 6- 184 ValveandInjectorOperatingMechanism . . . . . . 6-201 Exhaust Valves . . . . . . . . . . . . . . . . . . . . 6-125 Exhaust Valve Clearance Adjustment . . . . . . . . 6-231 Valve Rocker Cover . . . . . . . . . . . . . . . . . 6-233

LUBRICATING OIL COLER BYPASS VALVE . 6-160

Inspection . . . . . . . . . . . . . . . . . . . . . . 6-160

Inspection . . . . . . . . . . . . . . . . . . . . . . 6-167

'I93 1 1 -BD-MMO-O 10

Chapter

6-23 6-23.1 6-23.2 6-23.3 6-23.4 6-23.5 6-23.6 6-23.7 6-23.8 6-23.9 6-23.10 6-23.1 1 6-23.12 6-24 6-24.1 6-24.2 6-24.3 6-24.4 6-24.5 6-24.6 6-25 6-25.1 6-25.2 6-25.3 6-25.4 6-25.5 6-25.6 6-25.7 6-25.8 6-25.9 6-25.10 6-25.1 1 6-26 6-26.1 6-26.2 6-26.3 6-27 6-27.1 6-27.2

Title Page

CRANKSHAFT . . . . . . . . . . . . . . . . . . . 6-237

Remove Crankshaft . . . . . . . . . . . . . . . . . 6-238 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-240 Crankshaft Measurements . . . . . . . . . . . . . . 6-241 Journal Measurements . . . . . . . . . . . . . . . . 6-241 Inspection for Cracks . . . . . . . . . . . . . . . . 6-242 Crankshaft Grinding . . . . . . . . . . . . . . . . . 6-244 Install Crankshaft . . . . . . . . . . . . . . . . . . 6-245 Crankshaft Oil Seals . . . . . . . . . . . . . . . . . 6-246 Crankshaft Cap . . . . . . . . . . . . . . . . . . . . 6-252 Crankshaft Main Bearings . . . . . . . . . . . . . . 6-254 Engine Front Cover (Lower) . . . . . . . . . . . . . 6-262 Flywheel . . . . . . . . . . . . . . . . . . . . . . . 6-264

Remove Flywheel Housing . . . . . . . . . . . . . 6-268 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-269 Install Flywheel Housing . . . . . . . . . . . . . . 6-269 Borepace Runout . . . . . . . . . . . . . . . . . . 6-272 Bore Diameter . . . . . . . . . . . . . . . . . . . . 6-272 Installing Flywheel Housing Small Hole Covers . . 6-274

Inspect Piston Rings . . . . . . . . . . . . . . . . . 6-275 Remove Piston and Connecting Rod . . . . . . . . . 6-276 DisassemblePistonandConnectingRod . . . . . . 6-277 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 6-278 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-280 Crosshead Piston Dome Inspection . . . . . . . . . 6-280 Lubrication . . . . . . . . . . . . . . . . . . . . . . 6-281 Assemble Piston and Connecting Rod . . . . . . . . 6-28 1 Fitting Piston . . . . . . . . . . . . . . . . . . . . . 6-284 Fitting Piston Rings . . . . . . . . . . . . . . . . . 6-285 Install Piston Rings . . . . . . . . . . . . . . . . . . 6-285

CONNECTING ROD . . . . . . . . . . . . . . . . 6-290

DisassembleConnectingRodFromPiston . . . . . 6-290 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-290 Assemble Connecting Rod To Piston . . . . . . . . 6-295

CONNECTING ROD BEARINGS . . . . . . . . . 6-295

Remove Bearings Shells . . . . . . . . . . . . . . . 6-296 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-296

FLYWHEEL HOUSING . . . . . . . . . . . . . . 6-268

PISTON AND PISTON RINGS . . . . . . . . . . . 6-274

vi

Chapter

6-27.3 6-28 6-28.1 6-28.2 6-28.3 628.4 6-28.5

6-28.6 6-29 6-29.1 6-30 6-30.1 6-3 1 6-31.1 6-3 1.2 6-3 1.3 6-3 1.4 6-3 1.5 6-3 1.6 6-3 1.7 6-3 1.8 6-32 6-32.1 6-32.2 6-32.3 6-32.3 6-33 6-33.1

6-33.2 6-33.3 6-33.4 6-33.5 6-33.6 6-34 6-34.1

6-34.2

TABLE OF CONTENTS (Cont'd)

Title Page

Install Connecting Rod Bearing Shells . . . . . . . 6-298

Remove Cylinder Liner . . . . . . . . . . . . . . . 6-300 Inspect Cylinder Liner . . . . . . . . . . . . . . . . 6-301 Fitting Cylinder Liner in Block Bore . . . . . . . . 6-304 Install Piston and Connecting Rod Assembly . . . . 6-306 Install Cylinder Liner. Piston and Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-307 Engine Balance and Balance Weights . . . . . . . . 6-309

Lubrication . . . . . . . . . . . . . . . . . . . . . . 6-312

Check Engine Timing . . . . . . . . . . . . . . . . 6-3 12

Lubrication . . . . . . . . . . . . . . . . . . . . . . 6-314 Remove Camshafts . . . . . . . . . . . . . . . . . . 6-315 Remove Camshaft (Flywheel Housing in Place) . . 6-1 17 Disassemble Camshafts . . . . . . . . . . . . . . . 6-3 19 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-320 Assemble Camshafts . . . . . . . . . . . . . . . . . 6-323 Install Camshafts . . . . . . . . . . . . . . . . . . . 6-323 Install Camshaft (Flywheel Housing in Place) . . . . 6-325

CAMSHAFI' GEARS . . . . . . . . . . . . . . . . 6-326

Inspection . . . . . . . . . . . . . . . . . . . . . . 6-327 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-327 Install Camshaft Gears . . . . . . . . . . . . . . . . 6-327 Install Camshaft Gears . . . . . . . . . . . . . . . . 6-327

Remove Idler Gear. Hub and Bearing Assembly (Flywheel) Housing Previously Removed) . . . . . 6-330 Disassemble Idler Gear. Hub and Bearing Assembly 6-33 1 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-332

CYLINDER LINER . . . . . . . . . . . . . . . . . 6-299

GEAR TRAIN AND ENGINE TIMING . . . . . . 6-310

ENGINE TIMING . . . . . . . . . . . . . . . . . . 6-312

CAMSHAFT AND BEARINGS . . . . . . . . . . 6-314

IDLEGEARANDBEARINGASSEMBLY . . . . 6-328

Assemble Idler Gear. Hub and Bearing . . . . . . . 6-332 Check Idler Gear Bearing &-Load . . . . . . . . . 6-333 Install Idler Gear. Hub and Bearing Assembly . . . 6-336

CRANKSHAFT TIMING GEAR . . . . . . . . . . 6-337

Remove Crankshaft Timing Gear (Flywheel Housing Removed) . . . . . . . . . . . . 6-338 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-338 vii

"931 1-BD-MMO-010

Chapter

6-34.3 6-35

6-35.1

6-35.2

6-35.3

6-35.4 6-35.5

6-35.6 6-36 6-36.1 6-36.2 6-37 6-38 6-38.1 6-38.2 6-38.3 6-38.4 6-38.5 6-38.6 6-38.7 6-38.8 6-38.9 6-38.10 6-39 6-39.1 6-39.2 6-39.3 6-39.4 6-39.5 6-39.6 6-39.7 6-40 6-40.1 6-40.2

Title Page

Install Crankshaft Timing Gear . . . . . . . . . . . 6-339

BLOWER DRIVE GEAR AND SUPPORT

Remove Blower Drive Gear and Support Assembly(Flywhee1HousingRemoved) . . . . . . 6-339 Disassemble Blower Drive Gear and Support Assembly . . . . . . . . . . . . . . . . . . . . . . . 3-340 Non- turbocharged Engine (Figure 6-284) . . . . . . . . . . . . . . . . . . . . 6-341 Inspection . . . . . . . . . . . . . . . . . . . . . . . 6-342 Assemble Blower Drive Gear and Support Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-343 Install Blower Drive Gear and Support Assembly . . 6-344

RemoveCover . . . . . . . . . . . . . . . . . . . . 6-345 Install Cover . . . . . . . . . . . . . . . . . . . . . 6-345

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 6-339

BALANCE WEIGHT COVER . . . . . . . . . . . 6-344

CHECKINGBEARINGCLEARANCES . . . . . . 6-346

ENGINE COOLING SYSTEM MAINTENANCE . 6-346

Cooling System Capacity . . . . . . . . . . . . . . 6-347 Fill Cooling System . . . . . . . . . . . . . . . . . 6-347 Drain Cooling System . . . . . . . . . . . . . . . . 6-348

Cooling System Cleaners . . . . . . . . . . . . . . 6-348 Reverse Flushing . . . . . . . . . . . . . . . . . . . 6-348 MiscellaneousCooling Systemchecks . . . . . . . 6-349 Contaminated Engines . . . . . . . . . . . . . . . . 6-349 Maximum Engine Coolant Temperature . . . . . . . 6-350 Temperature Control Components . . . . . . . . . . 6-350

Lubrication . . . . . . . . . . . . . . . . . . . . . . 6-352 Replace Water Seal . . . . . . . . . . . . . . . . . 6-353 Remove Pump . . . . . . . . . . . . . . . . . . . . 6-357 Disassemble Pump . . . . . . . . . . . . . . . . . . 6-357

Flushing . . . . . . . . . . . . . . . . . . . . . . . 6-348

WATER PUMP . . . . . . . . . . . . . . . . . . . 6-350

Inspection . . . . . . . . . . . . . . . . . . . . . . 6-358 Assemble Pump . . . . . . . . . . . . . . . . . . . 6-360 Install Pump on Engine . . . . . . . . . . . . . . . 6-362

THERMOSTAT . . . . . . . . . . . . . . . . . . . 6-362

Operation . . . . . . . . . . . . . . . . . . . . . . . 6-362 Remove Thermostat . . . . . . . . . . . . . . . . . 6-363 viii

'1931 1-BD-MMO-010

TABLE OF CONTENTS (Cont'd) ' 0 Chapter

6-40.3 6-40.4 6-4 1 6-41.1 6-4 1.2 6-41.3 6-41.4 6-42 6-43 6-43.1 6-43.2 6-43.3 6-43.4

6-43.5 6-43.6

6-43.7 6-43.8 6-44 6-45

6-45.1 6-45.2 6-45.3 6-45.4

6-46

6-46.1 6-46.2 6-46.3 6-46.4 6-46.5 6-46.6 6-47 6-47.1

6-48

Title Page

Inspect Thermos tat . . . . . . . . . . . . . . . . . . 6- 364 Install Thermostat . . . . . . . . . . . . . . . . . . 6-364

RADIATOR . . . . . . . . . . . . . . . . . . . . . 6-365

Cleaning Radiator . . . . . . . . . . . . . . . . . . 6-365 Remove Radiator . . . . . . . . . . . . . . . . . . . 6-367 Inspection . . . . . . . . . . . . . . . . . . . . . . 6-367 Install Radiator . . . . . . . . . . . . . . . . . . . . 6-368

COOLANT PRESSURE CONTROL CAP . . . . . 6-368

ENGINE COOLING FAN . . . . . . . . . . . . . . 6-369

-Lubrication Fan Belt Adjustment . . . . . . . . . . . . . . . . . 6-369 Remove Fan. Hub and Adjusting Bracket . . . . . . 6-370 Disassemble Fan. Three Groove Pulley Hub and Bracket (FIg . 6-304 and 6- 305) Inspection . . . . . . . . . . . . . . . . . . . . . . 6-372 Assemble Three Groove Hub and Bracket (6-305) Current Install Fan. Hub and Bracket . . . . . . . . . . . . . 6-373 Drive Belts . . . . . . . . . . . . . . . . . . . . . . 6-373

ENGINE RUN-IN INSTRUCTIONS . . . . . . . . 6-374

DYNAMOMETER TEST AND RUN-IN

PROCEDURES . . . . . . . . . . . . . . . . . . . 6-374

The Basic Engine . . . . . . . . . . . . . . . . . . 6-374 Dynamometer . . . . . . . . . . . . . . . . . . . . 6-375 Instrumentation . . . . . . . . . . . . . . . . . . . 6-375 Block Oil Filter Bypass Before Initial Start-up and DynamometerTestofRebuiltEngines . . . . . . . 6-376

RUN-IN PROCEDURES (USE FIG . 6-306 TO

RECORD RESULTS) . . . . . . . . . . . . . . . . 6-377

&-Start . . . . . . . . . . . . . . . . . . . . . . . 6-377 Basic Engine Run-In . . . . . . . . . . . . . . . . . 6-378 Basic Run-In Inspection . . . . . . . . . . . . . . . 6-378 Inspection After Basic Run-In . . . . . . . . . . . . 6-379 Final Run-In . . . . . . . . . . . . . . . . . . . . . 6-379 Inspection After Final Run-In . . . . . . . . . . . . 6-380

CYLINDER BLOCK LINE BORING . . . . . . . . 6-382

Dimensions for Machine Shop Line Boring Cylinder Block . . . . . . . . . . . . . . . . . . . . 6-389

CYLINDER BLOCK PLUGGING . . . . . . . . . 6-392

ix

"93 11-BD-MMO-010

Chapter Title Page

7 PARTSLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7- 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . 7.1

7-2 PARTS LIST AND EXPLODED VIEW

ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . 7.1

7-3 LIST OF MANUFACTURERS . . . . . . . . . . . . 7-96

8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

8- 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . 8.1

8-2 INSTALLATION/REINSTALLATION . . . . . . . . 8. 1

8-3 START-UP AND CHECK OUT . . . . . . . . . . . . 8.2

X

LIST OF ILLUSTRATIONS

Figure

1-1 1-2

3- 1

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

3-8 3-9 3-10

3-1 1

3-12

3-13 5- 1 5-2 5-3

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

Title Page

Emergency Generator Diesel Engine . . . . . . . . . 1-2 Coolant Freezing and Boiling Temperatures vs .

Antifreeze Concentration (Sea Level) . . . . . . . . . 1-8 Typical Water-cooled Exhaust Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . 3.2 Fuel System . . . . . . . . . . . . . . . . . . . . . . 3.2 Fuel Pump Assembly . . . . . . . . . . . . . . . . . 3.3 Fuel Injector Assembly . . . . . . . . . . . . . . . . 3.4 Cutaway View of Fuel Injector . . . . . . . . . . . . 3.5 Fuel Metering From No Load To Full Load . . . . . 3.5 Phases of Injector Operation Through Vertical Travel of Plunger . . . . . . . . . . . . . . . . . . . 3.6 Fuel Injector Mounting . . . . . . . . . . . . . . . . 3.7 Hydraulic Governor Assembly . . . . . . . . . . . . 3.8 Position of Governor Mechanism When Load is Constant . . . . . . . . . . . . . . . . . . . . . . . 3.9 Position of Governor Mechanism As Load Increases and Engine Speed Tends to Decrease . . . . . . . . . 3.10 Position of Governor Mechanism As Load Decreases

. . . . . . . . . 3. 11 SchematicDiagramofLubricationSystem . . . . . . 3.12 and Engine Speed Tends to Increase

Checking Compression Pressure . . . . . . . . . . . 5.2 Inspecting Piston Rings . . . . . . . . . . . . . . . . 5.3 Comparison of Column Height for Mercury and Water Manometers . . . . . . . . . . . . . . . . 5.6 Adjusting Valve Clearance . . . . . . . . . . . . . . 6.7 Piston Firing Order . . . . . . . . . . . . . . . . . . 6.8 Timing Fuel Injector . . . . . . . . . . . . . . . . . 6.9 Hydraulic Governor Mounted on Engine . . . . . . . 6. 10 Positioning Number 1R Injector Rack Control Lever . . . . . . . . . . . . . . . . . . . . . 6. 11 Checking Injector Rack "Spring" . . . . . . . . . . . 6. 11 Positioning Governor Operating Lever . . . . . . . . 6.13 Adjusting Vertical Link . . . . . . . . . . . . . . . . 6.13 Adjusting Load Limit Screw . . . . . . . . . . . . . 6. 14 Adjusting Speed Droop . . . . . . . . . . . . . . . . 6.15 Adjusting Manximum No-Load Engine Speed . . . . 6.16 Schematic Diagram of Typical Fuel System . . . . . 6.21 Removing Injector From Cylinder Head . . . . . . . 6.24 Checking Rack for Freeness in Tester 529584 . . . . 6.25 Removing Filter Cap . . . . . . . . . . . . . . . . . 6.26 Location of Filter in Injector Body . . . . . . . . . . 6.26 Removing Injector Followers Stop Pin . . . . . . . . 6.27 Removing or Installing Plunger Follower, Plunger and Spring . . . . . . . . . . . . . . . . . . 6.27

. . . . 6.28 Removing Injector Nut Using Tool J4983-01 xi

0 LIST OF ILLUSTRATIONS (Cont’d)

Figure Title Page

6-20

6-21

6-22 6-23 6-24 6-25

6-26 6-27

6-28 6-29 6-30 6-3 1 6-32 6-33

6-34 6-35 6-36

6-37

6-39 6-38

6-40 6-4 1

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

Removing Spray Tip from Injector Nut

Injector Rack. Gear. Spray Tip and Valve Assembly Details and Relative Location of Parts . . . 6.29 Cleaning Injector Spray Tip with Tool 524838 . . . . 6.20 Cleaning Spray Tip Orifices with To0LT4298- 1 . . . 6.3 1 Cleaning Injector Body Ring With Tool 521089 . . . 6.32 Cleaning Injector Nut Lower End With Tool J9418-5 . . . . . . . . . . . . . . . . . . 6.33 Injector Follower . . . . . . . . . . . . . . . . . . . 6.34 Examining Sealing Surface With a Magnifying Glass . . . . . . . . . . . . . . . . . . . 6.35 Unusable Injector Plungers . . . . . . . . . . . . . . 6-36 Checking Needle Valve Lift with Tool 59462-02 . . 6.38 Spray Tip Sealing Surface Identification . . . . . . . 6-41 Sealing Surface which may Require Lapping . . . . 6.41 Lapping Spray Tip on Lapping Blocks 322090 . . . 6.41 Details of Injector Filters and Caps and Their Relative Location . . . . . . . . . . . . . . . . . . . 6-42 Location of Filter in Injector Body . . . . . . . . . . 6.43 Installing Filter Cap . . . . . . . . . . . . . . . . . . 6.43 Injector Rack. Gear. Spray Tip and Valve Assembly Details and Relative Location of Parts . . . 6.44 Cutaway View of Fuel Injector . . . . . . . . . . . . 6.45 Tightening Injector Nut By Hand . . . . . . . . . . 6.46 Tightening Injector Nut With Torque Wrench Using

Installing Injector Follower Stop Pin . . . . . . . . . 6.47 Injector Plunger. Follower and Relative Location

Injector in Position for Testing with Tester

Checking Rack for Freeness in Tester 329584 . . . . 6.50 Injector Tester 523010-A Clamping Heads . . . . . . 6-53 Injector Installed in Tester 523010-A with Clamping Head . . . . . . . . . . . . . . . . . . . . 6.54

. . . 6.54 Position of Rocker Arm Engagement Lever . . . . . 6.56 Installing Injector Nut . . . . . . . . . . . . . . . . . 6.57 Tester J22640-A with Shield Installed . . . . . . . . 6.58

. . . . . . . . . . . 6.60

. . . . . . . . . . . 6.60

Using To01 51291-02 . . . . . . . . . . . . . . . . . 6.29

To01 54983-01 . . . . . . . . . . . . . . . . . . . . 6.46

Of Parts . . . . . . . . . . . . . . . . . . . . . . . . 6.48

J23010-A . . . . . . . . . . . . . . . . . . . . . . . 6.49

Injector In Position for Testing with 523010-A

Injector in Calibrator J22410-A Injector in Calibrator J22410-A Setting Calibrator Stroke Counter . . . . . . . . . . . 6.61 Checking Fuel Output . . . . . . . . . . . . . . . . . 6.62 Types of Injector Plungers . . . . . . . . . . . . . . 6.63 PlungerBushing and Tip Flow Gage J25600-A . . . 6.64 xii

1931 1-BD-MMO-010

LIST OF ILLUSTRATIONS (Cont’d)

Figure

6-56 6-57 6-58 6-59 6-60 6-6 1 6-62

6-63

6-64

6-65

6-66

6-67

6-68

6-69 6-70 6-7 1 6-72 6-73 6-74 6-75 6-76 6-77 6-78

6-79 6-80 6-8 1 6-82

6-83

6-84

6-85 6-86 6-87 6-88

Title Page

Adjusting the Calibrating Valve . . . . . . . . . . . . 6.65 Spray Tip Installed in Tester . . . . . . . . . . . . . 6.66 Cradle Mounted on Fixture . . . . . . . . . . . . . . 6.67 End of Plunger Shown in Port . . . . . . . . . . . . 6.68 Refinishing Lapping Blocks . . . . . . . . . . . . . . 6.69 Injector Rack-TO-Gear Timing . . . . . . . . . . . . 6.60 Removing Injector Tube with Tools 55286-4C

Installing Injector Tube with 55286-4C

Upsetting Injector Tube with Tools J5286-4C

Reaming Injector Tube for Injector Body Nut and Spray Tip with Tool 522525-1 . . . . . . . . . . 6.80 Reaming Injector Tube for Injector Nut with

Measuring Relationship of Bevel Seal of Injector Tube to Fire Deck of Cylinder Head with Tool J25521 and Gage 522273 . . . . . . . . . . . . . . . . . . . 6.82 Measuring Relationship of Gage to Fire Deck of Cylinder Head with Tool J2552 . . . . . . . . . . . . 6.83 Typical Fuel Pump Assembly . . . . . . . . . . . . . 6.84 Typical Fuel Pump Mounting and Drive . . . . . . . 6.84 Fuel Pump Valving and Rotation . . . . . . . . . . . 6.85 Fuel Pump Oil Seal Arrangments . . . . . . . . . . 6.86 Removing Fuel Pump Cover . . . . . . . . . . . . . 6.87 Removing Oil Seals Using Tool J1508-13 . . . . . . 6.88 Fuel Pump Details and Relative Location of Parts . . 6.89 Installing Inner Oil Seal Using Tool J1508-8 . . . . 6.90

. . . . 6.91 Installing Fuel Pump Drive Shaft and Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . 6.91 Typical Spin-On Filter Mounting . . . . . . . . . . . 6.95 Hydraulic Governor Assembly . . . . . . . . . . . . 6.96 Hydraulic Governor Drive . . . . . . . . . . . . . . 6.97 Position of Governor Mechanism When Load is Constant . . . . . . . . . . . . . . . . . . . . . . . . 6.98 Position of Governor Mechanism as Load Increases and Engine Speed Tends to Decrease . . . . 6.98 Position of Governor Mechanism as Load Decreases and Engine Speed Tends to Increase . . . . . . . . . 6.99 Typical Hydraulic Governor Mounting Top View of Governor with Cover Removed Top View of Governor with Subcap Removed Removing Speed Adjusting Lever Roll Pin and 55286-5 . . . . . . . . . . . . . . . . . . . . . . 6.78 and 55286-5 . . . . . . . . . . . . . . . . . . . . . . 6.79 and 55286-6 . . . . . . . . . . . . . . . . . . . . . . 6.80

Tool J5286-98 . . . . . . . . . . . . . . . . . . . . 6.81

Installing Outer Oil Seal Using Tool J1508-9

. . . . . . . . 6.100 . . . . 6.101 . . . . 6.102

. . . . . 6.103 xiii

7931 1-BD-MMO-010

Figure

6-89

6-90 6-9 1A

6-91B

6-92

6-93

6-94

6-95

6-96

6-97 6-98 6-99A

6-99B

6- 100 6-101 6- 102 6-103 6- 104

6- 105

6- 106

6-107 6- 108

6- 109

6-110

6-111 6-1 12

6-113 6-114

LIST OF ILLUSTRATIONS (Cont'd)

Title Page

Removing Speed Adjusting Lever. Spring Fork.

Speed Spring and Pilot Valve Plunger Assembly . . . 6. 103 Removing Cup Plug from Governor Housing . . . . 6. 105 Hydraulic Governor Details Relative Location

Hydraulic Governor Details and Relative Location of Parts . . . . . . . . . . . . . . . . . . . 6. 108 Location of Speed Adjusting Lever and Terminal Lever Shaft Bushings in Governor Housing . . . . . 6.109 Location of Oil Relief Valve Plunger. Plunger Sleeve.

Springs. Oil Inlet Plug and Dummy Plug . . . . . . . 6. 110 Installing Terminal Lever Shaft in Governor Housing and Terminal Lever . . . . . . . . . . . . . . . . . . 6- 11 1 Installing Speed Adjusting Lever. Floating Lever. Speeder SpringandPilotValvePlungerAssembly . . . . . . 6.112 Installing Speed Adjusting Lever Shaft in Governor Housing and Adjusting Lever . . . . . . . . . . . . . 6.113 Air Flow Through Blower and Engine . . . . . . . . 6.116 Dry Type Air Cleaner . . . . . . . . . . . . . . . . . 6.117 Blower and Drive Assembly and Accessories Attached to Blower (Sheet 1 of 2) . . . . . . . . . . . 6.120 Blower and Drive Assembly and Accessories Attached to Blower (Sheet 2 of 2) . . . . . . . . . . . 6.121 Blower Lubrication . . . . . . . . . . . . . . . . . . 6.122 TypicalBlowerMounting (SingleBlower) . . . . . . 6.124 Removing Details and Relative Location of Parts . . 6. 126 Blower Details and Relative Location of Parts . . . . 6. 127 Removing Blower End Plate and Bearings from Housing and Rotors with Tool 56270-3 1 . . . . . . . 6. 128 Removing Oil Seal (or Oil Seal Ring Collar) and Bearing from End Palte with Tool 56270-3 . . . . . 6.129 Installing Oil Seal (or Oil Seal Ring Collar) in End Plate Using Tool 56270-3 . . . . . . . . . . . . . . . 6. 132 Location of Oil Seals in End Plate . . . . . . . . . . 6. 132 Assembling Blower Rotors in Housing and Front End Plate With Oil Seal Pilots (56270-5) . . . . . . . . . 6. 134 Installing Ball Bearings on Rotor Shaft and in Rear End Plate With Tool 56270- 13 . . . . . . . . . 6. 138 Installing Roller Bearings on Rotor Shafts and in Front End Plate With Tool 56270-13 . . . . . . . . . 6.138 Installing Blower Rotor Timing Gears . . . . . . . . 6. 139 Measuring "CC" and "C" Clearance Between Blower Rotor Lobes . . . . . . . . . . . . . . . . . . . . . . 6. 140 End View of Blower Rotor Clearances . . . . . . . . 6.141 Diagram Showing Proper Location of Shim for Correct Rotor Lobe Clearances . . . . . . . . . . . . 6. 142 of Parts . . . . . . . . . . . . . . . . . . . . . . . . 6.107 xiv

Figure

6-1 15

6-1 16 6-1 17 6-118 6-1 19

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 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

~ 0 6- 148 6- 149

LIST OF ILLUSTRATIONS (Cont'd)

Title Page

Measuring End Clearance Between Blower Rotors and End Plate . . . . . . . . . . . . . . . . . 6. 142 Front Hub Assembly . Large Bearing Blowers . . . . 6.143 Aligning Blower with Tool 533001 . . . . . . . . . . 6.145 Typical Lubricating Oil Pump Mounting . . . . . . . 6.148 Lubricating Oil Pump Details and Relative Locations of Parts . . . . . . . . . . . . . . . . . . . 6.148 Oil Pressure Regulator Valve and Relief Valve Mounting . . . . . . . . . . . . . . . . . . . . . . . 6- 15 1 Oil Pressure Regulator Valve and Relief Valve and Relative Location of Parts . . . . . . . . . . . . 6. 151 Typical Oil Cooler Mounting . . . . . . . . . . . . . 6. 154 Former and Current Oil Cooler Configuration . . . . 6.155 Oil Cooler Adaptor and Bypass Valve Mounting . . . 6.155 Location of Cylinder BLock Oil Gallery Cup Plug . . 6.157

. . . . 6.158 Oil Cooler Details and Relative Location of Parts . . 6. 159 Oil Cooler Adpators with Bypass Valve Assembly

Oil Cooler Core Prepared for Pressure Check

Components . . . . . . . . . . . . . . . . . . . . . . 6.161 Typical Dipstick Mounting . . . . . . . . . . . . . . 6.162 Typical One-Piece Oil Pan . . . . . . . . . . . . . . 6. 163 Cylinder Block to Cylinder Head Breather Systems . . . . . . . . . . . . . . . . . . . . . . . . 6. 165 Typical Mounting of Breather Assembly on Valve Rocker Cover . . . . . . . . . . . . . . . . . . . . . 6.165 Correct Installation of Breather Clamp . . . . . . . . 6. 166 Typical One-Piece Water-cooled Manifold . . . . . 6.167 Cylinder Block . . . . . . . . . . . . . . . . . . . . 6. 169 Engine Mounted on Overhaul Stand . . . . . . . . . 6. 170 Lifting Engine with Spreader and Sling . . . . . . . . 6.172 Cylinder Block Bore Measurement Diagram . . . . . 6.175 Checking Top Surfaces of Cylinder Block . . . . . . 6.176 Checking Depthof Counterbore withTool . . . . . . 6.177 Cylinder Block Markings . . . . . . . . . . . . . . . 6. 177 Cylinder Block Rear End Plate . . . . . . . . . . . . 6. 180 Installing Front End Plate . . . . . . . . . . . . . . . 6. 181 Early Air Box Drain Tube . . . . . . . . . . . . . . . 6. 185

System . . . . . . . . . . . . . . . . . . . . . . . . 6.183

Valve System . . . . . . . . . . . . . . . . . . . . . 6.183

Check Valve System . . . . . . . . . . . . . . . . . 6.184 Typical Clylinder Head Assembly . . . . . . . . . . 6.185 Cylinder Head Mounting . . . . . . . . . . . . . . . 6. 185

Open Air Box Drain Tube and Check Valve

Current Open Air Box Drain Tube and Check

Former Closed Air Box Drain Tube and xv

T93 11-BD-MMO-010

LIST OF ILLUSTRATIONS (Cont’d) I

I Figure

6-150

6- 15 1

I 6-152

. 6-153 6- 154

6- 155 6-156 6-157 6-158 6-159 6- 160

6-161 6- 162 6-163 6-164

6- 165

6-166 6- 167 6-168 6- 169 6- 170 6- 17 1 6- 172

6- 173 6- 174 6- 175 6-176 6- 177

6-178 6-179 6- 180 6-181 6- 182 6-183

6- 184

Title Page Coolant Passages Around Exhaust Valves and Fuel Injectors . . . . . . . . . . . . . . . . . . . . . 6. 186 Location and Position of Water Nozzles in Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 6.186 Removing or Installing Cylinder Head Using Tool

Checking Bottom Face Of Cylinder Head . . . . . . 6.193 Minimum Distance Between Top and Bottom Faces of Cylinder Head . . . . . . . . . . . . . . . . . . . 6. 194 Compression Gasket Mounting in Cylinder Block . . 6.197 Cylinder Head Support Shims in Place . . . . . . . . 6.197 CylinderHeadBoltTightening Sequence . . . . . . . 6.199 ValveandInjectorOperating Mechanism . . . . . . 6.202 Lubrication of Valve Operating Mechanism . . . . . 6.203 Removing Push Rod From Upper Side of Cylinder Head Using Tool J3092-01 . . . . . . . . . . . . . . 6.206 Cam Followers and Guide . . . . . . . . . . . . . . . 6.206 Cam Roller Clearances . . . . . . . . . . . . . . . . 6.207 Testing Cam Follower Spring with Tool 522738-02 . 6.208 Removing or Installing Cam Follower Roller Using

Valve and Injector Operating Mechanism and Relative Location of Parts . . . . . . . . . . . . . . . 6.2 11 Installation of Cam Followers . . . . . . . . . . . . . 6.212 Checking Cam Follower to Guide Clearance . . . . . 6.212 Adjusting Cam Follower Guide . . . . . . . . . . . . 6.213 Location of Exhaust Valves . . . . . . . . . . . . . . 6.215 AssemblyofExhaustValvesandGuides . . . . . . . 6.215 Removing Exhaust Valve Spring with Tool J7455 . . 6.217 Testing Exhaust Valve Spring Using Tool

Cleaning Exhaust Valve Guide with Tool 55437 . . . 6.220 Removing Exhaust Valve Guide with Tool 56569 . . 6.221 Installing Valve Guide with Tool 521520 . . . . . . . 6.221 Removing Press-Fit Exhaust Valve Bridge Guide . . 6.222 Removing Broken Exhaust Valve Bridge Guide With Tool J7453 and Slide Hammer 52619-01 . . . . 6.223 Installing Valve Seat Insert with Tool J24357 . . . . 6.224 Refacing Exhaust Valve . . . . . . . . . . . . . . . 6.224 Grinding Valve Seat Insert . . . . . . . . . . . . . . 6.225 Exhaust Valve Protrustion Beyond Cylinder Head . . 6.226 Grinding Wheel Dressing Tool of Set 524566 . . . . 6.226 Checking Relative Concentricity of Valve Seat Insert with Relation to Valve Guide . . . . . . . . . . 6.227 Exhaust Valve, Spring and Seal Configuration . . . . 6.228

J22062-01 . . . . . . . . . . . . . . . . . . . . . . . 6. 189

Tool J33421 . . . . . . . . . . . . . . . . . . . . . 6.209

522738-02 . . . . . . . . . . . . . . . . . . . . . . . 6.219 xvi

T9311-BD-MMO-010

LIST OF ILLUSTRATIONS (Cont’d)

Figure

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

6-206 6-207 6-208 6-209 6-210 6-21 1 6-212 6-213 6-214 6-2 15 6-216

6-2 17

6-218 6-219

6-220

Title Page

Checking Pressure Required to Open the Exhaust Valve in Cylinder Head with Tool 52507-01 . . . . . 6.229 Valve Bridge Adjustment . . . . . . . . . . . . . . . 6.230 Adjusting Valve Clearance . . . . . . . . . . . . . . 6.232 Typical Valve Rocker Cover Assembly (Current) . . 6.234 Typical Valve Rocker Cover Assembly (Former) . . 6.235 Typical Crankshaft . . . . . . . . . . . . . . . . . . 6.236 Cross-Section View of Crankshaft showing Offset, RelocatedMainBearingJournalOilHoles . . . . . . 6.237 Roll Pin Installed in End of Crankshaft . . . . . . . . 6.238 Removing or Installing Crankshaft . . . . . . . . . . 6.239 Dimensions of Crankshaft Journals . . . . . . . . . . 6.241 Standard Dimensions at Rear Main Bearing Thrust Washers . . . . . . . . . . . . . . . . . . . . 6.241 Critical Crankshaft Loading Zones . . . . . . . . . . 6.243 Crankshaft Fatigue Cracks . . . . . . . . . . . . . . 6.244 Typical Crankshaft Front Oil Seal Mounting . . . . . 6.247 Crankshaft Rear Oil Seal Mounting . . . . . . . . . . 6.247 Installing Crankshaft Rear Seal with Installer Set 321 112-B and Handle 53154-1 . . . . . . . . . . . . 6.250 CheckingCrankshaftRearSealSquareness . . . . . . 6.251

Main Bearing Shells, Bearing Caps and Crankshaft Thrust Washers . . . . . . . . . . . . . . 6.254 Removing Main Bearing Cap . . . . . . . . . . . . . 6.255 Removing Upper Main Bearing Shell (Except Rear Main) . . . . . . . . . . . . . . . . . . 6.256

RemovingUpperRearMainBearingShell . . . . . . 6.256 Comparison of Lower Main Bearings Shells . . . . . 6.257 Main Bearing Measurements . . . . . . . . . . . . . 6.258 Measuring Thickness of Bearing Shell . . . . . . . . 6.258 Stabilizers Mounted on Block . . . . . . . . . . . . . 6.259 Engine Front Cover Mounting . . . . . . . . . . . . 6.262 Front Cover Details and Relative Location of Parts . 6.264 Typical Flywheel Assembly . . . . . . . . . . . . . . 6.265 Pilot Bearing Retainer . . . . . . . . . . . . . . . . . 6-266 Torque-Turn Limits . . . . . . . . . . . . . . . . . . 6.267 Installing Flywheel Housing, Using Oil Seal

Flywheel Housing Cover Attaching Studs

Crankshaft Cap Mounting . . . . . . . . . . . . . . . 6.253

Expander Aligning Studs . . . . . . . . . . . . . . . 6.268

(Naturally Aspirated Engines) . . . . . . . . . . . . . 6.270 Idler Gear Hole Spacer Shim . . . . . . . . . . . . . . 6.270

(operation 1) . . . . . . . . . . . . . . . . . . . . . . 6.271

(operation 2) . . . . . . . . . . . . . . . . . . . . . . 6.272

Flywheel Housing Bolt Tightening Sequence

Flywheel Housing Bolt Tightening Sequence xvii

0 LIST OF ILLUSTRATIONS (Cont'd)

Figure

6-22 1 6-222 6-223 6-224 6-225 6-226

6-227

6-228 6-229 6-230 6-23 1

6-232

6-233 6-234 6-235 6-236 6-237 6-238 6-239 6-240

6-24 1

6-242 6-243

6-244 6-245 6-246 6-247 6-248 6-249 6-250 6-25 1 6-252

6-253

6-254

6-255

Title Page

Checking Flywheel Housing Concentricity . . . . . . 6.273 Cross-Head Piston and Connecting Rod Assembly . . 6.274 Criss-Head Piston and Connecting Rod Components . 6.275 Identification of Piston Using Gage 525397 . . . . . 6.276 Plasma-Faced Fire Ring . . . . . . . . . . . . . . . . 6.276 Removing or Installing Piston Rings Using

Checking Fire Ring Groove in Piston Crown with

Installing Seal Ring . . . . . . . . . . . . . . . . . . 6.279 Tightening Connecting Rod To Piston Pin Bolts . . . 6.283 Installing Piston Pin Retainer with Tool J23762-A . . 6.284 Checking Piston Pin Retainer for Proper Sealing with

Measuring Piston-To-Liner Clearance with Gage

Piston Ring Location . . . . . . . . . . . . . . . . . 6.286 Comparison of Pre-Stressed Compression Rings . . . 6.286 Measuring Piston Ring Gap . . . . . . . . . . . . . . 6.287 Measuring Piston Ring Side Clearance . . . . . . . . 6.288 Periphal Abutment Type Oil Control Ring Expander . 6.289 Piston Ring Installation Instructions . . . . . . . . . 6.289 Connecting Rod Details . . . . . . . . . . . . . . . . 6.290 Magnetic Particle Inspection Limits for Connecting Rod . . . . . . . . . . . . . . . . . . . . 6.292 Dimensional Inspection of Cross-Head Piston Connecting Rods . . . . . . . . . . . . . . . . . . . 6.293 Comparison of Connecting Rod . . . . . . . . . . . 6.294 Bearing Faces (I.D.) of Former and New Piston Pin Bushings . . . . . . . . . . . . . . . . . . . . . 6.295 Connecting Rod and Bearing Shells . . . . . . . . . 6.295 Cornparison of Connecting Rod Bearing Shells . . . 6.297 Typical Cylinder Liner . . . . . . . . . . . . . . . . 6.299 Removing Cylinder Liner . . . . . . . . . . . . . . . 6.300 Glazed Surface of Cylinder Liner . . . . . . . . . . . 6.302 Cylinder Liner Ridge Due To Wear . . . . . . . . . . 6.302 Cylinder Liner Measurement Diagram . . . . . . . . 6.303

. . . . . . . . . . 6.304 Checking Distance of Liner Flange Below Top Face of Block Using Clamp J24565-02 and

Installing Piston and Connecting Rod Assembly in ring compressor and Cylinder Liner Installing Piston, Connecting Rod and Liner

To01 J8128 . . . . . . . . . . . . . . . . . . . . . . 6.277

To01 J24599 . . . . . . . . . . . . . . . . . . . . . . 6.279

Tool J23987-01 . . . . . . . . . . . . . . . . . . . . 6.284

J5438-01 . . . . . . . . . . . . . . . . . . . . . . . . 6.285

Cylinder Liner Mounting in Block

Gage J24898 . . . . . . . . . . . . . . . . . . . . . . 6.305

. . 6.306

Assembly in Cylinder Block . . . . . . . . . . . . . 6.308 Typical Front Balance Weight Mounting . . . . . . . 6.309

0 ' xviii

"93 11-BD-MMO-010

LIST OF ILLUSTRATIONS (Cont'd)

Figure

6-256 6-257 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 6-27 1 6-272 6-273 6-274 6-275 6-276 6-277 6-278 6-279 6-280 6-28 1 6-282

6-283 6-284

6-285 6-286

6-287 6-288

6-289

6-290

6-29 1 6-292 6-293

Title Page

Gear Train . . . . . . . . . . . . . . . . . . . . . . . 6.310 Gear Train and Timing Marks . . . . . . . . . . . . 6.3 11 Camshaft Imtermediate Bearing (Lower Half) . . . . 6.315 LooseningCamshaftGearRetainingNut . . . . . . . 6.316 Removing Camshaft Pulley . . . . . . . . . . . . . . 6.3 16 Removing or Installing Camshaft End Bearing Retaining Bolts . . . . . . . . . . . . . . . . . . . . 6.3 17 Removing or Installing Camshaft Assembly . . . . . 6.3 17 Removing Camshaft with Camshaft Gear Puller J1902-01 and Adaptor Plage Set 56202 . . . . . . . . 6.318 Removing Gear (Camshaft Gear Puller J1902-01) . . 6.319 Checking Cam Lobe Wear . . . . . . . . . . . . . . 6.320 Camshaft Journal Fillet . . . . . . . . . . . . . . . . 6.321 Camshaft Details and Relative Location of Parts . . . 6.322 Camshaft Plug Installation . . . . . . . . . . . . . . 6.323 Camshaft Gears Mounted on Engine . . . . . . . . . 6.326 Removing Camshaft Gear . . . . . . . . . . . . . . . 6.327 Installing Camshaft Gear . . . . . . . . . . . . . . . 6.328 Idler Gear Mounting . . . . . . . . . . . . . . . . . . 6.329 Idler Gear Spacer . . . . . . . . . . . . . . . . . . . 6.329 Pressing Hub Out of Idler Gear Bearing . . . . . . . 6.330 Idler Gear Details and Relative Location of Parts . . . 6.331 Pressing Hub into Idler Gear Bearing . . . . . . . . . 6.333 Fixture for Testing Bearing Pre-Load . . . . . . . . . 6.335 Plates for Bearing Test Fixture . . . . . . . . . . . . 6.336 Checking Idler Gear Bearing Pre-Load . . . . . . . . 6.336 Installing Idler Gear, Hub and Bearing Assembly . . 6.337 Crankshaft Timing Gear Mounting . . . . . . . . . .