TJ-311-05 Engine Ship_s Service Generator Series 60.pdf

ATTENTION

This document is a guideline for qualified personnel. It is intended to be used by equipment manufacturers and contains Detroit Diesel Corporation's recommendations for the ancillary systems supporting the Detroit Diesel engines covered by this document. The equipment manufacturer is responsible for developing, designing, manufacturing and installing these systems, including component qualification. The equipment manufacturer is also responsible for furnishing equipment users complete service and safety information for these systems. Detroit Diesel Corporation makes no representations or warranties regarding the information contained in installation of these ancillary systems, or the preparation or distribution to equipment users of preliminary and incomplete and is subject to change without notice.

TRADEMARK INFORMATION

Series 50®, Series 60®, DDEC®, Ether Start®, and Diagnostic Link® are registered trademarks of Detroit Diesel Corporation. Fuel Pro® and Pro-Chek® are registered trademarks of Davco Manufacturing, L.L.C. Viton® is a registered trademark of Dupont Dow Elastomers L.L.C.

Loctite® is a registered trademark of Loctite Corporation. Delco Remy® is a registered trademark of Delco Remy America, Inc. Leece-Neville® is a registered trademark of Leece-Neville Company.

SERIES 60 AND SERIES 50 CONSTRUCTION

AND INDUSTRIAL AND MARINE APPLICATION AND INSTALLATION

SERIES 60 AND SERIES 50 CONSTRUCTION AND

INDUSTRIAL AND MARINE APPLICATION AND

INSTALLATION

ABSTRACT

This manual discusses the proper application and installation of the Detroit Diesel Series 50 and Series 60 engine. The intention of this manual is to provide information in general terms so that it may be applicable for all applications unless specifically noted or identified.

This manual contains the following information:

General information on safety precautions and on accessing installation drawings

Specific component and accessory information on varius production models

Information on the air inlet, exhaust, cooling, fuel, lubrication, electrical, mounting, and starting aid systems.

Information on the data to be found in the PowerEvolution Network (PEN), a web based computer system that provides information such as technical data and installation drawings.

Distributors may access PEN through the Detroit Diesel extranet. OEMs requiring access to PEN should contact Application Engineering for authorization.

All information subject to change without notice. (Rev. 10/04) i 7SA747 0410 Copyright © 2004 DETROIT DIESEL CORPORATION

ABSTRACT

ii All information subject to change without notice. (Rev. 10/04)

TABLE OF CONTENTS

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

2 SAFETY PRECAUTIONS ................................................................................................... 2- 1�

2.1 STANDS .......................................................................................................................... 2- 1�

2.2 GLASSES ....................................................................................................................... 2- 1�

2.3 WELDING ....................................................................................................................... 2- 2�

2.4 WORK PLACE ............................................................................................................... 2- 3�

2.5 CLOTHING ...................................................................................................................... 2- 4�

2.6 ELECTRIC TOOLS ......................................................................................................... 2- 4�

2.7 AIR .................................................................................................................................. 2- 5�

2.8 FLUIDS AND PRESSURE .............................................................................................. 2- 5�

2.9 BATTERIES ..................................................................................................................... 2- 6�

2.10 FIRE ................................................................................................................................ 2- 6�

2.11 FLUOROELASTOMER ................................................................................................... 2- 7�

3 ENGINE AND ACCESSORY IDENTIFICATION ................................................................ 3- 1�

3.1 MAJOR COMPONENT LOCATIONS ............................................................................. 3- 8�

3.1.1 SERIES 60 CONSTRUCTION AND INDUSTRIAL ENGINE ...................................... 3- 8�

3.1.2 SERIES 60 PETROLEUM ENGINE ........................................................................... 3-13�

3.1.3 SERIES 60 MARINE ENGINES ................................................................................. 3-18�

3.2 ENGINE IDENTIFICATION ............................................................................................. 3-28�

4 AIR INLET SYSTEM ........................................................................................................... 4- 1�

4.1 AIR INLET SYSTEM DESCRIPTION .............................................................................. 4- 1�

4.1.1 SERIES 60 AND SERIES 50 CONSTRUCTION AND INDUSTRIAL ENGINES ........ 4- 2�

4.1.2 SERIES 60 MARINE ENGINES ................................................................................. 4- 5�

4.2 INSTALLATION REQUIREMENTS ................................................................................. 4- 8�

4.2.1 DRY PAPER ELEMENT AIR CLEANERS .................................................................. 4- 8�

LIGHT-DUTY AIR CLEANER ............................................................................... 4- 9� MEDIUM-DUTY USE AIR CLEANER ................................................................... 4-10� HEAVY-DUTY USE AIR CLEANER ..................................................................... 4-11� EXTRA HEAVY-DUTY USE ................................................................................. 4-12� FOAM TYPE AIR CLEANERS .............................................................................. 4-13� OIL-BATH AIR CLEANERS .................................................................................. 4-13� AUXILIARY PRECLEANERS ................................................................................ 4-14� INLET SCREENS ................................................................................................. 4-14� RAIN CAPS AND INLET HOODS ........................................................................ 4-15� WATER DRAINS ................................................................................................... 4-15� INLET SILENCERS .............................................................................................. 4-15� AIR CLEANER SELECTION ................................................................................ 4-16�

4.2.2 RESTRICTION INDICATOR ....................................................................................... 4-16�

4.2.3 PIPEWORK ................................................................................................................ 4-18�

PIPEWORK MATERIAL SPECIFICATIONS ......................................................... 4-18� DIFFUSERS ......................................................................................................... 4-18�

All information subject to change without notice. (Rev. 10/04) iii

TABLE OF CONTENTS

4.2.4 HOSE CONNECTIONS .............................................................................................. 4-19�

4.2.5 MARINE ENGINE DUCTED AIR ................................................................................ 4-20�

4.2.6 MARINE ENGINE CHARGE AIR COOLER CONDENSATION DRAIN ...................... 4-21�

4.3 DESIGN GUIDELINES .................................................................................................... 4-22�

4.3.1 MAXIMUM AIR INLET FLOW .................................................................................... 4-22�

4.3.2 AIR INLET SYSTEM RESTRICTION ......................................................................... 4-22�

PETROLEUM ENGINE FLAMETRAP .................................................................. 4-23�

4.3.3 INLET LOCATION ....................................................................................................... 4-23�

4.3.4 AIR-TO-AIR CHARGE AIR COOLER ........................................................................ 4-24�

RESTRICTION AND TEMPERATURE REQUIREMENTS ................................... 4-25�

PETROLEUM ENGINE COMPRESSOR OUTLET TEMPERATURE

CONSIDERATIONS ............................................................................................. 4-26� CLEANLINESS ..................................................................................................... 4-26� LEAKAGE ............................................................................................................. 4-26� SIZE ...................................................................................................................... 4-27� COOLING AIR FLOW RESTRICTION ................................................................. 4-27� MATERIAL ............................................................................................................ 4-27� HEADER TANKS .................................................................................................. 4-27� LOCATION ............................................................................................................ 4-27� FAN SYSTEMS ..................................................................................................... 4-27� SHUTTERS .......................................................................................................... 4-28� WINTERFRONTS ................................................................................................. 4-28�

4.3.5 MARINE ENGINE ROOM VENTILATION ................................................................... 4-28�

4.4 TESTING REQUIREMENTS ........................................................................................... 4-29�

4.4.1 TESTING LOCATION ................................................................................................. 4-30�

4.4.2 INLET SYSTEM RESTRICTION ................................................................................ 4-30�

4.4.3 MAXIMUM TEMPERATURE RISE -– AMBIENT TO TURBOCHARGER INLET ....... 4-31�

4.4.4 AIR-TO-AIR SYSTEM EVALUATION TESTS ............................................................. 4-31�

MAXIMUM TEMPERATURE RISE--AMBIENT TO INTAKE MANIFOLD .............. 4-31�

CHARGE AIR COOLER SYSTEM RESTRICTION .............................................. 4-32�

4.5 TEST ............................................................................................................................... 4-32�

4.5.1 MOBILE AIR-TO-AIR .................................................................................................. 4-33�

4.5.2 MARINE ...................................................................................................................... 4-34�

5 EXHAUST SYSTEM ........................................................................................................... 5- 1�

5.1 EXHAUST SYSTEM DESCRIPTION .............................................................................. 5- 1�

5.1.1 TURBOCHARGER ..................................................................................................... 5- 4�

5.2 INSTALLATION REQUIREMENTS ................................................................................. 5- 8�

5.2.1 BACK PRESSURE ..................................................................................................... 5- 8�

5.2.2 NOISE ......................................................................................................................... 5- 9�

5.2.3 FLEXIBLE FITTINGS .................................................................................................. 5- 9�

5.2.4 MATERIAL SPECIFICATIONS FOR PIPEWORK ....................................................... 5-10�

5.2.5 EXHAUST ELBOWS AND STRAIGHT CONNECTIONS ........................................... 5-10�

5.2.6 SPARK ARRESTERS ................................................................................................. 5-11�

5.2.7 MANIFOLDING OF ENGINES INTO A COMMON EXHAUST SYSTEM ................... 5-11�

5.3 DESIGN REQUIREMENTS ........................................................................................... 5-12�

5.3.1 OUTLET LOCATION ................................................................................................... 5-12� iv All information subject to change without notice. (Rev. 10/04)

5.3.2 DRAINAGE ................................................................................................................. 5-12�

5.3.3 MUFFLER LOCATION ................................................................................................ 5-13�

5.3.4 SYSTEM INSULATION ............................................................................................... 5-13�

5.3.5 MARINE WET EXHAUST SYSTEMS ......................................................................... 5-13�

RISERS ................................................................................................................ 5-14� OVERBOARD RAW WATER DISCHARGE VALVE .............................................. 5-16� COMPONENT SUPPORT .................................................................................... 5-16�

5.3.6 MARINE DRY EXHAUST SYSTEMS ......................................................................... 5-18� PIPING .................................................................................................................. 5-18� INSULATION ......................................................................................................... 5-19� LARGE EXHAUST SYSTEM COMPONENTS ..................................................... 5-19� EXHAUST DISCHARGE PIPE ............................................................................. 5-20�

5.4 TESTING REQUIREMENTS ........................................................................................... 5-21�

5.4.1 MEASUREMENT OF EXHAUST BACK PRESSURE ................................................ 5-21�

5.4.2 MEASUREMENT OF MARINE EXHAUST BACK PRESSURE .................................. 5-24�

6 COOLING SYSTEM — AIR-TO-AIR CHARGE COOLING ................................................ 6- 1�

6.1 JACKET WATER COOLING SYSTEM ............................................................................ 6- 2�

6.2 THERMOSTAT ................................................................................................................ 6- 6�

6.2.1 VENTING ................................................................................................................... 6- 9� PETROLEUM ENGINES ...................................................................................... 6- 9�

6.3 WATER PUMP ............................................................................................................... 6-10�

6.3.1 SERIES 60 PETROLEUM ENGINE WATER PUMP ................................................... 6-11�

6.4 TYPES OF COOLING SYSTEMS ................................................................................... 6-11�

6.4.1 RAPID WARM-UP COOLING SYSTEM RECOMMENDED DESIGN ........................ 6-11�

6.4.2 CONVENTIONAL COOLING SYSTEM ...................................................................... 6-13�

6.4.3 AUXILIARY AIR-COOLED COOLER CORES ............................................................ 6-14�

6.4.4 COOLANT HEATERS ................................................................................................. 6-14�

6.5 AIR-TO-WATER CHARGE COOLING ............................................................................. 6-14�

6.6 AIR-TO-AIR CHARGE COOLING ................................................................................... 6-15�

6.6.1 CHARGE AIR COOLER ............................................................................................. 6-16�

6.7 COOLING SYSTEM PERFORMANCE REQUIREMENTS ............................................. 6-18�

6.7.1 SYSTEM FILL ............................................................................................................. 6-19�

6.7.2 SYSTEM DRAIN ......................................................................................................... 6-19�

6.7.3 DEAERATION ............................................................................................................. 6-19�

6.7.4 SYSTEM COOLANT CAPACITY ................................................................................ 6-20�

6.7.5 DRAWDOWN CAPACITY ........................................................................................... 6-21�

6.7.6 CORE CONSTRUCTION ............................................................................................ 6-21�

6.7.7 WATER PUMP INLET PRESSURE/MAXIMUM STATIC HEAD .................................. 6-21�

6.7.8 COOLANT FLOW RATE/EXTERNAL PRESSURE DROP ......................................... 6-21�

6.7.9 MINIMUM COOLANT TEMPERATURE ..................................................................... 6-22�

6.7.10 SYSTEM PRESSURIZATION ..................................................................................... 6-22�

6.7.11 COOLANTS ................................................................................................................ 6-22�

6.8 CHARGE AIR COOLING REQUIREMENTS .................................................................. 6-22�

6.8.1 COOLING CAPABILITY .............................................................................................. 6-22�

6.8.2 MAXIMUM PRESSURE LOSS ................................................................................... 6-22�

6.8.3 CLEANLINESS ........................................................................................................... 6-23�

All information subject to change without notice. (Rev. 10/04) v

6.8.4 LEAKAGE ................................................................................................................... 6-23�

6.9 END PRODUCT QUESTIONNAIRE ............................................................................... 6-23�

6.10 COOLING SYSTEM DESIGN CONSIDERATIONS ........................................................ 6-23�

6.10.1 COOLING SYSTEM REQUIREMENTS ..................................................................... 6-23� ENGINE OPERATING TEMPERATURE .............................................................. 6-23� INTAKE MANIFOLD TEMPERATURE .................................................................. 6-24�

6.10.2 ENGINE PERFORMANCE ......................................................................................... 6-24� ENGINE HEAT REJECTION ................................................................................ 6-24� COOLANT FLOW ................................................................................................. 6-24� HEAT TRANSFER CAPABILITIES ....................................................................... 6-24�

6.10.3 ENVIRONMENTAL AND OPERATING CONDITIONS ............................................... 6-25� AMBIENT TEMPERATURE .................................................................................. 6-25� ALTITUDE ............................................................................................................. 6-26� SPACE CONSTRAINTS ....................................................................................... 6-26� NOISE LIMITS ...................................................................................................... 6-26� TILT OPERATIONS OR INSTALLATIONS ............................................................ 6-26�

6.10.4 SYSTEM COMPONENTS .......................................................................................... 6-26� ADDITIONAL HEAT LOADS TO COOLANT ......................................................... 6-26� ADDITIONAL HEAT LOADS TO AIR .................................................................... 6-27� COOLANT TYPE .................................................................................................. 6-27� PLUMBING .......................................................................................................... 6-27� AUXILIARY COOLANT FLOW PATH CIRCUITRY ............................................... 6-29� WATER COOLED EXHAUST SYSTEMS ............................................................. 6-30� WATER PUMPS .................................................................................................... 6-30�

6.11 CHARGE AIR COOLING DESIGN GUIDELINES ........................................................... 6-31�

6.11.1 SIZE ............................................................................................................................ 6-32�

6.11.2 COOLING AIR FLOW RESTRICTION ........................................................................ 6-32�

6.11.3 MATERIAL .................................................................................................................. 6-32�

6.11.4 HEADER TANKS ........................................................................................................ 6-32�

6.11.5 LOCATION .................................................................................................................. 6-32�

6.11.6 PIPEWORK ................................................................................................................ 6-32�

6.12 HEAT EXCHANGER SELECTION .................................................................................. 6-33�

6.12.1 SHELL AND TUBE HEAT EXCHANGERS ................................................................. 6-34�

6.13 FAN SYSTEM RECOMMENDATIONS AND FAN SELECTION ...................................... 6-35�

6.13.1 BLOWER VS. SUCTION FANS .................................................................................. 6-36�

FAN PERFORMANCE .......................................................................................... 6-37� FAN BELTS ........................................................................................................... 6-40� FAN POSITION ..................................................................................................... 6-40� FAN SHROUDS .................................................................................................... 6-42� FAN SYSTEM ASSEMBLIES ............................................................................... 6-42� FAN DRIVES ........................................................................................................ 6-43� BAFFLES TO PREVENT AIR RECIRCULATION ................................................ 6-43� SHUTTERS .......................................................................................................... 6-44� WINTERFRONTS ................................................................................................. 6-44�

6.14 RADIATOR COMPONENT DESIGN ............................................................................... 6-45�

6.14.1 DOWN FLOW AND CROSS FLOW RADIATORS ...................................................... 6-45�

HORIZONTAL RADIATOR .................................................................................... 6-45� vi All information subject to change without notice. (Rev. 10/04)

RAPID WARM-UP DEAERATION TANK - DOWN FLOW RADIATOR ................. 6-46�

REMOTE MOUNTED RADIATORS/HEAT EXCHANGER .................................... 6-46� INTEGRAL TOP TANK ......................................................................................... 6-47� REMOTE TANK .................................................................................................... 6-50� RADIATOR BOTTOM TANK ................................................................................. 6-51�

COOLANT PRESSURE CONTROL CAPS AND RELIEF VALVES ...................... 6-53�

THERMOSTAT ...................................................................................................... 6-55� COOLANT SENSOR DEVICES ........................................................................... 6-56� COOLANT RECOVERY SYSTEM ........................................................................ 6-58�

6.14.2 COLD WEATHER OPERATING OPTIMIZATION ....................................................... 6-63� ENGINE ................................................................................................................ 6-63� VEHICLE .............................................................................................................. 6-63� COOLING SYSTEM ............................................................................................. 6-63� HEATER CIRCUIT ................................................................................................ 6-64�

6.14.3 COOLANT HEATERS ................................................................................................. 6-64�

6.14.4 MULTI-DUTY CYCLE ................................................................................................. 6-64�

6.14.5 OTHER CONSIDERATIONS ...................................................................................... 6-64�

6.15 COOLING SYSTEM EVALUATION TESTS .................................................................... 6-65�

6.15.1 SYSTEM DESCRIPTION ........................................................................................... 6-65�

6.15.2 INSTRUMENTATION .................................................................................................. 6-65�

THERMOCOUPLES AND ASSOCIATED HARDWARE ....................................... 6-66� PRESSURE GAUGES AND ASSOCIATED HARDWARE .................................... 6-66� THERMOSTATS ................................................................................................... 6-67� SIGHT GLASS AND TRANSPARENT TUBING ................................................... 6-67� GRADUATED CONTAINER .................................................................................. 6-68� PRESSURE CAP .................................................................................................. 6-68� STOP WATCH ...................................................................................................... 6-68� LIGHT .................................................................................................................. 6-68� WATER SUPPLY AND HOSE .............................................................................. 6-69� ENGINE LOADING METHOD .............................................................................. 6-69� TAPE MEASURE .................................................................................................. 6-69� FLOWMETERS AND ASSOCIATED HARDWARE .............................................. 6-69�

6.15.3 TEST PREPARATIONS .............................................................................................. 6-70�

6.15.4 TYPES OF TESTS ..................................................................................................... 6-71�

CONTINUOUS FILL ............................................................................................. 6-71� INTERRUPTED FILL ............................................................................................ 6-72� BUCKET FILL ....................................................................................................... 6-72� TOTAL SYSTEM CAPACITY ................................................................................. 6-72� DRAINING CAPABILITY ....................................................................................... 6-73� WATER PUMP BINDING TEST ............................................................................ 6-73� DEAERATION TEST ............................................................................................. 6-73� DRAWDOWN TEST ............................................................................................. 6-74� WATER FLOW AND PRESSURE TEST .............................................................. 6-76� COOLING INDEX TEST ....................................................................................... 6-77�

6.15.5 CHARGE AIR COOLING EVALUATION TEST ........................................................... 6-80�

6.15.6 SYSTEM DESCRIPTION ........................................................................................... 6-80�

6.15.7 INSTRUMENTATION .................................................................................................. 6-81�

All information subject to change without notice. (Rev. 10/04) vii

TEMPERATURE MEASUREMENT ...................................................................... 6-81� PRESSURE MEASUREMENT ............................................................................. 6-81�

6.15.8 LOCATION .................................................................................................................. 6-84�

6.15.9 INLET SYSTEM RESTRICTION ................................................................................ 6-84�

MAXIMUM TEMPERATURE RISE--AMBIENT TO TURBOCHARGER INLET .... 6-84�

AIR-TO-AIR SYSTEM EVALUATION TESTS ....................................................... 6-85�

MAXIMUM TEMPERATURE RISE--AMBIENT TO INTAKE MANIFOLD .............. 6-85�

CHARGE AIR COOLER SYSTEM RESTRICTION .............................................. 6-85�

6.15.10 TEST ........................................................................................................................... 6-86�

6.15.11 TEST ANALYSIS ........................................................................................................ 6-86�

6.16 COOLING SYSTEM DIAGNOSTICS AND TROUBLESHOOTING GUIDE .................... 6-88�

6.16.1 ENGINE OVERHEAT .................................................................................................. 6-88�

TROUBLESHOOTING FOR ENGINE OVERHEAT .............................................. 6-88�

6.16.2 COLD RUNNING ENGINE (OVERCOOLING) ........................................................... 6-90�

6.16.3 POOR CAB HEATER PERFORMANCE ..................................................................... 6-90�

THERMOSTAT LEAKAGE TEST .......................................................................... 6-92� CAC AIR LEAKAGE TEST ................................................................................... 6-93�

6.17 MAINTENANCE .............................................................................................................. 6-94�

7 COOLING SYSTEM — HEAT EXCHANGER-COOLED AND KEEL-COOLED ............... 7- 1�

7.1 HEAT EXCHANGER-COOLED SYSTEM ....................................................................... 7- 1�

7.1.1 THERMOSTATS ......................................................................................................... 7- 4�

7.1.2 HEAT EXCHANGE-COOLED INSTALLATION REQUIREMENTS ............................. 7- 4�

7.1.3 VERIFICATION TESTING .......................................................................................... 7- 5�

7.2 KEEL-COOLED SEPARATE CIRCUIT CHARGE COOLING .......................................... 7- 6�

7.2.1 EXPANSION TANK ..................................................................................................... 7- 8�

7.2.2 THERMOSTATS ......................................................................................................... 7- 8�

7.2.3 VENTING .................................................................................................................... 7- 9�

7.2.4 FILL LINES ................................................................................................................. 7- 9�

7.2.5 COOLANT HEATERS ................................................................................................. 7- 9�

7.3 KEEL-COOLED SYSTEM PERFORMANCE REQUIREMENTS .................................... 7-10�

7.3.1 SYSTEM FILL ............................................................................................................. 7-10�

7.3.2 SYSTEM DRAIN ......................................................................................................... 7-10�

7.3.3 DEAERATION ............................................................................................................. 7-10�

7.3.4 SYSTEM COOLANT CAPACITY ................................................................................ 7-11�

7.3.5 DRAWDOWN CAPACITY ........................................................................................... 7-12�

7.3.6 WATER PUMP INLET PRESSURE/MAXIMUM STATIC HEAD .................................. 7-12�

7.3.7 EXTERNAL PRESSURE DROP ................................................................................. 7-12�

7.3.8 MINIMUM COOLANT TEMPERATURE ..................................................................... 7-12�

7.3.9 SYSTEM PRESSURIZATION ..................................................................................... 7-13�

7.3.10 COOLANTS ................................................................................................................ 7-13�

7.4 KEEL-COOLED SYSTEM DESIGN ................................................................................ 7-14�

7.4.1 ENGINE RATING ........................................................................................................ 7-17�

7.4.2 ADDITIONAL HEAT LOADS ....................................................................................... 7-17�

7.4.3 FLUID TEMPERATURES ........................................................................................... 7-18�

7.4.4 COOLANT TYPE ........................................................................................................ 7-18�

7.4.5 MINIMUM HULL SPEED AT FULL POWER ............................................................... 7-18� viii All information subject to change without notice. (Rev. 10/04)

7.4.6 TYPE OF KEEL COOLER .......................................................................................... 7-18� ENGINEERED GRID COOLERS ......................................................................... 7-18� BOX COOLER ...................................................................................................... 7-19� CHANNEL COOLERS .......................................................................................... 7-20�

7.4.7 KEEL COOLER SIZE ................................................................................................. 7-20�

7.4.8 KEEL COOLER PLACEMENT ................................................................................... 7-21�

7.4.9 EXTERNAL SYSTEM RESTRICTION ........................................................................ 7-24�

7.4.10 TOTAL COOLANT VOLUME ...................................................................................... 7-24�

7.4.11 REQUIRED EXPANSION VOLUME ........................................................................... 7-24�

7.5 KEEL-COOLER COOLING SYSTEM COMPONENT DESIGN GUIDELINES ............... 7-25�

7.5.1 ENGINE COOLING SYSTEM SELECTION FACTORS .............................................. 7-25�

KEEL COOLER STYLE ........................................................................................ 7-25� EXPANSION TANK DESIGN ................................................................................ 7-25� GEAR COOLERS ................................................................................................. 7-26� THERMOSTATS ................................................................................................... 7-26� SYSTEM VENTING .............................................................................................. 7-27� WATER PUMPS .................................................................................................... 7-27� PLUMBING ........................................................................................................... 7-27�

7.6 KEEL-COOLER COOLING SYSTEM VERIFICATION TESTS ....................................... 7-29�

7.6.1 SYSTEM DESCRIPTION ........................................................................................... 7-29�

7.6.2 INSTRUMENTATION .................................................................................................. 7-30�

THERMOCOUPLES AND ASSOCIATED HARDWARE ....................................... 7-30� PRESSURE GAGES AND ASSOCIATED HARDWARE ...................................... 7-31� THERMOSTATS ................................................................................................... 7-32� SIGHT GLASS AND TRANSPARENT TUBING ................................................... 7-32� GRADUATED CONTAINER .................................................................................. 7-33� PRESSURE CAP .................................................................................................. 7-33� STOP WATCH ...................................................................................................... 7-33� LIGHT ................................................................................................................... 7-33� TAPE MEASURE .................................................................................................. 7-33�

7.6.3 TEST PREPARATIONS .............................................................................................. 7-34�

7.6.4 TYPES OF TESTS ..................................................................................................... 7-34�

FILL, SYSTEM CAPACITY AND WATER PUMP BINDING TEST ........................ 7-35�

DEAERATION TEST ............................................................................................. 7-36� EXTERNAL RESTRICTION TEST ....................................................................... 7-36� COOLING INDEX TEST ....................................................................................... 7-37�

8 FUEL SYSTEM ................................................................................................................... 8- 1�

8.1 FUEL SYSTEM DESCRIPTION ...................................................................................... 8- 1�

8.2 FUEL SYSTEM EQUIPMENT/INSTALLATION GUIDELINES ........................................ 8- 4�

8.2.1 FUEL TANK ................................................................................................................ 8- 4� MATERIAL ............................................................................................................ 8- 4� DESIGN ................................................................................................................ 8- 4� CAPACITY ............................................................................................................ 8- 5� POSITION ............................................................................................................. 8- 5�

8.2.2 PRIMARY FUEL/WATER SEPARATOR — MARINE .................................................. 8- 6�

8.2.3 FUEL FILTER CONFIGURATION ............................................................................... 8- 6�

All information subject to change without notice. (Rev. 10/04) ix

8.2.4 FUEL LINES ............................................................................................................... 8- 7� DESIGN ................................................................................................................ 8- 7� MATERIAL ............................................................................................................ 8- 7� SIZE ...................................................................................................................... 8- 8�

8.3 FUEL SELECTION .......................................................................................................... 8- 8�

9 LUBRICATION SYSTEM ................................................................................................... 9- 1�

9.1 LUBRICATION SYSTEM DESCRIPTION ....................................................................... 9- 1�

9.2 LUBRICATION OIL SELECTION .................................................................................... 9- 4�

9.3 LUBRICATION FILTER ................................................................................................... 9- 4�

9.3.1 REMOTE-MOUNTED FILTERS .................................................................................. 9- 5�

9.4 ENGINE COMPONENT OIL SUPPLY REQUIREMENTS ............................................... 9- 5�

9.4.1 TURBOCHARGER LUBRICATION ............................................................................ 9- 5�

9.4.2 AIR COMPRESSOR LUBRICATION .......................................................................... 9- 5�

9.5 INSTALLATION REQUIREMENTS ................................................................................. 9- 5�

9.5.1 SUPPLEMENTAL FILTRATION SYSTEMS ................................................................ 9- 6�

REMOTE MOUNT SUPPLEMENTAL OIL FILTER REQUIREMENTS ................. 9- 6�

REMOTE MOUNT SUPPLEMENTAL OIL FILTER CONNECTIONS .................... 9- 7�

9.5.2 OIL SAMPLING VALVE ............................................................................................. 9- 9�

9.5.3 MECHANICAL OIL PRESSURE GAUGES ................................................................ 9- 9�

9.6 COMPONENT OPTIONS ................................................................................................ 9- 9�

9.6.1 OIL CHECKS AND FILLS ........................................................................................... 9- 9�

9.6.2 BREATHERS .............................................................................................................. 9- 9�

9.6.3 OIL SUMPS ................................................................................................................ 9-10�

INSTALLATION REQUIREMENTS FOR OIL SUMPS .......................................... 9-10�

9.6.4 ENVIRONMENTALLY SAFE OIL CHANGE (ESOC) FITTINGS ................................. 9-10�

9.6.5 OIL IMMERSION HEATERS ....................................................................................... 9-10�

9.6.6 OIL LEVEL SENSORS ............................................................................................... 9-11�

9.7 OPERATION AND MAINTENANCE ................................................................................ 9-11�

9.7.1 FIRST TIME START .................................................................................................... 9-11�

9.7.2 OIL LEVEL MEASUREMENTS .................................................................................. 9-11�

9.7.3 USED OIL ANALYSIS ................................................................................................. 9-11�

9.7.4 OIL DRAIN INTERVALS ............................................................................................. 9-11�

10 ELECTRICAL SYSTEM ...................................................................................................... 10- 1�

10.1 ELECTRICAL SYSTEM DESCRIPTION ......................................................................... 10- 1�

10.2 INSTALLATION GUIDELINES ......................................................................................... 10- 3�

10.2.1 BATTERY .................................................................................................................... 10- 3� FILLER CAP BATTERIES ..................................................................................... 10- 3� SEMI-MAINTENANCE FREE BATTERIES .......................................................... 10- 3� MAINTENANCE-FREE BATTERIES .................................................................... 10- 3� DEEP CYCLE BATTERIES .................................................................................. 10- 3� GEL-CELL AND NICKEL CADMIUM BATTERIES ............................................... 10- 4� BATTERY CAPACITY ........................................................................................... 10- 4� BATTERY MOUNTING AND LOCATION .............................................................. 10- 4�

10.2.2 CRANKING MOTOR ................................................................................................... 10- 7�

10.2.3 ALTERNATORS .......................................................................................................... 10-11�

CONSTRUCTION AND INDUSTRIAL ALTERNATORS ....................................... 10-11� x All information subject to change without notice. (Rev. 10/04)

MARINE ALTERNATORS ..................................................................................... 10-13� BATTERY ISOLATORS ......................................................................................... 10-16� ALTERNATOR MOUNTING .................................................................................. 10-17�

10.2.4 GROUNDING REQUIREMENTS ................................................................................ 10-18�

10.2.5 WIRING ...................................................................................................................... 10-18�

GUIDELINES FOR ELECTRICAL WIRING .......................................................... 10-18� CABLE LOSS TEST PROCEDURE ..................................................................... 10-19� MEASURING CIRCUIT RESISTANCE ................................................................. 10-20� CALCULATING CIRCUIT RESISTANCE .............................................................. 10-21�

11 MOUNTING SYSTEM ......................................................................................................... 11- 1�

11.1 MOUNTING SYSTEM DESCRIPTION ........................................................................... 11- 1�

11.1.1 THREE-POINT MOUNTING ....................................................................................... 11- 2�

11.1.2 FOUR-POINT MOUNTING — MARINE ONLY ........................................................... 11- 4�

11.1.3 FIVE-POINT AND SIX-POINT MOUNTS – CONSTRUCTION AND INDUSTRIAL

ENGINES .................................................................................................................... 11- 5� SIX POINT MOUNTING FOR MARINE ENGINES ............................................... 11- 7�

11.1.4 INSTALLATION OF MARINE RESILIENT MOUNTS .................................................. 11- 8�

11.2 SOLID MOUNTING SYSTEMS ....................................................................................... 11-10�

11.3 FLEXIBLE MOUNTING SYSTEMS ................................................................................. 11-11�

11.3.1 FLEXIBLE MOUNT SELECTION ............................................................................... 11-11� METHOD A ........................................................................................................... 11-12� METHOD B ........................................................................................................... 11-13�

11.4 INSTALLATION CHECK LIST ......................................................................................... 11-14�

11.5 ENGINE SUPPORT ........................................................................................................ 11-15�

12 TORSIONAL ANALYSIS .................................................................................................... 12- 1�

12.1 MASS ELASTIC DATA .................................................................................................... 12- 1�

13 ENGINE ELECTRONIC CONTROLS ................................................................................. 13- 1�

13.1 ORIGINAL EQUIPMENT MANUFACTURER REQUIREMENTS – CONSTRUCTION

AND INDUSTRIAL .......................................................................................................... 13- 2�

13.2 ORIGINAL EQUIPMENT MANUFACTURER REQUIREMENTS – PETROLEUM

ENGINE .......................................................................................................................... 13- 2�

13.3 ORIGINAL EQUIPMENT MANUFACTURER REQUIREMENTS – MARINE .................. 13- 2�

13.4 ELECTRONIC CONTROL MODULE .............................................................................. 13- 3�

13.5 ELECTRONIC UNIT INJECTOR ..................................................................................... 13- 4�

13.6 CONSTRUCTION AND INDUSTRIAL HARNESSES ..................................................... 13- 5�

13.6.1 POWER HARNESS .................................................................................................... 13- 5�

13.6.2 INJECTOR HARNESSES ........................................................................................... 13- 5�

13.6.3 VEHICLE INTERFACE HARNESS ............................................................................. 13- 5�

13.6.4 ENGINE SENSOR HARNESS ................................................................................... 13- 7�

13.6.5 COMMUNICATION HARNESS ................................................................................... 13- 9�

13.7 MARINE HARNESSES ................................................................................................... 13-10�

13.7.1 INTERFACE AND POWER HARNESSES .................................................................. 13-11�

13.7.2 COMMUNICATION HARNESS ................................................................................... 13-11�

13.8 SYSTEM SENSORS ....................................................................................................... 13-12�

13.9 WELDING .............................................................