W911RQ18Q0016__NMWRs.pdf

NMWR 9-2355-355 0049

SUSTAINMENT MAINTENANCE

DT 570 ENGINE ASSEMBLY TESTING

INITIAL SETUP:

Tools and Special Tools General Mechanic’s Tool Kit (GMTK) (WP 0298, Item 16) Wrench, torque, 3/8-inch drive (10-100 lb-ft) (WP 0298, Item 42)

Materials/Parts Gloves, nitrile, large (WP 0297, Item 10)

Lubricating oil, engine crankcase (WP 0297, Item 14) Lubricating oil, preservation (WP 0297, Item 15) Rag, wiping (WP 0297, Item 18)

References

AR 750-1

WP 0050

TEST AND INSPECTION

Equipment

Provide a dynamometer with the following requirements:

• Sufficient capacity to permit testing of 375 horsepower and 1250 lb-ft (1695 N•m) of torque @ 2000 rpm

• System to approximate vehicle engine cooling capability

• System to approximate vehicle Charge Air Cooler (CAC) and intake air filtration system

• System to approximate vehicle exhaust system

• System to approximate vehicle fuel system regulated to 110°F (47°C) or below

• System to approximate vehicle engine electrical system

• Interface for manufacturer’s software or equivalent

• Engine oil level tube and gauge, or equivalent

• Instrumentation to provide readings of the following:

• Revolutions per minute (rpm)

• Torque output

• Horsepower output

• Oil pressure

• Coolant temperature

• Oil temperature

• Fuel pressure

• Injector control pressure

• Battery voltage

0049–1

DT 570 ENGINE ASSEMBLY TESTING - (CONTINUED)

Preparing Engine for Testing

WARNING

Engine fluids (oil, fuel, and coolant) may be hazardous to human health and the environment.

Wear solvent-resistant gloves and handle all fluids and other contaminated materials (such as filters and rags) in accordance with standard operating procedures. Clean up all fluid spills.

Recycle or dispose of engine fluids, filters, and other contaminated materials in accordance with standard operating procedures. Failure to comply may result in environmental damage and injury to personnel.

Fuel is flammable and can explode. Keep all open flames, flammable materials, ignition sources, and sparks away from diesel fuel and keep fire extinguisher nearby. Do not smoke when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited by hot engine. Failure to comply may result in serious injury or death to personnel.

1. Install engine on dynamometer per manufacturer’s instructions.

2. Connect dynamometer engine cooling system to engine per manufacturer’s instructions.

3. Connect dynamometer fuel system to engine per manufacturer’s instructions.

4. Connect dynamometer exhaust to engine turbocharger per manufacturer’s instructions.

5. Connect dynamometer air intake to engine turbocharger per manufacturer’s instructions.

6. Connect dynamometer CAC to engine turbocharger and intake manifold per manufacturer’s instructions.

7. Connect dynamometer electrical connections to engine per manufacturer’s instructions.

8. Install engine oil level tube and gauge, or equivalent on engine.

9. Fill engine with 25 quarts (23.7 liters) of lubricating oil.

10. Remove oil filter from oil cooler module.

11. Fill oil filter with approximately 3 quarts (2.8 liters) of lubricating oil.

12. Using clean lubricating oil, lubricate oil filter seal.

13. Install oil filter on oil cooler module until oil filter seal contacts oil cooler module. Tighten oil filter ¾ turn.

14. Remove dust cap from bleed valve on intake manifold.

15. Place rag under bleed valve to collect excess fuel.

16. Press center stem on bleed valve inward and hold.

17. Operate priming pump until fuel discharges from bleed valve. Release center stem on bleed valve.

18. Install dust cap on bleed valve and remove rag.

0049–2

Engine Run-In Test

CAUTION

Do not crank engine for longer than 30 seconds. If engine does not start within 30 seconds, wait 2 minutes to allow starter motor to cool. Failure to comply may result in damage to starter motor.

Stop test immediately if engine oil pressure does not maintain 15-80 psi (103-552 kPa) shortly after initial engine start up. Failure to comply may result in damage to engine.

Stop test immediately if engine coolant temperature rises above 230°F (110°C). Failure to comply may result in damage to engine.

Stop test immediately if engine oil temperature rises above 250°F (121°C). Failure to comply may result in damage to engine.

NOTE

Battery voltage must stay at 9 volts or above while cranking for engine to start properly.

Perform the following tests and inspections and record results in appropriate line of Engine Run-In Test table in DT 570 Engine Assembly Test Report (WP 0050).

If any item is found to be out of specification, record appropriate information in Deficiencies table in DT 570 Engine Assembly Test Report (WP 0050), remove engine from test cell, repair engine as needed, and retest engine.

1. Using manufacturer’s software, clear all engine Diagnostic Trouble Codes (DTCs).

2. Using dynamometer, start and run engine at idle and perform the following:

• Check engine oil pressure

• Check engine fuel pressure

• Check injector control pressure

• Check engine rpm

• Inspect engine for any abnormal noise or vibration.

• Inspect engine for leaks.

• Using manufacturer’s software, inspect for any engine DTCs.

3. Using dynamometer, run engine at idle for five minutes and perform the following:

• Check engine rpm

• Check engine oil pressure

• Check engine coolant temperature

• Check engine oil temperature

• Inspect engine for any abnormal noise or vibration.

• Inspect engine for leaks.

• Using manufacturer’s software, inspect for any engine DTCs.

0049–3

4. Using dynamometer, run engine at 1200-1400 rpm for five minutes and perform the following:

• Check engine rpm

• Check engine oil pressure

• Check engine coolant temperature

• Check engine oil temperature

• Inspect engine for any abnormal noise or vibration.

5. Using dynamometer and manufacturer’s software, run engine at idle for two minutes and inspect for any engine DTCs.

6. Using dynamometer, shut engine off and inspect engine for leaks.

Engine Performance Test

CAUTION

Do not crank engine for longer than 30 seconds. If engine does not start within 30 seconds, wait 2 minutes to allow starter motor to cool. Failure to comply may result in damage to starter motor.

Stop test immediately if engine oil pressure does not maintain 15-80 psi (103-552 kPa) shortly after initial engine start up. Failure to comply may result in damage to engine.

Stop test immediately if engine coolant temperature rises above 230°F (110°C). Failure to comply may result in damage to engine.

Stop test immediately if engine oil temperature rises above 250°F (121°C). Failure to comply may result in damage to engine.

NOTE

Battery voltage must stay at 9 volts or above while cranking for engine to start properly.

Perform the following tests and inspections and record results in appropriate line of Engine Performance Test table in DT 570 Engine Assembly Test Report (WP 0050).

If any item is found to be out of specification, record appropriate information in Deficiencies table in DT 570 Engine Assembly Test Report (WP 0050), remove engine from test cell, repair engine as needed, and retest engine.

1. Using dynamometer, start and run engine at idle for two minutes and perform the following:

• Check engine oil pressure

• Check engine fuel pressure

• Check injector control pressure

• Check engine rpm

• Inspect engine for any abnormal noise or vibration.

2. Using dynamometer, run engine at 1200-1400 rpm until engine coolant temperature reaches 190-212°F

(88-100°C) and perform the following:

• Check engine rpm

• Check engine oil pressure

• Check engine coolant temperature

• Check engine oil temperature

• Inspect engine for any abnormal noise or vibration.

0049–4

3. Using dynamometer, run engine at 2000-2100 rpm for one minute and perform the following:

• Check engine rpm

• Check engine oil pressure

• Check engine coolant temperature

• Check engine oil temperature

• Inspect engine for any abnormal noise or vibration.

• Inspect engine for leaks.

• Using manufacturer’s software, inspect for any engine DTCs.

4. Using dynamometer, maintain 2000-2100 rpm and slowly apply load until maximum engine torque is achieved.

Once engine readings stabilize, perform the following:

• Check engine rpm

• Check engine oil pressure

• Check engine coolant temperature

• Check engine oil temperature

• Check engine torque

• Check engine horse power

• Inspect engine for any abnormal noise or vibration.

5. Using dynamometer, maintain 2000-2100 rpm and slowly decrease load to zero. Once engine readings stabilize, run engine for two minutes and perform the following:

• Check engine rpm

• Check engine oil pressure

• Check engine coolant temperature

• Check engine oil temperature

• Inspect engine for any abnormal noise or vibration.

6. Using dynamometer, run engine at 1200-1400 rpm for two minutes and perform the following:

• Check engine rpm

• Check engine oil pressure

• Check engine coolant temperature

• Check engine oil temperature

• Inspect engine for any abnormal noise or vibration.

0049–5

7. Using dynamometer, run engine at idle for four minutes and perform the following:

• Check engine rpm

• Check engine oil pressure

• Check engine coolant temperature

• Check engine oil temperature

• Inspect engine for any abnormal noise or vibration.

• Using manufacturer’s software, inspect for any engine DTCs.

8. Using dynamometer, shut engine off and inspect engine for leaks.

Engine Preservation

WARNING

Engine fluids (oil, fuel, and coolant) may be hazardous to human health and the environment.

Wear solvent-resistant gloves and handle all fluids and other contaminated materials (such as filters and rags) in accordance with standard operating procedures. Clean up all fluid spills.

Recycle or dispose of engine fluids, filters, and other contaminated materials in accordance with standard operating procedures. Failure to comply may result in environmental damage and injury to personnel.

1. Collect oil sample as specified in AR 750-1.

2. Remove oil drain plug from oil pan and allow lubricating oil to drain into appropriate container.

3. Install oil drain plug in oil pan. Using torque wrench, torque oil drain plug to 50 lb-ft (68 N•m).

4. Fill engine with 24 quarts (22.7 liters) of preservative oil.

5. Using dynamometer, start and operate engine at 500-800 rpm until engine coolant temperature reaches

190°F (88°C).

6. Using dynamometer, stop engine and inspect engine for leaks.

7. Remove oil drain plug from oil pan and allow preservative oil to drain into appropriate container.

8. Install oil drain plug in oil pan. Using torque wrench, torque oil drain plug to 50 lb-ft (68 N•m).

0049–6

Post Test Procedures

WARNING

Engine fluids (oil, fuel, and coolant) may be hazardous to human health and the environment.

Wear solvent-resistant gloves and handle all fluids and other contaminated materials (such as filters and rags) in accordance with standard operating procedures. Clean up all fluid spills.

Recycle or dispose of engine fluids, filters, and other contaminated materials in accordance with standard operating procedures. Failure to comply may result in environmental damage and injury to personnel.

Fuel is flammable and can explode. Keep all open flames, flammable materials, ignition sources, and sparks away from diesel fuel and keep fire extinguisher nearby. Do not smoke when working with fuel. Do not work on fuel system when engine is hot. Fuel can be ignited by hot engine. Failure to comply may result in serious injury or death to personnel.

1. Remove engine oil level tube and gauge, or equivalent from engine.

2. Disconnect dynamometer electrical connections from engine.

3. Disconnect dynamometer air intake ducts from engine intake manifold.

4. Disconnect dynamometer intake and output turbocharger ducts from engine turbocharger.

5. Disconnect dynamometer exhaust pipe from engine exhaust manifold.

6. Disconnect dynamometer fuel system from engine.

7. Disconnect dynamometer engine cooling system from engine.

8. Remove engine from dynamometer per manufacturer’s instructions.

END OF TASK

END OF WORK PACKAGE

0049–7/blank

NMWR 9-2815-242 0020

NATIONAL MAINTENANCE WORK REQUIREMENT

FINAL ASSEMBLY TESTING

0020-1

GENERAL

This section contains instructions for final assembly testing of the complete VTA-903T-600 engine.

INSPECTION

Engine will be inspected for completeness, obvious damage, and tag that indicates engine has been overhauled and is ready for test.

LUBRICATION

Prior to testing, fill engine with oil, as specified in paragraph 26f below.

TESTING/PERFORMANCE CHECK

1. General.

a. The acceptance test of the VTA-903T-600 engine will be conducted according to the test requirements and acceptance criteria prescribed in this section.

b. In the event of conflicting instructions between this test procedure and other references, this procedure will take precedence.

c. Final acceptance test results shall be recorded as specified in Table 1.

EQUIPMENT

2. Dynamometer capable of 3,000 rpm minimum, 750 horsepower/1,500 lb-ft (1,79 mkg) torque absorption minimum.

3. Engine pre-lubing equipment capable of developing a minimum of 25 psi (172kPa).

4. Tachometer for reading engine rpm.

5. Gage to measure engine oil pressure at STC solenoid, 0 to 100 psi (0-690 kPa) range.

6. Temperature gage to measure lubricating oil temperature, within 4 ft. (1.22 mm) of coolant pump inlet, with range of 32˚ to 300˚F (0˚C to 49˚C).

7. Gage to measure coolant “in” temperature, within 4 ft. (1.22 mm) of coolant pump inlet, with range of 32˚ to 300˚F (149˚C).

8. Gage to measure coolant “out” (before thermostat) temperature located in thermostat housing of transmission oil cooler with range of 32˚F to 300˚F (149˚C).

9. Gage to measure coolant “out” (after thermostat) temperature located in thermostat housing of transmission oil cooler with range of 32˚F to 300˚F (149˚C).

10. Gage to measure fuel temperature mounted within 6 ft. (1.83mm) of fuel pump inlet with range of 32˚F to 300 (149˚C).

11. Gage to measure fuel manifold (rail) pressure mounted in rear or head/heads, range 0 to 300 psi (0 to 2,069 kPa).

12. Gage to measure air intake temperature mounted between air filter and turbocharger air inlet with range of 32˚F to 150˚F (66˚C).

13. Gage to measure air intake pressure mounted between the turbocharger air outlet and after-cooler inlet with range of 0 to 60 in-Hg (0 to 30psi).

14. Manometer, with minimum range of 16in. (406.4MM) water, to measure crankcase blow-by pressure.

0020-2

EQUIPMENT – CONTINUED

15. Blow-by checking tool 3822566.

16. Full-flow oil filter, remote mounted, with hoses and fittings to connect oil filter to engine oil cooler assembly.

17. Manometer, with minimum range of 40 in. (1,016mm) mercury, connected to intake manifold to measure intake manifold pressure.

18. External fan capable of controlling test cell ambient temperature.

19. Air filter mounted on air intake system, with minimum intake size of 5.5 in. (139.7 mm) inside diameter, with minimum rating of 1,150 standard cubic feet per minute (SCFM) (32.2 cm).

20. Fuel cooler installed in pump suction line from flow tank with cooling capacity sufficient to control temperature of supply fuel to engine pump at 110˚F (43˚C) or below.

21. Manometer, with minimum range of 30 in. (762 mm) water, connected to air inlet system to measure air cleaner restriction.

22. Engine coolant system, in test cell, with coolant tank and automatic, thermostatically controlled method (by adding fresh water, by heat exchanger, or by other means) to maintain maximum coolant temperature within specified limit on all specified operating and load conditions. Test cell engine coolant system will be capable of maintaining engine coolant temperature within specified limits when engine is run under full-load conditions for extended periods of time. Tank will have an adjustable pressure relief valve and will be set for a pressure 4 to 7 psi (27.6 to 48.3 kPa).

23. Source of 24 volt dc capable of supplying approximately 350 amps current to operate starter motor.

24. Source of clean DF2 fuel with test cell supply vacuum regulated 3 to 6 in-Hg (20.69 to 41.37 kPa).

25. Control mechanisms for operating accelerator lever and fuel shut-off valve on engine fuel pump.

26. INSTALLATION OF ENGINE ON TEST STAND.

a. Mount engine to dynamometer test stand.

b. If universal drive coupling is used, install engine so that centerline of engine crankshaft and centerline of dynamometer driveshaft are out of plane either horizontally or vertically 1/4 to 1/2 in. (635 to 12.7 mm). True alignment will cause universal bearing failure.

c. Radial run-out of shaft and adapter plates at engine and dynamometer ends of shaft should be as low as possible to prevent vibration. A reading of 0.012 to in. (0.305 mm) maximum is desired.

d. Make connections of test equipment outlined in paragraph b above.

e. Fill engine with water. As engine is being filled with water, open vent cocks to prevent trapping of air in cooling system. When a solid stream of water comes from vent cocks, close vent cocks.

f. Fill engine with oil per LO 9-2350-284-12. Pre-lube engine for a sufficient time for all bearings to be coated with clean oil (WP 0027, Item 13). Rotate engine a minimum of 10 revolutions at two intervals during pre-lubing process. Assure that turbocharger has oil supplied to turbocharger oil inlet.

g. Prime fuel system.

h. Connect flow tank fuel return line to fuel return fitting on rear of cylinder head.

i. Attach flow tank fuel supply line to fuel pump suction connection and prime fuel system.

j. When fuel system is primed, disconnect flow tank supply line from fuel pump suction connection and connect to flow tank. Connect fuel pump supply line from flow tank to fuel pump suction connection.

0020-3

OPERATIONAL PRECAUTIONS

1. During test of VTA903-T600 engine, the following precautions will be observed:

a. Engine shall not be run with less than 10 psi (68.9 kPa) oil pressure.

b. Engine oil pressure shall not exceed 90n psi (689.5 kPa) at any time.

c. Engine oil temperature shall not exceed 250˚F (121˚C) at any time.

d. Engine coolant temperature shall not exceed 205˚F (96.1˚C) at any time.

e. Engine shall not be operated when blow-by exceeds 8 in-H2O. ( 2 kPa).

f. Engine shall not be run under full power/load conditions when either the oil temperature, water-in temperature, or water-out temperature is below 160˚F (71˚C).

g. Engine shall not be shut down following heavy power/load runs without a minimum of a five-minute cool down no-load idle run.

h. Engine exhaust back-pressure shall not exceed 3 in-hg (10.15 kPa).

FINAL ACCEPTANCE TEST

1. Start engine and operate at idle for five minutes. Check for low oil pressure, high coolant temperature, leaks and unusual noises. No fuel leaks are allowed. Only Class I oil leaks are allowed as described below. If any of these conditions are observed, stop engine immediately and correct problem prior to restarting test.

a. Class I – Seepage or fluid (as indicated by wetness or discoloration) not great enough to form drops.

b. Class II – Leakage of fluid great enough to form drops but not enough to cause drops to drop from item being checked/inspected.

c. Class III – Leakage of fluid great enough to form drops that fall from the item being checked/inspected.

2. Stop engine after five minutes operation. Allow engine to stand for two minutes while checking for leaks and unusual conditions. Check oil and add as necessary.

CAUTION

Except in emergency, engine will not be stopped immediately after completion of power/torque runs. Sudden stop without cool down will cause damage to engine components. Cool down period is five minutes minimum after any power/torque run.

3. Start engine and test in accordance with Table 1. Record actual readings in block provided.

4. After completion of test, disconnect engine and remove from test stand.

OIL ANALYSIS

Prior to removal of engine from test stand, whether accepted or rejected, an oil sample will be taken as specified in

AR 750-22.

PRESERVATION, PACKAGING, AND MARKING

Refer to WP 0022.

0020-4

Table 1. Final Acceptance Test.

ENGINE RUN-IN

Run No.

Duration

(min) Load

(lb – ft) Rpm Actual Recording

1 A/R to Achieve 160˚F (71˚C) minimum inlet water temperature

260 1200

2 2 590 1600

3 5 750 2100

4 5 875 2400

5 8 1140 2600

6 5 Cool-Down 1000

NO-LOAD GOVERNOR CHECK

No. Check Test Minimum Maximum Actual Recording

1 No load rpm 2900 3073

POWER CHECK

Engine will not be power checked unless temperatures (oil and water out) are within operating range.

No. Check Test Minimum Maximum Actual Recording

1 Hp (a 2600 ≠ 10 rpm (≠ 5%) Note: With JP8 fuel, HP may read low.

570 630

2 Rail Press Psi (kPa) 141 (972.2)

(1123.9)

3 Fuel Rate lb./hr per hp (kg/hr per hp)

0.328 (0.149)

0.362 (0.164)

4 Int Man Press In-Hg (mm) 41 (1041.4)

(1320.8)

5 Blow-By In.-water (kPa) 0 (0)

(2)

6 Oil Press Psi (kPa) 40 (275.8)

(413.7)

7 Oil Temp ˚F (˚C) 200 (93.3)

(121)

8 Fuel Temp ˚F (˚C) 90 (32.2)

(43.3)

9 Water Out Temp ˚F (˚C)

(87.7)

(96.1)

10 Inlet Air Temp ˚F (˚C)

(26.7)

(32.2)

0020-5/6 blank

Table 1. Final Acceptance Test – Continued.

TORQUE CHECK

Engine will not be torque checked unless temperatures (oil and water-out) are within operating range.

Check No Test Minimum Maximum Actual Recording

1 Engine rpm 2000 2800

2 Load lb to ft (mkg) 1176 (162)

(129)

IDLE PARAMETER CHECK (After 5 minute idle)

1 Idle rpm 775 ---

2 Idle Oil Press Psi (kPa)

(103.4)

NMWR 9-2815-274 0040 00

0040 00-1

6.5 LITER ENGINE

HMMWV FOV

Detuned 6.5 Liter 6.5 Liter Naturally Aspirated 6.5 Liter Turbo

NSN 2815-01-439-6664 NSN 2815-01-461-7078 NSN 2815-01-439-8164

NSN 2815-01-406-6675 NSN 2815-01-410-9710 NSN 2815-01-420-4180

NSN 2815-01-453-7404 NSN 2815-01-439-6665 NSN 2815-01-453-7402

NSN 2815-01-472-6312 NSN 2815-01-453-7403 NSN 2815-01-547-1716

AFTER REPAIR PERFORMANCE TEST REPORT

THIS WORK PACKAGE (WP) COVERS:

Performance Report and 6.5L Engine Points of Contact

PERFORMANCE REPORT

A test report, containing at a minimum, the data in Tables 1-3 as appropriate and work orders must be maintained by the repair activity for a minimum of two years following the repair of each engine.

NOTE

The Repair Facility Quality Representative must verify the testing of all repaired engines.

Table 1. 6.5L Detuned Engine

After Repair Performance Test Report.

TEST

PERIOD

NUMBER

REQUIRED

TIME IN

MINUTES

ENGINE

RPM

OIL

PRESSURE

OIL

TEMP.

COOLANT

TEMP.

TORQUE

(ft-lb)

1 5 700 2 15 1200 3 30 2000 4 15 3000 5 5 3600 6 5 700

NMWR 9-2815-274 0040 00

0040 00-2

PERFORMANCE REPORT - Continued

Table 2. 6.5L Naturally Aspirated Engine

NUMBER

REQUIRED

TIME IN

MINUTES

ENGINE

RPM

OIL

PRESSURE

OIL

TEMP.

COOLANT

TEMP.

TORQUE

(ft-lb)

1 5 700 2 15 2000 3 30 3000 4 15 3400 5 5 3400

Table 3. 6.5L Turbo Engine

NUMBER

REQUIRED

TIME IN

MINUTES

ENGINE

RPM

OIL

PRESSURE

OIL

TEMP.

COOLANT

TEMP.

TORQUE

(ft-lb)

1 5 700 2 15 2000 3 30 3000 4 15 3400 5 5 3400

6.5L ENGINE POINTS OF CONTACT

Item Manager (AMSTA-LCC-HL) Ted.F.Robinson@us.army.mil

Quality Representative (AMSTA-TR-E/LTV) Paul.Whitney@us.army.mil

Engineering (AMSTA-TR-E/LTV) Brad.Brinker@us.army.mil

Maintenance Log Manager (AMSTA-LCC-HL) Bucky.McCuiston@us.army.mil

NMWR 9-2815-278 0033 00

0033 00-2

ENGINE RUN-IN, PERFORMANCE TESTING, AND TEST REPORT (Contd)

GENERAL INFORMATION

The engine test is a combination of a run-in procedure and a performance check. The run-in procedure provides an operating period that allows engine parts to achieve a final finish and fit. The performance check confirms that the engine operates at its specified speed and torque rating, that it is leak free and free of abnormal noises, and that its various systems are operating within specified values.

The dynamometer used for engine testing must be equipped to take the following readings:

1. Engine speed

2. Torque

3. Oil pressure

4. Oil temperature

5. Coolant temperature

6. Blowby

7. Intake manifold air temperature

The dynamometer must have sufficient capacity to permit testing at 100 percent of engine’s 250 horsepower @ 2100 rpm and torque rated at 685 lb-ft (929 N•m).

When mounting engine on dynamometer, follow manufacturer’s instructions.

0033 00-3

ENGINE RUN-IN, PERFORMANCE TESTING, AND TEST REPORT (Contd)

PRELIMINARY STEPS

1. Thoroughly inspect engine for missing, broken, improperly installed, and damaged components.

2. Close all coolant draincocks.

3. Fill engine to proper level with coolant.

4. Fill engine to proper level with appropriate oil.

WARNING

Eye protection must be worn when working with compressed air. Failure to wear eye protection may result in injury to personnel.

CAUTION

To avoid internal engine damage, lubrication system must be pressurized before starting engine.

NOTE

If external pressure source equipment is available, perform step 5. Otherwise, proceed to step 6.

5. Lubrication system may be pressurized using external pressure source equipment capable of delivering 30 psi (210 kPa) of continuous pressure. Pressure supply hose is to be connected by removing pipe plug located on front of oil cooler. To pressurize system, follow manufacturer’s instructions.

6. If external pressure source is not available, proceed as follows:

a. Remove oil filter from filter head and fill with engine oil.

b. Install oil filter on filter head.

CAUTION

Do not crank engine for more than 30 seconds. Excessive cranking will overheat and damage starter motor. Wait 2 minutes between 30-second cranking periods to allow starter motor to cool.

c. Crank engine in 30-second periods until oil pressure gauge reads at least 30 psi (207 kPa).

NOTE

Air compressor must be unloaded during engine test sequence.

To provide necessary air pressure, use metal tubing or high-temperature hose to connect compressor outlet to air tank. Air line connected to air compressor must contain a shutoff valve. Tank must be equipped with pressure regulator that can maintain tank pressure at 50–75 psi (345–517 kPa) at minimum and maximum engine speeds. If high-temperature hose is used, it must be rated to at least 500° F (260° C).

7. Connect air line (1) to air compressor (2) outlet.

0033 00-4

ENGINE RUN-IN, PERFORMANCE TESTING, AND TEST REPORT (Contd)

NOTE

Maintain intake air temperature at 150° F (66° C) or below during run-in and test sequences. If air temperature exceeds this limit, stop procedure and run engine at idle to cool it down. Do not allow engine to idle for more than 10 minutes.

Under no circumstances is intake air temperature to exceed 170° F (77° C).

8. Connect air intake to filtered air source.

9. Make necessary electrical connections at starter motor.

10. Make necessary electrical connections at throttle control solenoid.

11. Make necessary exhaust connections.

12. Connect tachometer per manufacturer’s instructions.

Figure 1. Unloading Air Compressor.

PRELIMINARY STEPS (Contd)

PRESSURE

GAUGE

PRESSURE

RELIEF

VALVE

AIR TANK

SHUTOFF VALVE

0033 00-5

ENGINE RUN-IN, PERFORMANCE TESTING, AND TEST REPORT (Contd)

ENGINE RUN-IN AND PERFORMANCE TEST SEQUENCE

The specifications in table 1 are to be used during engine run-in and test sequence. Because piston rings are seating during run-in, blowby reading may not be within specifications until end of sequence.

If sudden increase in blowby occurs or if blowby exceeds maximum allowable amount during any run-in step, return to previous step and continue run-in. If blowby does not reach an acceptable level, discontinue run-in and determine cause. If, at any time, engine operates outside of these specifications, it must be shut down and cause determined.

Table 1. Basic Limits.

WARNING

All personnel must stand clear of moving parts when engine is started and once it is running. A loose or broken part may result in death or injury to personnel.

CAUTION

If oil pressure is not within specifications when engine is started, shut engine down immediately. Excessively low or high oil pressure will cause engine damage. Oil pressure must be within 10–40 psi (69–310 kPa) at 700 rpm.

Do not crank engine for more than 30 seconds. Excessive cranking will overheat and damage starter motor. Wait 2 minutes between 30-second cranking periods to allow starter motor to cool.

1. Start engine.

2. Listen for unusual noises. Check for coolant, fuel, and oil leaks. If any problems are present, stop sequence and make necessary repairs.

3. Check tachometer. If idle speed is not within specifications, adjust to 600–650 rpm.

NOTE

Do not proceed to step 4 until a steady blowby reading is obtained.

4. Increase engine speed to 1200 rpm and set test load to 25 percent of rated load.

Idle Speed 550–650 rpm

Oil Pressure Idle Rated Speed

15 psi (69 kPa) minimum 30 psi (207 kPa)

Coolant Temperature 212°F (100°C)

Blowby By check tool

Air Inlet Temperature 150° F (38° C)

0033 00-6

ENGINE RUN-IN, PERFORMANCE TESTING, AND TEST REPORT (Contd)

ENGINE RUN-IN AND PERFORMANCE TEST SEQUENCE (Contd)

CAUTION

Normal operating temperature for this engine is 190°–200° F (88–93° C). If normal temperature is exceeded, shut down engine and determine cause.

5. Operate engine at specified speed and load until coolant temperature reaches 160° F (71° C).

6. Check all gauges and record readings on Test Report.

CAUTION

The times specified for the following steps in run-in sequence are minimums. Engine may be operated for longer periods of time at each run-in sequence step except at engine idle.

Periods of engine idle must not exceed 10 minutes. If engine is idled for long periods of time, carbon formation will occur and cause damage to engine.

NOTE

Do not proceed to step 7 until blowby is steady and within specifications.

7. Open throttle to speed at which peak engine torque occurs and adjust dynamometer to 50 percent of rated load. Operate engine at this speed and load for 2 minutes.

8. Check all gauges and record data on Test Report.

NOTE

Do not proceed to step 9 until blowby is steady and within specifications.

9. Maintain engine at speed at which peak engine torque occurs and adjust dynamometer to 75 percent of rated load. Operate engine at this speed and load for 2 minutes.

10. Check all gauges and record data on Test Report.

11. Move throttle to fully open position and increase dynamometer load until engine speed is at peak torque rpm. Operate engine at this speed and load for 10 minutes.

CAUTION

Shutting down engine immediately after operating at full load may damage internal components. Allow engine to cool before shutting down.

12. Remove dynamometer load and operate engine at idle for 3–5 minutes to allow it to cool.

1200 RPM @ 25% OF RATED LOAD

Gauge readings Specifications Measured Engine speed 550–650 rpm

Oil pressure 30 psi (207 kPa)

Oil temperature 260° F (127° C)

Coolant temperature 212° F (100° C)

Blowby 113 L/min

Air inlet temperature 150° F (38° C)

Unsatisfactory (explain)

PEAK TORQUE @ 50% OF LOAD

Gauge readings Specifications Measured Engine speed Peak torque

Oil pressure 30 psi (207 kPa)

Oil temperature 260° F (127° C)

Coolant temperature 212° F (100° C)

Blowby 113 L/min

Air inlet temperature 150° F (38° C)

Unsatisfactory (explain)

PEAK TORQUE @ 75% OF LOAD

Gauge readings Specifications Measured Engine speed Peak torque

Oil pressure 30 psi (207 kPa)

Oil temperature 260° F (127° C)

Coolant temperature 212° F (100° C)

Blowby 113 L/min

Air inlet temperature 150° F (38° C)

Unsatisfactory (explain)

PEAK TORQUE RPM

Gauge readings Specifications Measured Engine speed WOT

Oil pressure 30 psi (207 kPa)

Oil temperature 260° F (127° C)

Coolant temperature 212° F (100° C)

Blowby 113 L/min

Air inlet temperature 150° F (38° C)

Unsatisfactory (explain)

NMWR 9-2815-278 0033 00

0033 00-7/8 blank

ENGINE RUN-IN, PERFORMANCE TESTING, AND TEST REPORT (Contd)

DATE

INSPECTED BY

PART NO.

SERIAL NO.

MODEL NO.

TEST REPORT FOR CUMMINS NHC-250 DIESEL ENGINE

Because piston rings are seating during run-in, blowby reading may not be within specifications until end of sequence. If, at any time, engine operates outside of these specifications, it must be shut down and cause determined.

NMWR 9-2815-518 0031

NATIONAL MAINTENANCE

TESTING (CAT C7)

INITIAL SETUP:

Materials/Parts Fuel (WP 0039, Item 31) Oil (WP 0039, Item 38)

References

WP 0032

WP 0033

WP 0039

SCOPE

This work package contains procedures for final testing of the engine assemblies after overhaul.

END OF TASK

INSPECTION

Engine will be inspected for completeness, obvious damage and tagged that indicates engine has been overhauled and is ready for test.

END OF TASK

TESTING

1. The acceptance test of the C7 engine assembly will be conducted according to the test requirements and acceptance criteria prescribed in this work package.

2. In the event of conflicting instructions between this test procedure and other references, this procedure will take precedence.

3. Final acceptance test results shall be recorded as specified in Table 1.

END OF TASK

EQUIPMENT

1. Dynamometer capable of 3,000 rpm minimum, 450 horsepower/1,500 lb-ft (2,034 N·m) minimum torque absorption.

2. Engine prelubing equipment capable of developing a minimum of 25 psi (172 kPa).

3. Gage to measure engine oil pressure at STC solenoid, 0-100 psi (0-690 kPa) range.

4. Gage to measure coolant IN temperature, within 4 feet (1.22 meters) of coolant pump inlet, with range of 32-

300°F (0-149°C).

5. Gage to measure coolant OUT (after thermostat) temperature, located in thermostat housing, with range of 32-300°F (0-149°C).

6. Gage to measure fuel temperature mounted, within six feet (1.83 meters) of fuel pump inlet, with range of 32-150°F (0-66°C).

7. Gage to measure air intake temperature mounted, between air filter and turbo supercharger air inlet, with range of 32-150°F (0-66°C).

8. External fan capable of controlling test cell ambient temperature.

9. Air filter mounted on air intake system.

10. Fuel cooler, installed in pump suction line from tank, with cooling capacity sufficient to maintain temperature of supply fuel to engine pump at 110°F (43°C) or below.

0031-1

EQUIPMENT - CONTINUED

11. Manometer, with range of 30 inches (762 mm) water, connected to air inlet system to measure air cleaner restriction.

12. Engine coolant system, in test cell, with coolant tank and automatic, thermostatically controlled method (by adding fresh water, by heat exchanger or by other means) capable of maintaining maximum coolant temperature within specified limit on all specified operating and load conditions. Test cell engine coolant system will be capable of maintaining engine coolant temperature within specified limits when engine is run under full-load conditions for extended periods of time. Tank will have an adjustable pressure relief valve to simulate the pressurized coolant system. Relief valve will be set for a pressure of 4 to 7 psi (27.6 to 48.3 kPa).

13. 24 Vdc source of capable of supplying approximately 350 amps of current to operate starter motor.

14. Source of clean fuel (WP 0039, Item 31) with test cell supply pressure regulated to 3-6 psi (20.69-41.37 kPa).

15. Control mechanisms for operating accelerator lever and fuel shut-off valve on engine fuel pump.

END OF TASK

INSTALLATION OF ENGINE ON TEST STAND

NOTE

• DO NOT overfill any fluid reservoir/tank. If a fluid starts to flow out of reservoir/tank, stop IMMEDIATELY to avoid spillage. Immediately clean up spilled fluid before proceeding with any task.

• Refer to local procedures and plans for preventing and responding to fluid spills or leaks.

Comply with local regulations when disposing of clean up material and leaked and spilled fluids.

1. Mount engine to dynamometer test stand.

a. If universal drive coupling is used, install engine so that centerline of engine crankshaft and centerline of dynamometer driveshaft are out of plane either horizontally or vertically 1/4-1/2 inch (6.35-12.7 mm).

True alignment will cause universal bearing failure.

b. Radial runout of shaft and adapter plates at engine and dynamometer ends of shaft should be as low as possible to prevent vibration. A reading of 0.012 inch (0.305 mm) maximum is desired.

2. Make connections of test equipment as outlined in EQUIPMENT.

3. Fill engine with water. As engine is being filled with water, open vent cocks to prevent trapping of air in cooling system. When a solid stream of water comes from vent cocks, close vent cocks.

4. Fill engine with 25 quarts of oil (WP 0039, Item 38). Prelube engine for a sufficient time for all bearings to be coated. Rotate engine a minimum of 10 revolutions at two intervals during prelubing process. Ensure turbo supercharger has oil supplied to turbo supercharger oil inlet.

5. Connect flow tank fuel return line and flow tank fuel supply line to engine and prime fuel system.

END OF TASK

OPERATIONAL PRECAUTIONS

1. Engine shall not be run with less than 10 psi (68.9 kPa) oil pressure.

2. Engine oil pressure shall not exceed 90 psi (621 kPa) at any time.

3. Engine oil temperature shall not exceed 250 °F (121 °C) at any time.

4. Engine coolant temperature shall not exceed 200 °F (93.3 °C) at any time.

5. Engine shall not be operated when blow-by exceeds 10 inches (254 mm).

0031-2

OPERATIONAL PRECAUTIONS - CONTINUED

6. Engine shall not be run under full power/load conditions when oil temperature, water IN temperature or water OUT temperature is below 160 °F (71 °C).

7. Engine shall not be shut down following heavy power/load runs without a minimum of a five-minute cool down no-load idle run.

END OF TASK

FINAL ACCEPTANCE TEST

1. Start engine and operate at idle for five minutes. Check for low oil pressure, high coolant temperature, leaks and unusual noises. No fuel leaks are allowed. Only Class I oil leaks are allowed as described below. If any of these conditions are observed, stop engine immediately and correct problem prior to restarting test.

a. Class I - Seepage or fluid (as indicated by wetness or discoloration) not great enough to form drops.

b. Class II - Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected.

c. Class III - Leakage of fluid great enough to form drops that fall from item being checked/inspected.

2. Stop engine after five minutes of operation. Allow engine to stand for two minutes while checking for leaks and unusual conditions. Check oil and add as necessary.

CAUTION

Except in emergency, engine will not be stopped immediately after completion of power/torque runs. Sudden stop without cool down will cause damage to engine components. Cool down period is five minutes minimum after any power/torque run.

3. Start engine and test in accordance with Table 1.

4. After completion of test, disconnect engine and remove from test stand.

Table 1. Final Acceptance Test for 350 HP Engine.

ENGINE RUN-IN

Run No. Duration

(minutes) RPM HP Load (lb-ft) Actual Recording

1 5 750 0 2 20 1500 69 226-256 3 10 1800 138 387-417 4 10 2200 206 476-506 5 5 2600 275 540-570 6 5 1000 0

7 AR IDLE 0

POWER CHECK:

Engine will not be power checked unless temperatures (oil and water OUT) are within operating range.

Check No. Test Minimum Maximum Actual Recording

1 HP (@ 2200 ±10

rpm) 321 Corrected

BHP

341 (C7 engine) Corrected BHP

2 Fuel Rate Lb/hr per hp (kg/hr per hp)

0.338 (0.15) (C7 Engine)

0.358 (0.16) (C7 Engine)

0031-3

FINAL ACCEPTANCE TEST - CONTINUED

Table 1. Final Acceptance Test for 350 HP Engine. - (CONTINUED)

ENGINE RUN-IN

3 Blow-By in.-water (cfm) 0 10

4 Oil Pressure psi (kPa)

29 (200) 87 (600)

5 Oil Temperature °F (°C)

190° (87.7°) 250° (121°)

6 Fuel Temperature °F (°C)

— 100° (38°)

7 Water Out Temperature °F (°C)

160° (71°) 200° (93.2°)

IDLE PARAMETER CHECK

(after 5 minute idle)

Check No. Test Minimum Maximum Actual Recording 1 Idle rpm 750 750 2 Idle Oil

Pressurepsi (kPa)

10 (68.95)

3 Oil Temperature °F (°C)

190 (88) 250 (121)

END OF TASK

PAINTING

Refer to WP 0032, General Maintenance for paint requirements on engine assemblies.

END OF TASK

PRESERVATION, PACKAGING AND MARKING

Refer to WP 0033, Preservation, Packaging, and Marking for preservation, packaging and marking of engine assemblies.

END OF TASK

0031-4

ENGINE TEST RUN

INITIAL SETUP:

Tools and Special Tools Adapter, Cable Breakout (WP 0100, Table 1, Item

2) Adapter, Communication (WP 0100, Table 1, Item

3) Adapter, Transducer (WP 0100, Table 1, Item 6) Cable Assembly, Special Purpose (WP 0100, Table 1, Item 11) Cover, Pump (WP 0100, Table 1, Item 17) Harness (WP 0100, Table 1, Item 36) Harness, Service Tool Connection (WP 0100, Table 1, Item 37) Packing, Preformed (WP 0100, Table 1, Item 53) Plug (WP 0100, Table 1, Item 61) Receptacle (WP 0100, Table 1, Item 71) Software, Electronic Technician (WP 0100, Table

1, Item 81)

Tools and Special Tools (cont.)

Throttle Control (WP 0100, Table 1, Item 87) Transducer (WP 0100, Table 1, Item 95)

Materials/Parts Lubricating Oil, Engine, Grade 10 (WP 0099, Table 1, Item 45, 46) Lubricating Oil, Engine, Grade 30 (WP 0099, Table 1, Item 47, 48)

References

DD1397 (WP 0098)

TM 9-2320-326-13&P (WP 0098)

WP 0089

Equipment Condition Belt tensioner installed. (WP 0013)

PREPARATION FOR TESTING

NOTE

Use Engine Test Run Checklist (WP 0089) when performing engine test run.

1. Visually inspect engine for general condition and suitability for test run.

2. Install cover on steering pump mounting pad.

3. Install engine on dynamometer.

NOTE

• Inlet air to engine will be filtered. Inlet air will also be drawn from outside engine test cell so that ambient air conditions are not affected by operation of engine.

• Inlet air pressure shall be monitored.

• Inlet air temperature shall be monitored.

• Inlet air restriction shall be monitored.

• Dry barometric pressure shall be monitored.

• Inlet water temperature for separate circuit aftercooler (SCAC) may be from 81 to

91 °F (27 to 33 °C) to 126 to 136 °F (52 to 58 °C).

4. Install engine inlet air to suitable filtered air system and SCAC.

NMWR 9-2815-554 0087

0087-1 02/13/2013 root(maintwp) wpno(M03230)

PREPARATION FOR TESTING - Continued

• Engine power, torque, and fuel rates will be corrected for variation in fuel density from 35.0 API (American Petroleum Institute). Use of a fuel additive is permitted to control white smoke.

• Pressure of fuel supply at full load to engine fuel inlet will be constant and not to exceed 3.6 psi (25 kPa). Temperature will be 83 to 89 °F (28 to 32 °C). If fuel temperature does not exceed 90 °F (32 °C), there will be no noticeable loss of horsepower. Loss of horsepower will occur if fuel temperature exceeds 90 °F (32 °C) due to decreased density of fuel.

• Fuel supply lines will be vented to atmosphere in a manner which permits any gas in fuel to be monitored and released. If there is a detectable fuel leak in any metered fuel lines, readings for fuel rate will not be correct. If performance test reaches a point of full load and visible gas is being discharged from fuel system, test is considered invalid.

• Fuel temperature shall be monitored at fuel inlet.

5. Install fuel supply and return hoses to engine.

NOTE

• Cooling water for engine outlet will be 203 to 214 °F (95 to 101 °C).

• Cooling water temperature shall be monitored at inlet to water pump and at engine outlet.

6. Install coolant system to engine.

NOTE

Test facility exhaust system will create static pressure at outlet of engine exhaust of -8.0 inches of water (-2 kPa) to 8.0 inches of water (2 kPa) at full load and speed.

7. Install exhaust system to engine.

CAUTION

Lubricating oil film on rotating parts and bearings of an overhauled engine may be insufficient for proper lubrication when engine is started for the first time. Charge engine oil system with a pressure pre-lubricator. Failure to comply may result in damage to equipment.

NOTE

Pre-lubricator may be installed on air compressor oil supply line.

8. Install pre-lubricator.

9. Remove turbocharger oil supply lines.

10. Start pressure pre-lubricator and fill engine with lubricating oil until oil is observed flowing from turbocharger oil supply lines.

11. Pour 0.5 qt (0.5 L) of lubricating oil in turbocharger center housings and install turbocharger oil supply lines.

NOTE

Engine oil capacity is 42 qt (40 L).

0087-2 02/13/2013 root(maintwp) wpno(M03230)

12. Start pressure pre-lubricator and finish filling engine with lubricating oil.

13. Remove pre-lubricator from engine. Rotate engine several revolutions to circulate lubrication oil within engine.

14. Prime fuel system.

15. Proceed to ECU TIMING CALIBRATION or PERFORMANCE TEST.

END OF TASK

ECU TIMING CALIBRATION

1. Remove 12 screws (Figure 1, Item 1) from front housing (Figure 1, Item 2).

1 2

4,5,6

Figure 1. ECU Timing Calibration.

2. Remove two locknuts (Figure 1, Item 4), spacers (Figure 1, Item 5), preformed packings (Figure 1, Item 6), and front cover (Figure 1, Item 3) from front housing (Figure 1, Item 2). Do not discard locknuts or preformed packings.

NOTE

• Camshaft gear rotates same direction as crankshaft.

• Top dead center (TDC) may also be located using turning tool and TDC locator hole on flywheel.

3. Rotate crankshaft in normal direction of rotation (clockwise, when looking at front of engine) until timing mark on camshaft gear aligns with timing mark on top of front housing. Refer to Figure 2.

0087-3 02/13/2013 root(maintwp) wpno(M03230)

ECU TIMING CALIBRATION - Continued

FRONT HOUSING

TIMING MARK

CAMSHAFT

GEAR

Figure 2. ECU Timing Calibration.

CAUTION

Ensure crankshaft is in correct position. Failure to comply may result in damage to transducer.

4. Rotate crankshaft in opposite direction of rotation (counterclockwise) for 60 degrees (30 degrees on camshaft gear). Refer to Figure 3.

0087-4 02/13/2013 root(maintwp) wpno(M03230)

CAMSHAFT

GEAR TIMING

MARK

DEGREES

Figure 3. ECU Timing Calibration.

5. Remove plug (Figure 4, Item 2) from cylinder block (Figure 4, Item 1).

Figure 4. ECU Timing Calibration.

0087-5 02/13/2013 root(maintwp) wpno(M03230)

6. Install 7X-1171 transducer adapter (Figure 5, Item 3) in cylinder block (Figure 5, Item 4).

1,2 43

Figure 5. ECU Timing Calibration.

7. Lightly lubricate preformed packing (Figure 5, Item 1) with clean engine oil and install preformed packing (Figure 5, Item 1) on 6V-2197 transducer (Figure 5, Item 2).

8. Push 6V-2197 transducer (Figure 5, Item 2) through 7X-1171 transducer adapter (Figure 5, Item 3) until 6V-2197 transducer (Figure 5, Item 2) contacts crankshaft counterweight.

9. Withdraw 6V-2197 transducer (Figure 5, Item 2) 0.04 in. (1.0 mm) and hand tighten nut on 7X-1171 transducer adapter (Figure 5, Item 3). Move preformed packing (Figure 5, Item 1) against 7X-1171 transducer adapter (Figure 5, Item 3).

10. Install front cover (Figure 6, Item 3) on front housing (Figure 6, Item 2) with 2 preformed packings (Figure 6, Item 6), spacers (Figure 6, Item 5), locknuts (Figure 6, Item 4), and 12 screws (Figure 6, Item 1).

0087-6 02/13/2013 root(maintwp) wpno(M03230)

1 2

4,5,6

Figure 6. ECU Timing Calibration.

11. Connect 167-9225 service tool connection harness (Figure 7, Item 1) to ECU connector P1 (Figure 7, Item 3).

4 5

Figure 7. ECU Timing Calibration.

12. Install throttle control (Figure 7, Item 6) to engine assembly (Figure 7, Item 7) and connect throttle control harness connector (Figure 7, Item 9) to 167-9225 service tool connection harness connector (Figure 7, Item 10).

0087-7 02/13/2013 root(maintwp) wpno(M03230)

13. Connect white wire (Figure 7, Item 4) of 170-3519 harness (Figure 7, Item 2) to back of service tool connection harness (Figure 7, Item 1) connector P1, position 24.

14. Connect yellow wire (Figure 7, Item 5) of 170-3519 harness (Figure 7, Item 2) to back of service tool connection harness (Figure 7, Item 1) connector P1, position 25.

15. Connect 7X-1695 cable assembly (Figure 7, Item 8) to 170-3519 harness connector (Figure 7, Item 2) and to transducer connector (Figure 7, Item 11).

16. Connect 207-6845 adapter cable assembly (Figure 8, Item 1) to 167-9225 service tool connection harness (Figure 8, Item 3) and to 171-4401 communication adapter assembly (Figure 8, Item 2).

Figure 8. ECU Timing Calibration.

17. Connect 196-0055 adapter cable assembly (Figure 8, Item 4) to 171-4401 communication adapter assembly (Figure 8, Item 2) and to laptop computer or MSD.

18. Connect positive and negative battery clips of 167-9225 service tool connection harness (Figure 8, Item 3) to source of power and ground.

19. Initiate CAT ET software for engine start or refer to TM 9-2320-326-13&P (WP 0098) ECU Timing Calibration/Engine Test Run.

CAUTION

• Engine should be cranked at 100 to 1,000 rpm with engine speed control set for maximum fuel delivery. A minimum of 5.8 psi (40 kPa) of oil pressure must be obtained within 30 seconds, otherwise engine will stop cranking. Discontinue cranking if engine has not started within 2 minutes.

• A minimum oil pressure of 5.8 psi (40 kPa) must be obtained within 3 seconds after engine startup or engine must be stopped.

20. Start engine and let idle (590 to 610 rpm) for 2 minutes.

0087-8 02/13/2013 root(maintwp) wpno(M03230)

21. Inspect engine for fuel, coolant, and oil leaks.

22. With engine running, gradually increase engine speed and load until normal operating temperatures are reached (engine outlet water temperature at 185 °F [85 °C]).

NOTE

Check for active diagnostic codes. Wait at least 30 seconds in order for codes to become active. Engine must not have any active diagnostic codes during ECU Timing Calibration except for 261-13, Engine Timing Calibration required. Troubleshoot and repair any active diagnostic codes before continuing with this procedure.

23. Set engine speed to 1,050 to 1,150 rpm. Engine speed must be in this range for calibration to be successful.

24. Perform ECU Timing Calibration from CAT ET software or refer to TM 9-2320-326-13&P (WP 0098) ECU Timing Calibration/Engine Test Run.

25. Set engine speed to low idle (590 to 610 rpm).

26. Shut engine OFF.

27. Disconnect ground clip of 167-9225 service tool connection harness (Figure 9, Item 7) from ground source.

28. Loosen nut on 7X-1171 transducer adapter (Figure 9, Item 2) and remove 6V-2197 transducer (Figure 5, Item 2) and preformed packing (Figure 9, Item 1) from cylinder block (Figure 9, Item 9).

5321 4 8 9

Figure 9. ECU Timing Calibration.

29. Remove 7X-1171 transducer adapter (Figure 9, Item 2) from cylinder block (Figure 9, Item 3).

30. Install plug (Figure 9, Item 8) on cylinder block (Figure 9, Item 3).

31. Disconnect 7X-1695 cable assembly (Figure 9, Item 6) from 170-3519 harness connector (Figure 9, Item 5).

NOTE

170-3519 harness may be left installed for future use. Obtain a 3E-3364 receptacle and two 8T-8737 plugs to connect to 170-3519 harness connector to prevent corrosion and contamination.

0087-9 02/13/2013 root(maintwp) wpno(M03230)

32. Connect 3E-3364 receptacle (Figure 9, Item 4) to 170-3519 harness connector (Figure 9, Item 5).

33. Connect ground clip of 167-9225 service tool connection harness (Figure 9, Item 7) to a ground source.

34. Proceed to…