CHAPTER 3ENGINE MAINTENANCEKeeping an internal combustion engine (dieselor gasoline) in good operating condition demandsa well-planned procedure of periodic inspection,adjustments, maintenance, and repair. If inspec-tions are made regularly, many malfunctions canbe detected and corrected before a serious casualtyresults. A planned maintenance program will helpto prevent major casualties and the occurrence ofmany operating troubles.The Maintenance and Material Management(3-M) System provides a logical and efficientapproach to many maintenance problems. It pro-duces a large reservoir of information aboutequipment disorder and indicates what correctivesteps must be taken to prevent them.Another aspect that must be considered inconnection with maintenance problems is thesafety requirement aboard ship. On some ships,the 3-M System includes safety requirement cards.A safety requirement card provides guidelines andperiodicity for the inspection of selected areas notcovered in the regular maintenance schedule.Complete information about the 3-M Systemis contained in the Maintenance and MaterialManagement (3-M) Manual, OPNAVINST4790.4.There may be times when service requirementswill interfere with a planned maintenance pro-gram. In such event, routine maintenance mustbe performed as soon as possible after thespecified interval of time has elapsed. Allnecessary corrective measures should beaccomplished as soon as possible. Repair jobsshould not be allowed to accumulate, otherwisehurried and inadequate work will result.Since the Navy uses many models of internalcombustion engines, it is impossible to specify adetailed overhaul procedure that would beadaptable to all models. However, there areseveral general rules which apply to all engines.They are:1. Detailed repair procedures are listed inmanufacturers’ instruction manuals and inmaintenance pamphlets. Study the appropriatemanuals and pamphlets before attempting anyrepair work. Pay particular attention to tolerancelimits, and adjustments.2. Observe the highest degree of cleanlinessin handling engine parts during overhaul.3. Before starting repair work, be sure thatall required tools and replacements for knowndefective parts are available.4. Keep detailed records of repairs. Suchrecords should include the measurements of parts,hours in use, and the names of the new parts in-stalled. Analyses of such records will indicate thehours of operation that may be expected from thevarious engine parts. This knowledge is helpfulas an aid in determining when a part should berenewed in order to avoid a failure.Since maintenance cards, the manufacturers’maintenance manuals, and the various types ofinstructions discuss repair procedures in detail,this chapter will be limited to general informa-tion on engine inspections, adjustments, andmaintenance, as well as some of the troublesencountered during overhaul, the causes of suchtroubles, and the methods of repair to be used.INSPECTIONSInspections and maintenance are vital in orderto maintain engines (diesel and gasoline) in3-1
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