CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
FIELD MAINTENANCE ENGINE GENERAL MAINTENANCE
CORROSION PREVENTION AND CONTROL (CPC) - Continued
LIST OF ABBREVIATIONS/ACRONYMS - Continued
LIST OF ABBREVIATIONS/ACRONYMS - Continued
FIELD MAINTENANCE ENGINE EQUIPMENT DESCRIPTION AND DATA
Figure 2. Propulsion Module.
Figure 3. Diesel Engine External Components Top View.
Figure 5. Diesel Engine External Components Starboard Side View.
Figure 7. Diesel Engine External Components Aft View.
Lubrication System
Figure 8. Diesel Engine Internal Components.
Table 1. Equipment Data.
Table 1. Equipment Data - Continued.
FIELD MAINTENANCE ENGINE THEORY OF OPERATION
Figure 1. Two-Cycle Sequence.
Figure 2. Air Induction System.
Figure 3. Turbocharger.
Engine Blower
Figure 4. Fuel System.
Figure 5. Fuel Injector.
FUEL SYSTEM - Continued
Figure 6. Fuel Pump.
Figure 7. Cooling System.
Figure 8. Water Pump.
Heat Exchanger
Coolant Filter and Conditioner
LUBRICATION SYSTEM - Continued
Figure 11. Oil Pump Gears.
Figure 12. Oil Pump Pressure Regulator.
Figure 13. Oil Cooler.
Water-Cooled Exhaust Manifold
Overspeed Governor
CHAPTER 2 - TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING INDEX
TROUBLESHOOTING PROCEDURES - ENGINE WILL NOT TURN OVER
Defective engine start pushbutton.
TROUBLESHOOTING PROCEDURES - ENGINE TURNS OVER BUT WILL NOT START
Water in fuel/water separator.
Fuel pump relief valve sticks open or partially open.
The emergency air shutdown was activated.
Replace starting motor (WP 0164).
FIELD MAINTENANCE ENGINE TROUBLESHOOTING PROCEDURES - ENGINE DOES NOT START IN COLD TEMPERATURES
TROUBLESHOOTING PROCEDURES - ENGINE STARTS WITH DIFFICULTY AND RUNS ROUGH
Water is discovered in the fuel/water separator.
Low compression.
TROUBLESHOOTING PROCEDURES - SUDDEN LOSS OF POWER
The air inlet is blocked.
TROUBLESHOOTING PROCEDURES - ENGINE LACKS POWER
The engine is not getting enough air.
TROUBLESHOOTING PROCEDURES - ENGINE NOT RECEIVING FUEL FROM TANK
Loose connections or cracked fuel lines.
Power from diesel engine is lost and heavy black smoke is coming from exhaust plenum.
TROUBLESHOOTING PROCEDURES - HIGH OIL CONSUMPTION
Overfilled crankcase.
Turbocharger seals are leaking.
Piston pin retainer loose.
Dirt in air intake system.
TROUBLESHOOTING PROCEDURES - LOW READING ON OIL PRESSURE GAUGE
Poor circulation, oil cooler clogged.
Electrical instrument panel sending units are faulty.
TROUBLESHOOTING PROCEDURES - EXCESSIVE READING ON OIL PRESSURE GAUGE
Cylinder blow-by, piston rings worn or broken.
Faulty exhaust piping.
TROUBLESHOOTING PROCEDURES - ABOVE NORMAL READING ON ENGINE COOLANT TEMPERATURE GAUGE
Faulty thermostat.
CORRECTIVE ACTION - Continued
TROUBLESHOOTING PROCEDURES - BELOW NORMAL READING ON ENGINE COOLANT TEMPERATURE GAUGE
Below normal coolant temperature, excessive leakage at thermostat seal.
TROUBLESHOOTING PROCEDURES - ENGINE FAILS TO STOP WHEN EMERGENCY STOP IS ACTIVATED
Emergency stop solenoid is defective.
Fuel return line is clogged.
TROUBLESHOOTING PROCEDURES - NOISY OPERATION OR VIBRATION IN TURBOCHARGER
Leak in engine air intake piping and housing.
TROUBLESHOOTING PROCEDURES - ELECTRICAL GENERATING SYSTEM SHOWS LOW BATTERY AND LOW OR NO CHARGING RATE
Defective alternator.
TROUBLESHOOTING PROCEDURES - ELECTRICAL GENERATING SYSTEM SHOWS FULLY CHARGED BATTERY AND HIGH CHARGING RATE
TROUBLESHOOTING PROCEDURES - ELECTRONIC GOVERNOR ACTUATOR STAYS AT MINIMUM POSITION WHEN POWER IS APPLIED
Binding electronic governor drive.
ELECTRONIC GOVERNOR ACTUATOR STAYS AT MINIMUM POSITION WHEN POWER IS APPLIED - Continued
ELECTRONIC GOVERNOR ACTUATOR STAYS AT MINIMUM POSITION WHEN POWER IS APPLIED - Continued
TROUBLESHOOTING PROCEDURES - ELECTRONIC GOVERNOR GOES TO FULL STROKE WHEN DC POWER IS APPLIED AND ENGINE IS NOT OPERATING
ELECTRONIC GOVERNOR GOES TO FULL STROKE WHEN DC POWER IS APPLIED AND ENGINE IS NOT OPERATING - Continued
FIELD MAINTENANCE ENGINE TROUBLESHOOTING PROCEDURES - FUEL SYSTEM TESTING
Engine runs rough/low on power.
Figure 1. A3 Breaker Switch.
PERFORM FUEL FLOW TEST - Continued
PERFORM INJECTOR CUT OUT TEST - Continued
PERFORM INJECTOR CUT OUT TEST - Continued
Figure 4. Injector Manifold.
PERFORM FUEL SPILL BACK TEMPERATURE TEST
PERFORM FUEL SPILL BACK TEMPERATURE TEST - Continued
FIELD MAINTENANCE ENGINE TROUBLESHOOTING PROCEDURES - FRESH WATER COOLING SYSTEM PRESSURE TESTING
Figure 1. Heat Exchanger Pressure Cap.
Figure 2. Pressure Tester.
FIELD MAINTENANCE ENGINE TROUBLESHOOTING PROCEDURES - FRESH WATER COOLING SYSTEM THERMOSTAT TESTING
TEST FRESH WATER COOLING SYSTEM THERMOSTAT - Continued
TEST FRESH WATER COOLING SYSTEM THERMOSTAT - Continued
CHAPTER 3 - MAINTENANCE INSTRUCTIONS
FIELD MAINTENANCE ENGINE SERVICE UPON RECEIPT
SERVICE UPON RECEIPT OF MATERIEL
FIELD MAINTENANCE ENGINE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
CLEANING AND LUBRICATION
CORROSION PREVENTION AND CONTROL (CPC) - Continued
FIELD MAINTENANCE ENGINE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS), INCLUDING LUBRICATION INSTRUCTIONS
Table 1. Preventive Maintenance Checks and Services for Engine - Continued.
Table 1. Preventive Maintenance Checks and Services for Engine - Continued.
PMCS Mandatory Replacement Parts List
SUSTAINMENT MAINTENANCE ENGINE PERFORM TUNE-UP
FIELD MAINTENANCE ENGINE ENGINE MOUNTS INSPECTION
SUSTAINMENT MAINTENANCE ENGINE TESTING
PERFORM ENGINE COMPRESSION TEST - Continued
PERFORM ENGINE COMPRESSION TEST - Continued
PERFORM ENGINE COMPRESSION TEST - Continued
FIELD MAINTENANCE ENGINE REPLACEMENT
Figure 1. Fuel Supply and Return Valves Removal.
Figure 3. Air Inlet Housing Removal.
Figure 5. Engine Junction Box Removal.
Figure 6. Fuel Supply Check Valve Removal.
Figure 8. Gear Shifting Solenoids Removal.
Figure 10. Raw Water Supply Hose Removal.
Figure 12. Oil Filter Supply/Return Lines Removal.
Figure 14. Marine Gear Mounting Bracket Removal.
Figure 15. Forward Hull Saddle Removal.
Figure 16. Engine/Marine Gear Removal.
Figure 17. Marine Gear Removal.
Figure 19. Engine/Marine Gear Installation.
Figure 20. Forward Hull Saddle Installation.
Figure 22. Lifting Brackets.
Figure 24. Raw Water Hose Installation.
Figure 26. Gear Shifting Solenoid Installation.
Figure 28. Fuel Supply Check Valve Installation.
Figure 30. Starter Solenoid and Alternator Installation.
Figure 32. Fire Suppression System Installation.
Install SINCGARS antenna (TM 11-5820-890-10-8).
SUSTAINMENT MAINTENANCE ENGINE MAINTENANCE STAND INSTALLATION AND REMOVAL
Connect lifting slings and shackles to engine (Figure 1, Item 1).
Figure 1. Engine Stand.
SUSTAINMENT MAINTENANCE ENGINE ALIGNMENT
Figure 1. Engine Alignment.
Install transfer case to pump-jet machinery guard (TM 55-1945-205-10).
SUSTAINMENT MAINTENANCE ENGINE AIR BOX TESTING
Figure 1. Air Box Check Valve.
Start engine and warm up for five minutes (TM 55-1925-205-10).
Figure 3. Air Box Drain Hose.
Service cooling system (TM 55-1925-205-10).
SUSTAINMENT MAINTENANCE ENGINE AIR BOX COVERS REPLACE
Remove marine gear cooler (TM 55-2040-211-24).
Remove fuel system cooler (WP 0081).
Coat seven hex head screws (Figure 1, Item 6) with antiseize compound.
Perform operational checks (TM 55-1925-205-10).
FIELD MAINTENANCE ENGINE AIR BOX DRAINS REPLACEMENT
Figure 1. Air Box Drains Removal.
Do not exceed 40 PSI (276 kPa) when using compressed air for drying components
Apply antiseize compound to all fitting threads.
Install fuel system cooler (WP 0081).
FIELD MAINTENANCE ENGINE AIR BOX DRAIN HOSE REPLACEMENT
Figure 1. Air Box Drain Hose Replacement.
Install fuel system cooler (WP 0081).
SUSTAINMENT MAINTENANCE ENGINE REAR CYLINDER BLOCK PLATE REPAIR
Figure 1. Cylinder Block Plate.
SUSTAINMENT MAINTENANCE ENGINE REAR CYLINDER BLOCK PLATE REMOVAL AND INSTALLATION
Figure 1. Rear End Plate.
Coat rear end plate (Figure 2, Item 4) and engine block (Figure 2, Item 1) with sealing compound.
Using torque wrench, torque hex head screws (Figure 1, Item 10) to 420 in-lb (47 N·m).
Install air box covers (WP 0036).
SUSTAINMENT MAINTENANCE ENGINE FRONT CYLINDER BLOCK PLATE REMOVAL AND INSTALLATION
Figure 1. Cam Bearings.
Figure 2. Front Block Plate Removal.
Figure 4. Engine Block.
Figure 5. Front Block Plate Installation.
Install marine gear oil cooler (TM 55-2040-211-24).
SUSTAINMENT MAINTENANCE ENGINE FRONT CYLINDER BLOCK PLATE REPAIR
Support cylinder block plate (Figure 1, Item 1) on a flat surface.
SUSTAINMENT MAINTENANCE ENGINE BLOCK REPAIR
Exhaust manifolds removed. (WP 0157)
33. Fresh water cooling system starboard thermostat housing removed. (WP 0140)
59. Remove oil galley plugs (1, 2 and 3) from front of engine block (4).
63. Remove two plugs (10) from right side of engine block (4).
70. Remove reducing bushing (20) and ether starting aid thermostat (21).
The plugs and dowels in the following steps should be removed only if damaged.
86. Remove two dowels (46) from rear of engine block (4).
Clean gasket material and sealant off engine block (4) surfaces using scraper.
Inspect cylinder bore (51), grooves (52) and lands (53) for pitting and corrosion.
Position C measurement shall not exceed 5.2180 in. (132.5372 mm). d.
Counterbore depth at point A shall be between 0.4755 and 0.477 in. (12.13 and 12.12 mm) or between
20. Remove hex head screws (55) and five main bearing caps (54).
Coat core plug (34) threads with sealing compound.
Coat oil galley plugs (38) threads with sealing compound.
Install two dowels (43) in top of engine block (4) until they are flush.
12. Coat three plugs (47) and two plugs (48) threads with pipe thread sealing compound.
16. Install cup plug (49) on bottom of engine block (4).
21. Torque plug (1) to 396-444 in. lbs (45-50 N-m) using torque wrench and socket set.
25. Coat oil galley plug (3) threads with sealing compound.
38. Torque plug (8) to 276-324 in. lbs (31-37 N-m) using torque wrench and socket set.
43. Install two plugs (10) in right side of engine block (4).
53. Coat oil galley plug (14) threads with sealing compound.
66. Install two plugs (19) in left side of engine block (4).
72. Torque plugs (22) to 228-264 in. lbs (26-30 N-m) using torque wrench and socket set.
86. Coat elbow (27) threads with sealing compound.
90. Coat two seal rings (57) with lubricating oil.
94. Install eight compression gaskets (60).
99. Torque engine block pressure test core plug to 230 270 ft lbs (311 366 N-m) using torque wrench.
101. Add water until engine block water jacket is full.
105. Apply 40 PSI of pressure to engine block (4) and maintain for at least two hours.
112. Torque water inlet adaptor (36) to 230-250 ft lbs (311-339 N-m) using torque wrench.
114. Remove eight compression gaskets (60) from cylinders (51).
120. Coat engine block (4) with engine oil to prevent rust.
22. Install fuel injector control tube. (WP 0086)
49. Install starter motor. (WP 0164)
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD POPPET VALVE ROCKER ARM COVERS REPLACEMENT
This task is typical for the replacement of poppet valve rocker arm covers on both port and starboard engines
Figure 1. Cylinder Head Poppet Valve Rocker Arm Covers.
Install chain hook (Figure 1, Item 9) on strainer (Figure 1, Item 10).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD CRANKCASE BREATHER CLEANING
Figure 1. Engine Cylinder Head Crankcase Breathers.
FOLLOW-ON MAINTENANCE
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVES ADJUSTMENT
Figure 2. Injector Follower.
Figure 5. Push Rod Adjustment.
Install cylinder head poppet valve rocker arm covers (WP 0044).
CYLINDER HEAD REMOVAL AND INSTALLATION
Loosen four hose clamps (Figure 1, Item 3) from two fuel rod cover tube hoses (Figure 1, Item 4).
Position wood wedges on bench for setting cylinder head (Figure 2, Item 11).
Figure 3. Cylinder Head Gasket Removal.
Attach lifting fixture (Figure 4, Item 10) to cylinder head and lift.
Figure 4. Cylinder Block and Cylinder Head.
Figure 5. Cylinder Head Bolt Torque Sequence.
Figure 7. Fuel Rod Installation.
Install operator's cab (TM 55-1925-205-23).
REAR LIFTING BRACKETS REPLACEMENT
Figure 1. Turbocharger Air Hoses Removal.
Figure 2. Lifting Bracket.
Figure 3. Turbocharger Air Hoses Installation.
Perform operational check (TM 55-1925-205-10).
CYLINDER HEAD POPPET VALVE ROCKER ARM REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
Remove two brackets (Figure 1, Item 10) from cylinder head (Figure 1, Item 6).
Figure 1. Rocker Arm Shaft Brackets.
Wash rocker arms, shaft, brackets, and bolts with cleaning compound.
Inspect rocker arm shaft brackets (Figure 1, Item10) for cracks. Install new bracket if damaged.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD POPPET VALVE ROCKER ARM REPAIR
Figure 2. Rocker Arm Pin and Bushing Disassembly.
Inspect clevis (Figure 2, Item 1) for damage. Discard defective part.
Figure 3. Rocker Arm Pin and Bushing Assembly.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD FUEL MANIFOLD REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
Remove metal tube assembly (Figure 1, Item 1).
Figure 1. Cylinder Head Fuel Manifold.
Install cylinder head poppet valve rocker arm cover (WP 0044).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD REPAIR
Figure 1. Cylinder Head Disassembly.
Figure 2. Cylinder Head Cleaning.
Figure 3. Cylinder Head Inspection.
Figure 4. Cam Follower Bore Inspection.
Figure 5. Dummy Injectors in Cylinder Head.
Figure 6. Cover Plates on Cylinder Head.
Figure 7. Test Fixture Installation.
Observe water tank for 20 minutes watching for bubbles indicating a leak or crack.
Figure 8. Dummy Injector Removal.
Figure 10. Cylinder Head Cover Plates.
Install fuel system injector control tube (WP 0086).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD CAM FOLLOWER REPLACEMENT
Figure 1. Cam Follower Removal.
Remove cam follower (Figure 2, Item 4) from heated lubricating oil.
Install cylinder head valve guide bridge (WP 0058).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD PUSH ROD REPLACEMENT
Remove push rod (Figure 1, Item 3) assembly from cylinder head (Figure 1, Item 1).
Install new retaining ring (Figure 1, Item 2) in cylinder head (Figure 1, Item 1).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVE REMOVAL AND INSTALLATION
Support cylinder head (Figure 1, Item 5), with bottom side down, on two wood blocks.
Set cylinder head (Figure 1, Item 5) on its side.
Figure 2. Valve Clearance.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVE REPAIR
Figure 1. Exhaust Valve Components.
Figure 2. Exhaust Valve.
Dispose of contaminated cloths in accordance with local procedures.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVE SEAT INSERTS REPLACEMENT
Support cylinder head (Figure 1, Item 3) on two wooden wedges (Figure 1, Item 4).
Figure 2. Lifting Fixture.
Using replacing tool and hammer, drive inserts (Figure 1, Item 1) into cylinder head (Figure 1, Item 3).
Install cylinder head exhaust valves (WP 0055).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVE GUIDE BRIDGE REPLACEMENT
Figure 2. Valve Guide Bridge.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD VALVE GUIDES AND SEALS REPLACEMENT
Figure 1. Valve Guide Oil Seal.
Place cylinder head (Figure 2, Item 1), bottom side up, on two wood wedges.
Place cylinder head (Figure 3, Item 2), right side up, on arbor press.
Install new valve guide oil seal (Figure 4, Item 1) as follows:
Figure 4. Valve Guide Installation.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVE GUIDES CLEANING AND INSPECTION
Place cylinder head (Figure 1, Item 3) in cleaning tank filled with cleaning solution.
Inspect valve guides (Figure 1, Item 2) for fractures, chipping, scoring or wear. Replaced damaged parts.
SUSTAINMENT MAINTENANCE ENGINE CRANKSHAFT AND STABILIZER REMOVAL, CLEANING, INSPECTION, REPAIR, AND INSTALLATION
Remove hex bolts with washer (Figure 1, Item 3) from stabilizers (Figure 1, Item 1).
Figure 1. Crankshaft, Bearings, and Stabilizer.
Soak crankshaft (Figure 2, Item 6) in cleaning compound to remove dirt and oil.
Figure 2. Crankshaft and Thrust Washer Surface Dimensions.
Figure 3. Checking Crankshaft Bow.
Figure 4. Crankshaft Journal Specifications.
Figure 5. Crankshaft Woodruff Key and Plugs.
Install the lower main bearing caps (Figure 6, Item 5) in their original locations.
Figure 6. Crankshaft, Bearings, and Stabilizer.
Figure 7. Crankshaft End Play.
Figure 8. Crankshaft, Bearings, and Stabilizer.
Figure 9. Checking Crankshaft Distortion.
Install blower drive shaft (WP 0112).
SUSTAINMENT MAINTENANCE ENGINE CRANKSHAFT REAR OIL SEAL REPLACEMENT
Lay flywheel housing (Figure 1, Item 1) engine side down on wooden blocks on workbench.
Figure 2. Rear Crankshaft Oil Seal Installation.
Install flywheel housing (WP 0072).
SUSTAINMENT MAINTENANCE CAMSHAFT AND BEARINGS REPLACEMENT
On the rear of the engine, remove four screws (1), adaptor (2) and retainer (3) from left camshaft gear (4).
Using puller J 24420, remove accessory drive pulley (14) from camshaft (10).
Remove six intermediate bearing lock screws from camshafts.
Only the left cam bearing has a gasket.
Remove six lock rings and three intermediate cam bearing sets from camshafts.
Install a new woodruff key (26) in the keyway on camshafts (10 and 11).
Put six halves of intermediate bearings (30) onto the bearing journals of camshafts (10 and 11).
2. Install the right-hand camshaft (11) into the engine block (21).
Install six screws (19) and lock washers (20) into both rear bearings (27).
14. On the front of engine, apply engine oil to both front cam bearing journals.
20. Install woodruff key (15) into camshaft (10).
27. Position two retainers (3 and 7) on cam shaft gears (4 and 8).
33. Install fresh water cooling system pump drive gear. (WP 0148)
50. Install cylinder head poppet valve rocker arms. (WP 0049)
CAMSHAFT VIBRATION DAMPER REPLACEMENT
Figure 1. Vibration Damper.
Align woodruff key with woodruff key slot in camshaft.
SUSTAINMENT MAINTENANCE CAMSHAFT GEARS REPLACEMENT
Remove four cap screws (5), adaptor (6) and retainer (7) from left camshaft gear (8).
Install the right-hand cam gear (8) onto the camshaft (11).
Position two retainers (3, 7) on cam gears (4, 8).
28. Install fuel cooler. (WP 0081)
CAMSHAFT BALANCE WEIGHT REPLACEMENT
Figure 1. Balance Weight.
Install fresh water cooling system pump drive gear (WP 0148).
CAMSHAFT ACCESSORY DRIVE PULLEY REPLACEMENT
Remove woodruff key (Figure 1, Item 4) and discard.
Figure 1. Accessory Drive Pulley.
CAMSHAFT IDLER GEAR REMOVAL AND INSTALLATION
Figure 1. Gear Train.
Place cleaning cloth between camshaft gears to stop gears from rotating.
Install turbochargers (WP 0114).
SUSTAINMENT MAINTENANCE CAMSHAFT IDLER GEAR REPAIR
Clean excess grease and oil from idler gear and hub assembly (3) with cleaner.
Remove bearings (6) from idler gear (4).
Inspect idler gear (4) for corrosion, pitting or cracking. Replace defective part.
7. Position the other bearing cup, number side down, on the idler gear
16. Install inner spacer (7) over hub (5).
1. Mount idler gear and hub assembly (3) in vise by plate (11).
Install retainer (2) on idler gear and hub assembly (3).
ENGINE FLYWHEEL REPLACEMENT
Attach engine and transmission lifting sling to flywheel
Coat 10 flywheel bolts with antiseize compound.
Figure 1. Flywheel Replacement.
ENGINE FLYWHEEL REPAIR
Note the direction of the chamfer on the ring gear.
Figure 1. Flywheel.
Using torch set and heat protective mittens, flash heat ring gear uniformly.
FLYWHEEL HOUSING REPLACEMENT
Lube oil dipstick tube assembly removed
Install two lifting eye bolts in flywheel housing.
Remove four cap screws and washers from flywheel housing
Remove cap screw and copper washer.
Remove gasket and discard.
Remove two cap screws and lockwashers. Discard lockwashers.
Remove cap screw from access hole.
Remove gasket from engine rear end plate and discard.
Remove lifting eye bolts from flywheel housing
Polish end of crankshaft with abrasive cloth wet with engine lubricating oil.
Coat threads on pipe plugs (Figure 13, Items 3 and 4) with pipe sealing compound,.
Install new cap screw (Figure 16, Item 1) into access hole.
Install two new cap screws and new lockwashers into flywheel housing
Install access plate (Figure 19, Item 4) on flywheel housing (Figure 19, Item 1).
Install new gasket (Figure 20, Item 11) on flywheel housing (Figure 20, Item 3).
Remove slings, shackles, two lifting eye bolts and four aligning studs from flywheel housing
Install six new cap screws and new lockwashers into flywheel housing
Flywheel Tightening Sequence Diagram
Flywheel Housing Torque Sequence Diagram
Apply ultra blue sealing compound to flywheel housing (Figure 29, Item 1) and to access cover
Install flywheel (WP 0071).
Install crankcase breather limiter (WP 0106).
PISTON AND LINER ASSEMBLY REMOVAL AND INSTALLATION
Figure 1. Oil Distribution Inlet Tube and Screen Assembly Removal.
Figure 2. Piston and Air Inlet Ports.
Figure 4. Connecting Rod Cap and Bearing Removal.
Figure 6. Cylinder Liner Seal Rings Removal.
Figure 7. Cylinder Liner Seal Rings Installation.
Figure 8. Piston and Liner Installation.
Figure 9. Connecting Rod Bearings Installation.
Figure 10. Oil Distribution Inlet Tube and Screen Hardware Installation.
Install port thermostat housing (WP 0141).
SUSTAINMENT MAINTENANCE PISTON AND CYLINDER LINER REBUILD
Slide the piston (1) out through the bottom of the cylinder liner (2).
Slide the piston pin (10) from the piston (1).
Use compressed air to dry piston crown.
3. Check the tapered fire ring groove width in the piston crown (12) with groove gage.
Inspect the liners (2) for poor contact on the outer surfaces.
Measure the inside bore of the cylinder liner at (A, B, C, D, E, F and G) on both the (X) and (Y) axis.
{1} Calculate the general inside diameter of the liner, it should measure a minimum of 4.8390 in.
{3} Clamp the liner into place with hold down clamp.
Hold the piston assembly (1) in one hand by the piston skirt (11).
Using the skirt of the piston (1), push the ring down slightly
Ensure the piston ring grooves are clean and free of debris.
1. Install new compression and fire rings (5).
Lightly coat threads of bolt (8) with engine oil.
10. Ensure the piston pin retainer (7) is seated properly.
Lubricate the inside of the cylinder liner (2) with engine oil.
VIBRATION DAMPENER REPLACEMENT
Figure 1. Vibration Dampener Removal.
Figure 2. Inner Cone Installation.
Figure 4. Vibration Dampener/Hub Assembly.
Figure 5. Vibration Dampener Installation.
FRONT BALANCE WEIGHT COVER REPAIR
Dry cover (Figure 1, Item 1) with compressed air.
Figure 1. Oil Seal Removal.
Lightly lubricate outer surface of new oil seal with lubricating oil.
Figure 2. Oil Seal Installation.
FRONT BALANCE WEIGHT COVER REMOVAL AND INSTALLATION
Figure 1. Front Balance Weight Cover.
Remove gasket (Figure 2, Item 2) and discard.
Install engine forward lifting bracket (WP 0135).
FUEL SYSTEM PRIMING
Figure 2. Fuel Priming Pump.
FUEL FILTER CARTRIDGE REPLACEMENT
Figure 1. A3 Breaker Switch.
Figure 2. Fuel Filter Adapter Removal.
Remove LO/TO from A3 breaker switch. Refer to FM 4-01.502 for LO/TO procedure.
FUEL HOSES AND TUBES REPLACEMENT
Figure 1. A3 Breaker Switch.
Figure 2. Fuel Supply and Return Valves.
REMOVAL FUEL RUBBER HOSES
Start engine (TM 55-1925-205-10).
FUEL COOLER REPLACEMENT
Figure 2. Butterfly Valve.
Figure 3. Fuel Cooler Removal.
Figure 4. Fuel Cooler Removal.
Figure 5. Fuel Cooler Installation.
Figure 6. Fuel Cooler Hoses Installation.
Clean up spilled fluids with spill clean-up kit
FUEL COOLER MOUNTING BRACKET REPLACEMENT
Figure 1. Fuel Cooler Bracket.
FUEL FILTER ADAPTER REPAIR
Place a drain pan under fuel filter adapter (Figure 1, Item 8).
Figure 1. Fuel Filter Adapter Removal.
Figure 2. Fuel Filter Adapter Removal and Installation.
Figure 3. Fuel Filter Adapter Installation.
FUEL FILTER MOUNTING BRACKET REPLACEMENT
Perform operational check of diesel engine (TM 55-1925-205-10).
FUEL ADAPTER BLOCK REPLACEMENT
Figure 1. Fuel Adapter Block Lines Removal.
Figure 2. Fuel Adapter Block Removal.
Figure 3. Fuel Adapter Block Installation.
Figure 4. Fuel Adapter Block Lines Installation.
FUEL INJECTOR CONTROL TUBE AND LEVER ASSEMBLY REMOVAL AND INSTALLATION
Disengage rack control levers from injector control racks.
Figure 1. Fuel Injector Control Tube.
FUEL INJECTOR CONTROL TUBE AND LEVER ASSEMBLY REPAIR
Remove stationary bracket from control tube.
Figure 1. Injector Rack.
Remove control lever from injector control tube assembly.
Figure 2. Indexing Bracket and Injector Control Tube.
Figure 3. Injector Control Tube.
FUEL INJECTOR MODULATOR ASSEMBLY REMOVAL AND INSTALLATION
Figure 1. Fuel Modulator Removal and Installation.
Figure 2. Control Tube.
FUEL IGNITION MODULATOR ASSEMBLY REPAIR
Using cleaner, clean modulator assembly components.
Install pin and roller on lever assembly.
FUEL IGNITION MODULATOR ASSEMBLY ADJUSTMENT
Figure 2. Injector Body.
Figure 3. Ignition Modulator Adjustment.
Install cylinder head poppet valve rocker arm cover (WP 0044).
FUEL INJECTOR ASSEMBLY REMOVAL, CLEANING, INSPECTION AND INSTALLATION
Slide injector control rack lever (3) away from injector control rack (4).
Cover injector hole (9) with clean, lint free cloth.
Inspect injector follower spring for rust and corrosion. If found, replace fuel injector.
6. Slide injector rack control lever (3) into injector control rack (4).
19. Install intake plenum assembly. (TM 55-1945-205-24-3-1)
FUEL INJECTOR TIMING ADJUSTMENT
Figure 2. Exhaust Valves.
Figure 3. Injector Adjustment.
FUEL INJECTOR RACK CONTROL LEVER ADJUSTMENT
Figure 1. Fuel Supply and Return Valves.
Figure 3. Right Cylinder Head.
Figure 5. Left Cylinder Head.
Verify the adjustment of the control lever is not too tight.
Disconnect the fuel rod from the clevis lever
Tighten the adjusting screw an additional 1/8 turn.
Figure 8. Left Cylinder Head.
Figure 10. Left Cylinder Head.
Repeat Steps 33 through 36 for remaining two injector rack control levers
Figure 11. S1 Switch
FUEL PUMP REMOVAL AND INSTALLATION
Figure 1. A3 Breaker Switch.
Figure 2. Fuel Valves.
Figure 3. Fuel Pump.
Install heat exchanger (WP 0134).
FUEL PUMP REPAIR
Figure 2. Fuel Pump Secured in Vise.
Figure 4. Driveshaft, Drive Gear and Retaining Ball Disassembly.
Figure 5. Relief Valve Plug Disassembly.
Figure 6. Oil Seal Removal.
Inspect driven shaft for wear or scoring. Replace defective parts.
Figure 7. Fuel Pump On Wooden Wedges.
Ensure fuel pump body sits flush on wedge wood
Figure 10. Relief Valve Plug Assembly.
Figure 11. Driveshaft, Drive Gear and Retaining Ball Assembly.
Use lubricating oil to lubricate gear assembly (Figure 13, Item 7).
Figure 14. Fuel Pump Elbow Fitting Installation.
FUEL PRIMING PUMP REPLACEMENT
Figure 2. Fuel Supply and Return Valves.
Figure 3. Fuel Priming Pump.
Clean up spilled fluid with a spill clean-up kit and dispose
ELECTRONIC GOVERNOR ROD ASSEMBLY REPAIR
Figure 1. A3 Breaker Switch.
Figure 2. Electronic Governor.
ELECTRONIC GOVERNOR ACTUATOR REPLACEMENT
Figure 1. A3 Breaker Switch.
Figure 2. Electronic Governor Actuator.
Figure 3. Governor Actuator.
ELECTRONIC GOVERNOR CONTROLLER REPLACEMENT
Remove governor controller (Figure 2, Item 2).
Figure 2. Electrical Enclosure.
Start the engine TM 55-1925-205-10.
Figure 3. Electronic Governor Controller.
Figure 4. Actuator Lever.
Figure 5. Electrical Enclosure.
ELECTRONIC GOVERNOR MAGNETIC PICK-UP REPLACEMENT
Flywheel & Electronic Governor.
Install electronic control valve (TM 55-1925-319-23).
ELECTRONIC GOVERNOR DRIVE ASSEMBLY REMOVAL AND INSTALLATION
Figure 1. Injector Rack and Fuel Rods.
Figure 2. Governor Drive.
Install intake plenum assembly (TM 55-1925-205-10).
ELECTRONIC GOVERNOR DRIVE ASSEMBLY REPAIR
Figure 1. Electronic Governor Drive Assembly.
Clean all parts with cleaner.
Install woodruff key into shaft of shaft and lever assembly.
AIR INTAKE HOUSING REPAIR
Figure 1. A3 Breaker Switch.
Figure 3. Blower Gasket Removal.
Using type II cleaner, clean all parts of dirt and grease.
Figure 4. Springs and Valves.
Figure 5. Blower Gasket Installation.
Figure 6. Air Intake Housing Installation.
AIR INLET COLLECTOR ASSEMBLY REPLACEMENT
Slide collector assembly out of band.
Figure 1. Collector Assembly.
AIR INLET COLLECTOR ASSEMBLY REPAIR
Coat air filter element with filter element oil from filter cleaning kit
Use cleaner to clean retainer springs, air inlet collector assembly
Figure 2. Air Inlet Collector Disassembly.
CRANKCASE BREATHER LIMITER ASSEMBLY REPLACEMENT
Remove six hose clamps (Figure 1, Item 1) from hoses (Figure 1, Item 2).
CRANKCASE VENTILATION BREATHER PIPE REPLACEMENT
Figure 1. Crankcase Breather Hose.
Figure 2. Crankcase Breather Hose Elbow.
Install electronic governor actuator (WP 0098).
BLOWER BYPASS VALVE REPLACEMENT
Remove hose (Figure 2, Item 2) from valve (Figure 2, Item 7).
Perform operational check of diesel engine
BLOWER DRIVESHAFT AND SPRING ASSEMBLY REPLACEMENT
Figure 1. Broken Blower Driveshaft Portion Removal.
Figure 3. Blower Driveshaft Retaining Ring.
Install driveshaft alignment tool into hole of blower driveshaft
Install electronic governor actuator (WP 0098).
BLOWER REMOVAL AND INSTALLATION
Using sling, lift blower (Figure 1, Item 2) up and away from block
Figure 1. Blower.
Using torque wrench and socket set, tighten four long bolts
Perform operational check of diesel engine (TM 55-1925-205-10).
BLOWER ASSEMBLY REPAIR
Remove nine bolts (Figure 1, Item 2) and washers
Both gears must be pulled at the same time.
Remove two fillister head screws securing rear end plate
Remove fuel pump drive bolt (Figure 5, Item 5), lock washers
Remove bearings (Figure 7, Item 4), oil seals
Remove seal rings and seal ring carriers and bearing race from rotor shafts
Discard oil seal ring carriers (Figure 9, Item 6)
Examine the blower timing gears
Install the oversize seal and sleeve.
Install remaining oversize seal sleeves on rotors
Install the blower front end plate.
Install blower rotors in the blower housing.
Install the blower rear end plate (Figure 15, Item 4).
h. Using a torque wrench and screwdriver socket wrench set, torque
Install rear blower rotor shaft bearings
Reverse the position of the blower housing
Install self locking screws.
Lubricate the splines with light engine oil.
Figure 20. VIEWS FROM GEAR END OF BLOWER.
Check the clearance between each rotor lobe
Table 1. Chart of Minimum Blower Clearances.
Table 1. Chart of Minimum Blower Clearances - Continued.
BLOWER DRIVE ASSEMBLY REMOVAL AND INSTALLATION
Figure 1. Blower Hardware.
Figure 2. Blower Drive.
BLOWER DRIVE ASSEMBLY REPAIR
Figure 2. Spring Plates.
Figure 4. Thrust Washers.
Clean all metal parts with cleaner.
Place blower support shaft into soft jaw vise caps of vise.
TURBOCHARGER REPLACEMENT
Figure 1. Turbo Exhaust Elbow Removal.
Figure 2. Turbocharger Removal.
Figure 4. Oil Drain Hose Removal.
Figure 5. Exhaust Flange Removal.
Figure 6. Turbocharger Gasket Installation.
Figure 8. Coolant Lines Installation.
Figure 9. Turbocharger Exhaust Elbow Installation.
Install air intake housing (WP 0103).
LUBE OIL SYSTEM CRANKCASE SERVICING
Figure 1. A3 Breaker Switch.
Connect a combination hose coupling and pipe nipple to end of pump suction hose.
Figure 2. Dust Cap.
Figure 3. Dipstick.
Replace dust cap on forward coupling half.
LUBE OIL SYSTEM CRANKCASE PRESSURE TESTING
Figure 2. Oil Level Dipstick.
Shut down engine (TM 55-1925-205-10).
LUBE OIL SYSTEM TURBOCHARGER FLANGED OIL TUBE TO ENGINE OIL HOSE REPLACEMENT
Position drain pan under flanged oil tube
Figure 2. Flanged Oil Tubes.
LUBE OIL SYSTEM HOSES REPLACEMENT
Using a wrench, hold the elbow or fitting
Figure 1. Oil Hoses Replacement.
LUBE OIL PUMP REMOVAL AND INSTALLATION
Figure 1. Oil Pump Brackets.
Figure 2. Oil Pump.
Using oil seal expander with guide studs, install oil pump
Install air box covers (WP 0036).
LUBE OIL PUMP REPAIR
Figure 1. Oil Pump Gear Retaining Plate.
Clean all metal parts with cleaner.
Figure 2. Oil Pump Gears.
Figure 3. Front Cover Assembly.
LUBE OIL PUMP INLET SCREEN REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
Remove screen (Figure 1, Item 5) from cover (Figure 1, Item 1).
Figure 1. Oil Pump Inlet Screen.
Install exhaust manifolds (WP 0157).
LUBE OIL SYSTEM DISTRIBUTION COMPONENTS REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
Figure 1. Lube Oil System Distribution Components.
Remove two support brackets as follows:
Using torque wrench, torque boltsto 156 to 204 in-lb
LUBE OIL PRESSURE REGULATOR VALVE REMOVAL AND INSTALLATION
Figure 1. Lube Oil Pressure Regulator Valve.
Remove engine from stand (WP 0033).
LUBE OIL PRESSURE REGULATOR VALVE REPAIR
Remove lube oil pressure regulator valve body
Inspect spring for deformation, pitting, breaks or corrosion. Replace defective part.
LUBE OIL PRESSURE RELIEF VALVE REMOVAL AND INSTALLATION
Figure 1. Lube Oil Pressure Relief Valve Removal and Installation.
Remove engine from stand (WP 0033).
LUBE OIL PRESSURE RELIEF VALVE REPAIR
Figure 1. Vise With Lube Oil Pressure Relief Valve Body.
Remove lube oil pressure relief valve body
Insert lube oil pressure relief valve
LUBE OIL PAN REPLACEMENT
Figure 1. Oil Pan.
Using cleaner, clean new oil pan (Figure 2, Item 2).
Figure 2. Oil Pan Gasket.
Install marine gear oil cooler (TM 55-2040-211-24).
LUBE OIL COOLER REPLACEMENT
Figure 1. A3 Breaker Switch.
Figure 2. Oil Filter Supply Lines.
Figure 4. Cover Plate Removal.
Figure 6. Cover Plates Removal.
Figure 8. Oil Cooler Mounting Plates Removal.
Use cleaner and a force pump to clean oil cooler core oil passages, as follows:
Remove drain pan and dispose of contents in accordance with local procedures.
Figure 9. Oil Cooler Mounting Plates Installation.
Figure 11. Oil Cooler Installation.
Figure 13. Mounting Hardware Installation.
Figure 15. Oil Cooler Housing Installation.
Perform operational checks (TM 55-1925-205-10).
LUBE OIL COOLER BYPASS VALVE REPLACEMENT
Figure 1. Oil Cooler Adapter.
Figure 2. Oil Cooler Adapter.
LUBE OIL DIPSTICK TUBE ASSEMBLY REPLACEMENT
Remove O-ring from lube oil dipstick tube assembly
Perform operational checks (TM 55-1925-205-10).
LUBE OIL PRESSURE SENDING UNIT REPLACEMENT
Tag and disconnect two wires from oil pressure sending unit
Clean spilled fluid with spill clean-up kit
LUBE OIL TEMPERATURE SWITCH REPLACEMENT
Position a drain pan under lube oil temperature switch
Perform operational check of the diesel engine (TM 55-1925-205-10).
FRESH WATER COOLING SYSTEM FLUSH
Place A3 breaker switch, located on A10 panel
Position drain pan under drain cocks
Remove engine thermostats and install thermostat covers
Figure 2. Coolant Drain Cocks.
Remove drain pans and dispose of contents
Figure 3. Coolant Flush Drain Cocks.
Drain cooling system completely, as follows:
Figure 4. Coolant Drain Cocks.
Ensure drain cocks are closed.
Figure 5. Pressure Control Cap.
Perform operational checks (TM 55-1925-205-10).
FRESH WATER COOLING SYSTEM HEAT EXCHANGER REPLACEMENT
Loosen clamp on inlet hose/tube assembly
Figure 2. Expansion Tank Removal.
Install new gasket on new heat exchanger core
Figure 3. Expansion Tank Installation.
FORWARD LIFTING BRACKET REPLACEMENT
Remove support (Figure 1, Item 1) from engine
Install heat exchanger (WP 0134).
FRESH WATER COOLING SYSTEM FILTER ELEMENT REPLACEMENT
Figure 2. Fresh Water Filter Valves.
FRESH WATER COOLING SYSTEM FILTER HEAD COVER REPLACEMENT
Place drain pan under filter cover
Figure 2. Filter Head Cover.
Wrap bushing threads with antiseizing tape.
Install fresh water cooling system filter (WP 0136).
FRESH WATER COOLING SYSTEM FILTER HEAD COVER MOUNTING BRACKET REPLACEMENT
Figure 2. Heat Exchanger.
Figure 3. Mounting Bracket.
Install fresh water cooling system filter (WP 0137).
FRESH WATER COOLING SYSTEM THERMOSTAT REPLACEMENT
Remove port thermostats (Figure 1, Item 5).
Figure 1. Port Thermostats.
Figure 2. Starboard Thermostats.
Figure 3. Port Thermostats.
Figure 4. Starboard Thermostats.
Install fresh water cooling system bypass tube (WP 0143).
FRESH WATER COOLING SYSTEM STARBOARD THERMOSTAT HOUSING REPLACEMENT
Apply sealing compound to gasket surface of cylinder head
Install fresh water cooling system thermostat (WP 0139).
FRESH WATER COOLING SYSTEM PORT THERMOSTAT HOUSING REPLACEMENT
Using putty knife, clean gasket surface of cylinder head
Figure 1. Thermostat Housing.
Shut engine down (TM 55-1925-205-10).
FRESH WATER TEMPERATURE SENDING UNIT REPLACEMENT
Remove drain pan and dispose of contents in accordance with local procedures.
Figure 2. Thermostat Housing.
FRESH WATER COOLING SYSTEM BYPASS HOSES REPLACEMENT
Figure 1. Cooling System Bypass Hoses.
Service fresh water cooling system (TM 55-1925-205-10).
FRESH WATER COOLING SYSTEM COOLANT HOSES REPLACEMENT
Figure 1. Cooling Hose.
Drain residual coolant into drain pan.
Fill cooling system (TM 55-1925-205-10).
FRESH WATER COOLING SYSTEM PORT WATER OUTLET MANIFOLD REPLACEMENT
Figure 1. Fresh Water Cooling System Port Water Outlet Manifold.
Install new gaskets (Figure 1, Item 10) on cylinder head
FRESH WATER COOLING SYSTEM STARBOARD WATER OUTLET MANIFOLD REPLACEMENT
Figure 1. Fresh Water Cooling System Starboard Water Outlet Manifold.
Position new water outlet manifold
FRESH WATER COOLING SYSTEM PUMP REPLACEMENT
Figure 1. Pump Body.
Figure 3. Water Pump Body.
Figure 4. Water Pump Cover.
Install fuel system fuel filter (WP 0079).
FRESH WATER COOLING SYSTEM PUMP DRIVE GEAR REPLACEMENT
Install new woodruff key on shaft
Install camshaft vibration damper (WP 0064).
FRESH WATER COOLING SYSTEM PUMP REPAIR
Using retaining ring pliers, slide pliers into slot of gear
Install impeller puller onto impeller
Using a brass drift as a buffer between the arbor press
14. Remove inner bearing
Lubricate the bearing surface of the new shaft with grease.
10. Install the new oil seal in the pump body
Install gear installation tool on threaded end of shaft.
Apply a thin coat of adhesive to outside diameter of water seal
AFTERCOOLER REPLACEMENT
Verify fuel supply and return valves
Figure 3. Engine Aftercooler.
Tighten hose clamps (Figure 3, Item 9).
FUEL COOLER ZINC ANODE PLUG REPLACEMENT
Remove zinc anode from fuel cooler
Tighten zinc anode (Figure 3, Item 2).
MARINE GEAR COOLER ZINC ANODE PLUG REPLACEMENT
Verify butterfly valve on seachest is off.
Figure 3. Zinc Anode.
HEAT EXCHANGER ZINC ANODE PLUG REPLACEMENT
Figure 2. Butterfly Valve.
Wrap support plug threads with antiseizing tape.
RAW WATER PUMP ZINC ANODE PLUG REPLACEMENT
Figure 2. Butterfly Valve.
Figure 3. Raw Water Pump.
RAW WATER PUMP REPLACEMENT
Figure 2. Raw Water Pump and Tubes.
Figure 3. Outlet Elbow.
Figure 4. Raw Water Pump.
Figure 5. Outlet Elbow.
Start engine and verify there are no leaks
RAW WATER PUMP REPAIR
Figure 1. Raw Water Pump.
Figure 3. Drive Gear.
Figure 4. Arbor Press.
Figure 5. Slinger and Bearing Seal.
Figure 7. Slotted Screw, Cam, and Wear Plate.
Support bearing on wooden wedges.
EXHAUST MANIFOLD REPLACEMENT
Figure 1. Water Inlet Tube.
Using torque wrench and socket set, torque bolts
Install six bolts (Figure 1, Item 5) and new lockwashers
MARINE GEAR OIL COOLER MOUNTING BRACKET REPLACEMENT
Figure 1. Mounting Bracket.
ELECTRICAL SYSTEM NORMAL STOP PUSHBUTTON REPLACEMENT
Remove cover (Figure 2, Item 4) from box
Perform operational check of diesel engine
ELECTRICAL SYSTEM NORMAL STOP PUSHBUTTON MOUNTING BRACKET REPLACEMENT
Figure 1. Mounting Bracket.
ELECTRICAL SYSTEM HOUR METER REPLACEMENT
Figure 2. Hour Meter Bracket.
ELECTRICAL SYSTEM HOUR METER MOUNTING BRACKET REPLACEMENT
Figure 2. Hour Meter Mounting Bracket.
STARTER RELAY REPLACEMENT
Remove two bolts, lockwashers, and nuts
Figure 2. Starter Relay.
STARTING MOTOR REPLACEMENT
Tag and remove wires from solenoid switch
Figure 1. Starter Motor.
ENGINE COLD PACK STARTING AID REPLACEMENT
Remove cylinder by turning it counterclockwise.
Figure 1. Cold Pack Starting Aid.
COLD START TEMPERATURE SWITCH REPLACEMENT
Figure 2. Cold Start Switch.
TACHOMETER SENDING UNIT REPLACEMENT
Figure 2. Tachometer Sending Unit.
TACHOMETER DRIVE REPAIR
Install new tachometer drive in housing assembly
Install tachometer sending unit (WP 0167).
OVERSPEED GOVERNOR REPLACEMENT AND ADJUSTMENT
Figure 2. Overspeed Governor Box Cover Removal.
Figure 3. Stuffing Tube.
Figure 4. Mounting Plate and Speed Switch.
Figure 5. Set Points.
Verify ohmmeter reads zero ohms.
Figure 6. Jumper Terminals.
Figure 7. Overspeed Governor Box Cover Installation.
AUTO SHUTDOWN SYSTEM EMERGENCY STOP SOLENOID REPLACEMENT
Tag emergency stop solenoid electrical wire
Figure 3. Emergency Stop Solenoid Link.
Figure 5. Emergency Stop Solenoid Bracket.
Figure 7. Emergency Stop Solenoid Mounting.
Figure 8. Emergency Stop Solenoid Link.
Install SINCGARS antenna (TM 11-5820-890-10-8).
AUTO SHUTDOWN SYSTEM HIGH WATER TEMPERATURE SWITCH REPLACEMENT
Tag and disconnect wires from switch
Service fresh water cooling system (TM 55-1925-205-23).
AUTO SHUTDOWN SYSTEM LOW OIL PRESSURE SWITCH REPLACEMENT
Tag and disconnect wires from oil pressure switch
Figure 2. Oil Pressure Switch.
AUTO SHUTDOWN SYSTEM FUEL OIL PRESSURE SWITCH REPLACEMENT
Figure 2. Fuel Supply and Return Valves.
Figure 3. Fuel Oil Pressure Switch.
Perform operational check of diesel engine
TORQUE LIMITS
Figure 2. Torque Wrench Adapter Centerline.
Figure 4. Bolt Head Markings.
Table 1. SAE Standard Torque Table.
Table 2. SAE Standard Torque Table.
Table 3. Metric Standard Torque Table.
Table 4. Metric Standard Torque Table.
CHAPTER 4 - SUPPORTING INFORMATION
REFERENCES
SUPPLY CATALOGS
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
Maintenance Functions
Explanation of Columns in the MAC
Explanation of Columns in the Tools and Test Equipment Requirements
Table 1. Maintenance Allocation Chart for Engine
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
EXPENDABLE AND DURABLE ITEMS LIST (EDIL)
Table 1. Expendable and Durable Items List
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
WARPING TUG DIESEL ENGINE TOOL IDENTIFICATION LIST (TIL)
Table 1. Tool Identification List. (TIL) (Continued)
Table 1. Tool Identification List. (TIL) (Continued)
Table 1. Tool Identification List. (TIL) (Continued)
Table 1. Tool Identification List. (TIL) (Continued)
Table 1. Tool Identification List. (TIL) (Continued)
Table 1. Tool Identification List. (TIL) (Continued)
MANDATORY REPLACEMENT PARTS (MRP) LIST
Table 1. Mandatory Replacement Parts List
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
FIELD MAINTENANCE ENGINE GENERAL MAINTENANCE
CORROSION PREVENTION AND CONTROL (CPC) - Continued
LIST OF ABBREVIATIONS/ACRONYMS - Continued
LIST OF ABBREVIATIONS/ACRONYMS - Continued
FIELD MAINTENANCE ENGINE EQUIPMENT DESCRIPTION AND DATA
Figure 2. Propulsion Module.
Figure 3. Diesel Engine External Components Top View.
Figure 5. Diesel Engine External Components Starboard Side View.
Figure 7. Diesel Engine External Components Aft View.
Lubrication System
Figure 8. Diesel Engine Internal Components.
Table 1. Equipment Data.
Table 1. Equipment Data - Continued.
FIELD MAINTENANCE ENGINE THEORY OF OPERATION
Figure 1. Two-Cycle Sequence.
Figure 2. Air Induction System.
Figure 3. Turbocharger.
Engine Blower
Figure 4. Fuel System.
Figure 5. Fuel Injector.
FUEL SYSTEM - Continued
Figure 6. Fuel Pump.
Figure 7. Cooling System.
Figure 8. Water Pump.
Heat Exchanger
Coolant Filter and Conditioner
LUBRICATION SYSTEM - Continued
Figure 11. Oil Pump Gears.
Figure 12. Oil Pump Pressure Regulator.
Figure 13. Oil Cooler.
Water-Cooled Exhaust Manifold
Overspeed Governor
CHAPTER 2 - TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING INDEX
TROUBLESHOOTING PROCEDURES - ENGINE WILL NOT TURN OVER
Defective engine start pushbutton.
TROUBLESHOOTING PROCEDURES - ENGINE TURNS OVER BUT WILL NOT START
Water in fuel/water separator.
Fuel pump relief valve sticks open or partially open.
The emergency air shutdown was activated.
Replace starting motor (WP 0164).
FIELD MAINTENANCE ENGINE TROUBLESHOOTING PROCEDURES - ENGINE DOES NOT START IN COLD TEMPERATURES
TROUBLESHOOTING PROCEDURES - ENGINE STARTS WITH DIFFICULTY AND RUNS ROUGH
Water is discovered in the fuel/water separator.
Low compression.
TROUBLESHOOTING PROCEDURES - SUDDEN LOSS OF POWER
The air inlet is blocked.
TROUBLESHOOTING PROCEDURES - ENGINE LACKS POWER
The engine is not getting enough air.
TROUBLESHOOTING PROCEDURES - ENGINE NOT RECEIVING FUEL FROM TANK
Loose connections or cracked fuel lines.
Power from diesel engine is lost and heavy black smoke is coming from exhaust plenum.
TROUBLESHOOTING PROCEDURES - HIGH OIL CONSUMPTION
Overfilled crankcase.
Turbocharger seals are leaking.
Piston pin retainer loose.
Dirt in air intake system.
TROUBLESHOOTING PROCEDURES - LOW READING ON OIL PRESSURE GAUGE
Poor circulation, oil cooler clogged.
Electrical instrument panel sending units are faulty.
TROUBLESHOOTING PROCEDURES - EXCESSIVE READING ON OIL PRESSURE GAUGE
Cylinder blow-by, piston rings worn or broken.
Faulty exhaust piping.
TROUBLESHOOTING PROCEDURES - ABOVE NORMAL READING ON ENGINE COOLANT TEMPERATURE GAUGE
Faulty thermostat.
CORRECTIVE ACTION - Continued
TROUBLESHOOTING PROCEDURES - BELOW NORMAL READING ON ENGINE COOLANT TEMPERATURE GAUGE
Below normal coolant temperature, excessive leakage at thermostat seal.
TROUBLESHOOTING PROCEDURES - ENGINE FAILS TO STOP WHEN EMERGENCY STOP IS ACTIVATED
Emergency stop solenoid is defective.
Fuel return line is clogged.
TROUBLESHOOTING PROCEDURES - NOISY OPERATION OR VIBRATION IN TURBOCHARGER
Leak in engine air intake piping and housing.
TROUBLESHOOTING PROCEDURES - ELECTRICAL GENERATING SYSTEM SHOWS LOW BATTERY AND LOW OR NO CHARGING RATE
Defective alternator.
TROUBLESHOOTING PROCEDURES - ELECTRICAL GENERATING SYSTEM SHOWS FULLY CHARGED BATTERY AND HIGH CHARGING RATE
TROUBLESHOOTING PROCEDURES - ELECTRONIC GOVERNOR ACTUATOR STAYS AT MINIMUM POSITION WHEN POWER IS APPLIED
Binding electronic governor drive.
ELECTRONIC GOVERNOR ACTUATOR STAYS AT MINIMUM POSITION WHEN POWER IS APPLIED - Continued
ELECTRONIC GOVERNOR ACTUATOR STAYS AT MINIMUM POSITION WHEN POWER IS APPLIED - Continued
TROUBLESHOOTING PROCEDURES - ELECTRONIC GOVERNOR GOES TO FULL STROKE WHEN DC POWER IS APPLIED AND ENGINE IS NOT OPERATING
ELECTRONIC GOVERNOR GOES TO FULL STROKE WHEN DC POWER IS APPLIED AND ENGINE IS NOT OPERATING - Continued
FIELD MAINTENANCE ENGINE TROUBLESHOOTING PROCEDURES - FUEL SYSTEM TESTING
Engine runs rough/low on power.
Figure 1. A3 Breaker Switch.
PERFORM FUEL FLOW TEST - Continued
PERFORM INJECTOR CUT OUT TEST - Continued
PERFORM INJECTOR CUT OUT TEST - Continued
Figure 4. Injector Manifold.
PERFORM FUEL SPILL BACK TEMPERATURE TEST
PERFORM FUEL SPILL BACK TEMPERATURE TEST - Continued
FIELD MAINTENANCE ENGINE TROUBLESHOOTING PROCEDURES - FRESH WATER COOLING SYSTEM PRESSURE TESTING
Figure 1. Heat Exchanger Pressure Cap.
Figure 2. Pressure Tester.
FIELD MAINTENANCE ENGINE TROUBLESHOOTING PROCEDURES - FRESH WATER COOLING SYSTEM THERMOSTAT TESTING
TEST FRESH WATER COOLING SYSTEM THERMOSTAT - Continued
TEST FRESH WATER COOLING SYSTEM THERMOSTAT - Continued
CHAPTER 3 - MAINTENANCE INSTRUCTIONS
FIELD MAINTENANCE ENGINE SERVICE UPON RECEIPT
SERVICE UPON RECEIPT OF MATERIEL
FIELD MAINTENANCE ENGINE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
CLEANING AND LUBRICATION
CORROSION PREVENTION AND CONTROL (CPC) - Continued
FIELD MAINTENANCE ENGINE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS), INCLUDING LUBRICATION INSTRUCTIONS
Table 1. Preventive Maintenance Checks and Services for Engine - Continued.
Table 1. Preventive Maintenance Checks and Services for Engine - Continued.
PMCS Mandatory Replacement Parts List
SUSTAINMENT MAINTENANCE ENGINE PERFORM TUNE-UP
FIELD MAINTENANCE ENGINE ENGINE MOUNTS INSPECTION
SUSTAINMENT MAINTENANCE ENGINE TESTING
PERFORM ENGINE COMPRESSION TEST - Continued
PERFORM ENGINE COMPRESSION TEST - Continued
PERFORM ENGINE COMPRESSION TEST - Continued
FIELD MAINTENANCE ENGINE REPLACEMENT
Figure 1. Fuel Supply and Return Valves Removal.
Figure 3. Air Inlet Housing Removal.
Figure 5. Engine Junction Box Removal.
Figure 6. Fuel Supply Check Valve Removal.
Figure 8. Gear Shifting Solenoids Removal.
Figure 10. Raw Water Supply Hose Removal.
Figure 12. Oil Filter Supply/Return Lines Removal.
Figure 14. Marine Gear Mounting Bracket Removal.
Figure 15. Forward Hull Saddle Removal.
Figure 16. Engine/Marine Gear Removal.
Figure 17. Marine Gear Removal.
Figure 19. Engine/Marine Gear Installation.
Figure 20. Forward Hull Saddle Installation.
Figure 22. Lifting Brackets.
Figure 24. Raw Water Hose Installation.
Figure 26. Gear Shifting Solenoid Installation.
Figure 28. Fuel Supply Check Valve Installation.
Figure 30. Starter Solenoid and Alternator Installation.
Figure 32. Fire Suppression System Installation.
Install SINCGARS antenna (TM 11-5820-890-10-8).
SUSTAINMENT MAINTENANCE ENGINE MAINTENANCE STAND INSTALLATION AND REMOVAL
Connect lifting slings and shackles to engine (Figure 1, Item 1).
Figure 1. Engine Stand.
SUSTAINMENT MAINTENANCE ENGINE ALIGNMENT
Figure 1. Engine Alignment.
Install transfer case to pump-jet machinery guard (TM 55-1945-205-10).
SUSTAINMENT MAINTENANCE ENGINE AIR BOX TESTING
Figure 1. Air Box Check Valve.
Start engine and warm up for five minutes (TM 55-1925-205-10).
Figure 3. Air Box Drain Hose.
Service cooling system (TM 55-1925-205-10).
SUSTAINMENT MAINTENANCE ENGINE AIR BOX COVERS REPLACE
Remove marine gear cooler (TM 55-2040-211-24).
Remove fuel system cooler (WP 0081).
Coat seven hex head screws (Figure 1, Item 6) with antiseize compound.
Perform operational checks (TM 55-1925-205-10).
FIELD MAINTENANCE ENGINE AIR BOX DRAINS REPLACEMENT
Figure 1. Air Box Drains Removal.
Do not exceed 40 PSI (276 kPa) when using compressed air for drying components
Apply antiseize compound to all fitting threads.
Install fuel system cooler (WP 0081).
FIELD MAINTENANCE ENGINE AIR BOX DRAIN HOSE REPLACEMENT
Figure 1. Air Box Drain Hose Replacement.
Install fuel system cooler (WP 0081).
SUSTAINMENT MAINTENANCE ENGINE REAR CYLINDER BLOCK PLATE REPAIR
Figure 1. Cylinder Block Plate.
SUSTAINMENT MAINTENANCE ENGINE REAR CYLINDER BLOCK PLATE REMOVAL AND INSTALLATION
Figure 1. Rear End Plate.
Coat rear end plate (Figure 2, Item 4) and engine block (Figure 2, Item 1) with sealing compound.
Using torque wrench, torque hex head screws (Figure 1, Item 10) to 420 in-lb (47 N·m).
Install air box covers (WP 0036).
SUSTAINMENT MAINTENANCE ENGINE FRONT CYLINDER BLOCK PLATE REMOVAL AND INSTALLATION
Figure 1. Cam Bearings.
Figure 2. Front Block Plate Removal.
Figure 4. Engine Block.
Figure 5. Front Block Plate Installation.
Install marine gear oil cooler (TM 55-2040-211-24).
SUSTAINMENT MAINTENANCE ENGINE FRONT CYLINDER BLOCK PLATE REPAIR
Support cylinder block plate (Figure 1, Item 1) on a flat surface.
SUSTAINMENT MAINTENANCE ENGINE BLOCK REPAIR
Exhaust manifolds removed. (WP 0157)
33. Fresh water cooling system starboard thermostat housing removed. (WP 0140)
59. Remove oil galley plugs (1, 2 and 3) from front of engine block (4).
63. Remove two plugs (10) from right side of engine block (4).
70. Remove reducing bushing (20) and ether starting aid thermostat (21).
The plugs and dowels in the following steps should be removed only if damaged.
86. Remove two dowels (46) from rear of engine block (4).
Clean gasket material and sealant off engine block (4) surfaces using scraper.
Inspect cylinder bore (51), grooves (52) and lands (53) for pitting and corrosion.
Position C measurement shall not exceed 5.2180 in. (132.5372 mm). d.
Counterbore depth at point A shall be between 0.4755 and 0.477 in. (12.13 and 12.12 mm) or between
20. Remove hex head screws (55) and five main bearing caps (54).
Coat core plug (34) threads with sealing compound.
Coat oil galley plugs (38) threads with sealing compound.
Install two dowels (43) in top of engine block (4) until they are flush.
12. Coat three plugs (47) and two plugs (48) threads with pipe thread sealing compound.
16. Install cup plug (49) on bottom of engine block (4).
21. Torque plug (1) to 396-444 in. lbs (45-50 N-m) using torque wrench and socket set.
25. Coat oil galley plug (3) threads with sealing compound.
38. Torque plug (8) to 276-324 in. lbs (31-37 N-m) using torque wrench and socket set.
43. Install two plugs (10) in right side of engine block (4).
53. Coat oil galley plug (14) threads with sealing compound.
66. Install two plugs (19) in left side of engine block (4).
72. Torque plugs (22) to 228-264 in. lbs (26-30 N-m) using torque wrench and socket set.
86. Coat elbow (27) threads with sealing compound.
90. Coat two seal rings (57) with lubricating oil.
94. Install eight compression gaskets (60).
99. Torque engine block pressure test core plug to 230 270 ft lbs (311 366 N-m) using torque wrench.
101. Add water until engine block water jacket is full.
105. Apply 40 PSI of pressure to engine block (4) and maintain for at least two hours.
112. Torque water inlet adaptor (36) to 230-250 ft lbs (311-339 N-m) using torque wrench.
114. Remove eight compression gaskets (60) from cylinders (51).
120. Coat engine block (4) with engine oil to prevent rust.
22. Install fuel injector control tube. (WP 0086)
49. Install starter motor. (WP 0164)
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD POPPET VALVE ROCKER ARM COVERS REPLACEMENT
This task is typical for the replacement of poppet valve rocker arm covers on both port and starboard engines
Figure 1. Cylinder Head Poppet Valve Rocker Arm Covers.
Install chain hook (Figure 1, Item 9) on strainer (Figure 1, Item 10).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD CRANKCASE BREATHER CLEANING
Figure 1. Engine Cylinder Head Crankcase Breathers.
FOLLOW-ON MAINTENANCE
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVES ADJUSTMENT
Figure 2. Injector Follower.
Figure 5. Push Rod Adjustment.
Install cylinder head poppet valve rocker arm covers (WP 0044).
CYLINDER HEAD REMOVAL AND INSTALLATION
Loosen four hose clamps (Figure 1, Item 3) from two fuel rod cover tube hoses (Figure 1, Item 4).
Position wood wedges on bench for setting cylinder head (Figure 2, Item 11).
Figure 3. Cylinder Head Gasket Removal.
Attach lifting fixture (Figure 4, Item 10) to cylinder head and lift.
Figure 4. Cylinder Block and Cylinder Head.
Figure 5. Cylinder Head Bolt Torque Sequence.
Figure 7. Fuel Rod Installation.
Install operator's cab (TM 55-1925-205-23).
REAR LIFTING BRACKETS REPLACEMENT
Figure 1. Turbocharger Air Hoses Removal.
Figure 2. Lifting Bracket.
Figure 3. Turbocharger Air Hoses Installation.
Perform operational check (TM 55-1925-205-10).
CYLINDER HEAD POPPET VALVE ROCKER ARM REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
Remove two brackets (Figure 1, Item 10) from cylinder head (Figure 1, Item 6).
Figure 1. Rocker Arm Shaft Brackets.
Wash rocker arms, shaft, brackets, and bolts with cleaning compound.
Inspect rocker arm shaft brackets (Figure 1, Item10) for cracks. Install new bracket if damaged.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD POPPET VALVE ROCKER ARM REPAIR
Figure 2. Rocker Arm Pin and Bushing Disassembly.
Inspect clevis (Figure 2, Item 1) for damage. Discard defective part.
Figure 3. Rocker Arm Pin and Bushing Assembly.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD FUEL MANIFOLD REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
Remove metal tube assembly (Figure 1, Item 1).
Figure 1. Cylinder Head Fuel Manifold.
Install cylinder head poppet valve rocker arm cover (WP 0044).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD REPAIR
Figure 1. Cylinder Head Disassembly.
Figure 2. Cylinder Head Cleaning.
Figure 3. Cylinder Head Inspection.
Figure 4. Cam Follower Bore Inspection.
Figure 5. Dummy Injectors in Cylinder Head.
Figure 6. Cover Plates on Cylinder Head.
Figure 7. Test Fixture Installation.
Observe water tank for 20 minutes watching for bubbles indicating a leak or crack.
Figure 8. Dummy Injector Removal.
Figure 10. Cylinder Head Cover Plates.
Install fuel system injector control tube (WP 0086).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD CAM FOLLOWER REPLACEMENT
Figure 1. Cam Follower Removal.
Remove cam follower (Figure 2, Item 4) from heated lubricating oil.
Install cylinder head valve guide bridge (WP 0058).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD PUSH ROD REPLACEMENT
Remove push rod (Figure 1, Item 3) assembly from cylinder head (Figure 1, Item 1).
Install new retaining ring (Figure 1, Item 2) in cylinder head (Figure 1, Item 1).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVE REMOVAL AND INSTALLATION
Support cylinder head (Figure 1, Item 5), with bottom side down, on two wood blocks.
Set cylinder head (Figure 1, Item 5) on its side.
Figure 2. Valve Clearance.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVE REPAIR
Figure 1. Exhaust Valve Components.
Figure 2. Exhaust Valve.
Dispose of contaminated cloths in accordance with local procedures.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVE SEAT INSERTS REPLACEMENT
Support cylinder head (Figure 1, Item 3) on two wooden wedges (Figure 1, Item 4).
Figure 2. Lifting Fixture.
Using replacing tool and hammer, drive inserts (Figure 1, Item 1) into cylinder head (Figure 1, Item 3).
Install cylinder head exhaust valves (WP 0055).
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVE GUIDE BRIDGE REPLACEMENT
Figure 2. Valve Guide Bridge.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD VALVE GUIDES AND SEALS REPLACEMENT
Figure 1. Valve Guide Oil Seal.
Place cylinder head (Figure 2, Item 1), bottom side up, on two wood wedges.
Place cylinder head (Figure 3, Item 2), right side up, on arbor press.
Install new valve guide oil seal (Figure 4, Item 1) as follows:
Figure 4. Valve Guide Installation.
SUSTAINMENT MAINTENANCE ENGINE CYLINDER HEAD EXHAUST VALVE GUIDES CLEANING AND INSPECTION
Place cylinder head (Figure 1, Item 3) in cleaning tank filled with cleaning solution.
Inspect valve guides (Figure 1, Item 2) for fractures, chipping, scoring or wear. Replaced damaged parts.
SUSTAINMENT MAINTENANCE ENGINE CRANKSHAFT AND STABILIZER REMOVAL, CLEANING, INSPECTION, REPAIR, AND INSTALLATION
Remove hex bolts with washer (Figure 1, Item 3) from stabilizers (Figure 1, Item 1).
Figure 1. Crankshaft, Bearings, and Stabilizer.
Soak crankshaft (Figure 2, Item 6) in cleaning compound to remove dirt and oil.
Figure 2. Crankshaft and Thrust Washer Surface Dimensions.
Figure 3. Checking Crankshaft Bow.
Figure 4. Crankshaft Journal Specifications.
Figure 5. Crankshaft Woodruff Key and Plugs.
Install the lower main bearing caps (Figure 6, Item 5) in their original locations.
Figure 6. Crankshaft, Bearings, and Stabilizer.
Figure 7. Crankshaft End Play.
Figure 8. Crankshaft, Bearings, and Stabilizer.
Figure 9. Checking Crankshaft Distortion.
Install blower drive shaft (WP 0112).
SUSTAINMENT MAINTENANCE ENGINE CRANKSHAFT REAR OIL SEAL REPLACEMENT
Lay flywheel housing (Figure 1, Item 1) engine side down on wooden blocks on workbench.
Figure 2. Rear Crankshaft Oil Seal Installation.
Install flywheel housing (WP 0072).
SUSTAINMENT MAINTENANCE CAMSHAFT AND BEARINGS REPLACEMENT
On the rear of the engine, remove four screws (1), adaptor (2) and retainer (3) from left camshaft gear (4).
Using puller J 24420, remove accessory drive pulley (14) from camshaft (10).
Remove six intermediate bearing lock screws from camshafts.
Only the left cam bearing has a gasket.
Remove six lock rings and three intermediate cam bearing sets from camshafts.
Install a new woodruff key (26) in the keyway on camshafts (10 and 11).
Put six halves of intermediate bearings (30) onto the bearing journals of camshafts (10 and 11).
2. Install the right-hand camshaft (11) into the engine block (21).
Install six screws (19) and lock washers (20) into both rear bearings (27).
14. On the front of engine, apply engine oil to both front cam bearing journals.
20. Install woodruff key (15) into camshaft (10).
27. Position two retainers (3 and 7) on cam shaft gears (4 and 8).
33. Install fresh water cooling system pump drive gear. (WP 0148)
50. Install cylinder head poppet valve rocker arms. (WP 0049)
CAMSHAFT VIBRATION DAMPER REPLACEMENT
Figure 1. Vibration Damper.
Align woodruff key with woodruff key slot in camshaft.
SUSTAINMENT MAINTENANCE CAMSHAFT GEARS REPLACEMENT
Remove four cap screws (5), adaptor (6) and retainer (7) from left camshaft gear (8).
Install the right-hand cam gear (8) onto the camshaft (11).
Position two retainers (3, 7) on cam gears (4, 8).
28. Install fuel cooler. (WP 0081)
CAMSHAFT BALANCE WEIGHT REPLACEMENT
Figure 1. Balance Weight.
Install fresh water cooling system pump drive gear (WP 0148).
CAMSHAFT ACCESSORY DRIVE PULLEY REPLACEMENT
Remove woodruff key (Figure 1, Item 4) and discard.
Figure 1. Accessory Drive Pulley.
CAMSHAFT IDLER GEAR REMOVAL AND INSTALLATION
Figure 1. Gear Train.
Place cleaning cloth between camshaft gears to stop gears from rotating.
Install turbochargers (WP 0114).
SUSTAINMENT MAINTENANCE CAMSHAFT IDLER GEAR REPAIR
Clean excess grease and oil from idler gear and hub assembly (3) with cleaner.
Remove bearings (6) from idler gear (4).
Inspect idler gear (4) for corrosion, pitting or cracking. Replace defective part.
7. Position the other bearing cup, number side down, on the idler gear
16. Install inner spacer (7) over hub (5).
1. Mount idler gear and hub assembly (3) in vise by plate (11).
Install retainer (2) on idler gear and hub assembly (3).
ENGINE FLYWHEEL REPLACEMENT
Attach engine and transmission lifting sling to flywheel
Coat 10 flywheel bolts with antiseize compound.
Figure 1. Flywheel Replacement.
ENGINE FLYWHEEL REPAIR
Note the direction of the chamfer on the ring gear.
Figure 1. Flywheel.
Using torch set and heat protective mittens, flash heat ring gear uniformly.
FLYWHEEL HOUSING REPLACEMENT
Lube oil dipstick tube assembly removed
Install two lifting eye bolts in flywheel housing.
Remove four cap screws and washers from flywheel housing
Remove cap screw and copper washer.
Remove gasket and discard.
Remove two cap screws and lockwashers. Discard lockwashers.
Remove cap screw from access hole.
Remove gasket from engine rear end plate and discard.
Remove lifting eye bolts from flywheel housing
Polish end of crankshaft with abrasive cloth wet with engine lubricating oil.
Coat threads on pipe plugs (Figure 13, Items 3 and 4) with pipe sealing compound,.
Install new cap screw (Figure 16, Item 1) into access hole.
Install two new cap screws and new lockwashers into flywheel housing
Install access plate (Figure 19, Item 4) on flywheel housing (Figure 19, Item 1).
Install new gasket (Figure 20, Item 11) on flywheel housing (Figure 20, Item 3).
Remove slings, shackles, two lifting eye bolts and four aligning studs from flywheel housing
Install six new cap screws and new lockwashers into flywheel housing
Flywheel Tightening Sequence Diagram
Flywheel Housing Torque Sequence Diagram
Apply ultra blue sealing compound to flywheel housing (Figure 29, Item 1) and to access cover
Install flywheel (WP 0071).
Install crankcase breather limiter (WP 0106).
PISTON AND LINER ASSEMBLY REMOVAL AND INSTALLATION
Figure 1. Oil Distribution Inlet Tube and Screen Assembly Removal.
Figure 2. Piston and Air Inlet Ports.
Figure 4. Connecting Rod Cap and Bearing Removal.
Figure 6. Cylinder Liner Seal Rings Removal.
Figure 7. Cylinder Liner Seal Rings Installation.
Figure 8. Piston and Liner Installation.
Figure 9. Connecting Rod Bearings Installation.
Figure 10. Oil Distribution Inlet Tube and Screen Hardware Installation.
Install port thermostat housing (WP 0141).
SUSTAINMENT MAINTENANCE PISTON AND CYLINDER LINER REBUILD
Slide the piston (1) out through the bottom of the cylinder liner (2).
Slide the piston pin (10) from the piston (1).
Use compressed air to dry piston crown.
3. Check the tapered fire ring groove width in the piston crown (12) with groove gage.
Inspect the liners (2) for poor contact on the outer surfaces.
Measure the inside bore of the cylinder liner at (A, B, C, D, E, F and G) on both the (X) and (Y) axis.
{1} Calculate the general inside diameter of the liner, it should measure a minimum of 4.8390 in.
{3} Clamp the liner into place with hold down clamp.
Hold the piston assembly (1) in one hand by the piston skirt (11).
Using the skirt of the piston (1), push the ring down slightly
Ensure the piston ring grooves are clean and free of debris.
1. Install new compression and fire rings (5).
Lightly coat threads of bolt (8) with engine oil.
10. Ensure the piston pin retainer (7) is seated properly.
Lubricate the inside of the cylinder liner (2) with engine oil.
VIBRATION DAMPENER REPLACEMENT
Figure 1. Vibration Dampener Removal.
Figure 2. Inner Cone Installation.
Figure 4. Vibration Dampener/Hub Assembly.
Figure 5. Vibration Dampener Installation.
FRONT BALANCE WEIGHT COVER REPAIR
Dry cover (Figure 1, Item 1) with compressed air.
Figure 1. Oil Seal Removal.
Lightly lubricate outer surface of new oil seal with lubricating oil.
Figure 2. Oil Seal Installation.
FRONT BALANCE WEIGHT COVER REMOVAL AND INSTALLATION
Figure 1. Front Balance Weight Cover.
Remove gasket (Figure 2, Item 2) and discard.
Install engine forward lifting bracket (WP 0135).
FUEL SYSTEM PRIMING
Figure 2. Fuel Priming Pump.
FUEL FILTER CARTRIDGE REPLACEMENT
Figure 1. A3 Breaker Switch.
Figure 2. Fuel Filter Adapter Removal.
Remove LO/TO from A3 breaker switch. Refer to FM 4-01.502 for LO/TO procedure.
FUEL HOSES AND TUBES REPLACEMENT
Figure 1. A3 Breaker Switch.
Figure 2. Fuel Supply and Return Valves.
REMOVAL FUEL RUBBER HOSES
Start engine (TM 55-1925-205-10).
FUEL COOLER REPLACEMENT
Figure 2. Butterfly Valve.
Figure 3. Fuel Cooler Removal.
Figure 4. Fuel Cooler Removal.
Figure 5. Fuel Cooler Installation.
Figure 6. Fuel Cooler Hoses Installation.
Clean up spilled fluids with spill clean-up kit
FUEL COOLER MOUNTING BRACKET REPLACEMENT
Figure 1. Fuel Cooler Bracket.
FUEL FILTER ADAPTER REPAIR
Place a drain pan under fuel filter adapter (Figure 1, Item 8).
Figure 1. Fuel Filter Adapter Removal.
Figure 2. Fuel Filter Adapter Removal and Installation.
Figure 3. Fuel Filter Adapter Installation.
FUEL FILTER MOUNTING BRACKET REPLACEMENT
Perform operational check of diesel engine (TM 55-1925-205-10).
FUEL ADAPTER BLOCK REPLACEMENT
Figure 1. Fuel Adapter Block Lines Removal.
Figure 2. Fuel Adapter Block Removal.
Figure 3. Fuel Adapter Block Installation.
Figure 4. Fuel Adapter Block Lines Installation.
FUEL INJECTOR CONTROL TUBE AND LEVER ASSEMBLY REMOVAL AND INSTALLATION
Disengage rack control levers from injector control racks.
Figure 1. Fuel Injector Control Tube.
FUEL INJECTOR CONTROL TUBE AND LEVER ASSEMBLY REPAIR
Remove stationary bracket from control tube.
Figure 1. Injector Rack.
Remove control lever from injector control tube assembly.
Figure 2. Indexing Bracket and Injector Control Tube.
Figure 3. Injector Control Tube.
FUEL INJECTOR MODULATOR ASSEMBLY REMOVAL AND INSTALLATION
Figure 1. Fuel Modulator Removal and Installation.
Figure 2. Control Tube.
FUEL IGNITION MODULATOR ASSEMBLY REPAIR
Using cleaner, clean modulator assembly components.
Install pin and roller on lever assembly.
FUEL IGNITION MODULATOR ASSEMBLY ADJUSTMENT
Figure 2. Injector Body.
Figure 3. Ignition Modulator Adjustment.
Install cylinder head poppet valve rocker arm cover (WP 0044).
FUEL INJECTOR ASSEMBLY REMOVAL, CLEANING, INSPECTION AND INSTALLATION
Slide injector control rack lever (3) away from injector control rack (4).
Cover injector hole (9) with clean, lint free cloth.
Inspect injector follower spring for rust and corrosion. If found, replace fuel injector.
6. Slide injector rack control lever (3) into injector control rack (4).
19. Install intake plenum assembly. (TM 55-1945-205-24-3-1)
FUEL INJECTOR TIMING ADJUSTMENT
Figure 2. Exhaust Valves.
Figure 3. Injector Adjustment.
FUEL INJECTOR RACK CONTROL LEVER ADJUSTMENT
Figure 1. Fuel Supply and Return Valves.
Figure 3. Right Cylinder Head.
Figure 5. Left Cylinder Head.
Verify the adjustment of the control lever is not too tight.
Disconnect the fuel rod from the clevis lever
Tighten the adjusting screw an additional 1/8 turn.
Figure 8. Left Cylinder Head.
Figure 10. Left Cylinder Head.
Repeat Steps 33 through 36 for remaining two injector rack control levers
Figure 11. S1 Switch
FUEL PUMP REMOVAL AND INSTALLATION
Figure 1. A3 Breaker Switch.
Figure 2. Fuel Valves.
Figure 3. Fuel Pump.
Install heat exchanger (WP 0134).
FUEL PUMP REPAIR
Figure 2. Fuel Pump Secured in Vise.
Figure 4. Driveshaft, Drive Gear and Retaining Ball Disassembly.
Figure 5. Relief Valve Plug Disassembly.
Figure 6. Oil Seal Removal.
Inspect driven shaft for wear or scoring. Replace defective parts.
Figure 7. Fuel Pump On Wooden Wedges.
Ensure fuel pump body sits flush on wedge wood
Figure 10. Relief Valve Plug Assembly.
Figure 11. Driveshaft, Drive Gear and Retaining Ball Assembly.
Use lubricating oil to lubricate gear assembly (Figure 13, Item 7).
Figure 14. Fuel Pump Elbow Fitting Installation.
FUEL PRIMING PUMP REPLACEMENT
Figure 2. Fuel Supply and Return Valves.
Figure 3. Fuel Priming Pump.
Clean up spilled fluid with a spill clean-up kit and dispose
ELECTRONIC GOVERNOR ROD ASSEMBLY REPAIR
Figure 1. A3 Breaker Switch.
Figure 2. Electronic Governor.
ELECTRONIC GOVERNOR ACTUATOR REPLACEMENT
Figure 1. A3 Breaker Switch.
Figure 2. Electronic Governor Actuator.
Figure 3. Governor Actuator.
ELECTRONIC GOVERNOR CONTROLLER REPLACEMENT
Remove governor controller (Figure 2, Item 2).
Figure 2. Electrical Enclosure.
Start the engine TM 55-1925-205-10.
Figure 3. Electronic Governor Controller.
Figure 4. Actuator Lever.
Figure 5. Electrical Enclosure.
ELECTRONIC GOVERNOR MAGNETIC PICK-UP REPLACEMENT
Flywheel & Electronic Governor.
Install electronic control valve (TM 55-1925-319-23).
ELECTRONIC GOVERNOR DRIVE ASSEMBLY REMOVAL AND INSTALLATION
Figure 1. Injector Rack and Fuel Rods.
Figure 2. Governor Drive.
Install intake plenum assembly (TM 55-1925-205-10).
ELECTRONIC GOVERNOR DRIVE ASSEMBLY REPAIR
Figure 1. Electronic Governor Drive Assembly.
Clean all parts with cleaner.
Install woodruff key into shaft of shaft and lever assembly.
AIR INTAKE HOUSING REPAIR
Figure 1. A3 Breaker Switch.
Figure 3. Blower Gasket Removal.
Using type II cleaner, clean all parts of dirt and grease.
Figure 4. Springs and Valves.
Figure 5. Blower Gasket Installation.
Figure 6. Air Intake Housing Installation.
AIR INLET COLLECTOR ASSEMBLY REPLACEMENT
Slide collector assembly out of band.
Figure 1. Collector Assembly.
AIR INLET COLLECTOR ASSEMBLY REPAIR
Coat air filter element with filter element oil from filter cleaning kit
Use cleaner to clean retainer springs, air inlet collector assembly
Figure 2. Air Inlet Collector Disassembly.
CRANKCASE BREATHER LIMITER ASSEMBLY REPLACEMENT
Remove six hose clamps (Figure 1, Item 1) from hoses (Figure 1, Item 2).
CRANKCASE VENTILATION BREATHER PIPE REPLACEMENT
Figure 1. Crankcase Breather Hose.
Figure 2. Crankcase Breather Hose Elbow.
Install electronic governor actuator (WP 0098).
BLOWER BYPASS VALVE REPLACEMENT
Remove hose (Figure 2, Item 2) from valve (Figure 2, Item 7).
Perform operational check of diesel engine
BLOWER DRIVESHAFT AND SPRING ASSEMBLY REPLACEMENT
Figure 1. Broken Blower Driveshaft Portion Removal.
Figure 3. Blower Driveshaft Retaining Ring.
Install driveshaft alignment tool into hole of blower driveshaft
Install electronic governor actuator (WP 0098).
BLOWER REMOVAL AND INSTALLATION
Using sling, lift blower (Figure 1, Item 2) up and away from block
Figure 1. Blower.
Using torque wrench and socket set, tighten four long bolts
Perform operational check of diesel engine (TM 55-1925-205-10).
BLOWER ASSEMBLY REPAIR
Remove nine bolts (Figure 1, Item 2) and washers
Both gears must be pulled at the same time.
Remove two fillister head screws securing rear end plate
Remove fuel pump drive bolt (Figure 5, Item 5), lock washers
Remove bearings (Figure 7, Item 4), oil seals
Remove seal rings and seal ring carriers and bearing race from rotor shafts
Discard oil seal ring carriers (Figure 9, Item 6)
Examine the blower timing gears
Install the oversize seal and sleeve.
Install remaining oversize seal sleeves on rotors
Install the blower front end plate.
Install blower rotors in the blower housing.
Install the blower rear end plate (Figure 15, Item 4).
h. Using a torque wrench and screwdriver socket wrench set, torque
Install rear blower rotor shaft bearings
Reverse the position of the blower housing
Install self locking screws.
Lubricate the splines with light engine oil.
Figure 20. VIEWS FROM GEAR END OF BLOWER.
Check the clearance between each rotor lobe
Table 1. Chart of Minimum Blower Clearances.
Table 1. Chart of Minimum Blower Clearances - Continued.
BLOWER DRIVE ASSEMBLY REMOVAL AND INSTALLATION
Figure 1. Blower Hardware.
Figure 2. Blower Drive.
BLOWER DRIVE ASSEMBLY REPAIR
Figure 2. Spring Plates.
Figure 4. Thrust Washers.
Clean all metal parts with cleaner.
Place blower support shaft into soft jaw vise caps of vise.
TURBOCHARGER REPLACEMENT
Figure 1. Turbo Exhaust Elbow Removal.
Figure 2. Turbocharger Removal.
Figure 4. Oil Drain Hose Removal.
Figure 5. Exhaust Flange Removal.
Figure 6. Turbocharger Gasket Installation.
Figure 8. Coolant Lines Installation.
Figure 9. Turbocharger Exhaust Elbow Installation.
Install air intake housing (WP 0103).
LUBE OIL SYSTEM CRANKCASE SERVICING
Figure 1. A3 Breaker Switch.
Connect a combination hose coupling and pipe nipple to end of pump suction hose.
Figure 2. Dust Cap.
Figure 3. Dipstick.
Replace dust cap on forward coupling half.
LUBE OIL SYSTEM CRANKCASE PRESSURE TESTING
Figure 2. Oil Level Dipstick.
Shut down engine (TM 55-1925-205-10).
LUBE OIL SYSTEM TURBOCHARGER FLANGED OIL TUBE TO ENGINE OIL HOSE REPLACEMENT
Position drain pan under flanged oil tube
Figure 2. Flanged Oil Tubes.
LUBE OIL SYSTEM HOSES REPLACEMENT
Using a wrench, hold the elbow or fitting
Figure 1. Oil Hoses Replacement.
LUBE OIL PUMP REMOVAL AND INSTALLATION
Figure 1. Oil Pump Brackets.
Figure 2. Oil Pump.
Using oil seal expander with guide studs, install oil pump
Install air box covers (WP 0036).
LUBE OIL PUMP REPAIR
Figure 1. Oil Pump Gear Retaining Plate.
Clean all metal parts with cleaner.
Figure 2. Oil Pump Gears.
Figure 3. Front Cover Assembly.
LUBE OIL PUMP INLET SCREEN REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
Remove screen (Figure 1, Item 5) from cover (Figure 1, Item 1).
Figure 1. Oil Pump Inlet Screen.
Install exhaust manifolds (WP 0157).
LUBE OIL SYSTEM DISTRIBUTION COMPONENTS REMOVAL, CLEANING, INSPECTION, AND INSTALLATION
Figure 1. Lube Oil System Distribution Components.
Remove two support brackets as follows:
Using torque wrench, torque boltsto 156 to 204 in-lb
LUBE OIL PRESSURE REGULATOR VALVE REMOVAL AND INSTALLATION
Figure 1. Lube Oil Pressure Regulator Valve.
Remove engine from stand (WP 0033).
LUBE OIL PRESSURE REGULATOR VALVE REPAIR
Remove lube oil pressure regulator valve body
Inspect spring for deformation, pitting, breaks or corrosion. Replace defective part.
LUBE OIL PRESSURE RELIEF VALVE REMOVAL AND INSTALLATION
Figure 1. Lube Oil Pressure Relief Valve Removal and Installation.
Remove engine from stand (WP 0033).
LUBE OIL PRESSURE RELIEF VALVE REPAIR
Figure 1. Vise With Lube Oil Pressure Relief Valve Body.
Remove lube oil pressure relief valve body
Insert lube oil pressure relief valve
LUBE OIL PAN REPLACEMENT
Figure 1. Oil Pan.
Using cleaner, clean new oil pan (Figure 2, Item 2).
Figure 2. Oil Pan Gasket.
Install marine gear oil cooler (TM 55-2040-211-24).
LUBE OIL COOLER REPLACEMENT
Figure 1. A3 Breaker Switch.
Figure 2. Oil Filter Supply Lines.
Figure 4. Cover Plate Removal.
Figure 6. Cover Plates Removal.
Figure 8. Oil Cooler Mounting Plates Removal.
Use cleaner and a force pump to clean oil cooler core oil passages, as follows:
Remove drain pan and dispose of contents in accordance with local procedures.
Figure 9. Oil Cooler Mounting Plates Installation.
Figure 11. Oil Cooler Installation.
Figure 13. Mounting Hardware Installation.
Figure 15. Oil Cooler Housing Installation.
Perform operational checks (TM 55-1925-205-10).
LUBE OIL COOLER BYPASS VALVE REPLACEMENT
Figure 1. Oil Cooler Adapter.
Figure 2. Oil Cooler Adapter.
LUBE OIL DIPSTICK TUBE ASSEMBLY REPLACEMENT
Remove O-ring from lube oil dipstick tube assembly
Perform operational checks (TM 55-1925-205-10).
LUBE OIL PRESSURE SENDING UNIT REPLACEMENT
Tag and disconnect two wires from oil pressure sending unit
Clean spilled fluid with spill clean-up kit
LUBE OIL TEMPERATURE SWITCH REPLACEMENT
Position a drain pan under lube oil temperature switch
Perform operational check of the diesel engine (TM 55-1925-205-10).
FRESH WATER COOLING SYSTEM FLUSH
Place A3 breaker switch, located on A10 panel
Position drain pan under drain cocks
Remove engine thermostats and install thermostat covers
Figure 2. Coolant Drain Cocks.
Remove drain pans and dispose of contents
Figure 3. Coolant Flush Drain Cocks.
Drain cooling system completely, as follows:
Figure 4. Coolant Drain Cocks.
Ensure drain cocks are closed.
Figure 5. Pressure Control Cap.
Perform operational checks (TM 55-1925-205-10).
FRESH WATER COOLING SYSTEM HEAT EXCHANGER REPLACEMENT
Loosen clamp on inlet hose/tube assembly
Figure 2. Expansion Tank Removal.
Install new gasket on new heat exchanger core
Figure 3. Expansion Tank Installation.
FORWARD LIFTING BRACKET REPLACEMENT
Remove support (Figure 1, Item 1) from engine
Install heat exchanger (WP 0134).
FRESH WATER COOLING SYSTEM FILTER ELEMENT REPLACEMENT
Figure 2. Fresh Water Filter Valves.
FRESH WATER COOLING SYSTEM FILTER HEAD COVER REPLACEMENT
Place drain pan under filter cover
Figure 2. Filter Head Cover.
Wrap bushing threads with antiseizing tape.
Install fresh water cooling system filter (WP 0136).
FRESH WATER COOLING SYSTEM FILTER HEAD COVER MOUNTING BRACKET REPLACEMENT
Figure 2. Heat Exchanger.
Figure 3. Mounting Bracket.
Install fresh water cooling system filter (WP 0137).
FRESH WATER COOLING SYSTEM THERMOSTAT REPLACEMENT
Remove port thermostats (Figure 1, Item 5).
Figure 1. Port Thermostats.
Figure 2. Starboard Thermostats.
Figure 3. Port Thermostats.
Figure 4. Starboard Thermostats.
Install fresh water cooling system bypass tube (WP 0143).
FRESH WATER COOLING SYSTEM STARBOARD THERMOSTAT HOUSING REPLACEMENT
Apply sealing compound to gasket surface of cylinder head
Install fresh water cooling system thermostat (WP 0139).
FRESH WATER COOLING SYSTEM PORT THERMOSTAT HOUSING REPLACEMENT
Using putty knife, clean gasket surface of cylinder head
Figure 1. Thermostat Housing.
Shut engine down (TM 55-1925-205-10).
FRESH WATER TEMPERATURE SENDING UNIT REPLACEMENT
Remove drain pan and dispose of contents in accordance with local procedures.
Figure 2. Thermostat Housing.
FRESH WATER COOLING SYSTEM BYPASS HOSES REPLACEMENT
Figure 1. Cooling System Bypass Hoses.
Service fresh water cooling system (TM 55-1925-205-10).
FRESH WATER COOLING SYSTEM COOLANT HOSES REPLACEMENT
Figure 1. Cooling Hose.
Drain residual coolant into drain pan.
Fill cooling system (TM 55-1925-205-10).
FRESH WATER COOLING SYSTEM PORT WATER OUTLET MANIFOLD REPLACEMENT
Figure 1. Fresh Water Cooling System Port Water Outlet Manifold.
Install new gaskets (Figure 1, Item 10) on cylinder head
FRESH WATER COOLING SYSTEM STARBOARD WATER OUTLET MANIFOLD REPLACEMENT
Figure 1. Fresh Water Cooling System Starboard Water Outlet Manifold.
Position new water outlet manifold
FRESH WATER COOLING SYSTEM PUMP REPLACEMENT
Figure 1. Pump Body.
Figure 3. Water Pump Body.
Figure 4. Water Pump Cover.
Install fuel system fuel filter (WP 0079).
FRESH WATER COOLING SYSTEM PUMP DRIVE GEAR REPLACEMENT
Install new woodruff key on shaft
Install camshaft vibration damper (WP 0064).
FRESH WATER COOLING SYSTEM PUMP REPAIR
Using retaining ring pliers, slide pliers into slot of gear
Install impeller puller onto impeller
Using a brass drift as a buffer between the arbor press
14. Remove inner bearing
Lubricate the bearing surface of the new shaft with grease.
10. Install the new oil seal in the pump body
Install gear installation tool on threaded end of shaft.
Apply a thin coat of adhesive to outside diameter of water seal
AFTERCOOLER REPLACEMENT
Verify fuel supply and return valves
Figure 3. Engine Aftercooler.
Tighten hose clamps (Figure 3, Item 9).
FUEL COOLER ZINC ANODE PLUG REPLACEMENT
Remove zinc anode from fuel cooler
Tighten zinc anode (Figure 3, Item 2).
MARINE GEAR COOLER ZINC ANODE PLUG REPLACEMENT
Verify butterfly valve on seachest is off.
Figure 3. Zinc Anode.
HEAT EXCHANGER ZINC ANODE PLUG REPLACEMENT
Figure 2. Butterfly Valve.
Wrap support plug threads with antiseizing tape.
RAW WATER PUMP ZINC ANODE PLUG REPLACEMENT
Figure 2. Butterfly Valve.
Figure 3. Raw Water Pump.
RAW WATER PUMP REPLACEMENT
Figure 2. Raw Water Pump and Tubes.
Figure 3. Outlet Elbow.
Figure 4. Raw Water Pump.
Figure 5. Outlet Elbow.
Start engine and verify there are no leaks
RAW WATER PUMP REPAIR
Figure 1. Raw Water Pump.
Figure 3. Drive Gear.
Figure 4. Arbor Press.
Figure 5. Slinger and Bearing Seal.
Figure 7. Slotted Screw, Cam, and Wear Plate.
Support bearing on wooden wedges.
EXHAUST MANIFOLD REPLACEMENT
Figure 1. Water Inlet Tube.
Using torque wrench and socket set, torque bolts
Install six bolts (Figure 1, Item 5) and new lockwashers
MARINE GEAR OIL COOLER MOUNTING BRACKET REPLACEMENT
Figure 1. Mounting Bracket.
ELECTRICAL SYSTEM NORMAL STOP PUSHBUTTON REPLACEMENT
Remove cover (Figure 2, Item 4) from box
Perform operational check of diesel engine
ELECTRICAL SYSTEM NORMAL STOP PUSHBUTTON MOUNTING BRACKET REPLACEMENT
Figure 1. Mounting Bracket.
ELECTRICAL SYSTEM HOUR METER REPLACEMENT
Figure 2. Hour Meter Bracket.
ELECTRICAL SYSTEM HOUR METER MOUNTING BRACKET REPLACEMENT
Figure 2. Hour Meter Mounting Bracket.
STARTER RELAY REPLACEMENT
Remove two bolts, lockwashers, and nuts
Figure 2. Starter Relay.
STARTING MOTOR REPLACEMENT
Tag and remove wires from solenoid switch
Figure 1. Starter Motor.
ENGINE COLD PACK STARTING AID REPLACEMENT
Remove cylinder by turning it counterclockwise.
Figure 1. Cold Pack Starting Aid.
COLD START TEMPERATURE SWITCH REPLACEMENT
Figure 2. Cold Start Switch.
TACHOMETER SENDING UNIT REPLACEMENT
Figure 2. Tachometer Sending Unit.
TACHOMETER DRIVE REPAIR
Install new tachometer drive in housing assembly
Install tachometer sending unit (WP 0167).
OVERSPEED GOVERNOR REPLACEMENT AND ADJUSTMENT
Figure 2. Overspeed Governor Box Cover Removal.
Figure 3. Stuffing Tube.
Figure 4. Mounting Plate and Speed Switch.
Figure 5. Set Points.
Verify ohmmeter reads zero ohms.
Figure 6. Jumper Terminals.
Figure 7. Overspeed Governor Box Cover Installation.
AUTO SHUTDOWN SYSTEM EMERGENCY STOP SOLENOID REPLACEMENT
Tag emergency stop solenoid electrical wire
Figure 3. Emergency Stop Solenoid Link.
Figure 5. Emergency Stop Solenoid Bracket.
Figure 7. Emergency Stop Solenoid Mounting.
Figure 8. Emergency Stop Solenoid Link.
Install SINCGARS antenna (TM 11-5820-890-10-8).
AUTO SHUTDOWN SYSTEM HIGH WATER TEMPERATURE SWITCH REPLACEMENT
Tag and disconnect wires from switch
Service fresh water cooling system (TM 55-1925-205-23).
AUTO SHUTDOWN SYSTEM LOW OIL PRESSURE SWITCH REPLACEMENT
Tag and disconnect wires from oil pressure switch
Figure 2. Oil Pressure Switch.
AUTO SHUTDOWN SYSTEM FUEL OIL PRESSURE SWITCH REPLACEMENT
Figure 2. Fuel Supply and Return Valves.
Figure 3. Fuel Oil Pressure Switch.
Perform operational check of diesel engine
TORQUE LIMITS
Figure 2. Torque Wrench Adapter Centerline.
Figure 4. Bolt Head Markings.
Table 1. SAE Standard Torque Table.
Table 2. SAE Standard Torque Table.
Table 3. Metric Standard Torque Table.
Table 4. Metric Standard Torque Table.
CHAPTER 4 - SUPPORTING INFORMATION
REFERENCES
SUPPLY CATALOGS
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
Maintenance Functions
Explanation of Columns in the MAC
Explanation of Columns in the Tools and Test Equipment Requirements
Table 1. Maintenance Allocation Chart for Engine
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 1. MAC for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
Table 2. Tools and Test Equipment Requirements for Engine - Continued.
EXPENDABLE AND DURABLE ITEMS LIST (EDIL)
Table 1. Expendable and Durable Items List
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
WARPING TUG DIESEL ENGINE TOOL IDENTIFICATION LIST (TIL)
Table 1. Tool Identification List. (TIL) (Continued)
Table 1. Tool Identification List. (TIL) (Continued)
Table 1. Tool Identification List. (TIL) (Continued)
Table 1. Tool Identification List. (TIL) (Continued)
Table 1. Tool Identification List. (TIL) (Continued)
Table 1. Tool Identification List. (TIL) (Continued)
MANDATORY REPLACEMENT PARTS (MRP) LIST
Table 1. Mandatory Replacement Parts List
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
Table 1. Mandatory Replacement Parts List - Continued.
