Deisel Engines

S9233-C9-MMA-010

[SGML Version See Change Record ] TECHNICAL MANUAL DESCRIPTION, OPERATION, MAINTENANCE AND ILLUSTRATED PARTS BREAKDOWN

DIESEL ENGINES

DISTRIBUTION STATEMENT B: DISTRIBUTION AUTHORIZED TO U. S. GOVERNMENT AGENCIES ONLY; ADMINISTRATIVE/OPERATIVE USE OTHER REQUESTS FOR THIS DOCUMENT MUST ME REFERRED TO NAVAL SEA SYSTEMS COMMAND (SEA-09T). WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC. 2751 ET SEQ.) OR THE EXPORT ADMINISTRATION ACT OF 1979, AS AMENDED, TITLE 50 U.S.C., APP 2401, ET SEQ. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH PROVISIONS OF OPNAVINST 5510.161, REFERENCE (JJ). DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT. PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

30 OCT 1990

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S9233-C9-MMA-010

RECORD OF CHANGES CHANGE DATE

DESCRIPTION OF CHANGE

CHANGE NO.

NOTE THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONIC SOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NO LOEP. ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOT MATCH THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE CONTENT IS EXACTLY THE SAME. ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TM WILL ONLY FIT IN THIS PAGINATED VERSION.

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S9233-C9-MMA-010

FOREWORD This Technical Manual is intended to provide operation, maintenance, and repair information for the models 6B5.9-M and 6BT5.9-M diesel engines. The manual contains descriptive and functional information, operating instructions, and maintenance and repair instructions for this system. This manual is one volume subdivided into the following chapters: CHAPTER 1 - GENERAL INFORMATION AND SAFETY PRECAUTIONS CHAPTER 2 - OPERATION CHAPTER 3 - FUNCTIONAL DESCRIPTION CHAPTER 4 - SCHEDULED MAINTENANCE CHAPTER 5 - TROUBLESHOOTING CHAPTER 6 - CORRECTIVE MAINTENANCE CHAPTER 7 - ILLUSTRATED PARTS BREAKDOWN CHAPTER 8 - INSTALLATION Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors, Omissions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be reported to Commanding Officer, Naval Ship Weapon Systems Engineering Station (Code 5H00), Port Hueneme, CA 930435007 on NAVSEA Technical Manual Deficiency/Evaluation Report, Form NAVSEA 9086/10. To facilitate such reporting, three copies of Form 9086/10 are included at the end of this technical manual. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting therefrom. Extra copies of NAVSEA Form 9086/10 may be requisitioned from the Naval Publications and Forms Center, Philadelphia, PA 19120.

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S9233-C9-MMA-010

TABLE OF CONTENTS Chapter/Paragraph

Page

1

GENERAL INFORMATION AND SAFETY PRECAUTIONS . . . . . . . . . . .

1-1

1-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1.1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1.2 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-1 1-1

1-2

EQUIPMENT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

OPERATION

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2-1

2-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2-2

NORMAL OPERATING RANGES. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2-3

OPERATING PROCEDURES. . . . . . 2-3.1 PRE-OPERATIONAL CHECKS. 2-3.2 NORMAL OPERATION. . . . . 2-3.3 SHUTDOWN. . . . . . . . . . . 2-3.4 EMERGENCY OPERATION. . 2-3.4.1 Low Oil Pressure. . 2-3.4.2 High Engine Coolant 2-3.4.3 Runaway Engine. .

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

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3-1

3-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3-2

GENERAL DESCRIPTION.

3-1

3-3

DETAILED DESCRIPTION. . . . . . . . . . . . . . 3-3.1 DIESEL ENGINE. . . . . . . . . . . . . . . 3-3.2 ELECTRICAL STARTING SYSTEM. . . . 3-3.3 AIR INTAKE AND EXHAUST SYSTEMS. 3-3.3.1 Air Intake System. . . . . . . . . 3-3.3.2 Exhaust System. . . . . . . . . . 3-3.4 FUEL SYSTEM. . . . . . . . . . . . . . . . 3-3.4.1 Fuel Pumps. . . . . . . . . . . . 3-3.4.2 Fuel Injection Nozzles. . . . . . 3-3.4.3 Fuel Drain Manifold. . . . . . . 3-3.4.4 Throttle. . . . . . . . . . . . . . 3-3.4.5 Fuel Shutoff Valve. . . . . . . . 3-3.5 LUBRICATION SYSTEM. . . . . . . . . . . 3-3.6 COOLING WATER SYSTEMS. . . . . . . . 3-3.6.1 Fresh Water Cooling System. . . 3-3.6.2 Sea Water Cooling System. . . . 3-3.7 CONTROLS AND INDICATORS. . . . . .

2

3

FUNCTIONAL DESCRIPTION

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3-1 3-1 3-1 3-2 3-2 3-7 3-7 3-7 3-7 3-7 3-7 3-7 3-7 3-7 3-7 3-8 3-8 i

S9233-C9-MMA-010 TABLE OF CONTENTS - Continued Chapter/Paragraph

Page 3-3.7.1 3-3.7.2 3-3.7.3 3-3.7.4 3-3.7.5

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3-8 3-8 3-8 3-8 3-8

4

SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

4-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

TROUBLESHOOTING

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5-1

5-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

5-2

TROUBLESHOOTING GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

5-3

TROUBLESHOOTING PROCEDURES. . . . . . . . . . . . . . . . . . 5-3.1 ENGINE WILL NOT CRANK. . . . . . . . . . . . . . . . . . . 5-3.2 ENGINE CRANKS BUT WILL NOT START (SMOKE FROM EXHAUST). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3.3 ENGINE STARTS BUT WILL NOT KEEP RUNNING. . . . . 5-3.4 ENGINE RUNNING HOT. . . . . . . . . . . . . . . . . . . . . .

5

Starter Switch. . . . . . . . Electrical Fuel Shutoff. . . Tachometer. . . . . . . . . Lube Oil Pressure Switch. Water Temperature Switch.

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5-10 5-10

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5-10 5-10 5-10

6

CORRECTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6-2

TOOLS AND EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

SECTION 1.

ADJUSTMENT AND ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3

6-3

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3

6-4

TACHOMETER ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3

6-5

VALVE CLEARANCE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . .

6-3

REPAIR

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6-5

6-6

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5

6-7

CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7.1 CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7.2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5 6-6 6-7

6-8

REPAIR/REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8.2 PRELIMINARY PROCEDURES AND SAFETY INFORMATION. . . . . .

6-7 6-7 6-8

SECTION 2.

ii

S9233-C9-MMA-010 TABLE OF CONTENTS - Continued Chapter/Paragraph 6-9

Page . . . . . . . . . .

6-9 6-9 6-9 6-11 6-16 6-20 6-20 6-21 6-22 6-22

6-10

GAUGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-22

6-11

AIR CLEANER/SILENCER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-23 6-23 6-23

6-12

ALTERNATOR. . . . . . . . 6-12.1 REMOVAL. . . . . . 6-12.2 REPAIR. . . . . . . . 6-12.3 REINSTALLATION.

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6-23 6-23 6-24 6-24

6-13

DRIVE BELT AND BELT TENSIONER. . . . . . . . . . . . . . . . . . . . . . . . . 6-13.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-24 6-24 6-25

6-14

FRESH WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-25 6-25 6-25

6-15

STARTER MOTOR. . . . . . . . . . . . . . . . . . . . 6-9.1 REMOVAL. . . . . . . . . . . . . . . . . . . . 6-9.2 DISASSEMBLY. . . . . . . . . . . . . . . . . 6-9.3 CLEANING AND INSPECTION. . . . . . . . 6-9.4 REASSEMBLY. . . . . . . . . . . . . . . . . . 6-9.5 TESTING. . . . . . . . . . . . . . . . . . . . . 6-9.5.1 Solenoid Engagement Mechanism. 6-9.5.2 Performance Tests. . . . . . . . . . 6-9.5.3 Relay Test. . . . . . . . . . . . . . 6-9.6 REINSTALLATION. . . . . . . . . . . . . . .

THERMOSTAT.

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6-16

SEA WATER PUMP. . . . . . 6-16.1 REMOVAL. . . . . . 6-16.2 DISASSEMBLY. . . 6-16.3 REASSEMBLY. . . . 6-16.4 REINSTALLATION.

6-17

HEAT 6-17.1 6-17.2 6-17.3

6-18

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6-26

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6-27 6-27 6-27 6-28 6-29

EXCHANGER. . . . . . . . . . . . . . REMOVAL. . . . . . . . . . . . . . . DISASSEMBLY. . . . . . . . . . . . REASSEMBLY/REINSTALLATION.

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6-30 6-30 6-30 6-31

MARINE TRANSMISSION OIL COOLER. . . . . . . . . . . . . . . . . . . . . . . 6-18.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-32 6-32 6-33

iii

S9233-C9-MMA-010 TABLE OF CONTENTS - Continued Chapter/Paragraph

iv

Page

6-19

WATER TRANSFER CONNECTION. . . . . . . . . . . . . . . . . . . . . . . . . . .

6-33

6-20

TEMPERATURE TRANSDUCER. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-34

6-21

FUEL LEFT PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-34 6-34 6-34

6-22

FUEL PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-34 6-34 6-35

6-23

FUEL FILTER AND FUEL/WATER SEPARATOR. . . . . . . . . . . . . . . . . . . 6-23.1 FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23.2 FUEL/WATER SEPARATOR. . . . . . . . . . . . . . . . . . . . . . . . . . .

6-35 6-35 6-35

6-24

FUEL DRAIN MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-36 6-36 6-36

6-25

FUEL INJECTION NOZZLES. . . . . . . . 6-25.1 REMOVAL. . . . . . . . . . . . . . 6-25.2 DISASSEMBLY. . . . . . . . . . . 6-25.3 CLEANING AND INSPECTION. . 6-25.4 REASSEMBLY. . . . . . . . . . . . 6-25.5 FUEL INJECTION NOZZLE TEST. 6-25.6 REINSTALLATION. . . . . . . . . 6-25.7 BLEEDING THE FUEL SYSTEM.

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6-36 6-36 6-37 6-37 6-38 6-38 6-40 6-40

6-26

FUEL INJECTION PUMP. . . . . . . . . . . . . . . . . 6-26.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . 6-26.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . 6-26.3 REASSEMBLY. . . . . . . . . . . . . . . . . . . 6-26.4 PRE-TEST. . . . . . . . . . . . . . . . . . . . . 6-26.4.1 Pressure Test. . . . . . . . . . . . . . 6-26.4.2 Seal Testing. . . . . . . . . . . . . . 6-26.4.3 General Testing Procedures. . . . . 6-26.4.4 Priming. . . . . . . . . . . . . . . . 6-26.4.5 Pump Output. . . . . . . . . . . . . 6-26.4.6 Shutoff Control. . . . . . . . . . . . 6-26.4.7 Maximum Fuel Setting. . . . . . . . 6-26.4.8 Governor Test. . . . . . . . . . . . . 6-26.4.9 Transfer Pump Setting. . . . . . . . 6-26.4.10 Transfer Pump Pressure Adjustment. 6-26.4.11 Pressurized Cam Boxes. . . . . . . . 6-26.4.12 Advance Device Test. . . . . . . . . 6-26.4.13 Timing. . . . . . . . . . . . . . . . .

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6-44 6-44 6-47 6-51 6-57 6-57 6-58 6-58 6-59 6-59 6-59 6-59 6-60 6-60 6-60 6-61 6-61 6-62

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S9233-C9-MMA-010 TABLE OF CONTENTS - Continued Chapter/Paragraph

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6-26.5

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6-63 6-63 6-63 6-65

6-27

INTAKE MANIFOLD COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-66 6-66 6-66

6-28

TURBOCHARGER. . . . . . . . . . . . . 6-28.1 REMOVAL. . . . . . . . . . . . . 6-28.2 DISASSEMBLY. . . . . . . . . . 6-28.3 CLEANING AND INSPECTION. 6-28.4 REASSEMBLY. . . . . . . . . . . 6-28.5 REINSTALLATION. . . . . . . .

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6-67 6-67 6-68 6-70 6-71 6-74

6-29

OIL PRESSURE REGULATOR VALVE. . . . . . . . . . . . . . . . . . . . . . . . . 6-29.1 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29.2 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-75 6-75 6-75

6-30

OIL COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-76 6-76 6-76

6-31

CRANKSHAFT OIL SEALS. . . . . . . . . . 6-31.1 FRONT CRANKSHAFT OIL SEAL. 6-31.1.1 Removal. . . . . . . . . . 6-31.1.2 Reinstallation. . . . . . . 6-31.2 REAR CRANKSHAFT OIL SEAL. . 6-31.2.1 Removal. . . . . . . . . . 6-31.2.2 Reinstallation. . . . . . .

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6-77 6-77 6-77 6-77 6-77 6-77 6-78

6-32

CAM FOLLOWER COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-78 6-78 6-78

6-33

OIL PRESSURE TRANSDUCER. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-79

6-34

VALVE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-79

6-26.6

6-35

TEST PARAMETERS. . . . . 6-26.5.1 Test Conditions. . 6-26.5.2 Test Procedure and REINSTALLATION. . . . . .

. . . . . . . . . . . . . . Conditions. . . . . . . .

ROCKER LEVER ASSEMBLY. . . . . . 6-35.1 REMOVAL. . . . . . . . . . . . . 6-35.2 DISASSEMBLY. . . . . . . . . . 6-35.3 CLEANING AND INSPECTION. 6-35.4 REASSEMBLY. . . . . . . . . . . 6-35.5 REINSTALLATION. . . . . . . .

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6-80 6-80 6-80 6-80 6-81 6-81

v

S9233-C9-MMA-010 TABLE OF CONTENTS - Continued Chapter/Paragraph 6-36

vi

Page

CYLINDER HEAD. . . . . . . . . . . . . 6-36.1 REMOVAL. . . . . . . . . . . . . 6-36.2 DISASSEMBLY. . . . . . . . . . 6-36.3 CLEANING AND INSPECTION. 6-36.4 VALVE SEAT GRINDING. . . . 6-36.5 REASSEMBLY. . . . . . . . . . . 6-36.6 REINSTALLATION. . . . . . . .

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6-82 6-82 6-82 6-82 6-83 6-84 6-84

6-37

OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-85

6-38

SUCTION TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-85

6-39

VALVE TAPPET. . . . . . . . . . . . . . . 6-39.1 REMOVAL. . . . . . . . . . . . . 6-39.2 CLEANING AND INSPECTION. 6-39.3 REINSTALLATION. . . . . . . .

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6-86 6-86 6-87 6-87

6-40

CAMSHAFT. . . . . . . . . . . . . . . . . 6-40.1 REMOVAL. . . . . . . . . . . . . 6-40.2 CLEANING AND INSPECTION. 6-40.3 CAMSHAFT GEAR. . . . . . . . 6-40.4 CAMSHAFT BUSHING. . . . . . 6-40.5 REINSTALLATION. . . . . . . .

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6-89 6-89 6-89 6-90 6-90 6-91

6-41

LUBE 6-41.1 6-41.2 6-41.3 6-41.4

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6-91 6-91 6-92 6-92 6-94

6-42

GEAR HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-94 6-94 6-95

6-43

FLYWHEEL/FLYWHEEL HOUSING. 6-43.1 FLYWHEEL. . . . . . . . . . 6-43.2 FLYWHEEL RING GEAR. . 6-43.3 FLYWHEEL HOUSING. . . .

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6-44

PISTON AND CONNECTING ROD. . . . . . . . . 6-44.1 REMOVAL. . . . . . . . . . . . . . . . . . . 6-44.2 DISASSEMBLY. . . . . . . . . . . . . . . . 6-44.3 CLEANING AND INSPECTION. . . . . . . 6-44.4 MEASURE ROD BEARING CLEARANCE. 6-44.5 REASSEMBLY. . . . . . . . . . . . . . . . . 6-44.6 CHECKING PISTON RING GAP. . . . . . 6-44.7 PISTON RING INSTALLATION. . . . . . .

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OIL PUMP. . . . . . . REMOVAL. . . . . . DISASSEMBLY. . . REASSEMBLY. . . . REINSTALLATION.

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6-95 6-95 6-96 6-96

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6-97 6-97 6-98 6-98 6-99 6-100 6-100 6-100

S9233-C9-MMA-010 TABLE OF CONTENTS - Continued Chapter/Paragraph

Page

6-44.8

REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-101

6-45

CRANKSHAFT. . . . . . . . . . . . . . . . . . . . 6-45.1 REMOVAL. . . . . . . . . . . . . . . . . . 6-45.2 CLEANING AND INSPECTION. . . . . . 6-45.3 CRANKSHAFT GEAR REPLACEMENT. 6-45.4 REINSTALLATION. . . . . . . . . . . . .

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6-102 6-102 6-102 6-103 6-103

6-46

CYLINDER BLOCK. . . . . . . . . . . . 6-46.1 REMOVAL. . . . . . . . . . . . . 6-46.2 CLEANING AND INSPECTION. 6-46.3 REINSTALLATION. . . . . . . .

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6-104 6-104 6-104 6-105

6-47

OIL PAN HEATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-105

6-48

START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-106

7

ILLUSTRATED PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . .

7-1

7-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

8

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

8-1

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

8-2

INSTALLATION.

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8-1

8-3

START-UP AND CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2

8-4

ENGINE OPTION LISTS:

8-2

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vii

S9233-C9-MMA-010 LIST OF TABLES Table

viii

Title

Page

1-1.

6B5.9-M Principal Characteristics

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1-2

1-2.

6BT5.9-M Principal Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

2-1.

Normal Operating Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2-2.

Fuel and Lubricating Oil

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3

5-1.

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

6-1.

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6-2.

Solenoid Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-12

6-3.

Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-14

6-4.

24-Vdc Starter Test Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-20

6-5.

Fuel Injection Pump Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-64

6-6.

Clearance Measurements

6-7.

Torque Specifications

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6-106

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-108

6-8.

Roller-to-Roller Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-110

6-9.

Torque for Pipe Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-110

7-1.

Belt Guard

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3

7-2.

Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5

7-3.

V-Belt Tensioner/Alternating Mounting

. . . . . . . . . . . . . . . . . . . . . . . . .

7-9

7-4.

Front Engine Support

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9

7-5.

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11

7-6.

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-13

7-7.

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-14

7-8.

Expansion Tank Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15

7-9.

Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-16

7-10.

Fresh Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-17

7-11.

Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-17

7-12.

Vibration Damper

7-18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S9233-C9-MMA-010 LIST OF TABLES - Continued Table

Title

Page

7-13.

Front Gear Cover/Gear Housing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-19

7-14.

Sea Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-20

7-15.

Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-21

7-16.

Water Inlet Connection

7-22

7-17.

Marine Transmission Oil Cooler

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-23

7-18.

Exhaust Manifold/Intake Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-26

7-19.

Exhaust Outlet Connection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-27

7-20.

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-29

7-21.

Oil Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-30

7-22.

Lube Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-31

7-23.

Lube Oil Cooler

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-32

7-24.

Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-33

7-25.

Fuel Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-35

7-26.

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-36

7-27.

Fuel Injection Nozzle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-37

7-28.

Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-43

7-29.

Flywheel

7-46

7-30.

Flywheel Housing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-47

7-31.

Cam Follower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-48

7-32.

Valve Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-49

7-33.

Rocker Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-51

7-34.

Cylinder Head

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-53

7-35.

Oil Pan

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-55

7-36.

Camshaft

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-56

7-37.

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-58

7-38.

Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-59

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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ix

S9233-C9-MMA-010 LIST OF TABLES - Continued Table

x

Title 7-39.

Crankshaft and Main Bearings

7-40.

Transmission Mounting Bracket

Page

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-60

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-61

7-41.

Vibration Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-62

7-42.

Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-63

S9233-C9-MMA-010 LIST OF ILLUSTRATIONS Figure

Title

Page

1-1.

Model 6B5.9-M Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

1-2.

Model 6BT5.9-M Diesel Engine

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

3-1.

Electrical Schematic (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3

3-1.

Electrical Schematic (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

6-1.

Adjusting Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3

6-2.

Adjusting Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

6-3.

Using Timing Pin to Locate TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

6-4.

Starter Motor Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-12

6-5.

Installing Oil Seal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-14

6-6.

Positions of Pole Shoes and Windings . . . . . . . . . . . . . . . . . . . . . . . . . .

6-15

6-7.

Adjusting Forward Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-18

6-8.

Adjusting Rear Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-19

6-9.

Connecting Starter Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-21

6-10.

Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-23

6-11.

Installing Thermostat in Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-26

6-12.

Cleaning Build-up in Heat Exchanger

. . . . . . . . . . . . . . . . . . . . . . . . . .

6-31

6-13.

Flushing Heat Exchanger

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-31

6-14.

Cleaning Build-up in Marine Transmission Oil Cooler . . . . . . . . . . . . . . . . .

6-32

6-15.

Flushing Marine Transmission Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . .

6-33

6-16.

Checking Injection Nozzle Opening Pressure

. . . . . . . . . . . . . . . . . . . . . .

6-39

6-17.

Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-40

6-18.

Energizing Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-41

6-19.

Venting Fuel Filter and Hand Lever

. . . . . . . . . . . . . . . . . . . . . . . . . . .

6-41

6-20.

Venting Fuel Injection Pump

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-42

6-21.

Venting Fuel Injection Pump through Fuel Drain Manifold

6-22.

Venting High-Pressure Fuel Tubes

. . . . . . . . . . . . . .

6-43

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-43

xi

S9233-C9-MMA-010 LIST OF ILLUSTRATIONS - Continued Figure

xii

Title

Page

6-23.

Venting High-Pressure Fuel Lines with Engine Idling

. . . . . . . . . . . . . . . . .

6-44

6-24.

Fuel Injection Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-45

6-25.

Locating TDC for Number 1 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .

6-46

6-26.

Loosening Fuel Pump Lock Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-46

6-27.

Removing Fuel Pump Drive Gear

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-46

6-28.

Governor Linkage Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-48

6-29.

Loosening Transfer Pump Rotor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-49

6-30.

Loosening Drive Plate Screws

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-50

6-31.

Fitting Corks to Retain Plungers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-50

6-32.

Removing the Drive Hub Seal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-51

6-33.

Rotor Screw Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-52

6-34.

Reinstalling Top Adjusting Plate

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-53

6-35.

Measuring Roller-to-Roller Dimension . . . . . . . . . . . . . . . . . . . . . . . . . .

6-54

6-36.

Adjusting Link Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-56

6-37.

Attaching Governor Spring

6-57

6-38.

Advancing Device Test Gauge

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-62

6-39.

Checking Intake Manifold for Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . .

6-67

6-40.

Removing Supply Lines to the Turbocharger

. . . . . . . . . . . . . . . . . . . . . .

6-69

6-41.

Seating Piston Ring

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-72

6-42.

Aligning Balance Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-72

6-43.

Measuring Turbocharger Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . .

6-73

6-44.

Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-74

6-45.

Checking Spring Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-75

6-46.

Positioning Fastener Devices

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-79

6-47.

Cylinder Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-85

6-48.

Retaining Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-86

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S9233-C9-MMA-010 LIST OF ILLUSTRATIONS - Continued Figure

Title

Page

6-49.

Valve Tappet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-87

6-50.

Inserting Installation Tool into Tappet Bore . . . . . . . . . . . . . . . . . . . . . . .

6-88

6-51.

Pulling Installation Tool/Tappet through Cam Bore . . . . . . . . . . . . . . . . . . .

6-88

6-52.

Measuring Camshaft Gear Backlash

. . . . . . . . . . . . . . . . . . . . . . . . . . .

6-89

6-53.

Lube Oil Pump Disassembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-92

6-54.

Measuring Gerotor Tip Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-93

6-55.

Measuring Gerotor Drive/Gerotor Planetary-to-Port Plate Clearance . . . . . . . . . .

6-93

6-56.

Measuring Gerotor Planetary-to-Body Bore Clearance . . . . . . . . . . . . . . . . .

6-94

6-57.

Flywheel Cap Screw Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . .

6-96

6-58.

Flywheel Housing Torque Sequence

. . . . . . . . . . . . . . . . . . . . . . . . . . .

6-97

6-59.

Using Plastigauge to Measure Clearance . . . . . . . . . . . . . . . . . . . . . . . . .

6-100

6-60.

Main Bearing Cap Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-104

7-1.

Belt Guard

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2

7-2.

Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4

7-3.

V-Belt Tensioner/Alternating Mounting

. . . . . . . . . . . . . . . . . . . . . . . . .

7-8

7-4.

Front Engine Support

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9

7-5.

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10

7-6.

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-13

7-7.

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-14

7-8.

Expansion Tank Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15

7-9.

Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-16

7-10.

Fresh Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-16

7-11.

Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-17

7-12.

Vibration Damper

7-18

7-13.

Front Gear Cover/Gear Housing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-19

7-14.

Sea Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xiii

S9233-C9-MMA-010 LIST OF ILLUSTRATIONS - Continued Figure

xiv

Title

Page

7-15.

Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-21

7-16.

Water Inlet Connection

7-22

7-17.

Marine Transmission Oil Cooler

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-23

7-18.

Exhaust Manifold/Intake Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-25

7-19.

Exhaust Outlet Connection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-27

7-20.

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-28

7-21.

Oil Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-30

7-22.

Lube Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-31

7-23.

Lube Oil Cooler

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-32

7-24.

Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-33

7-25.

Fuel Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-34

7-26.

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-36

7-27.

Fuel Injection Nozzle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-37

7-28.

Fuel Injection Pump (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-39

7-28.

Fuel Injection Pump (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-41

7-29.

Flywheel

7-46

7-30.

Flywheel Housing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-47

7-31.

Cam Follower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-48

7-32.

Valve Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-49

7-33.

Rocker Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-50

7-34.

Cylinder Head

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-52

7-35.

Oil Pan

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-54

7-36.

Camshaft

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-56

7-37.

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-57

7-38.

Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-59

7-39.

Crankshaft and Main Bearings

7-60

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S9233-C9-MMA-010 LIST OF ILLUSTRATIONS - Continued Figure

Title

Page

7-40.

Transmission Mounting Bracket

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-61

7-41.

Vibration Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-61

7-42.

Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-63

xv

S9233-C9-MMA-010

SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement specific warnings and cautions appearing elsewhere in this manual. General and specific precautions must be understood and applied during operation and maintenance. The Commanding Officer or other authority will issue orders as deemed necessary for any situation not covered in the general and specific safety precautions. KEEP AWAY FROM LIVE CIRCUITS Operating personnel must observe all safety regulations at all times. Do not replace components, make adjustments, or perform internal equipment maintenance without first securing electrical power. Dangerous potential may exist when the electrical power is in the OFF position because of charges retained by capacitors. Before touching, always secure electrical power and discharge the circuit by shorting through a load to ground with a shorting probe. DO NOT REPAIR OR ADJUST ALONE Under no circumstances should any person reach into or enter equipment enclosures for the purpose of servicing or adjusting equipment except in the presence of personnel capable of rendering aid. FIRST AID An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately. ENERGIZED EQUIPMENT Before working on energized equipment, ensure against grounding. If possible, make repairs/adjustments with one hand, leaving the other hand clear of the equipment. Never work alone. MOVING EQUIPMENT If equipment must be repaired/adjusted while in motion, a safety watch shall be posted. The safety watch must have a full view of the repair/adjustment operation and immediate access to controls that can stop the equipment in motion. SPECIFIC SAFETY NOTICES The specific safety warnings and cautions summarized below appear in appropriate chapters of this manual. Each is referenced to the text page on which it appears. A WARNING is an operating or maintenance procedure, practice, condition or statement which, if not strictly observed, could result in injury or death to personnel. A CAUTION is an operating or maintenance procedure, practice, condition or statement which, if not strictly observed, could result in damage to, or destruction of, equipment or loss of mission effectiveness. The following warnings and cautions appear in the text of this volume and are repeated here for emphasis.

WARNING

To prevent injury or death, exercise extreme caution when working on or around rotating parts of machinery or operating equipment. (Page 2-4) xvi

S9233-C9-MMA-010

WARNING

To prevent injury or death, shut down the engine when unusual noise or vibration occurs. Unusual noise or vibrations may be an indication of equipment failure. (Page 2-4)

WARNING

To prevent injury or death, control all oil and fuel leakage immediately. Oil or fuel spraying on hot components is an extreme fire hazard. (Page 2-5)

WARNING

To prevent injury or death, use extreme caution when removing the cap from the expansion tank. Steam formed by the sudden release of pressure from a heated cooling system may force hot coolant through the system’s openings. (Page 2-7)

WARNING

Use of cleaning solvent in a confined area can result in injury or death. Avoid prolonged breathing of fumes and solvent contact with skin or eyes. Avoid use near heat or open flame. (Page 6-5)

WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. (Page 6-5, page 6-14, page 6-37, page 6-70, page 6-80, page 6-83, page 6-92, page 6-99, page 6-102, page 6-105)

WARNING

Rotating machinery can cause injury or death. Ensure the engine is shut down before working on equipment and that the starter is tagged OUT-OFSERVICE. (Page 6-8) xvii

S9233-C9-MMA-010

WARNING

To prevent injury or death, ensure extreme care and proper lifting devices are used during handling. The equipment is heavy. (Page 6-8, page 6-82, page 6-102, page 6-106, page 8-1)

WARNING

To prevent injury or death, ensure the engine is securely mounted to the overhaul stand before releasing the lifting sling; engine damage may result if the engine breaks away from the overhaul stand. (Page 6-9)

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove.(Page6-10,page6-17,page6-18,page6-19,page6-28,page6-28,page6-29, page 6-51, page 6-70, page 6-71, page 6-80, page 6-98, page 6-100)

WARNING

To prevent serious eye injury while removing/installing refining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. (Page 6-10)

WARNING

To prevent injury or death when testing the engagement mechanism, under no circumstances should both main terminals be connected to the supply voltage source. Otherwise the pinion will rotate at high speed when pulled forward and present extreme danger to the operator. (Page 6-20)

WARNING

To prevent serious hand injury while removing/installing the drive belt, keep hands out of the path of the spring-loaded belt tensioner. (Page 6-24, page 6-24) xviii

S9233-C9-MMA-010

WARNING

To prevent injury, exercise extreme care and wear insulated gloves when handling heated components. Heated metal pans can cause serious burns. (Page 6-29)

WARNING

Fuel spray from an injection nozzle can penetrate the skin and cause serious injury. Use the proper equipment and keep hands clear when testing the nozzles. (Page 6-39)

WARNING

Fuel spray from an injection nozzle can penetrate the skin and cause serious injury. Use the proper equipment and keep hands clear when testing the nozzle. (Page 6-43)

WARNING

Do not bleed a hot engine. This action could cause fuel to spill onto a hot exhaust manifold thereby creating a danger from fire. (Page 6-44)

WARNING

To prevent serious eye injury while removing/installing retailing ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. (Page 6-81)

WARNING

To prevent serious eye injury, wear safety eye protection when removing springs under pressure. (Page 6-82, page 6-84) xix

S9233-C9-MMA-010

WARNING

To prevent injury, exercise extreme care and wear insulated gloves when handling heated solutions or metal. (Page 6-90, page 6-96, page 6-103)

WARNING

Wear eye protection when removing the ring gear from the flywheel. Do not use a steel drift pin. (Page 6-96) CAUTION

To prevent damage to equipment, prime the sea water pumps prior to operation. (Page 2-3) CAUTION

To prevent damage to equipment, ensure that oil in the engine is at the proper level. (Page 2-3) CAUTION

To prevent damage to equipment, this entire procedure and the emergency operating procedures must be understood before starting the engine. Rapid automatic sequence of some events without proper operator actions may damage the equipment. (Page 2-4) CAUTION

To prevent damage to equipment, do not engage the clutch at speeds greater than 850 rpm. (Page 2-5) CAUTION

To prevent damage to equipment, run the engine at 800 rpm or greater during extended idle periods. Running the engine at idle speed for prolonged periods will dilute oil with fuel and cause sludge build-up. (Page 2-5) xx

S9233-C9-MMA-010 CAUTION

To prevent damage to equipment, cool the engine before pressing the stop switch. Stopping the engine before it cools down may cause damage to equipment. (Page 2-5) CAUTION

If excessive oil must be repeatedly drained from the engine, troubleshoot the cause to prevent further damage to the engine. (Page 2-6) CAUTION

To prevent damage to the timing pin and camshaft gear, disengage the timing pin before rotating the crankshaft. (Page 6-4) CAUTION

Do not use harsh abrasives that might scratch, score, or otherwise mar surface finishes. (Page 6-5) CAUTION

Do not allow machined or lapped mating surfaces to contact any surface without protection against nicks, scratches, burrs, etc. (Page 6-6) CAUTION

Avoid scratching and nicking critical surfaces of balls and rollers in bearings; take care to protect surfaces of shaft/ bearing fit. (Page 6-6) CAUTION

Do not clean bearings ultrasonically; this method can pit bearing surfaces. Do not agitate any other parts longer than five minutes at a time. (Page 6-6) CAUTION

Ensure that low-pressure air used to dry components is clean and dry. Moisture in an air line can cause rust. (Page 6-6) xxi

S9233-C9-MMA-010 CAUTION

If polishing is required, avoid leaving deposits of metal dust in and around bearings. (Page 6-6)

CAUTION

To prevent damage to equipment, the diesel engine lifting device should be adjusted so the lifting hooks are vertical. (Page 6-8)

CAUTION

To prevent damage to equipment, a soft-jawed vise, cloth, or cardboard should be used to protect parts. (Page 6-10, page 6-16, page 6-17, page 6-37, page 6-38, page 6-68, page 6-71)

CAUTION

To prevent overheating, do not leave the pull-in winding energized more than 15 seconds. The current draw will decrease as the winding temperature increases. The purpose of the R terminal is to short out the ignition resistor during cranking, thereby providing high ignition coil output. (Page 6-12)

CAUTION

The retaining pad must be removed to prevent oil starvation of the bearing after assembly. On new drive end shields, the retaining pad is fitted in the oil way. (Page 6-13)

CAUTION

To prevent damage to equipment, the starter should always be run in conjunction with a flywheel. If this is not possible, do not operate the starter for more than five seconds. If the starter is allowed to run without a load, the pinion will not be restrained from rotating in the initial stages and will not complete the forward movement necessary to trip the second stage contacts. Under these conditions, the resistor will remain in the circuit and may be damaged by overheating. Prolonged operation on first stage contacts may cause grooving of the solenoid trip mechanism. (Page 6-21) xxii

S9233-C9-MMA-010 CAUTION

Do not scratch the white ceramic surface of the seat. (Page 6-29)

CAUTION

To prevent the fuel injection pump delivery valve holder from turning, use two wrenches. (Page 6-35)

CAUTION

To prevent serious damage to the injection nozzle, ensure the interior of the socket does not come in contact with the fuel drain outlet sealing surface. (Page 6-36)

CAUTION

To prevent damage to the injection nozzle and needle valve, place parts in a suitable bath of clean fuel oil. (Page 6-37)

CAUTION

To prevent damage to equipment, disengage the pin after locating TDC. (Page 6-45)

CAUTION

To prevent damage to equipment and excessive teardown, do not drop the fuel pump drive gear key from the pump shaft when removing the pump. (Page 6-47)

CAUTION

Do not exceed the specified pressure. Excess pressure can cause damage to the shoe assemblies and adjusting plates. (Page 6-63) xxiii

S9233-C9-MMA-010 CAUTION

Loose connections or cracks in the suction side of the intake pipe on turbocharged engines can allow debris to be ingested into the turbocharger compressor and forced into the engine. (Page 6-66)

CAUTION

Leaks at the intake manifold, unsealed bolt holes, or manifold cover gasket can allow dust and dirt to be ingested into naturally aspirated engines. (Page 6-66)

CAUTION

To prevent damage to equipment, the push rods must be correctly seated in the valve tappets. (Page 6-81)

CAUTION

To prevent damage to the connecting rod and bearing, avoid the use of metal objects during removal. (Page 6-98)

CAUTION

Do not bead blast the pistons. (Page 6-98)

CAUTION

Do not clean the pistons and rods in an acid tank. (Page 6-98)

CAUTION

If a strap-type ring compressor is used to install the piston and connecting rod assembly into the block, ensure the inside end of the strap does not hook on a ring gap and break the ring. (Page 6-101) xxiv

S9233-C9-MMA-010 CAUTION

Prior to installing the engine, ensure that all engine mounts and system interfaces are rust-free, clean, complete, and in good working order. (Page 8-1) CAUTION

When installing the diesel engine, care must be taken to ensure proper alignment of rotating components. (Page 8-1)

xxv / (xxvi Blank)

xxvi @@FIpgtype@@BLANK@@!FIpgtype@@

S9233-C9-MMA-010 CHAPTER 1 GENERAL INFORMATION AND SAFETY PRECAUTIONS

1-1.

INTRODUCTION.

1-1.1 GENERAL INFORMATION. This manual provides the necessary information to install, maintain, operate, and repair the models 6B5.9-M and 6BT5.9-M diesel engines. The engines are manufactured by the Cummins Engine Co., Defense Products, 1000 Fifth Street, P. O. Box 3005, Columbus, Indiana 47201-6574, tel: (800) 343-7357.

1-1.2 SAFETY PRECAUTIONS. Personnel involved with the installation, operation, and repair of the diesel engine shall comply with U.S. Navy Safety Precautions for Operations Afloat, OPNAV 5100 Series. Specific safety precautions are included in the appropriate chapters of this manual. General and specific warnings and cautions are contained in the Safety Summary, which is located in the front matter of this manual.

1-2.

EQUIPMENT DESCRIPTION.

The 6B5.9-M is a six-cylinder, naturally aspirated diesel engine (figure 1-1) and the 6BT5.9-M is a sixcylinder, turbocharged, diesel engine (figure 1-2). Each engine is provided with an instrument panel that monitors engine pressures and temperatures. Table 1-1 lists the principal characteristics of the 6B5.9-M diesel engine and table 1-2 lists the principal characteristics of the 6BT5.9-M diesel engine.

Figure 1-1. Model 6B5.9-M Diesel Engine 1-1

S9233-C9-MMA-010

Figure 1-2. Model 6BT5.9-M Diesel Engine Table 1-1. 6B5.9-M Principal Characteristics Item Diesel Engine Model Manufacturer Type Aspiration Bore x Stroke Engine Weight (dry) Displacement Duty Cycle Horsepower Shaft (at 2500 rpm) Brake (at 2500 rpm) Firing Order Compression Ratio Rotation (as viewed from front of engine) Normal Idle Speed Torque Capacity of Front of Crankshaft (max)

1-2

Data 6B5.9-M Cummins Engine Co. 4-cycle, in-line, 6-cylinder Natural 4.02 in. x 4.72 in. 855 lbs 359 cu. in. Medium continuous 112 shp 115 bhp 1-5-3-6-2-4 18.5:1 Clockwise 750 rpm 210 lb-ft

S9233-C9-MMA-010 Table 1-1. 6B5.9-M Principal Characteristics - Continued Item Crankshaft End Clearance (range) Engine Speed Piston Speed Brake Mean Effective Pressure Standard Flywheel Housing Size Lubrication System High Oil Level Capacity Low Oil Level Capacity Oil Temperature (max) Oil Pressure at Idle (min allowable) Oil Pressure at Rated (min allowable) Oil Regulating Valve Opening Pressure Differential Pressure to Open Bypass Valve Continuous Operational Angularity of Oil Pan (max) Front down Front Up Side-to-Side Cooling System Coolant Capacity (engine only) Engine w/Heat Exchange Thermostat Range Starting Fully Open Pressure External Pressure Loss in Cooling System (max) Allowable Coolant Expansion Space of System Capacity (min) Coolant Make-up Capacity (min) Engine Water Flow Fuel Oil System Fuel Consumption (max) Fuel Flow to Pump (max) Allowable Pressure Drop Across Fuel Filter (max) Allowable Return Line Restriction (max) Restriction to Fuel Pump with Dirty Filter (max) Fuel Supply Hose Size Fuel Return Hose Size Air Supply System Intake Air Flow Allowable Intake Restriction at Rated Speed and Load with Dirty Air Filter Element (max) Allowable Return Line Restriction (max) Intake Air Restriction (naturally aspirated) Ventilation Area (min) Exhaust System Exhaust Gas Flow

Data .0054 to.0104 in. 2500 rpm 1969 ft/min 101 psi SAE No. 3 15 qts 13 qts 250° F 10 psi 40-60 psi 60 psi 20 psi

45 degrees 45 degrees 45 degrees 13.6 gals 21.8 gals 180° F 203° F 15 psi 5 psi 5 percent 2.7 gals 55 gpm 6.3 gph 8 gph 3 psi 5.0-inHg 3.75-inHg 6 4 210 cfm 20-inH2 O 20.4-inHg 20-inH2 O 57 sq. in. 600 cfm

1-3

S9233-C9-MMA-010 Table 1-1. 6B5.9-M Principal Characteristics - Continued Item

Data

Exhaust Gas Temperature Exhaust Diameter (min) Dry Wet Heat Rejection to Coolant Heat Rejection to Ambient Sea Water System Sea Water Flow Sea Water Pressure (max) Sea Water Pump Inlet Restriction (max) Sea Water Strainer Open Area (min) Sea Water Pump Initial Suction Lift (max) Electrical System Recommended Battery Capacity (min) Cold soak at 0°F or Above (min/CCA) w/24-Vdc Starter Reserve Capacity Allowable Resistance of Starting Circuit w/24 volt Starteralign=″right″ (max)

1150°F 3.0-in. 3.5-in. 4500 Btu/min 800 Btu/min 23 gpm 15 psi 5 inHg 6.0-in. 10 ft 475 .0020 ohms

Table 1-2. 6BT5.9-M Principal Characteristics Item Diesel Engine Manufacturer Model Type Aspiration Installation Angle (max; up front) Bore x Stroke Engine Weight Dry Displacement Duty Cycle Firing Order Fuel Injection Engine Torque Valve Clearance (intake) Valve Clearance (exhaust) Horsepower Shaft (at 2500 rpm) Brake (at 2500 rpm) Shaft Power High Output Intermittent Compression Ratio Rotation Viewed from Front of Engine Rated Speed High Output Intermittent

1-4

Data Cummins Engine Co. 6BT5.9-M 4-cycle, in-line, 6-cylinder Turbocharged 15 degrees 4.02-in. x 4.72-in. 880 lbs, 359 cu. in. Medium continuous 1-5-3-6-2-4 Direct 378 lb-ft .010-in. .020-in. 175 shp 180 bhp 204 shp at 2600 rpm 175 shp at 2500 rpm 17.5:1 Clockwise 2600 rpm 2500 rpm

S9233-C9-MMA-010 Table 1-2. 6BT5.9-M Principal Characteristics - Continued Item Standard Flywheel Housing Size Normal Idle Speed Piston Displacement Fuel System Fuel Consumption High Output Intermittent Fuel Flow to Pump Allowable Restriction to Pump with Dirty Filter (max) Allowable Injector Return Line Restriction (max) Allowable Pressure Drop Across Fuel Filter (max) Fuel Supply Hose Diameter Fuel Supply Hose Size Fuel Return Hose Diameter Fuel Return Hose Size Air Supply System Intake Manifold Pressure Inlet Restriction Filter (max/clean) Inlet Restriction Filter (max/dirty) Allowable dirt Holding Capacity of Air Cleaner (min) Intake Air Flow Ventilation Area (min) Heat Rejection to Ambient Lubrication System Allowable Oil Pressure at Idle (min) Allowable Oil Pressure at Rated Speed (min) Regulating Valve Opening Pressure Differential Pressure to Open Bypass Valve Oil Capacity High Low Total System Capacity Continuous Operational Angularity of Oil Pan (Max) Front down Front Up Side-to-Side Cooling System Engine Water Flow High Output Intermittent Coolant Capacity (engine only) Thermostat Standard Modulating Range Starting

Data SAE No. 3 750 rpm 359 cu. in.

11.2 gph at 2600 rpm 9.7 gph at 2500 rpm 12 gph 3.75 inHg 5.0 inHg 3.0 psi 25-in 6 19-in 4 43 inHg 15-inH2 O 25-inH2 O 3.0 gpm/cfm 510 cfm 138 sq. in. 7100 BTU/min 10 40-60 60 20

psi psi psi psi

15 qts 13 qts 16 qts

45 degrees 45 degrees 45 degrees

56 gpm 55 gpm 13.6 gals 180°F

1-5

S9233-C9-MMA-010 Table 1-2. 6BT5.9-M Principal Characteristics - Continued Item Fully Open Coolant Temperature (max) External Pressure Loss in Cooling System (max) Static Pressure of Coolant (max; exclusive of pressure cap) Allowable Coolant expansion Space of System Capacity (min) Coolant Make-up Capacity (min) Sea Water System Sea Water Flow High Output Intermediate Sea Water Pressure (max) Sea Water Strainer Open Area (min) Sea Water Pump Inlet Restriction (max) Sea Water Pump Initial Suction Lift (max) Heat Rejection to Coolant Sea Water Pipe Size (min) Exhaust System Exhaust Gas Flow High Output Intermittent Exhaust Gas Temperature High Output Intermittent Heat Rejection to Coolant High Output Intermittent Exhaust Diameter (min; dry) Exhaust Diameter (min; wet) Electrical System Recommended Battery Capacity Cold Soak at 0°F or above (min/CCA) Reserve Capacity Allowable Resistance of Starting Circuit w/24-Volt Starter (max)

1-6

Data 203°F 210°F 5 psi 15 psi 5 percent 2.7 gals

25.5 gpm 23.5 gpm 15 psi 6.0-in. 5 inHg 10 ft 6900 Btu/min 1.25-in.

1230 cfm 777 cfm 835°F 750°F 7100 5594 4.0-in. 5.0-in. 475 .0020 ohms

S9233-C9-MMA-010 CHAPTER 2 OPERATION 2-1.

INTRODUCTION.

This chapter provides procedures to check, prepare, operate, and shut down the diesel engine. These procedures are sufficient to enable assigned personnel to operate the engine safely and efficiently. The applicable boat information book (BIB) and the Naval Ship’s Technical Manual (NSTM), Chapters 233 and 541, provide additional information and procedures for various operation conditions. 2-2.

NORMAL OPERATING RANGES.

Table 2-1 lists the normal operating ranges for the models 6B5.9-M and 6BTS.9-M. Indicator readings outside the normal operating range may require corrective maintenance to prevent equipment damage. Operating the engine below minimum values or above maximum values will damage the equipment. Table 2-1. Normal Operating Ranges Indication 6B5.9-M Air Inlet Restriction (max at rated speed and load) With Clean Filter Element With Dirty Filter Element Blowby (max; 0.221 in diameter orifice) Coolant Temperature Standard Thermostat (modulating range) Temperature (max) Exhaust Back Pressure at Rated Load and Speed (max) Fuel Inlet Restriction With Clean Filter Element (max) Idle Speed Injector Return Line Restriction Oil Pressure - Main Oil Passage Max at rated rpm Min at rated rpm Min at idle rpm Oil Temperature (max) 6BT5.9-M Air Inlet Restriction (max at rated speed and load) With Clean Filter Element With Dirty Filter Element Blow By (max; 0.221 in. dia. orifice) Coolant Temperature Standard Thermostat (modulating range) Temperature (max) Exhaust Back Pressure at Rated Load and Speed (max) Fuel Wet Restriction With Clean Filter Element (max) Idle Speed

Range

20 inH2 O 20.4 inH2 O 4.9 inHg at 2200 rpm; 7.0 at 2500 rpm 175 to 195°F 210°F 3 inHg 3.5 inHg 750 rpm 5.0 inHg 60 psi 30 psi 10 psi 250°F

15 inH2 O 25 inH2 O 4.9 inHg at 2200 rpm 7.0 at 2500 rpm 175 to 195°F 210°F 3 inHg 3.5 inH2 O 750 rpm

2-1

S9233-C9-MMA-010 Table 2-1. Normal Operating Ranges - Continued Indication

Range

Injector Return Line Restriction OH Pressure-Main Oil Passage Max at rated rpm Min at rated rpm Min at idle rpm Oil Temperature (max)

2-3.

5.0 inHg 60 psi 30 psi 10 psi 250°F

OPERATING PROCEDURES.

2-3.1 PRE-OPERATIONAL CHECKS. operation

The following steps shall be used to check and prepare the engine for

a. Test the emergency fuel shutdown according to the following steps. 1. Actuate the emergency fuel shutdown lever and ensure the emergency fuel shutdown device operates correctly. 2. Reset the emergency fuel shutdown lever and open the emergency fuel shutdown valve. b. Test the electrical shutdown valve. c. Ensure the fuel tanks are full of fuel and stripped in accordance with the appropriate BIB or local procedures. If fuel is required, refer to table 2-2 and refuel in accordance with the NSTM, Chapter 541, and the appropriate BIB. d. Check and drain the fuel strainer. e. Drain the fuel/water separator. f. Open the fuel supply shutoff valves, as required, to supply fuel from the on-service fuel tank to engine. g. Open the fuel return shutoff valves, as required, to ensure that fuel spill from the engines returns to on-service fuel tank only. h. Check the fuel piping, hoses, fittings, and valves for leaks. If leaks are found, refer to chapter 5 and troubleshooting. i. Check the starting motor and batteries; ensure the battery charge is sufficient to start the engine. j. Check the air silencer for dirt and clogging. Remove any foreign material. Clean as required. k. Operate compartment ventilation, as required, for engine operation. l. Remove the cap from the expansion tank assembly and check the coolant level. At normal operating temperature, the coolant level should be about two inches below the top of the filler neck; add engine coolant, as required. Replace the cap. m. Check the fresh water pipes, hoses, and fittings for leaks. If leaks are found, refer to chapter 5 and troubleshoot. n. Close the sea water drain and vent connections. o. Clean and inspect the sea water stainer. p. Open the sea water manual valves, as required, for engine operation 2-2

S9233-C9-MMA-010 Table 2-2. Fuel and Lubricating Oil Type

Usage

Primary Fuel, Naval Distillate (MIL-F-168834)

Use when ambient temperature is consistently above 30°F.

Secondary Turbine Fuel, Aviation, Grade JP-5 (MIL-T-5624) Use when ambient temperature is consistently below 30°F. Primary Lubricating Oil, Internal Combustion Engine, Use with ambient temperature above 20°F. Diesel (MIL-9000G, Sym 9250) Secondary Lubricating Oil, Internal Combustion Engine, Ambient temperature consistently below 20°F. Diesel (MIL-L-2104)

CAUTION

To prevent damage to equipment, prime the sea water pumps prior to operation. q. If necessary, prime the sea water pump. CAUTION

To prevent damage to equipment, ensure that oil in the engine is at the proper level. r. Ensure oil in the engine is at the high level mark on the dipstick. 1. Remove the dipstick from the oil pan and check the level. The oil level should be at the full mark. 2. If the level is low, refer to table 2-2. Remove the oil fill cap from the valve cover and add lubricating oil, as required, to bring the level to the full mark. 3. Reinstall the oil fill cap. 4. If the level is high, excess oil can be removed from the oil sump with the sump pump. Dispose of oil in accordance with the NSTM, Chapter 593. 5. Reinstall the dipstick in the dipstick tube. s. Ensure the marine transmission is prepared for operation, if equipped. Also, ensure the clutch is disengaged. t. Ensure the auxiliary driven equipment and associated systems are prepared for operation. u. Ensure the engine rotating components are unobstructed. v. Place the start switch in the OFF position. w. Ensure the oil pressure and alternator warning lights are on. x. Set the engine control lever in the idle position. 2-3.2 NORMAL OPERATION. The following steps shall be used for normal operation. This procedure covers electrical starting for cold and warm weather. 2-3

S9233-C9-MMA-010 CAUTION

To prevent damage to equipment, this entire procedure and the emergency operating procedures must be understood before starting the engine. Rapid automatic sequence of some events without proper operator actions may damage the equipment. a. Review this entire procedure and the emergency engineering operating procedures (EEOP) before performing any steps. This will ensure undemanding of required actions during rapid automatic sequence of events. Where conflicts exist, the EEOP takes precedence. b. Ensure the pre-operational checks have been performed. Refer to paragraph 2-3.1. c. Place throttle in the idle position. d. When the ambient temperature is 40°F or less and the engine is cold, start the engine using the cold start procedures contained in the BIB. e. When the ambient temperature is greater than 40°F or the engine is warm, start the engine with the electrical starting system.

WARNING

To prevent injury or death, exercise extreme caution when working on or around rotating parts of machinery or operating equipment. 1. Ensure the area around the engine is clear of personnel and loose equipment NOTE The start switch has three positions: OFF, RUN, and START. OFF and RUN are continuous contact positions and START is a momentary contact position. 2. Place the switch in the RUN position and observe that the engine’s gauges and instruments are energized. The temperature gauges should read normal temperatures and the alternator and low oil pressure warning lights should be lit. 3. Place and hold the switch in the START position to activate the starter motor and crank the engine. Proceed to step f. 4. If the engine does not start after 30 seconds, return the switch to the OFF position. Wait two minutes between unsuccessful attempts. 5. Repeat steps 1 through 4. If the engine does not start after four attempts, refer to chapter 5 and troubleshoot.

WARNING

To prevent injury or death, shut down the engine when unusual noise or vibration occurs. Unusual noise or vibrations may be an indication of equipment failure. 2-4

S9233-C9-MMA-010 f. Within 10 to 15 seconds after the engine starts, the alternator warning light and the low oil pressure warning light should go out, and the oil pressure gauge should indicate at least 10 psi. If this does not occur, place the switch in the OFF position and shut down the engine. Refer to chapter 5 and troubleshoot. g. If abnormal noises or vibrations are present in the engine or any driven equipment, shut down the engine according to the EEOP.

WARNING

To prevent injury or death, control all oil and fuel leakage immediately. Oil or fuel spraying on hot components is an extreme fire hazard. h. Periodically check the engine, attached piping, and hoses for oil, fuel, coolant, and sea water leakage. 1. If oil or fuel is spraying, shut down the engine according to the EEOP. 2. If the oil or coolant levels cannot be maintained, shut down the engine according to the EEOP. 3. If fuel is leaking, shut down the engine according to the EEOP. 4. If sea water is leaking and the coolant temperature is above 190°F and rising, shut down the engine. If the temperature reaches 210°F, shut down the engine according to the EEOP. i. Periodically monitor all engine indicators and record readings. Ensure the monitored parameters are within operating limits. Refer to table 2-1. j. Run the engine at idle speed for one minute. CAUTION

To prevent damage to equipment, do not engage the clutch at speeds greater than 850 rpm. k. With the boat moored to the dock, engage the clutch and run the engine at partial load for five minutes. CAUTION

To prevent damage to equipment, run the engine at 800 rpm or greater during extended idle periods. Running the engine at idle speed for prolonged periods will dilute oil with fuel and cause sludge build-up. l. Operate the engine, as required, for boat operations; maintain 800 rpm or greater when operating. Ensure the clutches are not engaged at speeds greater than 850 rpm. 2-3.3 SHUTDOWN.

Shut down the engine according to the following steps. CAUTION

To prevent damage to equipment, cool the engine before pressing the stop switch. Stopping the engine before it cools down may cause damage to equipment. 2-5

S9233-C9-MMA-010 a. To cool down the engine, run the engine for five minutes at idle speed with the clutch disengaged. b. Move the start switch to the OFF position; ensure the engine stops. c. If the engine does not stop, actuate the emergency manual shutdown lever. If the emergency fuel shutdown lever does riot stop the engine, determine and correct the cause. Refer to chapter 5 and troubleshoot. d. If the engine does not stop, actuate the emergency fuel shutdown lever for the on-service fuel tank. Ensure the engine stops in about 10 seconds. Determine and correct the cause of the stop switch not stopping the engine. e. If actuated, reset the emergency fuel shutdown lever and open the emergency fuel shutdown valve. f. Close the fuel supply shutoff valve supplying fuel from the on-service fuel tank to the engine. g. Close the fuel return shutoff valve which allows fuel spill to return to the on-service fuel tank. h. Close the sea water manual valves that were opened for engine operations i. Open the sea water vent and drain connections. j. After the engine has been stopped for 20 minutes, ensure oil in the engine is at the proper level. 1. Remove the dipstick from the oil pan and check the level. The oil level should be at the full mark. 2. If the level is low, remove the oil fill cap from the valve cover and add lubricating oil, as required to bring level to full mark. (Refer to table 2-2.) Reinstall the oil fill cap on the cover. CAUTION

If excessive oil must be repeatedly drained from the engine, troubleshoot the cause to prevent further damage to the engine. 3. If the level is high, pump oil from the oil pan into an appropriate disposal container. Dispose of oil in accordance with the NSTM, Chapter 593. 4. Reinstall the dipstick in the dipstick tube. k. Refer to table 2-2 and fill the fuel tanks with fuel in accordance with the NSTM, Chapter 541, and the BIB. l. Perform required engine maintenance. 2-3.4 EMERGENCY OPERATION. Emergency operation is necessary when the equipment malfunctions. If the equipment malfunctions, refer to chapter 5 and troubleshoot. Ensure equipment repair/replacement is performed as soon as possible. 2-3.4.1 Low Oil Pressure. a. If the warning light indicating low oil pressure comes on, check the oil pressure gauge. b. If the oil pressure gauge indicates greater than 10 psi, determine and correct the cause of the malfunctioning warning light. Refer to chapter 5 and troubleshoot. c. If the oil pressure gauge indicates 10 psi or less, stop the engine. d. If operation of the engine is not absolutely required, shut down the engine (refer to paragraph 2-3.3.). 2-6

S9233-C9-MMA-010 e. If the engine operation is required and low oil pressure is due to oil leakage, operate the engine while performing the following steps. 1. Remove the dipstick from the oil pan and check the level. 2. Remove the oil fill cap from the valve cover. Add lubricating oil (table 2-2), as required, to bring the level to the full mark. Reinstall the oil fill cap on the cover. 3. Reinstall the dipstick in the oil pan. 4. Continuously repeat steps 1 through 3 while the engine is running. 5. If the oil level cannot be maintained between the low and full marks on the dipstick or the oil pressure cannot be maintained greater than 10 psi, shut down the engine according to paragraph 2-3.3. f. Determine and correct the cause of low oil pressure. Refer to chapter 5 and troubleshoot. 2-3.4.2 High Engine Coolant Temperature. a. If the warning light indicating high engine coolant temperature comes on, check the water temperature gauge. 1. If the water temperature gauge indicates 210°F or greater, shut down the engine to determine and correct the malfunction. Refer to chapter 5 and troubleshoot. 2. If the water temperature gauge indicates 200°F or greater, decrease engine speed to attempt cooling of the engine. Refer to chapter 5 and troubleshoot. b. If engine operation is required and high engine coolant temperature is due to coolant leakage, operate the engine as follows: 1. Allow the engine to cool as long as possible.

WARNING

To prevent injury or death, use extreme caution when removing the cap from the expansion tank. Steam formed by the sudden release of pressure from a heated cooling system may force hot coolant through the system’s openings. 2. Using extreme caution, remove the cap from the expansion tank. 3. Add coolant, as required, to bring the tank to the proper level. 4. Operate the engine; refer to paragraph 2-3.2. Continuously monitor the tank and add coolant, as required, to maintain the proper level. 5. If the coolant level cannot be maintained, shut down the engine according to the EEOP. 6. When engine operations are complete, reinstall the cap on the tank. c. Determine and correct the cause of a high engine coolant temperature. Refer to chapter 5 and troubleshoot. 2-3.4.3 Runaway Engine. If oil is introduced into the cylinders, the engine will become uncontrollable and may overspeed. Excessive oil level in the oil pan will cause a runaway engine. If a runaway engine is suspected, proceed as follows: a. Shut down the engine according to the EEOP. 2-7

S9233-C9-MMA-010 b. If the engine speed is quickly approaching 2600 rpm, actuate the emergency manual shutdown lever. c. Determine and correct the cause of a runaway engine. Refer to chapter 5 and troubleshoot.

2-8

S9233-C9-MMA-010 CHAPTER 3 FUNCTIONAL DESCRIPTION 3-1.

INTRODUCTION. This chapter provides a detailed functional description of the diesel engine.

3-2.

GENERAL DESCRIPTION.

The diesel engine converts chemical energy into mechanical energy, which is used for propulsion and to provide power for boat accessories. The model 6B5.9-M diesel engine is a six-cylinder, four-cycle internal combustion engine that also drives its own accessory equipment and the model 6BT5.9-M diesel engine is a six-cylinder, four-cycle, internal combustion, turbocharged diesel engine. Each of the engines consists of an electric starting system, an air intake and exhaust system, a fuel system, lubrication system, cooling system, and various controls and indicators.

3-3.

DETAILED DESCRIPTION.

3-3.1 DIESEL ENGINE. The engine is a four-cycle, internal combustion engine that includes an intake air cleaner/silencer, six pistons and connecting rod assemblies, a crankshaft assembly, idler gear, camshaft assembly, cylinder head assembly, cylinder block assembly, and an accessory drive assembly. The piston and connecting rod assemblies convert the heat energy released by fuel combustion into mechanical energy to rotate the crankshaft assembly. Crankshaft assembly rotation is then transmitted by the idler gear to the camshaft assemblies through a gear train. The camshaft assemblies actuate the cylinder head assemblies to inject fuel into and conduct exhaust gases out of the cylinders in the required timed sequence. The cylinder head assembly forms the top enclosure for the cylinders and provides for cooling, lubrication, fuel injection, and exhaust gas removal. (The model 6BT5.9-M includes a turbocharger to increase intake air volume and pressure.) The cylinder block assembly supports and aligns the diesel engine components and provides internal passages for oil, coolant, and air flow. Various diesel and non-diesel accessory equipment is driven by the accessory drive assembly.

3-3.2 ELECTRICAL STARTING SYSTEM. The electrical starting system includes a starting circuit, 24-volt battery bank, starting motor, and an alternator. A deposition toggle switch (OFF, RUN, START) is included for engine control. The OFF position closes the fuel supply to the injection pump. The RUN position energizes the engine gauges, instruments, warning lights, and control devices, and also opens the fuel supply valve. The START position is a momentary contact. When held closed, the solenoid switch on the starter motor is closed to supply full battery power to the starter motor for cranking the engine. When released the switch returns to the RUN position where it remains until it is moved to the OFF position. An electrical interlock, which is included in the engine throttle and clutch control, prevents starting the engine unless the transmission is in neutral. The alternator includes a solid-state, integral voltage regulator. A positive battery lead supplies power for initial excitation of the alternator field. An alternator failure warning light is fed by the same line. As soon as the alternator begins to generate voltage, that voltage matches the battery voltage to the regulator and turns out the alternator failure warning light, and the alternator becomes self-excited. The voltage regulator senses battery condition and maintains alternator output voltage at an appropriate level throughout the full range of engine running speeds. When the alternator output stops, battery power returns to the warning light. 3-1

S9233-C9-MMA-010 3-3.3 AIR INTAKE AND EXHAUST SYSTEMS.

3-3.3.1 Air Intake System. The air intake system provides clean air to the cylinders at atmospheric pressure for the model 6135.9-M, and above atmospheric pressure for the model 6BT5.9-M. The model 6B5.9-M intake system includes air cleaner/ silencer piping and an intake manifold and intake valves, through which clean, cool air is admitted into the engine cylinders. The model 6BT5.9-M is equipped with an exhaust-driven turbocharger, which increases the intake air volume and pressure to the cylinders via the intake manifold and intake valves.

3-2

S9233-C9-MMA-010

Figure 3-1. Electrical Schematic (Sheet 1 of 2)

3-3 / (3-4 Blank)

3-4 @@FIpgtype@@BLANK@@!FIpgtype@@

S9233-C9-MMA-010

Figure 3-1. Electrical Schematic (Sheet 2 of 2)

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S9233-C9-MMA-010 3-3.3.2 Exhaust System. The exhaust system includes those components used to expel the engine’s exhaust gasses. It starts with the exhaust valves, one valve for each of the six cylinders. Each cylinder expels its exhaust gas into the manifold: in the model 6B5.9-M, the exhaust passes through a sea water-cooled exhaust elbow fitting, through a 2-1/2-inch to 3-inch piping, a muffler, and more piping to the atmosphere. The path of the exhaust gasses for the model 6BT5.9-M is the same from the cylinder exhaust valve to the exhaust manifold, but in this model, the exhaust gasses are used to drive the turbocharger. From the turbocharger, the exhaust gas passes through the sea water-cooled elbow, piping, muffler, and additional piping before it is discharged to the atmosphere. 3-3.4 FUEL SYSTEM. The fuel system consists of a fuel lift pump, injection pump, fuel drain manifold, throttle, shutoff valve, fuel injection nozzles, and fuel lines. 3-3.4.1 Fuel Pumps. The fuel lift pump is attached to the side of the engine block. The lift pump pulls fuel from the supply tank and supplies low-pressure fuel (3 to 5 psi) to the fuel filter head, through the filter, then to the fuel injection pump. The fuel injection pump increases fuel pressure and routes the high-pressure fuel to each Injection nozzle. 3-3.4.2 Fuel Injection Nozzles. Fuel is supplied through the high-pressure lines to the fuel injection nozzles in the cylinder head. When the high-pressure fuel reaches the injection nozzles, the pressure lifts the needle valve against spring tension and allows fuel to enter the combustion chamber. A common drain line returns unused fuel to the supply tank. 3-3.4.3 Fuel Drain Manifold. Any leakage past the fuel injection needle valve enters the fuel drain manifold. The fuel drain manifold routes controlled venting from the injection pump and leakage from the nozzles back to the main fuel tank. 3-3.4.4 Throttle. The throttle provides a means for the operator to manually control engine speed above idle, as required, by varying operating conditions of speed and load. 3-3.4.5 Fuel Shutoff Valve. The injection pump is equipped with an electrical shutoff valve. This solenoidoperated valve blocks the supply of fuel to the high-pressure pumping and distribution components. The valve is designed to be closed when there is no electrical power to the solenoid. 3-3.5 LUBRICATION SYSTEM. The engine is pressure-lubricated by a gerotor-type lube oil pump driven by the front crankshaft gear located in the oil pan at the front of the engine. A pressure regulator is mounted in the block to control pressure. Filters and screens are provided in the lubricating system to remove impurities in the oil. A bypass valve is provided in the full-flow oil filter head to continue lubrication if the element becomes clogged. The engines lube oil capacity at full level holds 15 quarts of oil. 3-3.6 COOLING WATER SYSTEMS. 3-3.6.1 Fresh Water Cooling System. Coolant in the fresh water cooling system consists of a mixture of fresh water and antifreeze. The engine fresh water cooling system includes an engine block, cylinder head, heat exchanger, fresh water pump, thermostat, expansion tank, and piping; it has a coolant capacity of 21.8 gallons. The coolant is pressurized up to 15 pounds psi when the diesel engine is running at normal operating speed (2500 rpm) by the fresh water pump. Coolant output from the fresh water pump empties into the oil cooler cavity of 3-7

S9233-C9-MMA-010 the cylinder block. The coolant circulates around each cylinder and crosses the cylinder block to the fuel injection pump side of the engine. As the coolant flows through the cylinder head and block toward the thermostat, it provides cooling for the fuel injection nozzles. When the engine is below operating temperature, the thermostat is closed and coolant flow bypasses the heat exchanger, trapped air goes to the water pump inlet via drilled passages in the block and head. When the operating temperature is reached, the thermostat opens, thereby blocking the bypass passage to the fresh water pump and opening the outlet to the heat exchanger. Coolant flowing through the heat exchanger to the fresh water pump is cooled by a counterflow of sea water pumped through the heat exchanger. Sea water exits from the heat exchanger via a sea water connection at the upper rear end of the heat exchanger. The expansion tank provides make-up coolant for the closed coolant system and provides a place for hot coolant to expand. 3-3.6.2 Sea Water Cooling System. The sea water cooling system furnishes sea water, which is used to cool oil passing through the transmission’s oil cooler, fresh water coolant passing through the heat exchanger, and exhaust gas passing through the exhaust manifold elbow to the muffler. The water pump, which has a maximum suction lift of 10 feet, draws sea water through a strainer with a minimum open area of six square inches. The sea water pump discharges coolant at a maximum pressure of 15 psi. 3-3.7 CONTROLS AND INDICATORS. Various controls and indicators are provided with the diesel engine installation to start, operate, and shut down the diesel engine and to monitor diesel engine parameters during operation. See figure 3-1 for an electrical schematic of the engine controls. 3-3.7.1 Starter Switch. When the starter switch is activated, 24-Vdc is supplied to the solenoid, completing the circuit to the starter motor on the engine. 3-3.7.2 Electrical Fuel Shutoff. The fuel shutoff is installed on the fuel injection pump. Its purpose is to stop the engine under normal operating conditions by stopping the fuel flow to the nozzles when the start switch is moved to the OFF position. 3-3.7.3 Tachometer. The tachometer is electrically connected to a sender attached to the engine. It converts mechanical motion to electrical impulses to cause the tachometer to indicate engine speed (rpm). 3-3.7.4 Lube Oil Pressure Switch. The lube oil pressure switch is a break-type switch set to actuate when the lube oil pressure drops to eight psi. This completes the low lube oil alarm circuit to the control panel to activate the engine warning light. The switch is located on the fuel pump side of the block. 3-3.7.5 Water Temperature Switch. The water temperature switch, which is located on the cylinder head, is operated by a high cooling water temperature condition. When the cooling water temperature exceeds 225°F, the switch closes a set of contacts that causes the engine warning light at the control panel to activate.

3-8

S9233-C9-MMA-010 CHAPTER 4 SCHEDULED MAINTENANCE 4-1.

INTRODUCTION.

Required preventive maintenance procedures to be performed on a scheduled basis are provided in the Planned Maintenance System (PMS) documentation OPNAVINST 4790.4 describes this system, which also covers departmental and work center record keeping, as well as the Maintenance Index Page (MIP) and Maintenance Requirements Cards (MRC’s). MRC’s cover scheduled inspection and lubrication procedures for the diesel engine. The extensive and comprehensive scheduled maintenance provided by PMS MRC’s eliminates the need for any coverage within this chapter. Specific corrective maintenance (adjustment, alignment, and repair) is covered in chapter 6 of this manual.

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S9233-C9-MMA-010 CHAPTER 5 TROUBLESHOOTING

5-1.

INTRODUCTION.

This chapter provides information for troubleshooting unsatisfactory operation or failure of the diesel engine. The procedures have been prepared for the operators rather than the more experienced and better equipped personnel in maintenance facilities. However, some of the diagnostic and corrective action procedures may require personnel assistance and/or tools or other equipment not available onboard the craft.

5-2.

TROUBLESHOOTING GUIDE.

The troubleshooting guide (table 5-1) is provided as an aid to locate and correct any malfunctions of the diesel engines. At the first sign of trouble, isolate the problem and evaluate before removing any components. Table 5-1 represents a list of potential problems, their probable causes, and suggested corrective actions.

Table 5-1. Troubleshooting Guide Problem/Malfunction Engine will not crank.

Probable Cause

Corrective Action

a. Loose or corroded battery cables. b. Loose or corroded connections in the starting circuit c. Battery charge low.

a. Clean and tighten battery connections. b. Clean and tighten connections. c. (1) Inspect battery for dead cell. Replace defective battery. (2) Inspect alternator output. Replace defective alternator. d. Faulty solenoid or starting d. Temporarily cross-connect motor. the starter solenoid terminals If the starter does not crank, replace the starter motor. e. Faulty auxiliary magnetic switch. e. Temporarily connect starter solenoid terminal P to S. if the engine does not crank, replace the switch. f. Faulty starter switch. f. Temporarily connect terminals I to S on the start switch. If the starter cranks, replace the switch.

5-1

S9233-C9-MMA-010 Table 5-1. Troubleshooting Guide - Continued Problem/Malfunction 2. Engine cranks but will not start (no smoke from exhaust).

Probable Cause

a. Replenish fuel supply. b. Inspect for loose wires; ensure the valve is operating. The manual shutoff valve must be in the run position. c. Air intake or exhaust plugged. c. Remove obstruction. d. Fuel filter plugged or water con- d. Drain fuel/water separator taminated. and replace fuel filter. e. Injection pump not receiving e. Inspect fuel flow and bleed fuel or air in fuel. air from fuel system. f. Worn or faulty injection pump. f. Check fuel delivery. Replace pump, if necessary. g. Internal pump timing incorrect. g. Time the pump. h. Camshaft out of time. h. Correct gear train timing. 3. Engine cranks but will not a. Incorrect starting procedure. a. Ensure the EEOP is used to start (smoke from exhaust). stan engine. b. No fuel in supply tank. b. Check fuel supply; replenish as necessary. c. Electric or manual fuel shutdown c. Ensure solenoid is energized. not open. If no voltage, inspect for broken wires. If voltage is present, inspect shutdown solenoid operation. Replace defective parts. d. Exhaust restriction. d. Locate and correct any exhaust restriction. e. Fuel filter plugged or contamie. Drain fuel/water separator nated. and renew fuel filter element. f. Injection pump not receiving fuel f. Inspect fuel flow and bleed or air in fuel. air from fuel system. g. Worn or faulty pump. g. Replace injection pump. 4. Engine hard to start or will a. Engine under load. a. Ensure clutch or transmisnot start (smoke from exhaust). sion is disengaged. b. Incorrect starting procedure. b. Refer to chapter 2. c. Cranking speed too low/slow. c. (1) Inspect battery, starting motor for loose or corroded wiring connections. Clean and tighten connections. (2) Bar engine over to check for excessive resistance. d. Crankcase heater not working. d. Check power source, thermostat and heater to ensure heater is operating properly. Replace defective parts. e. Insufficient intake air. e. Inspect/replace air filter and check for obstructions. f. Air in fuel system. f. Bleed air from fuel system. Determine cause of air in system and correct.

5-2

a. No fuel in supply tank. b. Electrical or manual fuel shutdown not open.

Corrective Action

S9233-C9-MMA-010 Table 5-1. Troubleshooting Guide - Continued Problem/Malfunction

Probable Cause g. External pump timing incorrect

h. Contaminated fuel. i. Injection nozzles worn or faulty.

5. Engine starts but will not keep running.

j. Valves incorrectly adjusted. k. Worn or faulty injection pump. a. Low fuel level in supply tank. b. Broken or loose correction to shutdown. c. Restricted exhaust.

6. Surging (speed change).

Corrective Action g. Ensure pump timing marks are in alignment and timing is correct. h. Drain and flush fuel supply tanks. Refill with clean fuel oil. i. Inspect and replace injection nozzles, as necessary. j. Adjust valves. k. Replace injection pump. a. Replenish fuel supply, as necessary. b. Inspect shutdown wiring and repair, as necessary. c. Inspect and correct exhaust restriction d. Remove restriction,

d. Fuel restriction in the suction side of the fuel system. e. Restricted fuel drain manifold or e. Remove restriction. return line. f. Fuel system leak/air in fuel sys- f. Visually inspect fuel system tem. for leak and correct leakage. Bleed air from fuel system. g. Contaminated fuel. g. Drain and flush the fuel supply tank. Refill with clean fuel oil. h. Injection nozzles worn or faulty. h. Inspect and replace nozzles, as necessary. i. Worn or faulty injection pump. i. Replace injection pump. a. If at idle, idle speed is set too a. Adjust idle speed. low. b. High-pressure fuel leak. b. Inspect and correct leaks in high-pressure fuel lines, fittings, nozzle sealing washers, or delivery valves. c. Worn or faulty injection nozzles. c. Replace nozzles, as necessary. d. Faulty delivery valve. d. Replace delivery valve. e. Faulty injection pump. e. Replace injection pump.

5-3

S9233-C9-MMA-010 Table 5-1. Troubleshooting Guide - Continued Problem/Malfunction 7. Rough idle.

Probable Cause

a. Refer to Coolant Temperature Below Normal. b. Idle speed too low. b. Adjust low idle screw. c. Engine mounts overtightened, c. Inspect condition of mounts. damaged, or loose. Replace, as necessary. d. High-pressure fuel leak. d. Correct leaks in highpressure lines, fittings, injection sealing washers, or delivery of valve seals. e. Air in fuel system. e. Locate and correct source of air in fuel system. Bleed air from fuel system. f. Sticking needle valve in nozzle. f. Replace injection nozzle. g. Faulty delivery valve. g. Replace delivery valve. h. Valves not seating. h. Adjust valves. i. One or more cylinders losing i. Perform compression check compression. and repair, as necessary. 8. Engine runs rough or misfir- a. Fuel injection lines leaking. a. Repair leaks in high-pressure ing. lines, fittings, nozzle seal washers, or delivery valves. b. Air in the fuel or the fuel supply b. Inspect flow rate and bleed is inadequate. air from the system. c. Contaminated fuel. c. Drain and flush fuel supply tanks. Refill with clean fuel oil. d. Incorrect valve adjustment. d. Inspect for bent push rod and readjust valves. e. Injection pump timing incorrect. e. Time pump. f. Low compression. f. Perform compression check and repair, as necessary. g. Faulty injection nozzle. g. Replace nozzle. h. Defective injection pump. h. Replace pump. i. Camshaft out of time. i. Retime gear train. j. Damaged camshaft or tappets. j. Inspect camshaft replace parts as necessary.

5-4

a. Cold engine.

Corrective Action

S9233-C9-MMA-010 Table 5-1. Troubleshooting Guide - Continued Problem/Malfunction 9. Engine will not reach rated speed.

10. Low power.

Probable Cause

Corrective Action

a. Engine overloaded.

a. Verify high-idle speed without load. Reduce engine load. b. Faulty tachometer. b. Ensure correct engine speed with hand tachometer. Replace tachometer or sending unit, if necessary. c. Throttle linkage worn or improp- c. Replace or adjust linkage for erly adjusted. stop fuel control lever travel. d. High-speed stop screw incord. Reset high-speed stop screw. rectly adjusted. e. Mechanical shutdown lever par- e. Reposition shutdown lever tially engaged. in run position f. Inadequate fuel supply. f. Inspect the fuel flow. Locate and correct the source of the restriction. g. Restricted manifold drain line, if g. Remove restriction. condition is intermittent h. Faulty injection pump. h. Replace pump. a. Fuel control lever not moving to a. Ensure throttle travel is from full speed. stop-to-stop. b. Mechanical shutdown lever par- b. Place shutdown lever in run tially engaged. position. c. High oil level. c. Reduce oil level to correct mark on dipstick. d. Engine overloaded. d. Inspect for added loading from faulty accessories or marine gear. Repair, as necessary. e. Incorrect external injection pump e. Ensure pump timing marks timing. are aligned. f. Air intake air inadequate or too f. Replace air cleaner element. high or low in temperature. Correct any restrictions. g. High-pressure fuel leak. g. Correct leaks in highpressure lines, fittings, nozzle sealing washers, or delivery valve seals. h. Inadequate fuel supply. h. Inspect the fuel flow through the filter to locate the source of the restriction. i. High fuel temperature. i. Ensure fuel heater is off in warm weather. j. Restricted fuel drain manifold (if j. Correct restriction. low power is intermittent). k. Poor quality fuel. k. Operate engine from a fuel tank known to have good fuel. l. Valve clearances incorrect. l. Adjust valves. m. Injection pump internal fault. m. Time pump.

5-5

S9233-C9-MMA-010 Table 5-1. Troubleshooting Guide - Continued Problem/Malfunction

Probable Cause n. Low compression.

11. Excessive exhaust smoke (white smoke).

12. Coolant temperature above normal.

5-6

Corrective Action

n. Perform compression check to determine faulty cylinders. Repair as necessary. o. Worn or faulty injection nozzles. o. Inspect nozzles. Repair or replace, as necessary. p. Faulty injection pump. p. Replace injection pump. q. Excessive exhaust restriction. q. Repair exhaust system, as necessary. r. Model 6BT5.9-M malfunctioning r. Inspect/replace, as necessary. turbocharger. a. Engine running too cold a. Refer to Coolant Temperature Below Normal, b. Inadequate air intake. b. Change air cleaner element; inspect and repair any other restrictions. c. Model 6BT5.9-M air leak at tur- c. Locate/correct turbocharger bocharger. air leak(s). d. More than one sealing washer d. Remove extra washer. under nozzle. e. Model 6BT5.9-M malfunctioning e. Replace turbocharger. turbocharger. f. Faulty injection nozzles. f. Replace nozzles. g. Faulty or overfueled injection g. Replace injection pump. fuel pump. h. Piston rings not sealing (blue h. Perform compression check smoke). and correct any deficiency discovered. a. Low coolant level. a. Replenish coolant as necessary. Repair any coolant leaks. b. Faulty pressure cap. b. Replace pressure cap. c. High lube oil level. c. Drain oil to correct level on dipstick. d. Loose drive belt on water pump. d. Adjust belt tension. e. Inadequate sea water flow to e. (1) Inspect sea water suction heat exchanger. for debris. Clean, as necessary. (2) Check sea water pump output. Rebuild or replace pump, as necessary. f. Heat exchanger plugged. f. Clean heat exchanger. g. Faulty temperature gauge. g. Ensure the gauge is accurate; if not, replace the gauge. h. Faulty, incorrect, or no thermo- h. Replace thermostat. stat i. Air in cooling system. i. (1) Ensure correct thermostat installed. (2) Inspect for head gasket leak. j. Faulty water pump. j. Replace water pump.

S9233-C9-MMA-010 Table 5-1. Troubleshooting Guide - Continued Problem/Malfunction

Probable Cause k. Incorrect injection pump timing. l. Incorrect external injection pump timing. m. Plugged cooling passages in head, head gasket, or block. n. Engine overloaded.

13. Coolant temperature below a. Incorrect thermostat, broken normal. jiggle pin, or contamination in the thermostat. b. Temperature sensor or gauge faulty.

14. Coolant loss.

15. Lubricating oil pressure low.

Corrective Action k. Time injection pump. l. Ensure pump timing marks are aligned. m. Flush the system and fill with clear coolant. n. Reduce engine load and speed. a. Replace thermostat.

b. Ensure the gauge and sensor am accurate. Replace as necessary. c. Coolant not flowing by tempera- c. Clean coolant passages in ture sensor. block. a. External leak. a. Inspect engine and components for leaking hoses or gaskets. Repair all leaks. b. Transmission cooler leak. b. Inspect transmission sump for coolant. Replace cooler if leaking. c. Lube oil cooler leak. c. Inspect for coolant in oil sump. Replace cooler. d. Head gasket leak. d. Replace head gasket. e. Cracked or porous head. e. Replace head. f. Leak in cylinder block coolant f. Replace the cylinder block. passages. a. Low oil level. a. Replenish oil to proper level on dipstick. Repair oil leaks. b. Oil viscosity thin, diluted, or b. Ensure correct oil is being wrong specification. used. Refer to table 2-2. c. Faulty pressure switch or gauge. c. Ensure the pressure switch and gauge are functioning correctly. Replace faulty switch or gauge. d. Relief valve stuck open. d. Replace valve. e. Plugged oil filter. e. Change oil filter. f. Shipping plugs left in cooler (if f. Remove plugs. cooler was replaced). g. incorrect lube oil pump installed g. Replace with correct pump. (if replaced). h. Loose or missing cup plugs. h. Replace cup plugs. i. Suction tube loose/seal leaking. i. Replace seal. j. Worn lube oil pump. j. Replace pump. k. Loose main bearing cap. k. Install new bearings and torque cap. l. Worn bearings. l. Replace bearings; replace piston cooling nozzles.

5-7

S9233-C9-MMA-010 Table 5-1. Troubleshooting Guide - Continued Problem/Malfunction

Probable Cause

Corrective Action

16. Lube oil pressure too high. a. Faulty pressure switch or gauge. a. Ensure pressure switch and gauge are functioning correctly. Replace if necessary. b. Engine running too cold. b. Refer to Coolant temperature below normal. c. Oil viscosity too thick. c. Ensure correct oil is being used. d. Relief valve stuck closed. d. Replace valve. e. Incorrect lube oil pump installed e. Replace with correct lube oil (if replaced). pump. 17. Loss of lube oil. a. External leaks. a. Inspect for leaks and correct as necessary. b. Crankcase overfilled. b. Drain oil to correct level on dipstick. c. Incorrect oil. c. Ensure oil is correct viscosity. Test oil for fuel dilution. d. Oil cooler leak. d. Inspect for oil in coolant. Replace cooler. e. Excessive blow-by forcing oil e. Measure blow-by and corout of the breather. rect as necessary. f. Worn valve seals. f. Replace valve seals. g. Worn piston rings. g. Perform compression check. Replace piston, rings, as necessary. h. Model 6BT5.9-M turbocharger h. Inspect model 6BT5.9-M leaking oil into the air intake. turbocharger for faulty seals. Replace seals, as necessary. 18. Contaminated coolant. a. Rusty coolant. a. Drain and flush cooling system. Fill with correct coolant mixture. b. Leaking marine gear oil cooler. b. Replace cooler. c. Oil leaks from oil cooler, head c. Refer to Loss of lube oil. gasket, head, and cylinder block. 19. Contaminated lube oil. a. Coolant in oil (internal leakage). a. Refer to Coolant loss. b. Excessive oil sludge. b. Decrease oil change intervals. Ensure correct oil viscosity in use. c. Fuel in oil (engine operating too c. Avoid excessive idling. cold). Ensure engine comes up to temperature. d. Fuel pump seal leaking. d. Replace pump. e. Injection nozzle needle valves e. Locate and replace nozzles, riot sealing. as necessary. 20. Fuel or oil leaking from a. Intake air restriction. a. Replace filter element Avoid exhaust manifold. excessive idling. b. Injection nozzle needle valve b. Locate and replace nozzles, stuck open. as necessary.

5-8

S9233-C9-MMA-010 Table 5-1. Troubleshooting Guide - Continued Problem/Malfunction 21. Compression knock.

Probable Cause a. Air in fuel system. b. Poor quality fuel. c. Engine overloaded.

22. Excessive fuel consumption.

d. Incorrect injection pump timing. a. Overloading from faulty accessories. b. Poor quality fuel.

23. Engine will not shut off.

c. Inadequate intake air or exhaust restriction. d. Fuel pump timing. e. Worn or faulty nozzles. f. Valves not seating. a. Fuel shutoff valve inoperative.

24. Excessive vibration.

b. Engine running on fumes drawn into the air intake. a. Engine not running smoothly. b. Loose or broken engine mounts. c. Faulty accessories.

25. Excessive engine noises.

d. Worn or damaged alternator bearing. e. Flywheel housing misaligned. f. Loose or broken component in engine. g. Unbalanced shaft gear(s) or flywheel. a. Drive belt squeal, insufficient tension, or excessive loading. b. Intake air or exhaust leaks. c. Excessive valve lash.

d. Gear train noise.

e. Internal engine components knocking.

Corrective Action a. Bleed fuel system. b. Clean and flush fuel supply tanks. Refill with clean fuel oil. c. Reduce engine load and speed. d. Time injection pump. a. Repair/replace accessories, as necessary. b. Ensure proper grade of fuel is in use. a. Refer to Excessive exhaust smoke. d. Time the pump. e. Replace nozzles. f. Adjust valves. a. Secure engine mechanically with lever on fuel pump. Replace sealing washer, piston, and spring. b. Inspect air intake ducts for source of fumes, and correct. a. Refer to Engine runs tough or is misfiring. b. Replace engine mounts. c. Replace vibrating components. d. Replace the alternator. e. Realign flywheel housing. f. Inspect internal engine components. Replace as necessary. g. Balance shaft or flywheel, as necessary. a. Ensure all belt drive components are properly adjusted. b. Refer to Excessive exhaust smoke. c. Ensure valves and pushrods are not bent and rocker arms are not excessively worn. Adjust valves. d. Inspect and measure gear train back lash. Replace gears, as necessary. e. Replace rod and main bearings.

5-9

S9233-C9-MMA-010 Table 5-1. Troubleshooting Guide - Continued Problem/Malfunction 26. Alternator not charging.

Probable Cause a. Loose or corroded battery connections. b. Alternator belt slipping. c. Alternator pulley loose on shaft. d. Faulty alternator.

5-3.

Corrective Action a. Clean and tighten battery connections b. Replace belt tensioner or tighten belt, as necessary. c. Tighten pulley. d. Replace alternator.

TROUBLESHOOTING PROCEDURES. The following procedures may be used to assist in troubleshooting the engine.

5-3.1 ENGINE WILL NOT CRANK. a. Measure the voltage between the positive battery cable and ground. Note the voltage. b. Using a remote start switch, attempt to engage the starter while observing voltage. c. If the voltage reads less than 20 Vdc, charge the battery. d. If the voltage drops rapidly more than 4.8 Vdc, replace the battery. e. If a low battery charge was found to be the problem, check the alternator. f. Ensure proper battery cable connection. With the engine running, measure the voltage between the positive battery to the ground. Replace the alternator if the voltage is less than 24 Vdc. 5-3.2 ENGINE CRANKS BUT WILL NOT START (SMOKE FROM EXHAUST). a. Remove the fuel shutdown valve. b. Connect 24 Vdc to the terminal and ground the body. Observe plunger movement. If no movement, replace the valve. c. Inspect fuel flow by removing the inlet line to the lift pump. d. Operate the fuel pump hand lever and check for suction. e. If suction is detected, rotate the engine 90 degrees and repeat the check. f. If there is suction, check for an obstruction in the fuel supply line or tank. 5-3.3 ENGINE STARTS BUT WILL NOT KEEP RUNNING. Inspect for broken or bare wires. Those wires not accessible can be checked for continuity between the wire and ground. 5-3.4 ENGINE RUNNING HOT. a. Check the temperature sensor for continuity. The sensor will have continuity only when coolant temperature is above 225°F. 5-10

S9233-C9-MMA-010 b. Check the thermostat for correct operation. With the thermostat suspended in water, it should begin to open when the heated water temperature reaches 181°F and be fully open at 203°F.

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S9233-C9-MMA-010 CHAPTER 6 CORRECTIVE MAINTENANCE 6-1.

INTRODUCTION.

This chapter provides specific corrective maintenance procedures for shipboard, intermediate, and depot level maintenance of the diesel engines. Adjustment and alignment procedures are presented in section 1 and repair procedures (detailing removal, disassembly, repair/replacement, reassembly, and reinstallation) are presented in section 2. 6-2.

TOOLS AND EQUIPMENT.

Most of the tools and equipment recommended for use in the maintenance procedures are standard shop items and should be readily available. Read maintenance procedures in full to identify necessary tools and equipment. Special tools required for servicing the fuel injection pump are listed in table 6-1. Table 6-1. Special Tools Tool Starter Motor Setting Gauge (for motors with pinion face to mounting flange dimension of 1.875inch) Setting Gauge (for motors with pinion face to mounting flange dimension of 0.8125inch) Setting Gauge (for motors with pinion face to mounting flange dimension of 1.000 inch) Extraction and Replacement Tool (for commutator end bearing) Plug Gauge (for drive end bearing) Extractor, Drive End Bearing Plug Gauge (for commutator end bearing) Fitting Tool (for inspection hole core plugs) Fitting Tool (for dust scraper ring on drive end shield) Fitting Tool (for lubricator core plug) End Float Gauge Check Gauge (for retaining ring on trip collar) Split Collar (for dust seal protection) Compression Spring Balance Scale (0 to 50 lb capacity in 1-lb units) Fuel Injection Pump Tool Kit Socket, Torque Spanner (cam advance screw) Torque Adapter, Drive Plate Screw (fused with 7144-511A) Gauge, Auto Advance Pin, Feeler Tool, Adjusting Max Fuel and Extractor End Plate Sleeve (steel plate only) Spanner Box, Transfer Pump Rotor Spanner, Drive Plate (slotted type) Spanner, Rotor Plug Protection Caps Cap and Plug Seals (auto advance)

Part Number 5693-222 5693-222A 5693-222B 5693-240 5693-267 5693-266 5693-275 5693-298 5693-299 5693-300 6244-4 6244-3 6244-6 NPN 7144-1580 7244-125A 7144-482 7244-59 7244-70 7144-875 7044-889 7144-744 7144-220 7044-898

6-1

S9233-C9-MMA-010 Table 6-1. Special Tools - Continued Tool Head Locating Fitting Seal (nearest bolt head) Head Locating Fitting Sleeve (top seal) End Plate Sleeve Seal (steel plates only) Throttle and Shut-off Shaft Upper Seal Throttle and Shut-off Shaft Lower Seal Drive Shaft Seal Metering Valve Pinion Seals Idling Stop and Maximum Speed Stop Seals Drive Shaft Seal, Standard Drive Shaft Seals (uprated type drive) Single Piece Drive (shaft seal) Adapter, Assembly Timing Valve, Relief Pipe, Stirrup Bolt, Blank-off Guide, Drive Hub Oil Seal Assembly Fixture, Governor Weight Tool, Drive Shaft Holding Extractor, Drive Hub Oil Seal Torque Adapter, Drive Shaft Screw Alignment Tool, Metering Valve Alignment Tool, Oversize Metering Valve Spanner, Drive Plate Screw Assembly Rod, Metering Valve Adapter, Transfer Pressure Gauge Testing Tool, Outer Seal Inspection Plug Plate, Pump Mounting Adjustment Tool, Shutoff Lever Key, Regulator Plug (steel end plates only) Gasket (for 7144-760) Gauge Flange Marking Insert Insert Insert Extractor Guide, Drive Hub Oil Seal Spanner, Slotted Nut Spanner, Holding Drive Nut Fixture, Fuel Pump Mounting Rachet Adapter

6-2

Part Number 7044-897 7144-18 7144-11 7144-459A 7144-458A 7144-900 7144-88 7144-124 7144-820 7244-15 7244-23A 7144-262 7144-155 7144-262A 7144-558 7144-260A 7144-894 7144-773 7044-893A 7144-261 7144-508B 7144-508C 7144-511A 7044-895 7044-892 7144-760 7144-13 7244-155 7144-559A 7144-465 7144-763 7244-26 7244-30 7244-31 7244-32 7244-105 7244-154 7244-25 7244-24 7044-888F 7144-14

S9233-C9-MMA-010 SECTION 1. ADJUSTMENT AND ALIGNMENT 6-3.

INTRODUCTION.

This section provides procedures necessary to perform adjustments and alignments to the diesel engine. Some adjustment and alignment procedures require that the component be partially disassembled. 6-4.

TACHOMETER ADJUSTMENT.

a. Ensure access to the tachometer adjusting screw (figure 6-1).

Figure 6-1. Adjusting Tachometer b. Start the engine. c. Use a calibrated tachometer to obtain the correct idle rpm (750). NOTE If the flywheel is accessible, a handheld type tachometer can be used. If the rpm can only be established from the front of the engine, an electrical type (strobe) tachometer should be used. d. Place the selector switch on the tachometer to the A position and adjust the tachometer to the engine idle rpm (750). 6-5.

VALVE CLEARANCE ADJUSTMENT. NOTE Valve clearance adjustment is made when the engine is cold, i.e., below 140°F.

a. Loosen the adjustment screw locknuts and back out all the way on the valve adjustment screws (figure 6-2). 6-3

S9233-C9-MMA-010

Figure 6-2. Adjusting Valve Clearance b. Turn the valve adjustment screws in until they just touch the push rod sockets. Loosen them one full turn. CAUTION

To prevent damage to the timing pin and camshaft gear, disengage the timing pin before rotating the crankshaft. c. Using the timing pin (figure 6-3), locate top dead center (TDC) for the number 1 cylinder.

Figure 6-3. Using Timing Pin to Locate TDC d. Disengage the timing pin. NOTE The clearance is correct when some friction is felt when the feeler gauge is moved between the valve stem and the rocker lever. e. Using the respective adjusting screw, adjust the number 1 intake valve clearance to 0.010 inch and the num6-4

S9233-C9-MMA-010 ber 1 exhaust valve clearance to 0.020 inch. By turning the adjusting screw clockwise or counterclockwise, as necessary, lock the setting by holding the screw and tightening the locknut. f. Adjust the number 2 and number 4 intake valves and the number 3 and number 5 exhaust valves with the number 1 cylinder at TDC. g. Ensure the timing pin is disengaged. h. Mark the vibration damper pulley and rotate the crankshaft 360 degrees (the timing pin will not engage). i. Set the number 2, 4, and 6 cylinder exhaust valves, the number 3. 5, and 6 cylinder intake valves; and the number 4 cylinder intake and exhaust valve. j. Torque all locknuts to 18 lb-ft. SECTION 2. REPAIR 6-6.

INTRODUCTION.

This section provides general cleaning, inspection, and overhaul procedures to be used during repair. It also provides specific procedures (including removal, disassembly, reassembly, and reinstallation) for the various components used on the diesel engine. 6-7.

CLEANING AND INSPECTION.

General cleaning and inspection procedures that must be performed during component repair are provided in the following paragraphs. These procedures shall be performed when applicable.

WARNING

Use of cleaning solvent in a confined area can result in injury or death. Avoid prolonged breathing of fumes and solvent contact with skin or eyes. Avoid use near heat or open flame.

WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. CAUTION

Do not use harsh abrasives that might scratch, score, or otherwise mar surface finishes. 6-5

S9233-C9-MMA-010 CAUTION

Do not allow machined or lapped mating surfaces to contact any surface without protection against nicks, scratches, burrs, etc. CAUTION

Avoid scratching and nicking critical surfaces of balls and rollers in bearings; take care to protect surfaces of shaft/ bearing fit. CAUTION

Do not clean bearings ultrasonically; this method can pit bearing surfaces. Do not agitate any other parts longer than five minutes at a time. CAUTION

Ensure that low-pressure air used to dry components is clean and dry. Moisture in an air line can cause rust. CAUTION

If polishing is required, avoid leaving deposits of metal dust in and around bearings. 6-7.1 CLEANING. following steps.

Observing all applicable warnings and cautions, clean components in accordance with the

a. In a well-ventilated area, wash all non-electrical metal parts with an approved mineral-based cleaning solvent. Give special attention to O-ring grooves, threads, internal passages, and bores. Use a stiff-bristled brush to remove hardened deposits of dirt or other contaminants. b. Remove grease, oil, and dirt from exterior surfaces with an approved water soluble detergent (MIL-D-16791) and water. c. Rinse bearings in an approved lubricating oil MIL-L-2104B). Allow bearings to air dry as much as possible. d. After cleaning, dry parts other than bearings thoroughly. Use filtered, dry, low-pressure air or a clean, lint-free cloth. e. Do not attempt to clean paper filter elements. f. When cleaning, keep related parts together so that reassembly of parts is as close to the same position is possible. 6-6

S9233-C9-MMA-010 g. Valves, pistons, sleeves, and other internal parts that have close tolerance fits in mating bores should be individually cleaned to prevent scoring and marring of surfaces. 6-7.2 INSPECTION. steps.

Inspect all disassembled parts for excessive wear and damage according to the following

a. Check all parts for discoloration (caused by overheating, fractures, and corrosion. b. Examine all parts for deformities, pitting, scoring, scratches, nicks, and accumulation of dirt and other contaminants. c. Inspect a threaded areas for stripped threads and evidence of cross-threading; examine area adjacent to threads for cracks. d. Inspect bearings for flat spots and corrosion; verify smooth operation. e. Inspect retainers for nicks, scratches, and burrs. f. Check shafts for flat spots and uneven wear. g. Check all springs for cracks and bends; verify uniform expansion/retraction capability. h. Inspect passages for corrosion and blockages. i. Inspect gears and pinions for broken or burred teeth and for cracks. j. Inspect V-belt tension and all flexible hoses, lines, and fittings by following PMS procedures. k. Replace parts in excess of stated wear limits. 6-8.

REPAIR/REPLACEMENT.

6-8.1 GENERAL. a. Work on a clean bench and protect gear teeth and oil seal surfaces from nicks and scratches. b. Repair by standard shop practices, using standard shop tools unless otherwise stated. c. Repair or replace pans as indicated by inspection. d. If the condition of any part is questionable following inspection and repair, replace the part. e. If replacement parts are available, replace all gasket seals, and O-rings each time they are removed. If original Parts are reused, check closely for leaks. f. Lubricate lips of new oil seals with an approved, clean, light grease before installation. Use a soft brush to apply. g. Refer to chapter 7 for listings of replacement parts. h. Disassemble components only to the extent necessary to effect desired repairs. i. Read procedures in full before starting repairs. Pay particular attention to safety precautions. j. Tables appearing throughout this chapter provide data that may be useful for intermediate and depot level maintenance. 6-7

S9233-C9-MMA-010 6-8.2 PRELIMINARY PROCEDURES AND SAFETY INFORMATION. diesel engine, proceed as follows:

Prior to performing any work on the

WARNING

Rotating machinery can cause injury or death. Ensure the engine is shut down before working on equipment and that the starter is tagged OUT-OFSERVICE. a. Shut down the engine and tag OUT-OF-SERVICE. b. De-energize the electrical starting system components. NOTE Unless an engine overhaul or removal is being performed, it is not necessary to proceed further. c. Drain the cooling system. d. Drain the lubricating oil. e. Disconnect the fuel lines. f. Remove the air cleaner and mounting bracket g. Disconnect the exhaust piping. h. Disconnect the throttle controls. i.

Disconnect, tag, and remove any electrical equipment and wiring.

j.

Disconnect any other lubricating oil lines, fuel lines, or electrical connections.

k. Close the sea water supply valve and drain the sea water system. l.

Remove the heat exchanger and other related cooling system parts.

m. Separate the engine from the marine transmission. n. Remove the engine mounting bolts.

WARNING

To prevent injury or death, ensure extreme care and proper lifting devices are used during handling. The equipment is heavy. CAUTION

To prevent damage to equipment, the diesel engine lifting device should be adjusted so the lifting hooks are vertical. 6-8

S9233-C9-MMA-010 o. Using a spreader bar with a suitable sling and adequate chain, lift the engine from its base. Mount the engine on an overhaul stand suitable to support the full weight of the engine.

WARNING

To prevent injury or death, ensure the engine is securely mounted to the overhaul stand before releasing the lifting sling; engine damage may result if the engine breaks away from the overhaul stand. p. Ensure the engine is securely mounted to the overhaul stand, then release the lifting sling. q. Prior to disassembly, clean the exterior of the engine using a steam cleaner or a high-pressure water wash. 6-9.

STARTER MOTOR.

6-9.1 REMOVAL. refer to figure 7-2.

Remove the starter motor according to the following steps. Unless otherwise noted, callouts

a. Identify and disconnect the positive lead cable from the battery. b. Identify and tag all wires attached to the starter motor terminals. c. Remove twelve point screws (26) securing the starter motor to the flywheel housing. d. Withdraw the starter motor from the flywheel mount and move to a suitable workbench. 6-9.2 DISASSEMBLY. Disassemble the starter motor according to the following steps. Unless otherwise noted, callouts refer to figure 7-2. a. Using a scribe or similar sharp-pointed tool, remove two core plugs (25) from drive end shield (7), exposing two field terminal screws. b. Remove the two field terminal screws. c. Loosen Phillips head screw (54) and remove commutator cover (55), and lining (56). NOTE Removal of the brush lead screws also frees the field coil connections. d. Remove brush lead screws and lock washers (71 and 23); raise brush springs and trigger (38) and remove brushes (72). NOTE Use caution not to lose the steel ball which is under pressure from the spring. e. Using a wrench, carefully unscrew and remove end cap (57). f. Remove steel ball (59) and spring (60). 6-9

S9233-C9-MMA-010

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. g. Remove internal retaining ring (66), retaining pad (58), and shim washers (67). h. Unscrew and remove two thru-bolts (69) and two lock washers (70). NOTE When removing the commutator end shield, retain the shims for reassembly; end float adjustment is simplified by fitting the original shims. i. Carefully remove commutator end shield (73) and shim washer (67) from the end of the armature shaft. j. Using a mallet, tap drive end shield (7) away from the housing; remove the end shield complete with armature (85). Remove and discard sealing ring (84). CAUTION

To prevent damage to equipment, a soft-jawed vise, cloth, or cardboard should be used to protect parts. k. Secure the armature in an armature clamp or a soft-jawed vise. Unscrew pinion stop nut (88) in the direction of starter rotation and remove thrust washer (87) and spring (86). l. Remove core plug (1) and spring (2) from the drive end shield. m. Release the ball lock mechanism by pushing the drive end shield (7) toward the armature (85). With the collar (48) held in position, unscrew the pinion until the helix disengages. Slide the pinion assembly (83), together with the drive end shield, off the armature shaft. Collect, note location, and retain lock ring balls and overspeed balls (82). Remove the armature from the clamp or vise.

WARNING

To prevent serious eye injury while removing/installing refining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. n. Remove and discard external retaining ring (52) from the end of the pinion sleeve. o. Remove trip plate (5 1), washer (50), lock collar spring (49), and collar (48). NOTE Inspect the pinion for burrs or similar damage before withdrawing it from the drive end shield. p. Remove any burrs from the pinion and withdraw pinion assembly (83) from the drive end shield. 6-10

S9233-C9-MMA-010 q. Detach the flexible lead from moving contact (37); remove the link to the binding post on the moving contact. r. Using a suitable punch, remove securing rivets (47) to free resistor (45) from the drive end shield; remove resistor bushing (44) and spacers (43). s. Remove main terminal nuts (16), lock washers (15), screw (18) and lock washer (17). Remove washers (13 and 14), sealing ring (12) and insulator bushing (11). Rotate main terminal (8), 180 degrees axially and remove from the drive end shield (7) along with support (9) and insulator (10). t. Remove nuts (24), lock washers (23), washer (22), and insulating bushings (20 and 21) from solenoid terminals (19). Push the solenoid terminal into the drive end shield and clear of its hole. u. Remove self-tapping screws (30), lock washers (23), and solenoid assembly (27) along with the main terminal insulator. Remove similar components from the adjacent relay (R) terminal. 6-9.3 CLEANING AND INSPECTION.

Clean and inspect the starter motor according to the following steps.

a. Inspect the brushes for wear. If excessively worn when compared with a new brush, they should be replaced. Ensure the brush holders are clean and the brushes do not bind in the holders. The full brush surface must ride on the commutator to provide Proper performance. Check by hand to ensure the brush springs provide firm contact between the brushes and commutator. If the springs are distorted or discolored, they should be replaced. NOTE Do not turn the commutator or undercut the insulation on the motor. Use 240grit emery paper to clean the commutator. If the commutator cannot be cleaned, replace the armature assembly. b. Check the armature for shorts, open circuits, and grounds according to the following steps. 1. Short circuits are located by rotating the armature in a growler with a steel strip (such as a hacksaw blade) held on the armature. The steel strip will vibrate on the area of the short circuit. Shorts between bars are sometimes produced by brush dust or copper between the bars. 2. Open circuits may be located by inspecting for loose connections at the points where the conductors am joined to the commutator. Loose or poor connections cause arcing and burning of the commutator. If the bars are not badly burned, leads originally soldered to the riser bars can be re-soldered. Check for insulation to ground by means of a 500-volt megger type tester between any commutator segment and the armature shaft. Resistance should be a minimum of one megohm. 3. Grounds in the armature can be detected by the use of a test lamp. If the lamp lights when one test probe is placed on the commutator and the other test probe on the armature core or shaft, the armature is grounded and must be replaced. c. Field coils. Using a test lamp, check the field coils for grounds and open circuits according to the following steps. 1. Grounds. Disconnect the field coil ground connections. Connect one test probe to the field frame and the other to the connector. If the lamp lights, the field coils are grounded and must be repaired or replaced. 2. Open circuits. Connect test lamp probes to the ends of the field coils. If the lamp does not light. the field coils are open. If the field coils need to be removed for repair or replacement, a pole shoe spreader and pole shoe screwdriver should be used. Care should be exercised in replacing the field coils to prevent 6-11

S9233-C9-MMA-010 grounding or shorting as they are tightened in place. Where the pole shoe has a long lip on one side, it should be reassembled in the direction of armature rotation. d. Solenoid coils and contacts. The coils can be checked for shorts or open circuits by measuring current consumption at nominal voltage. A link should be made between the green lead and the terminal lug, refer to table 6-2 and figure 6-4. Table 6-2. Solenoid Test Data Starter Type CA4524 Insulated Return

Ammeter in Supply Circuit

Read Ammeter

Apply 24 volts to black and green Check current consumption is approximately 16 amperes. leads*

*

On some starter solenoids, the green lead is replaced by a yellow lead.

Figure 6-4. Starter Motor Solenoid CAUTION

To prevent overheating, do not leave the pull-in winding energized more than 15 seconds. The current draw will decrease as the winding temperature increases. The purpose of the R terminal is to short out the ignition resistor during cranking, thereby providing high ignition coil output. 1. With all leads disconnected from the solenoid, make test connections to the solenoid switch terminal and to ground or to the second switch terminal (if present) to check the hold-in winding. Compare the amme6-12

S9233-C9-MMA-010 ter reading with the specifications. A high reading indicates a shorted or grounded hold-in winding and a low reading indicates excessive resistance. To check the pull-in winding, connect from the solenoid switch terminal to the solenoid motor terminal. 2. Examine the contacts and, if necessary, clean them with white spirit or very fine carborundum paper. The first stage gap should be 0.083 inch (2.1 mm) with a bottom limit of 0.076 inch (1.93 mm) and a maximum of 0.098 inch (2.5 mm). Press down the plunger and ensure the second stage contacts make, but only after the trigger is tripped. If the contacts are badly burned, the gap excessive, or the coils appear to have overheated, the solenoid should be replaced as a complete unit. e. Dismantling the solenoid. To replace defective components, dismantle the solenoid according to the following steps. Unless otherwise noted, callouts refer to figure 7-2. 1. Remove rivets (29) securing trigger guide (39) and the rivets securing contact stop (28); remove the contact stop and trigger guide. Examine the trigger guide for wear on the pivot points; replace the trigger guide, as required. 2. Remove plunger (36), spring (33), moving contact (37), and spring (35) as a complete assembly. 3. Unsolder the solenoid leads connected to the fixed contact lug and remove the fixed contact assembly (figure 6-4). f. Reassembling the solenoid. Following component replacement, reassemble the solenoid according to the following steps. 1. Locate the fixed contact assembly on the solenoid; ensure the contact plate rivet holes align with those in the solenoid coil plate. 2. Replace plunger (36), moving contact (37), and springs (33 and 35). The rectangular-shaped extension on one side of the moving contact must face the two rivet holes for the trigger guide (39). 3. Push the solenoid plunger fully home. With the plunger held in this position, replace contact stop (28) and trigger guide and rivet both into position. 4. Solder the solenoid leads, as required, to obtain circuit continuity. 5. Verify correct first stage contact gap of 0.076 inch to 0.096 inch; a slight gap adjustment can be obtained by bending the brass contact stop. g. Commutator end bearing. Ensure commutator end bearing bushing (68) is tight in its housing. Check the side play between the armature shaft and bearing. If the side play is excessive, replace the end bearing bushing as follows. 1. Press the old bearing bushing out of the commutator end shield. NOTE There should be no machining attempted on the commutator end shield. 2. Inspect the commutator end shield bore for any damage, clean thoroughly, and apply a coat of light oil; press the replacement bearing bushing in the commutator end shield. h. Drive end shield. Inspect and repair the drive end shield according to the following steps. CAUTION

The retaining pad must be removed to prevent oil starvation of the bearing after assembly. On new drive end shields, the retaining pad is fitted in the oil way. 6-13

S9233-C9-MMA-010 1. Check the internal diameter of the drive end shield (7). If bearing bushing (6) is worn, the drive end shield must be replaced with a new unit. 2. Ensure lubrication pad (4) is free to move under the influence of spring (2). i. Pinion. If the pinion teeth are badly worn or damaged, replace the pinion with a new unit. Ensure the new pinion has the same number of teeth and is a free-sliding fit on the armature shaft. If necessary, lightly lap the pinion bore and shaft with a fine lapping paste. Remove all traces of lapping paste using a bottle brush to ensure absolute cleanliness of the pinion helix. If the pinion is fitted with an oil seal in the bore, all burrs or sharp, edges must be removed or the seal will tear. Install a new oil seal with the U-channel facing toward the pinion teeth end (figure 6-5).

Figure 6-5. Installing Oil Seal j. Springs. Ensure the starter motor springs are not damaged, discolored, or deformed and retain their tension. Refer to table 6-3. Table 6-3. Spring Tension Spring Lock Spring Recoil Spring Pinion Spring Pinion Spring (oil sealed starter)

Compressed Length 0.375 1.313 1.250 1.469

in. in. in. in.

(9.53 mm) (33.35 mm) (31.75 mm) (37.3 mm)

Tension 1.69 to 1.94 lbs 26.50 to 29.50 lbs 7.75 to 8.50 lbs 9.81 to 10.19 lbs

k. Commutator. 1. If the commutator surface is dirty or discolored, it may be cleaned with a very fine grade of glass paper. Do not use emery cloth or carborundum paper. 2. In cases where the surface is badly pitted or grooved, set the armature up in a lathe and skim the commutator. With a rough cut, remove just enough copper to clear traces of the damage. After this, a very light cut should be taken using a diamond or tungsten carbide tip to obtain a high quality surface finish.

WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. 3. Remove all traces of dust using dry, compressed air. The minimum diameter to which the commutator can 6-14

S9233-C9-MMA-010 be machined is 1.56 inch (392 mm). Radius at the juncture of the risers and commutator must not exceed 0.040 inch (1.0 mm). The risers should not be skimmed and the commutator must not be undercut, as carbon tracking from the brush may occur. l. Armature shaft. Inspect the armature shaft for any burrs caused by the steel lock balls and overspeed balls. Carefully remove any visible burrs. Inspect the shaft helices for damage or excessive wear. Clean the helices with an approved solvent and apply a small quantity of lubricating grease. m. Field windings. Remove and replace field windings (80) according to the following steps. Unless otherwise noted, callouts refer to figure 7-2. 1. Using a pole shoe screwdriver, unscrew pole shoe screws (78). Remove the pole shoes and windings; note their original positions within the starter housing (figure 6-6). Mark number 1 position with tape or scribe mark on housing.

Figure 6-6. Positions of Pole Shoes and Windings NOTE As an aid to correct assembly, the pole shoes are numbered and must be replaced in the same positions as original. Otherwise, they might foul the armature during operation. 2. Fit the replacement windings into the housing and replace the pole shoes in their original positions (figure 6-6). 3. Carefully align the pole shoes in the housing; insert and torque the pole shoe screws (78) 25 to 30 lb-ft using a pole shoe screwdriver. When completed, ensure no space exists between the mating surfaces of the pole shoes and the housing. n. Brush gear. Using a 10-volt megger-type tester, check the insulation between all brush holders and the starter motor frame. The insulation resistance must be not less than one megohm. Ensure all brush holders am secure. o. Brushes. During overhaul, always renew the brushes to ensure maximum life between overhaul periods. Brushes must be fitted in complete sets and replacement brushes must be well bedded. To accomplish this, proceed as follows: 6-15

S9233-C9-MMA-010 CAUTION

To prevent damage to equipment, a soft-jawed vise, cloth, or cardboard should be used to protect parts. 1. Place the armature in an armature clamping device or a vise with protected jaws. Wrap a strip of fine glass paper (not emery cloth or carborundum) around the commutator with the abrasive side outward; secure the glass paper in place with an approved adhesive. 2. Slide the commutator end shield (73) onto the armature shaft; fit the brushes and place the brush springs in position. 3. Rotate the end shield in the opposite direction to the normal direction of rotation of the armature until the brushes are bedded over 80 percent of the contact surface. 4. Retain the brushes in the respective holders and remove the drive end shield from the armature. 5. Thoroughly clean all dust and abrasive from all components. 6. Remove the glass paper from the commutator and remove all traces of adhesive. p. Brush springs. The brush spring pressure should be within the range of 6 to 7.5 lbs. Using a suitable spring balance hooked under the lip of the spring, remove the brushes from the holder, raise the lip to the height of the brush. If the spring pressure is incorrect replace the springs. 6-9.4 REASSEMBLY. Reassemble the starter motor according to the following steps. Unless otherwise noted, callouts refer to figure 7-2. Refer to table 6-1 for special tools required for reassembly. a. Remove any burrs or sharp edges on segments (34); place spring (35) on a clean, flat surface and position the four segments inside the spring so they lie end-to-end in a circle; install the spring in the outer groove of the segments. b. Place the solenoid switch on the workbench, coil end facing upward. Gently push the spring and segment assembly into the solenoid plunger bore so it fits into the recess provided. c. Install split protection collar (tool 6244-6) in drive end shield (7) to protect oil seal (3) and insert pinion assembly (83). Remove the split protection collar. d. Place terminal insulator (10) under main terminal (8) of the assembled solenoid switch (figure 6-4); the end with the hole must be upright. e. Insert the solenoid assembly in the drive end shield and secure with self-tapping screws (30) and lock washers (23). f. Reinstall anodized metal strip support (9) on the inside face of terminal insulator (10). g. Place insulator bushing (20) over solenoid terminal (19), add the solenoid terminal tag black lead (figure 6-4) over the terminal, and push it through the hole in the drive end shield. Install insulating bushing (2 1), lock washer (23), and nut (24). h. Repeat step f and step g to connect the green (or yellow, as applicable) return lead to the R terminal. i. Press down the plunger (36) and insert main terminal (8) in position from inside the housing, through the anodized metal strip and insulator, and into the hole in the drive end shield. Install insulating bushing (11) sealing ring (12), washers (13), plain washers (14), lock washers (15), and nut (16) finger tight. j. Insert lock washer (17) and Phillips head screw (18). Torque nut (16) to 5 lb-ft. 6-16

S9233-C9-MMA-010 k. Reinstall collar (48) to the pinion assembly (83) pinion sleeve; ensure the 45-degree chamfer inside the collar is facing the solenoid assembly.

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. NOTE Install the retaining ring with the dished side facing down to ensure security. l. Reinstall spring (49). washers (50), and trip plate (51), and secure in position with a new external retaining ring (52). Ensure the external retaining ring locates properly in the ring groove; check with gauge 6244-3 to ensure it is squarely seated. m. Insert resistor (45) into its recess in the drive end shield; secure with insulating bushing (44) and spacer (43) and rivet (47). n. Connect the resistor flexible lead to the lug on the solenoid assembly (27) moving contacts (37). Secure with washer (41) and hex head cap screw (46). o. Reinstall the link bar between the lug and a corner of the moving contaCt. Attach one end with a washer and screw; attach the opposite end to a post together with the resistor flexible lead using a washer and nut. p. Insert the lock ring balls and overspeed balls (82) into the pinion assembly (83) pinion sleeve holes from inside the bore. Use a small screwdriver blade with a spot of grease to feed the balls and apply a small amount of grease to hold them in position. q. Reinstall the pinion assembly and drive end shield assembly to the armature as follows: 1. Pull the pinion assembly pinion out of the drive end shield until collar (48) is pressed back against its spring by the end of plunger (36). Hold the pinion in this position. 2. Press the lock ring balls fully into their holes to allow free entry of the armature shaft. 3. Slide the pinion assembly (83), and end shield assembly (7), onto the armature (85) shaft. Use care not to dislodge the lock ring balls. 4. Engage the pinion with the shaft helix and release the pinion. Screw the pinion onto the shaft and ensure the pinion assembly locking mechanism engages. 5. Support the weight of the drive end shield and rotate the pinion in both directions to ensure freedom of movement and that the locking mechanism functions correctly. The locking mechanism can be released by pulling the lock collar back against its spring. CAUTION

To prevent damage to equipment, a soft-jawed vise, cloth, or cardboard should be used to protect parts. 6-17

S9233-C9-MMA-010 NOTE On oil sealed starters only, use Loctite grade D on the threads when installing the pinion stop nut. r. Mount the armature in an armature clamping device or a vise with protected jaws. Reassemble spring (86) and thrust washer (87) on the pinion shaft Screw a new stop nut (88) on the shaft in the opposite direction of starter motor rotation. Torque the stop nut securely 40 to 50 lb-ft. s. Reassemble armature (85) and the drive end shield assembly (7) to housing using a new sealing ring (84) and ensuring the dowel (81) in the housing end locates in the commutator end shield slot. t. Ensure shim washer(s) (67) have all been removed from the armature shaft and reassemble commutator end shield (73). Reinstall two thru-bolts (69), lock washers (70), and torque securely 7 to 7-1/2 lb-ft.

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. u. Replace retaining pad (58) and internal retaining ring (66); do not install the shim washer(s). v. Adjust the armature end play according to the following steps. Refer to table 6-1 to determine the correct gauge (5693-222, 5693-222A, or 5693-222B) to be used according to the required mounting flange dimension. 1. Bolt the appropriate gauge on the starter motor mounting flange with the arm marked CHECK toward the pinion (figure 6-7); push the armature toward the drive end of the motor until the pinion face just touches the gauge. With the armature held in this position and using standard feeler gauges, measure gap X between the thrust washer and the commutator end shield. Shim washers having a total thickness equal to the measurement should then be fitted between the thrust washer and the retaining ring. Ensure the shim washers are well greased before use.

Figure 6-7. Adjusting Forward Movement

6-18

S9233-C9-MMA-010 NOTE Example: If gap X is now 0.120 inch, shim washers having a total thickness of 0.020 to 0.040 inch should be fitted (i.e., four shims, each 0.008 inch thick). These shims must be well greased before use. 2. Push the armature toward the commutator end of the motor (figure 6-8) and again measure gap X. The gap should now be within the limits of 0.079 inch, + 0.020 inch, - 0.00 inch. If the gap is beyond this limit, remove the commutator end shield (73) and reinstall the shim washers (67) on the armature shaft to the value of the excess.

Figure 6-8. Adjusting Rear Movement

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. 3. Replace the commutator end shield, thrust washers, shim washers, and the retaining ring as determined in step 1. NOTE If a screwed end cap is installed in place of a bayonet type, the starter must be held vertically (commutator end up) and the thrust pad attached to the cap with grease. The cap must be torqued 7 to 10 lb-ft and the two thin corners of the hexagon locked to slots in the bearing collar with a punch. 4. Apply grease to steel ball (59) and spring (60); refer to table 6-3. Insert spring, then the steel ball in the armature shaft bore. Replace end cap (57) turning it in the direction of starter motor rotation to lock it in place. 5. Ensure that any variation in the relationship of the pinion position to the check gauge is within the limits of 0.076 inch, + 0.003 inch, - 0.002 inch. Correct, as required, by varying the shim washer amounts. w. Fill the reservoir in the drive end shield with oil (table 6-4) and insert spring (2). Replace core plug (1) using tool number 5693-300. 6-19

S9233-C9-MMA-010 x. Connect the field windings and the free end of the resistor to the solenoid switch lugs with screws (30) and washers (23). y. Install brush kit (72) and trigger and springs (38). Connect the brush leads and the field winding leads to the brush gear. Ensure the brush leads allow free movement of the brushes in the holders. 6-9.5 TESTING. 6-9.5.1 Solenoid Engagement Mechanism. the following steps.

Test the solenoid engagement mechanism’s operation according to

Table 6-4. 24-Vdc Starter Test Data Nominal Voltage of Starter 24 Vdc

Type of Test

Minimum Battery Capacity

Torque Values

Current Ampere

LT RT

78 Ah 78 Ah

38.0 lb-ft 17.0 lb-ft

78 Ah

N/A

910 max 9.2 555 max 15.2 min. 60-100 24.0 LT = Locked Torque RT = Running Torque LR = Light Running (no load)

LR Brush spring tension: 6 to 7.5 lbs. Brush grade: DM100. Brush length (new): 19 mm.

Terminal Volt- Speed age (rpm) -1550 7000

WARNING

To prevent injury or death when testing the engagement mechanism, under no circumstances should both main terminals be connected to the supply voltage source. Otherwise the pinion will rotate at high speed when pulled forward and present extreme danger to the operator. a. With all electrical sources disconnected, pull the pinion forward by hand approximately 5/8 inch and release. The pinion should return to its original position. NOTE The batteries should be fully charged and in good condition before performing any starter motor performance tests. b. Connect the battery solenoid terminal S and solenoid terminal R. With the solenoid energized, the pinion should move forward approximately 1.25 inch. c. With the solenoid still energized, pull the pinion forward by rotating it opposite to normal rotation. The locking mechanism should now come into operation thus locking the pinion in the forward position. d. Disconnect the electrical supply to the solenoid; the pinion must return to the disengaged position in one sharp movement. e. Check the recoil spring action by applying a compression spring balance to the driving end of the armature shaft. The force required before backward movement of the shaft occurs should be 30 to 38 lbs. 6-20

S9233-C9-MMA-010 6-9.5.2 Performance Tests. a. Prior to performing any starter performance tests, ensure the brushes are thoroughly bedded on the commutator. Refer to paragraph 6-9.3, step o. CAUTION

To prevent damage to equipment, the starter should always be run in conjunction with a flywheel. If this is not possible, do not operate the starter for more than five seconds. If the starter is allowed to run without a load, the pinion will not be restrained from rotating in the initial stages and will not complete the forward movement necessary to trip the second stage contacts. Under these conditions, the resistor will remain in the circuit and may be damaged by overheating. Prolonged operation on first stage contacts may cause grooving of the solenoid trip mechanism. b. Mount the starter on a starter test bench with 0.125-inch clearance between the face of the pinion and the face of the flywheel. c. Connect starter terminals as shown in figure 6-9 to a fully charged 24-volt battery. Refer to table 6-4 for starter motor test values.

Figure 6-9. Connecting Starter Terminals d. Replace core plugs (25) following completion of the tests in step b. e. Replace commutator cover (55) ensuring the windows are, fully covered and holding screw (54) is located at the bottom of the starter in relation to mounting on the engine. 6-21

S9233-C9-MMA-010 6-9.5.3 Relay Test.

a. Check the continuity between B+ and ST terminals and the insulation to frame of all terminals (figure 6-10). b. Check relay contact gaps for 0.045 to 0.050 inch. When closed, the core gap should be 0.015 to 0.020 inch. c. Connect a 1000-ohm, 5-watt variable-resistance and milliammeter in series with a 24-Vdc battery and the relay winding, B+ to 5W + terminal, B- to junction of capacitor positive and the black relay winding start lead. Increase the variable resistance and set the relay by adjusting the armature spring tension so the contacts open between 32 and 34 milliamperes. d. Connect a voltage source not exceeding 20 volts to terminals SW+ and E; observe that the relay momentarily closes. Failure to close indicates a faulty capacitor, loose or broken connections, or an excessive core gap setting. e. Connect a 24-volt lamp and battery in series with the relay contacts, SW+ and SOL terminals. Press armature to coil to close contacts and observe if lamp lights. Failure to light indicates dirty contacts or loose or broken connections.

6-9.6 REINSTALLATION. Reinstall the starting motor in reverse order of removal, refer to paragraph 6-9.1. Ensure the commutator cover (55), Phillips head screw (54) is at the bottom when the starter motor is mounted on the engine. This is important, as fuel and water may enter the motor if the commutator cover is not correctly positioned. Torque hex head cap screws (26) to 32 lb-ft.

6-10.

GAUGES.

Remove/reinstall the gauges according to the following steps. Unless otherwise noted, refer to figure 7-6.

a. Identify, tag, and disconnect the wiring to the gauge to be removed. b. Remove the mounting nuts and bracket

6-22

S9233-C9-MMA-010

Figure 6-10. Relay Test c. Remove and discard the defective gauge. d. Reinstall a new gauge in the reverse order of removal. 6-11.

AIR CLEANER/SILENCER.

6-11.1 REMOVAL. Remove the air cleaner/silencer according to the following steps. Unless otherwise noted, callouts refer to figure 7-7. a. Loosen and remove T-bolt clamp (1). b. Remove air cleaner/silencer (2) from the turbocharger on model 6BT5.9-M engine and the air intake piping on the model 6B5.9-M engine. 6-11.2 REINSTALLATION. Reinstall the air cleaner/ silencer according to the following steps. Unless otherwise noted, callouts refer to figure 7-7. a. Reinstall air cleaner/silencer (2) with T-bolt clamp (1). b. Torque the T-bolt clamp to 6 lb-ft. 6-12.

ALTERNATOR.

6-12.1 REMOVAL. refer to figure 7-3.

Remove the alternator according to the following steps. Unless otherwise noted, callouts

6-23

S9233-C9-MMA-010 a. Loosen and remove cap screws (2, figure 7-1) and belt guard (1, figure 7-1) from the engine.

WARNING

To prevent serious hand injury while removing/installing the drive belt, keep hands out of the path of the spring-loaded belt tensioner. b. Using a 1/2-inch square drive ratchet handle, release V-belt (11) million and remove the V-belt. c. Tag and disconnect all electrical wires to the alternator. d. Loosen and remove the hex head cap screw (2) that is bolted to the water inlet connection (figure 7-16). e. Loosen and remove hex head cap screw (3) while supporting the alternator by hand. Lower and remove alternator with alternator brace (1). f. Remove mounting spacer (6). 6-12.2 REPAIR. MMA-010.

For repair procedures to the alternator, refer to the NAVSEA technical manual S9313-A5-

6-12.3 REINSTALLATION. Reinstall the alternator on alternator support (5) in the reverse order of removal; refer to paragraph 6-12.1. Torque alternator brace cap screws (2) to 32 lb-ft and alternator mounting cap screw (3) to 32 lb-ft. 6-13.

DRIVE BELT AND BELT TENSIONER.

6-13.1 REMOVAL. Remove the drive belt and belt tensioner according to the following steps. Unless otherwise noted, callouts refer to figure 7-3. a. Loosen and remove hex flange head screw (2, figure 7-1) and belt guard (1, figure 7-1) from the engine.

WARNING

To prevent serious hand injury while removing/installing the drive belt, keep hands out of the path of the spring-loaded belt tensioner. b. Using a 1/2-inch square drive ratchet handle, release V-belt (11) tension and remove the V-belt. c. Loosen and remove hex head cap screw (8) and belt tensioner (9). d. Loosen and remove two flat head screws (7) and belt tensioner bracket (10). e. Loosen and remove four hex head cap screws (1, figure 7-12) and vibration damper (2 and 3, figure 7-12) from the crankshaft f. Clean and inspect parts according to paragraph 6-7.1 and paragraph 6-7.2. 6-24

S9233-C9-MMA-010 6-13.2 REINSTALLATION. Reinstall the drive belt and belt tensioner according to the following steps. Unless otherwise noted, callouts refer to figure 7-3. NOTE The maximum V-belt deflection is 3/8 inch to 1/2 inch. a. Reinstall belt tensioner (9) and hex head cap screw (8). b. Reinstall V-belt (11). c. Prior to reinstalling belt guard (1, figure 7-1), check V-belt tension. Measure the belt deflection using the thumb and pressing m the belt at the longest span of the belt. d. Torque belt tensioner hex head cap screw (8) to 32 lb-ft, the vibration damper cap screw (1, figure 7-12) to 92 lb-ft. e. Reinstall the remaining pans and belt guard in the reverse order of removal. Refer to paragraph 6-13.1. 6-14.

FRESH WATER PUMP.

6-14.1 REMOVAL. Remove the fresh water pump according to the following steps. Unless otherwise noted, callouts refer to figure 7-10. a. Remove filler cap (19, figure 7-15) from the expansion tank and pipe plug (5, figure 7-15) from water transfer tube (6, figure 7-15). Drain the coolant into a suitable drain pan. Reinstall the pipe plug upon completion of drainage. b. Refer to paragraph 6-13.1 and remove drive belt (11, figure 7-3). c. Loosen and remove two hex head cap screws (3). d. Remove fresh water pump (1) and rectangular ring seal (2). Discard the rectangular ring seal. NOTE The fresh water pump is serviced as an assembly. e. Clean and inspect the pans according to paragraph 6-7.1 and paragraph 6-7.2. 6-14.2 REINSTALLATION. Reinstall the fresh water pump according to the following steps. Unless otherwise noted, callouts refer to figure 7-10. a. Ensure the sealing surface on the cylinder block is clean. b. Install new rectangular ring seal (2) into fresh water pump (1) groove. c. Reinstall the fresh water pump on the engine block using two hex head cap screws (3). Torque to 18 lb-ft. d. Refer to paragraph 6-13.2 and reinstall drive belt (11, figure 7-3). e. Reinstall the belt guard using hex flange head screws (2, figure 7-1). Torque to 18 lb-ft. 6-25

S9233-C9-MMA-010 f. If required, refill the coolant system with a 50-percent mixture of fresh water and ethylene glycol-based antifreeze. 6-15.

THERMOSTAT.

Replace the thermostat according to the following steps. Unless otherwise noted, callouts refer to figure 7-11. a. Remove filler cap (19, figure 7-15) from the expansion tank and pipe plug (5, figure 7-15) from fresh water transfer tube (6, figure 7-15). Drain the coolant into a suitable drain pan. Reinstall the pipe plug and tighten upon completion of drainage. b. Loosen and remove hex flange head screw and belt guard (2 and 1, figure 7-1) from the engine. c. Using a 1/2-inch square drive, lift belt tensioner (9, figure 7-3) and remove drive belt (11, figure 7-3) from the alternator pulley. d. Loosen lower hose clamp (16, figure 7-18) and disconnect thermostat housing upper plain hose (17, figure 7-18). e. Loosen alternator brace (1, figure 7-3), hex head cap screw (2, figure 7-3), and alternator mounting hex head cap screw (4, figure 7-3). Lower the alternator to gain access to the thermostat housing. f. Remove cap screws (1 and 2), lifting bracket (6), thermostat housing (3), thermostat (4), and gasket (5). Discard the gasket. g. Clean and inspect parts according to paragraph 6-7.1 and paragraph 6-7.2. h. Install a new thermostat into the housing. Ensure the jiggle pin is in its notch and the tang on the thermostat is in the notch on the thermostat housing. See figure 6-11.

Figure 6-11. Installing Thermostat in Housing i. Install new gasket (5). j. Reinstall thermostat housing (3) and lifting bracket (6) on the block using hex head cap screws (1 and 2). Torque the hex head cap screws to 18 lb-ft. 6-26

S9233-C9-MMA-010 k. Reinstall all other components in the reverse order of removal. Torque the front cover cap screws to 18 lb-ft. l. Refill the coolant system with a 50-percent mixture of fresh water and ethylene glycol-based antifreeze. 6-16.

SEA WATER PUMP.

6-16.1 REMOVAL. Remove the sea water pump according to the following steps. Unless otherwise noted, callouts refer to figure 7-14. NOTE If repairs are being made with the engine in the craft, ensure the sea water system’s suction and discharge valves are shut and tagged. a. Remove transmission oil cooler sea water drain plug and drain. Loosen hose clamp on sea water suction hose connection and lower hose clamp (6) at sea water pump (4) discharge hose. Loosen suction hose to allow sea water drainage. b. Disconnect suction and discharge hose from the sea water pump. c. Loosen and remove pump flange mounting hex head cap screws (3). d. Remove the sea water pump and flange assembly with gasket (5). Discard the gasket. e. Place sea water pump and flange assembly on a clean work bench. 6-16.2 DISASSEMBLY. Disassemble the sea water pump according to the following steps. Unless otherwise noted, refer to figure 7-14. NOTE The sea water pump and flange assembly consists of the sea water pump, which is attached to the flange by two hex head cap screws, with the pump’s drive gear on the pump’s shaft. a. Pull pump drive gear from pump shaft with a T-bar puller and two M8 x 1.25 hex head cap screws. b. Using a 9/16-inch open-end wrench, loosen and remove two hex head cap screws and remove the sea water pump from the mounting flange. c. Remove and discard the pump to flange sealing ring. d. Loosen and remove three impeller housing mounting cap screws. NOTE Usually the impeller will stay in its housing when it is removed. e. Remove the impeller housing. Mark the impeller housing to ensure proper reinstallation. It must be installed in the same direction as removed. f. Remove the impeller and rubber bushing from the housing. 6-27

S9233-C9-MMA-010 g. Remove the spacer plate. h. Remove the key.

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. i. Remove the retaining ring, seal, and shoulder washer. j. Using a screwdriver to pry on the edges of the seal housing, loosen the seal from the seal bore and remove the seal from the housing with needle nose pliers. Discard the seal. k. Support the pump body and press the shaft and bearing assembly out through the drive gear end. l. Remove the remaining two rings from the pump shaft m. Support the inner face of the bearing on a press and press the pump shaft out of the bearing and spacer. n. Clean and inspect the parts according to paragraph 6-7.1 and paragraph 6-7.2. If the impeller requires replacing due to rips, tears, or chunks of material missing, then the heat exchanger and marine transmission oil cooler should be flushed. 6-16.3 REASSEMBLY.

Reassemble the sea water pump according to the following steps.

a. Press a new seat into pump housing.

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. b. Install a brass retaining ring on the pump shaft into the middle groove. c. Install a new bearing on the drive gear end of the shaft. Press on the bearing inner race until the bearing contacts the retaining ring. d. Install a large retaining ring in the pump body. e. Press the bearing and shaft assembly into the body until the bearing contacts the large retaining ring; use a tool that will give uniform pressure on the bearing outer race. f. Install the spacer over the drive shaft. g. Press the second new bearing onto the drive gear end of the shaft. Press only on the inner race of the bearing, do not press the bearing into the housing. h. Support the housing and shaft in such a manner as to allow the bearing to be pressed into the housing and on the shaft at the same time. Press the bearing in until the second bearing has contacted the spacer. 6-28

S9233-C9-MMA-010

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. i. Install large retaining ring. j. Install external retaining ring. CAUTION

Do not scratch the white ceramic surface of the seat. k. Install the seat and shoulder washer onto the shaft. Locate the white ceramic surface against the seal. l. Compress the seat and seal assembly and install the external retaining ring. m. Install a new O-ring in the mounting flange and install the flange on the pump body using the cap screws. Torque the cap screws securely.

WARNING

To prevent injury, exercise extreme care and wear insulated gloves when handling heated components. Heated metal pans can cause serious burns. n. Heat the drive gear in a 400°F oven for 30 minutes. o. Lubricate the pump shaft. p. Support the impeller end of the shaft and install the drive gear flush with the end of the shaft. Ensure the gear is installed with the lip up. q. Reinstall the key on the shaft r. Install a new gasket and spacer plate on the body. s. Install a new O-ring in the housing. Use a small amount of general purpose grease to hold the O-ring in place. NOTE If reusing an impeller, install it in the same direction as removed. t. Reinstall the impeller on the shaft. u. Lubricate the impeller and impeller housing with silicone spray. Do not use a petroleum product such as oil. v. Reinstall the impeller housing over the impeller with a counterclockwise twisting motion while pushing the housing over the impeller. Rotate the housing until the water connections are in the correct position and reinstall the three hex head cap screws. Torque the hex head cap screws securely. 6-16.4 REINSTALLATION. Reinstall the sea water pump according to the following steps. Unless otherwise noted, callouts refer to figure 7-14. 6-29

S9233-C9-MMA-010 a. Reinstall the pump assembly (4) and gasket (5) on the engine using hex head cap screws (3). Torque the hex head cap screws to 57 lb-ft. b. Reconnect the water connections and tighten band clamps (6) securely. 6-17.

HEAT EXCHANGER.

6-17.1 REMOVAL. Remove the heat exchanger according to the following steps. Unless otherwise noted, callouts refer to figure 7-15. a. Remove filler cap (19) from expansion tank (18). Remove pipe plug (5) from transfer tube (6) and drain coolant. Open expansion tank drain cock (17). Check for coolant in the system. Reinstall pipe plug (5) into the water transfer tube hand-tight. b. Remove drain plug on the marine transmission oil cooler and drain sea water from system. c. Loosen the sea water inlet and outlet hose clamps at the heat exchanger sea water hoses. d. Loosen upper hose clamp (7) and front lower hose clamp (7), and remove water transfer tube (6) from the heat exchanger and fresh water pump outlet to the heat exchanger. Place the water transfer tube on wood surface. e. Disconnect hose (13) from male adapter elbow (15). f. Loosen hose clamps (16) at the heat exchanger elbow supply to the expansion tank and expansion tank discharge to the fresh water make-up. g. Loosen and remove cap screws (3, figure 7-8) with bracket (1, figure 7-8) and expansion tank (18) from the engine. h. Support the heat exchanger while loosening and removing cap screws (21), retaining clamps (22), heat exchanger (1), vibration isolators (2), and heat exchanger brackets (3) from the engine block. i. Bag and tag the forward and after heat exchanger mounting components separately. j. Rest the heat exchanger on wooden surface. 6-17.2 DISASSEMBLY. Disassemble the heat exchanger according to the following steps. Unless otherwise noted, callouts refer to figure 7-15. a. Loosen hose clamps (7) and remove plain hoses (4) from water transfer tube (6). b. Bag and tag hose clamps (7) and plain hoses (4) as to relative position of removal, upper or lower. c. Loosen hose clamps (16) and remove plain hose (20 and 14). Bag and tag the hose clamps and hoses to the relative position of removal. d. Loosen and remove zinc plug (8). NOTE Both ends of the heat exchanger are fitted with a removable end cover. e. Loosen and remove cap screw (12), fiber washer (11), end cover (10), and gasket (9). f. Remove drain cock (17) from expansion tank (18). 6-30

S9233-C9-MMA-010 g. Clean and flush the heat exchanger as follows: NOTE The heat exchanger can be cleaned while attached to the engine. 1. Use a 3/16-inch diameter brass rod to clean out any build-up in the heat exchanger tubes. Run the brass rod from the rear to the front. This will push the debris out where it can be flushed out of the zinc plug hole. See figure 6-12. 2. Flush the heat exchanger tubes from the rear with clean water. Make sure the end cavities are cleared of all debris. See figure 6-13. h. Clean and inspect parts according to paragraph 6-7.1 and paragraph 6-7.2.

Figure 6-12. Cleaning Build-up in Heat Exchanger

Figure 6-13. Flushing Heat Exchanger

6-17.3 REASSEMBLY/REINSTALLATION. Reassemble/reinstall the heat exchanger in the reverse order of disassembly/removal; refer to paragraph 6-17.1 and paragraph 6-17.2 respectively . Use new gaskets (9), new fiber washers (11), new zinc plug (8), and liquid Teflon sealant on threads of drain cock (17) in expansion tank (18). Torque the retaining cap screws to 35 lb-ft. 6-31

S9233-C9-MMA-010 6-18.

MARINE TRANSMISSION OIL COOLER.

6-18.1 REMOVAL. Remove the marine transmission oil cooler according to the following steps. Unless otherwise noted, callouts refer to figure 7-17. NOTE If repairs are being made with the engine in the craft, ensure the sea water system’s suction and discharge valves are shut and tagged. a. Tag the transmission’s oil inlet and outlet lines to the oil cooler. b. Loosen and remove the oil supply and discharge hoses from cooler male adapter elbows (1). Cap or plug the elbows and hose ends. c. Clean up wasted oil. Discard rags or paper towels in accordance with PMS instructions. d. Loosen and remove sea water drain plug and drain sea water from the cooler. 1. Loosen the cooler’s sea water supply and discharge hose clamps (3). 2. Disconnect supply and discharge elbow hoses (4 and 10) from the cooler. 3. While holding up on U-bolts (5), loosen and remove hex nuts (8). Remove the U-bolts and noise isolator (6). 4. Remove the cooler (2). e. Loosen and remove two cap screws (7) and remove oil cooler bracket (9). NOTE The marine transmission can be cleaned while attached to the engine. f. Use a 3/16-inch diameter brass rod to clean out any build-up in the sea water inside the cooler tubes. See figure 6-14.

Figure 6-14. Cleaning Build-up in Marine Transmission Oil Cooler

6-32

S9233-C9-MMA-010 NOTE When back flushing the cooler, apply water pressure from the cooler discharge side. g. Flush all debris from the cooler with clean pressurized water. See figure 6-15.

Figure 6-15. Flushing Marine Transmission Oil Cooler h. Clean and inspect pans according to paragraph 6-7.1 and paragraph 6-7.2. 6-18.2 REINSTALLATION. Reinstall the marine transmission oil cooler in the reverse order of removal; refer to paragraph 6-18.1. Apply liquid Teflon sealant to the threads of male adapter elbows (1) before securing the supply and discharge oil hoses to the cooler. 6-19.

WATER TRANSFER CONNECTION.

Replace the water transfer connection according to the following steps. Unless otherwise noted, callouts refer to figure 7-18. a. Drain coolant level down; refer to paragraph 6-14.1. b. Loosen hose clamps (16) and disconnect plain hose (17) from elbow coupling (19) and upper thermostat housing (3, figure 7-11). c. Loosen and remove four mounting nuts (20). d. Match mark transfer connection (18) and exhaust manifold (12). e. Remove the water transfer connection; it may be necessary to loosen the plate by tapping it with a plastic hammer. f. Remove gasket (9) and any gasket material from the water transfer connection plate and exhaust manifold. Do not allow any debris to fall into the manifold. Discard the gasket. g. Install new gasket (9) and water transfer connection (18). h. Install nuts (20) and torque to 24 lb-ft. i. Place hose clamps (16) in position and reconnect plain hose (17) to elbow coupling (19) and upper thermostat housing (3, figure 7-11); tighten hose clamps securely. j. If required, refill the engine with coolant. 6-33

S9233-C9-MMA-010 6-20.

TEMPERATURE TRANSDUCER.

Replace the temperature transducer according to the following steps. Unless otherwise noted, callouts refer to figure 7-6. a. Disconnect the water temperature transducer wiring. b. Remove water temperature transducer sensor (4). c. Apply liquid Teflon sealant to the threads before installing the replacement water temperature transducer. d. Install replacement transducer (4) and torque to 37 lb-ft (steel) or 22 lb-ft (aluminum). e. Reconnect the wiring. 6-21.

FUEL LEFT PUMP.

6-21.1 REMOVAL. Remove the fuel lift pump according to the following steps. Unless otherwise noted, callouts refer to figure 7-24. a. Shut the fuel oil supply tank discharge valve. b. Loosen and remove banjo connector screw (3) and sealing washers (1). Discard the sealing washers. c. Loosen fuel supply tube (2) lower coupling nut and remove the fuel supply tube. d. Loosen and remove two cap screws (5) while holding lift pump (4) with one hand. e. Remove lift pump and cover plate gasket (6). Discard the cover plate gasket. f. Ensure the cover plate gasket surface on the cylinder block is clean. g. Clean and inspect parts according to paragraph 6-7.1 and paragraph 6-7.2. 6-21.2 REINSTALLATION. Reinstall the fuel transfer pump in the reverse order of removal; refer to paragraph 6-21.1. Use new sealing washers (1) and cover plate gasket (6). 6-22.

FUEL PIPING.

6-22.1 REMOVAL. refer to figure 7-25.

Remove the fuel piping according to the following steps. Unless otherwise noted, callouts

NOTE Individual high-pressure fuel line(s) can be removed without removing the complete set. a. Disconnect high-pressure fuel lines (16, 17, 18, 20, 21, and 22) from the fuel injection nozzles, b. Loosen and remove cap screws (15) from the intake cover. 6-34

S9233-C9-MMA-010 CAUTION

To prevent the fuel injection pump delivery valve holder from turning, use two wrenches. c. Using two wrenches, loosen and remove high-pressure fuel lines (16, 17, 18, 20, 21. and 22) from the fuel injection pump. d. Loosen and remove cap screws (4), plain washer (3), tube brace (2), and vibration isolators from the highpressure fuel lines. 6-22.2 REINSTALLATION. Torque to 18 lb-ft. 6-23.

Reinstall the fuel piping in the reverse order of removal; refer to paragraph 6-22.1

FUEL FILTER AND FUEL/WATER SEPARATOR.

6-23.1 FUEL FILTER. Replace the fuel filter according to the following steps. Unless otherwise noted, callouts refer to figure 7-26. a. Using a strap wrench, remove the fuel filter element complete with Brings (2). Discard the element and O-ring. NOTE Unless the engine is to be immediately placed in service, do not fill the replacement filter element. b. Fill the new fuel filter canister with fresh, clean diesel fuel. c. Lubricate the fuel filter canister gasket with fresh, clean engine oil. Position the canister on the mount and turn clockwise until the gasket contacts the filter head; turn the canister an additional 1/2 turn after the gasket contacts the filter head. 6-23.2 FUEL/WATER SEPARATOR. Replace the fuel/water separator element according to the following steps. Unless otherwise noted, callouts refer to figure 7-42. NOTE Use a suitable container to catch any fuel/water drained from the fuel/separator bowl. a. Loosen the separator vent plug (2) mid open the separator bowl drain knob (7) to drain all fuel/water from the separator bowl. Close both after draining. b. Disconnect the water level sending probe wiring and remove the element (4) with the bowl (6) connected. c. Remove the bowl; discard the element and O-ring (5). d. Clean the bowl and O-ring gland; lubricate a new O-ring (5) with fresh, clean diesel fuel and insert it in the bowl O-ring gland. e. Spin the bowl (6) onto a new element (4). Do not overtighten. 6-35

S9233-C9-MMA-010 f. Lubricate the element gasket with fresh, clean engine oil; fill the bowl/element assembly with fresh, clean diesel fuel. g. Spin the bowl/element assembly onto the head. Do not overtighten. h. Reconnect the water level sending probe wiring. 6-24.

FUEL DRAIN MANIFOLD.

6-24.1 REMOVAL. Remove the fuel drain manifold according to the following steps. Unless otherwise noted, callouts refer to figure 7-25. a. Loosen and remove injection nozzle banjo connector screws (13). b. Loosen fuel manifold (5) coupling nut to male union tee (7). c. Remove fuel manifold and banjo connector seal (12) from the cylinder block. d. Loosen and remove hex head cap screws (9) and seal rings (10). e. Disconnect fuel drain tube (8) at the flexible connection. f. Loosen fuel drain tube (11) from the fuel injection pump. Remove fuel drain tube (11), male union tee, and fuel drain tube (8) from the cylinder block. 6-24.2 REINSTALLATION. Reinstall the fuel drain manifold in the reverse order of removal; refer to paragraph 6-24.1. Use liquid Teflon sealant on the fuel manifold and fuel drain tube end fittings. Use new banjo seal connectors (12) and torque the banjo connector screws (13) to 18 lb-ft. 6-25.

FUEL INJECTION NOZZLES.

6-25.1 REMOVAL. Remove the fuel injection nozzles according to the following steps. Unless otherwise noted, callouts refer to figure 7-25. a. Shut the fuel oil supply valve(s). b. Clean the area around fuel injection nozzle. c. Loosen high-pressure fuel supply tubes (16, 17, 18, 20, 21, and 22) from the fuel injection nozzle. d. Loosen and remove banjo connector screws (13). e. Loosen fuel manifold (5) coupling nut and remove the fuel manifold and banjo connector seals (12). CAUTION

To prevent serious damage to the injection nozzle, ensure the interior of the socket does not come in contact with the fuel drain outlet sealing surface. f. Using a deep-well 24-mm socket, loosen and remove the fuel injection nozzle. Tag each fuel injection nozzle with the cylinder number from which it was removed. g. Place the fuel injection nozzle(s) on a clean working surface. 6-36

S9233-C9-MMA-010 6-25.2 DISASSEMBLY. Disassemble the fuel injection nozzles according to the following steps. Unless otherwise noted, callouts refer to figure 7-27. a. Remove and discard copper sealing washer (5). CAUTION

To prevent damage to equipment, a soft-jawed vise, cloth, or cardboard should be used to protect parts. b. Clamp the nozzle holder in a soft-jawed vise and remove nozzle nut (6). CAUTION

To prevent damage to the injection nozzle and needle valve, place parts in a suitable bath of clean fuel oil. NOTE Hold the needle valve by the stem; skin oils will corrode the finely lapped surfaces. Also, the needle valve and nozzle tip are matched to fit and should not be intermixed. c. Remove nozzle needle valve (8), nozzle (7), and intermediate disc (9). Place the needle valve and nozzle in a bath of clean fuel oil. d. Remove the nozzle holder from the vise, then remove pressure spindle (4), compression spring (3), and shims (2). e. Clean and inspect parts according to paragraph 6-25.3. 6-25.3 CLEANING AND INSPECTION. ing steps.

Clean and inspect the fuel injection nozzles according to the follow-

WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. a. Clean the edge filter in the nozzle by applying clean, dry, compressed air to the fuel passage from the nozzle side of the nozzle body. Edge filters are not removable. NOTE Never use emery paper or any other metal scraper to clean the nozzle. b. Clean the nozzle seat with the scraper and polish needle valve (8) seat with a piece of hardwood dipped in test oil. 6-37

S9233-C9-MMA-010 c. Clean the interior of the nozzle ring groove with the scraper. Rinse in an approved solvent to remove all dirt and carbon residue and dip in clean test oil. Refer to paragraph 6-7.1. d. Clean the spray holes in the injection nozzles with an appropriate size cleaning needle. Remove burned on deposits with an approved solvent and rinse in test oil. e. Clean the needle valve tip with a brass brush. Inspect for rough surfaces Or erosion. The pressure shoulder will normally have a rough machined appearance. Deteriorated needle valves must be replaced. f. Dip the needle valve in clean test oil and insert the needle valve all the way into the nozzle body. Now pull the needle valve one-third of the way out of the nozzle body. The needle valve must slide all the way back into the nozzle body under its own weight. If the nozzle fails the slide test, re-clean and re-test. Any nozzle body and needle valve that cannot pass this test must be replaced. g. Clean the nozzle bore with a bore brush. 6-25.4 REASSEMBLY. Reassemble the fuel injection nozzles according to the following steps. Unless otherwise noted, callouts refer to figure 7-27. NOTE Prior to reassembly, ensure all mating surfaces and pressure faces are absolutely clean and lubricated with fuel oil. NOTE Install the same thickness of shims that were removed at disassembly. a. Reinstall shims (2). Use compression spring (3) to ensure the shims are installed flat. CAUTION

To prevent damage to equipment, a soft-jawed vise, cloth, or cardboard should be used to protect parts. b. Invert and clamp nozzle (7) in a soft-jawed vise and install pressure spindle (4). c. Reinstall intermediate disc (9). NOTE While handling the valve, hold the needle valve by the stem. The needle valve and nozzle tip are matched to fit. They must not be intermixed. d. Reinstall needle valve (8) and nozzle (7). e. Reinstall nozzle nut (6). Torque the nut to 22 lb-ft. 6-25.5 FUEL INJECTION NOZZLE TEST. 6-38

Test the fuel injection nozzles according to the following steps.

S9233-C9-MMA-010

WARNING

Fuel spray from an injection nozzle can penetrate the skin and cause serious injury. Use the proper equipment and keep hands clear when testing the nozzles.

NOTE All injection nozzles must be tested for opening pressure, chatter, and spray pattern.

a. Check opening pressure with an injection nozzle testing pump. 1. Open the pump valve. 2. Operate the pump lever at one stroke per second (figure 6-16). 3. Read the pressure indicated when the spray begins. The spray should begin between 3160 to 3307 psi. If the opening pressure is out of specifications, change the shim pack; adding shims will increase pressure. b. Leakage test.

Perform the leakage test according to the following steps.

1. Open the valve. 2. Operate the pump lever to hold the pressure 290 psi below the opening pressure (figure 6-17).

Figure 6-16. Checking Injection Nozzle Opening Pressure

6-39

S9233-C9-MMA-010

Figure 6-17. Leakage Test 3. Fuel drops should not fall from the tip within 10 seconds. NOTE A used injection nozzle should not be evaluated for chatter at lower speeds. A used nozzle can generally be placed in service if it passes the leakage test, chatters audibly at high lever speeds, and uniformly atomizes the fuel. c. Chatter test. The chatter test indicates the ability of the needle valve to move freely and correctly atomize the fuel. You should hear the valve open and should observe a well atomized spray pattern. 6-25.6 REINSTALLATION. Reinstall the fuel injection nozzles according to the following steps. Unless otherwise noted, callouts refer to figure 7-27. a. Apply a coat of antiseize compound to the threads of the fuel injection nozzle nozzle hold-down nut and between the top of the nut and fuel injection nozzle nozzle body. b. Install new copper washer (5) on nozzle (7). c. Reinstall the fuel nozzle. Ensure the protrusion on the side of the nozzle fits into a notch in the head to orient the nozzle. d. Using a deep-well, 24-mm socket that will not damage the sealing surface of the fuel drain outlet, torque fuel injection nozzle nut (6) to 44 lb-ft. 6-25.7 BLEEDING THE FUEL SYSTEM. Bleed the fuel system according to the following procedure. Unless otherwise noted, callouts refer to figure 7-25. NOTE Manual bleeding of the fuel system is required if the fuel filter is not filled prior to installation and if fuel injection pump is replaced. a. Vent the low-pressure fuel lines and fuel filter as follows. 1. Re-energize electrical power to the engine starting system and remove the OUT-OF-SERVICE tag. 6-40

S9233-C9-MMA-010 2. Ensure the fuel oil supply valve(s) are open. 3. Place the switch (figure 6-18) at the instrument panel in the RUN position in order to energize the fuel injection pump solenoid. 4. Using an 8-mm box wrench, open filter bleed screw (figure 6-19). 5. Operate the hand lever on the fuel oil transfer pump until fuel oil flows from the filter bleed screw free of air (figure 6-19).

Figure 6-18. Energizing Solenoid

Figure 6-19. Venting Fuel Filter and Hand Lever 6. Torque the bleed screw to 6 lb-ft. NOTE Control venting is provided at the fuel injection pump through the fuel drain manifold. Small amounts of air introduced while changing the fuel oil filter/fuel 6-41

S9233-C9-MMA-010 injection pump supply line will be automatically vented if the fuel oil filter is changed in accordance with the instructions. b. Vent the fuel injection pump at the bleed screw (figure 6-20) as follows.

Figure 6-20. Venting Fuel Injection Pump

NOTE The fuel injection pump can be vented both manually and through the use of the starting motor. 1. Open fuel injection pump bleed screw. 2. Energize fuel injection pump solenoid and hand pump air/fuel oil from the low-pressure fuel line and fuel injection pump through the injection pump bleed screw with the hand lever on the fuel oil transfer pump (figure 6-20). 3. Close the bleed screw on the fuel injection pump. Torque the bleed screw to 6 lb-ft.

NOTE The engine may start. 4. Ensure the throttle is in neutral and move the start switch to the START position. 5. Vent the fuel injection pump through the fuel drain manifold (5, figure 7-25) while operating the starting motor (figure 6-21). c. Vent the high-pressure fuel lines as follows: 1. Loosen the high-pressure fuel tube fittings at the nozzle. 6-42

S9233-C9-MMA-010

Figure 6-21. Venting Fuel Injection Pump through Fuel Drain Manifold NOTE The engine may start. 2. Refer to the engine technical manual and place the throttle in the RUN position. 3. Move the start switch to the START position (figure 6-22).

Figure 6-22. Venting High-Pressure Fuel Tubes

WARNING

Fuel spray from an injection nozzle can penetrate the skin and cause serious injury. Use the proper equipment and keep hands clear when testing the nozzle. 4. Crank the engine to allow air to bleed from the high-pressure fuel tubes (figure 6-22). Torque the highpressure fuel tube fittings at the nozzle. 6-43

S9233-C9-MMA-010

WARNING

Do not bleed a hot engine. This action could cause fuel to spill onto a hot exhaust manifold thereby creating a danger from fire. 5. Refer to the engine technical manual and place the throttle in idle and start the engine. With the engine running, vent one high-pressure tube at a time until the engine runs smoothly (figure 6-23).

Figure 6-23. Venting High-Pressure Fuel Lines with Engine Idling 6. Stop the engine when the fuel system has been bled. 6-26.

FUEL INJECTION PUMP.

6-26.1 REMOVAL. refer to figure 6-24.

Remove the fuel injection pump according to the following steps. Unless otherwise noted,

a. Disconnect the fuel drain manifold tube. b. Remove the injection pump fuel supply line. c. Remove all high-pressure fuel injection supply tubes. d. Disconnect the electrical wiring to the fuel shutoff valve solenoid. e. Remove the fuel air control tube, if installed. NOTE Do not remove the fuel pump control lever. The lever is indexed to the shaft during pump calibration. f. Using a 13-mm wrench, loosen the hex head adjustment cap screw and the mount brace cap screws; remove the fuel pump brace. g. Remove access cover and seal (17 and 18, figure 7-13). h. Remove the fuel pump drive gear mount nut and lock washer. 6-44

S9233-C9-MMA-010 CAUTION

To prevent damage to equipment, disengage the pin after locating TDC. i. Using a socket and pull bar on the alternator pulley retaining nut while pushing in on the top dead center (TDC) pin, turn the engine over to locate TDC for the number 1 cylinder (figure 6-25). Disengage the pin after locating TDC. j. Loosen the fuel pump lock screw (figure 6-26); position the special washer as shown, then tighten the lock screw against the pump shaft. Torque the lock screw to 5 lb-ft.

Figure 6-24. Fuel Injection Pump Disassembly

k. Using a 75-mm T-bar type gear puller (figure 6-27), remove the fuel pump drive gear from the fuel pump shaft.

6-45

S9233-C9-MMA-010

Figure 6-25. Locating TDC for Number 1 Cylinder

Figure 6-26. Loosening Fuel Pump Lock Screw

Figure 6-27. Removing Fuel Pump Drive Gear

6-46

S9233-C9-MMA-010 NOTE If the pump is to be reinstalled, it must be match marked to the mount flange. l. Using a chisel punch and hammer, match mark the pump mount flange with the engine mount flange to ensure correct alignment and gear backlash when reinstalled. CAUTION

To prevent damage to equipment and excessive teardown, do not drop the fuel pump drive gear key from the pump shaft when removing the pump. m. Remove the three hex flange head mount nuts (figure 6-24) from the mount studs and remove the fuel pump. Use care not to drop the drive gear key from the pump shaft when removing the pump. n. Remove the pump mount gasket and thoroughly clean the mount surfaces. 6-26.2 DISASSEMBLY. Disassemble the fuel injection pump according to the following steps. Unless otherwise noted, callouts refer to figure 7-28. a.

Place the pump on its side with inspection cover plate (19) upwards.

b.

Remove lead seal (15), hex head screws (17), and washers (18).

c.

Remove nameplate (16), cover plate (19), and gasket (24). Discard the gasket and drain the oil into a suitable receptacle.

d.

Secure fixture part number 7044-888F in vise. Secure the pump to the fixture with governor control cover (85) positioned on top.

e.

Remove cap nut (82), lock washer (83), lever (84). NOTE Do not remove the lever break back assembly unless absolutely necessary to complete repairs. The throttle is indexed to the lever. Note the location of index marks prior to disassembly.

f.

If necessary, remove lever break back assembly (79) by removing self-locking nut (78), spring (77), washer (76), and spring guide (75).

g.

Remove lead seals and locking wire from cap nuts (80). Unscrew and remove the cap nuts, washers (81), vent screw (70), and washer (71). NOTE The throttle shaft must be pressed through the cover and remain with the pump and connected to the governor spring.

h.

Lift off the governor control cover while at the same time lightly pressing down on throttle shaft (89). Discard gasket (86).

i.

Unhook and remove spring (91).

j.

Remove idling spring (96) and spring guide (97). 6-47

S9233-C9-MMA-010 k.

Remove shutoff bar (93).

l.

Press down tabs on lock washer (92). Remove studs (87), lock washers, keep plate (90), hex head screw (33), and tab washer (34).

m. As an assembly, remove the control bracket complete with governor arm (94), metering valve (32), and the linkage hook assembly. Detach the metering valve from the linkage hook and immerse in clean test oil. n.

Disassemble the governor single spring linkage in the following order (figure 6-28): linkage locking nut, linkage nut, pivot ball washer, linkage pivot ball, linkage spring washer, long linkage spring, and spring retainer from the linkage hook.

o.

Invert fixture with pump in vise. Remove piston plug (101), sealing ring (108), spring cap (113), sealing ring (108), shim (110), and spring (109).

p.

Loosen and remove head locating fitting (105) complete with steel ball (104) and sealing rings (106).

Figure 6-28. Governor Linkage Spring Removal q.

Remove cap nut (103) with washer (102) and housing and piston (116).

r.

Remove the piston for inspection. If the condition is satisfactory, reassemble the piston to the housing. Remove and discard housing gasket (107).

s.

Using tool number 7144-14, loosen screw (52). If necessary, lightly tap the screw to release cam ring (25). Invert the fixture, in a vise.

t.

Remove pressure valves (100), and fuel injection tube (99); note the position, type, and the letter identification against the outer holes.

u.

Remove fuel connection (2) and washer (3).

6-48

S9233-C9-MMA-010 v.

Remove screws (64); detach clamping plate (63) and end plate (62). Remove screws (12) and bracket (13) from the hydraulic head.

w. Remove sleeve and piston (7), spring (5), filter (4), piston (6), and spring (9), and guide spring (10). x.

Remove transfer pump sealing ring (58) and transfer pump blades (61). Note the position of the slot in the transfer pump liner (59), i.e., 3 or 9 o’clock when viewed from the transfer rotor end, then remove transfer pump liner.

y.

Hold the drive hub with a wrench and loosen the transfer pump rotor with tool number 7044-889 (figure 6-29). The direction in which the transfer pump rotor is loosened is indicated by an arrow marked on the face of the rotor. Unmarked rotors are loosened in the direction of pump rotation. Remove tools, then fingertighten the transfer pump rotor.

Figure 6-29. Loosening Transfer Pump Rotor

z.

Note the location of socket head screw (20), and remove the screw and washer (21). Remove head and rotor assembly (57) with a slight twisting motion in each direction. Remove and discard sealing ring (22).

aa. Place the head and rotor assembly on a clean work bench. Hold the drive plate with tool number 7144-744 and loosen the drive plate screws with tool number 7144-511A (figure 6-30). bb. Remove the transfer pump rotor (60). Position the hydraulic head on a bench with the drive plate uppermost. Remove the drive plate screws, drive plate, top adjusting plate (56), and shoes and roller assemblies (23). Immerse the shoes and roller assemblies in clean test oil. cc. Fit corks into the transverse rotor slots to retain the plungers (figure 6-31).

6-49

S9233-C9-MMA-010

Figure 6-30. Loosening Drive Plate Screws

Figure 6-31. Fitting Corks to Retain Plungers dd. Remove distributor rotor from head and detach bottom adjusting plate (56). ee. Insert the distributor rotor into the head to ensure protection of the bearing surfaces. Secure the rotor in position with the transfer pump rotor finger-tightened.

6-50

S9233-C9-MMA-010

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. ff. Remove the screw (52). Note the direction of the arrow on the cam ring (25), then remove the cam ring. Note the position of the ears on retaining ring (26), and remove retaining ring. gg. Remove drive shaft (48) with governor weights (49). Remove shaft ring spring (51), thrust sleeve (50), thrust washer (47), and governor weight from drive shaft. hh. Remove the pump from the fixture. Carefully note the way the drive hub seals are inserted, then remove and discard oil seal (45) using tool number 7044-893A (figure 6-32). Remove housing retaining ring (46) with retaining ring pliers. Also remove and discard second oil seal (45).

Figure 6-32. Removing the Drive Hub Seal ii. Clean and inspect all parts according to paragraph 6-7.1 and paragraph 6-7.2. 6-26.3 REASSEMBLY. Reassemble the fuel injection pump according to the following steps. Unless otherwise noted, callouts refer to figure 7-28. a.

Immerse the two new replacement oil seals (45) in clean test oil. The oil seals must be inserted in the same position noted prior to disassembly. Use tool number 7244-154. Install inner oil seal (45). Next, reassemble housing retaining ring (46) with its open end adjacent to tell-tale holes where provided, then install outer oil seal (45) using tool number 7244-154.

b.

Secure fixture part number 7044-888F in a vise. Secure the pump to the fixture with the pump governor control machined face upwards. 6-51

S9233-C9-MMA-010 c.

Screw the drive shaft nut onto the drive shaft and stand the drive shaft, tapered end down, on a level surface with the governor weight retainer face upwards. Place governor weights (49) into the governor weight retainer with lips resting against the shaft.

d.

Assemble thrust washer (47) and thrust sleeve (50) over drive shaft (48). Press down the thrust sleeve and install shaft spring ring (51). Unscrew and remove the shaft nut.

e.

Install protection cap number 7144-900 over the tapered end of drive shaft. Dip the protection cap in clean test oil and insert the drive shaft with a rotating action through the oil seals. When the drive shaft is securely home, remove the protection cap.

f.

Install retaining ring (26) against the shoulder in the pump housing bore, positioning the square ear of the retaining ring centrally in the housing inspection cover opening.

g.

Install cam ring (25) against the retaining ring with the arrow facing the open end of the pump and in the same direction as the arrow on the pump nameplate (16).

h.

Invert the fixture in vise and screw hex head screw (52) into the cam ring. Torque to the correct value using tool number 7144-14. Remove the tool and lightly tap the cam advance screw to ensure the cam ring is not binding in the pump body. NOTE If the distributor head rotor screw has been removed or is loose, a new screw and washer must be installed.

i.

Unscrew and remove transfer pump rotor (60). Detach the distributor rotor from hydraulic head (57). Screw the two drive plate screws fully home into the distributor rotor. Position the rotor so the heads of the screws are gripped lightly by the jaws of a vise. Thoroughly de-grease the threads of the rotor and screw and lightly coat the threads of the screw with Araldite. Insert the screw and, using tool number 7144-220 (figure 6-33), torque to correct value. Allow Araldite to harden for six hours at room temperature before putting the pump into service.

Figure 6-33. Rotor Screw Installation j. 6-52

Position the hydraulic head on a bench with the machined surfaces upward. Position bottom adjusting plate

S9233-C9-MMA-010 (56) on the hydraulic head with its chamfered edges upward. Insert the distributor rotor and line up the guide slots on the bottom adjusting plate with the tapered end cutouts on the rotor head. k.

Remove the corks retaining the twin pumping plungers (figure 6-31) in the rotor transverse slots. Insert roller and shoe assemblies (23) with the ears in the roller shoe guides. The projecting ears on the shoes must be placed in the eccentric slots of the bottom adjusting plate so the contour of the ears match the contour of the slots.

l.

Reinstall the top adjusting plate (figure 6-34) with its chamfered edges downward and engage the legs of the plate in the guide slots of the bottom adjusting plate. Locate the two plates so the fuel adjusting slot in the top plate coincides with the scribed line on the distributor rotor head. Reassemble the drive plate machined recess downwards and align the slot between letters A and H with the top adjusting plate slot. Reassemble the drive plate screws and finger-tighten.

Figure 6-34. Reinstalling Top Adjusting Plate m.

Lift head and rotor assembly (57) and screw transfer pump rotor (60) finger-tight into the distributor rotor body. NOTE Relief valve number 7144-155 must be fitted in the fuel line to ensure that the test pressure of 440 psi (30 atm) is not exceeded. When other test pressures are stated on test plans, this relief valve can be omitted but care must be taken not to exceed the specified pressure. Excess pressure can cause damage to shoe assemblies and adjusting plates. 6-53

S9233-C9-MMA-010 n.

Install stirrup pipe tool number 7144-262A (figure 6-35) to two of the high-pressure outlet ports on the head and connect it to a nozzle testing unit. Operate the nozzle testing unit to raise the pressure to 440 psi (30 atm).

Figure 6-35. Measuring Roller-to-Roller Dimension o.

Turn the pump rotor until the pumping plungers and rollers are forced outwards to the maximum fuel position. Using a micrometer, measure the overall roller-to-roller dimension. The roller-to-roller dimension must be set to the correct test specification figure by movement of the adjusting plates. NOTE Drive plate screws are tightened using spanner tool 7144-511A and an adapter fitted in a torque wrench. In use, the torque wrench handle and spanner must form a straight line with the handle extending away from the spanner. The distance between the center of the adapter and the center of the ring spanner is 5 inches (127 mm). If the tools used are not kept in a straight line, the applied torque will be incorrect.

p.

Hold the drive plate with tool number 7144-744 and torque the drive plate screws evenly with spanner tool number 7144-511A to the correct value. Slacken these screws and re-tighten to the same value. It is important that this procedure of tightening, slackening, and re-tightening is followed. Tighten screws evenly to avoid rotor distortion, which can cause sticking plungers.

q.

Relieve pressure. Disconnect the nozzle testing outfit and remove the stirrup pipe from the high-pressure outlets on the head.

r.

Install a new housing gasket (107) to the pump housing. Ensure the blank end of the piston is toward the

6-54

S9233-C9-MMA-010 oil feed drilling end of the piston housing. Reassemble the housing and piston assembly (116) to the pump housing, ensure the cam advance screw engages with the piston and lightly secure it in place with washer (102) and cap nut (103). s.

Assemble seal (108) to piston plug (101) and install into the housing. Reinstall outer piston spring (109), seal (108), insert shim washers (110), and piston spring cap (113) into the piston housing.

t.

Invert the pump assembly and fixture in vise so the governor housing faces upwards.

u.

Install new seal (22) into hydraulic head and rotor assembly (57). Lubricate the portion of the head that fits into the pump with clean test oil and install the hydraulic head into the pump housing. Insert the head into position, with a rotating motion, so the splines on the inner end of the drive shaft engage with the splines in the drive plate. Rotating the head on entry prevents damage to the distributor head seal.

v.

Align the metering valve bore with the contour in the machined face of the housing. When the head is in position, secure with washer (29), screw vent (31), vent screw (30), and washer (29) finger-tightened. Ensure the screw vent and vent screw are in the same location as noted during disassembly.

w.

Invert the fixture in a vise and assemble sealing ring (106) and washer (102) to head locating fitting (105). Screw in the head location fitting to secure the auto-advance housing to the pump housing. Progressively and evenly torque cap nut (103) head location fitting, screw vent, and vent screw to the correct values. Unscrew and remove piston plug (101). Ensure the piston is free, then reassemble and torque the plug to the correct value. (Refer to table 6-7 for all torque values.) NOTE The transfer pump rotor must be tightened in the opposite direction of pump rotation.

x.

Hold the drive hub with a spanner and torque the transfer pump rotor with tool number 7044-889 to the correct value (figure 6-29).

y.

Insert transfer pump liner (59) into the pump housing with the slot in the same position (3 o’clock viewed from rotor end) it occupied prior to disassembly.

z.

Hold the transfer pump liner in position so the slot is located accurately and insert transfer pump blades (61).

aa.

Place spring (9) into end plate (62). Insert the piston (6), then spring (5) into the large diameter end of piston and sleeve (7). Insert the small end of spring guide (10) into the same end of the piston and sleeve. Install a new sleeve and piston (7) onto the other end and place the complete assembly into the end plate, spring guide peg upward.

bb.

Install filter (4) and spring (9) into the end plate and secure with fuel connection (2) and washer (3).

cc.

Place the end plate with the fuel connection facing upward onto the hydraulic head ensuring that the dowel on the inner face of the end plate engages in the slot in the transfer pump lines.

dd.

Install bracket (13) and screws (12) onto the hydraulic head; torque all screws and the inlet connection to the correct values.

ee.

Reassemble governor arm (94) to the control bracket and reinstall the spring (95). Refer to figure 6-28 and reassemble the spring linkage components onto the linkage hook as follows: spring retainer (large end first), long linkage spring, and linkage spring washer. Pass the linkage hook through the correct hole in the governor arm and continue assembling the linkage pivot ball, pivot ball washer, linkage nut, and locking nut. Engage metering valve (32) to the hook linkage.

ff.

Position the governor control linkage assembly into the pump housing by engaging the toe on the lower 6-55

S9233-C9-MMA-010 end of the governor arm on top of the step of the thrust sleeve and at the same time insert the metering valve into the metering valve bore in the hydraulic head. gg.

Position keep plate (90) on the control bracket so the slotted end faces away from the linkage hook assembly. Position two new lock washers (92) with the lips positioned nearest to the metering valve and engaging the long edge of the keep plate. Screw in two studs (87) and finger-tighten. Place a new bracket screw tab washer with the tail bent down over that edge of the control bracket lying under the hook of the linkage assembly. Insert new hex head screw (33) with lock washer (34) and torque the hex head screw and studs to the correct torque value; refer to table 6-7. Lock all tabs.

hh.

Set the link length with a vernier gauge (figure 6-36) so the correct internal dimension [2.10 inch (53.5 mm) .020 inch (0.5 mm)] is obtained between the larger diameters of the governor control cover stud and the metering valve lever pin. Adjustment is made by slackening the linkage locking nut and tightening or loosening the linkage nut on the end of the hook linkage. When setting, apply light pressure to the governor control arm to hold the metering valve in the fully open position. Ensure the vernier gauge is held parallel to the axis of the pump. After setting, tighten the linkage locking nut.

ii.

Position gasket (86) on the governor housing face with the gasket tongues placed in the slots of the control bracket. Slide shutoff bar (93) into the cutout in the control bracket.

Figure 6-36. Adjusting Link Length jj.

Install protection cap number 7144-459A onto the end of throttle shaft (89) and install new sealing rings (88).

kk.

Place idling spring (96) onto spring guide (97); insert the spring guide into the correct hole in the governor arm (94) and attach governor spring (91) to the correct hole on the throttle shaft link and spring guide (figure 6-37).

ll.

Place new sealing rings (88) onto shutoff shaft (98) and install into the governor control cover (85). Position the peg towards the edge of the cover.

mm. Insert the throttle shaft into the governor control cover and, at the same time, locate the governor control cover onto the two studs (87). While lowering the governor control cover into position onto the pump housing, engage the shutoff shaft peg in the crook of the shutoff bar (93). nn. 6-56

Reinstall washers (81) and cap nuts (80) and tighten.

S9233-C9-MMA-010 oo.

Reinstall spring guide (75), washer (76), spring (77), and break back lever (79). Secure with self-locking nut (78).

pp.

Reinstall lever (84), lock washer (83), and cap nut (82). Torque all screws and nuts to the correct values; refer to table 6-7.

qq.

Reinstall nameplate (16) if removed, cover plate (19), and gasket (24) to the pump housing and secure with hex head screws (17) and lock washers (18). Torque hex head screws to the correct torque values.

Figure 6-37. Attaching Governor Spring rr.

Reinstall high pressure fuel injection tubes (99) to the hydraulic head and secure with pressurizing valves (100) in their respective positions as noted during disassembly. Torque all pressure valves to the correct values.

ss.

Where possible, ensure all other components have been torqued to the correct values.

tt.

Wire and seal cap nuts (80) in accordance with the PMS. Ensure that a locking sleeve, a suitable length of locking wire with an unclenched seal, is loosely attached to the pump for sealing the throttle adjusting screw after the final setting on the engine.

6-26.4 PRE-TEST. 6-26.4.1 Pressure Test.

Pressure test the fuel injection pump according to the following steps. 6-57

S9233-C9-MMA-010 NOTE All pumps must undergo a pressure test before and after a machine test. a. Drain all fuel from the pump and connect an air line to the pump inlet connection. Ensure the air supply is clean and free from water. b. Seal off the low-pressure outlet connection on the pump and completely immerse pump in a bath of clean test oil. c. Raise the air pressure in the pump to 20 lb-in2 (1.41 kg cm2 ). Leave the pump immersed in oil for 10 minutes to allow any trapped air to escape. d. Observe for leaks after pump has been immersed for 10 minutes; if the pump is not leaking, reduce the air pressure to 2 lb-in2 (0.14 kg cm2 ) for 30 seconds. If there is still no leak, increase the pressure to 20 lb-in2 (1.41 kg cm2 ); if the pump is still leak-free after 30 seconds, it can be passed as satisfactory. e. Repair any and all leaks before testing and setting the pump. 6-26.4.2 Seal Testing.

Test the fuel injection pump’s seals according to the following steps. NOTE

Certain pumps have a single-piece drive shaft with two inward-facing lipped oil seals. The gap in the retaining ring between the seals lines up with a tell-tale hole in the pump body. The inner seal, nearest to the governor sleeve, is checked by the normal pressure test, leakage being indicated at the tell-tale hole. NOTE A special tool is used for testing the outer seal. This tool consists of a flanged cylinder with three fixing studs, an air pressure connection, and a sealing gasket. a. Attach the tool number 7144-760 to the pump mounting flange and supply filtered air to the connection. b. Immerse the pump and tool in a bath of clean test oil and apply air pressure at 4 lb-in2 (0.28 kg cm2 ) for 20 seconds. Bubbles at the tell-tale hole normally indicate an oil seal failure, but first ensure that these are not caused by a faulty gasket. 6-26.4.3 General Testing Procedures. are observed.

When testing the fuel injection pump, ensure the following precautions

a. The test machine must be set to run in the correct direction of rotation for the pump under test. b. The pump should not be run with a low output for long periods at high speed. c. The pump should not be run for long periods with the shutoff control in the closed position. d. The correct test machine adapter plate must be used. A plate with a 50-mm hole must never be used for a pump with 46-mm spigot. e. Unless otherwise stated, standard radial high-pressure connections must be fitted prior to testing. 6-58

S9233-C9-MMA-010 f. Prime the pump thoroughly before testing; also at all times indicated in the test plan. 6-26.4.4 Priming. Prior to performing any tests on the fuel injection pump, ensure the pump is primed according to the following steps. a. Loosen both the vent valve on the governor control casing and the head vent screw. b. Connect the oil feed pipe to the pump inlet and connect the back leakage pipe. c. Turn on the oil supply to feed pressure 2 lb-in2 (0.14 kg cm2 ) to fill the pump. Run the pump at 100 rpm. When test oil free from bubbles flows from the vents, re-tighten the vent valve and the head locking screw. d. Loosen the connections at the nozzle end of the high-pressure pipes or, if installed on the test machine, open the bleeder valves at the nozzles. e. Run the pump at 100 rpm. When test oil free of bubbles flows from all high-pressure pipes, re-tighten the connections or close the bleeder valves. f. Examine the pump after priming for oil leaks at all jointing faces, connections, and oil seals. The pump must be free from leaks both when running and when stationary. 6-26.4.5 Pump Output. Fuel delivery is checked at the full throttle setting at one or more speeds of rotation by measuring the volume passing through each nozzle during 200 pump cycles. The pump test data outlines the maximum fuel delivery, overall tolerance, and the maximum permissible delivery variation spread between the nozzles. 6-26.4.6 Shutoff Control. The shutoff control is checked by running the pump at 325 rpm with the shutoff control closed. The maximum fuel delivery permitted on this setting is not to exceed 1/2 pint (0.5 cm3 ). 6-26.4.7 Maximum Fuel Setting. On internally adjusted pumps, the maximum fuel delivery is checked at a specified speed with the throttle and shutoff controls fully open; refer to the injection pump nameplate. If output is not within the specified limits, adjust according to the following steps. a. Loosen the screws securing the inspection cover and drain the pump. b. Remove the inspection cover. c. Loosen the two drive plate screws. d. Engage tool number 7144-875 with the slot in the periphery of the adjusting plate. e. Adjust the plate by lightly tapping the knurled end of the tool. The direction in which the drive plate is turned to increase or to decrease fueling depends on the type of adjusting plates fitted. f. Torque the drive plate screws evenly to the correct value using adapter tool number 7144-482, spanner tool number 7144-511A, and a torque wrench. When using the recommended spanner tool, the distance between the spanner and the adapter centers is 5 inches (127 mm). The torque spanner and the ring spanner must form a straight line when tightening the screws and care must be taken to ensure the spanner does not contact the side of the inspection aperture. g. Replace and secure the inspection cover, refill the pump, vent as necessary, and re-check the maximum fuel delivery. Repeat until the volumes are within the specified limits. 6-59

S9233-C9-MMA-010 6-26.4.8 Governor Test.

Test the fuel injection pump governor according to the following steps. NOTE

The final governor setting must be carried out with the pump fitted to the engine and in accordance with the engine manufacturer’s instructions. a. Run the pump at more than half the maximum permissible speed of the engine to which it will be fitted and adjust the maximum speed stop until the specified fuel delivery is obtained. This specified volume is less than that at the maximum fuel setting. b. Reduce the speed of rotation, whereupon the fuel delivery should increase to a specified volume approximately equal to the maximum fuel delivery. 6-26.4.9 Transfer Pump Setting. steps.

Check the fuel injection pump’s transfer setting according to the following

NOTE Transfer pump vacuum is checked while the pump is running at a low speed, with the two-way cock in the fuel feed line turned to the position that cuts off the fuel supply and connects the pump inlet to the vacuum gauge. A given depression must be obtained in a specified time. NOTE The pump may need re-priming after this test. a. Transfer pressure is checked at one or more specified speeds by removing one head locating screw and installing adapter tool number 7044-892 into the hydraulic head, and a pipe fitted between the pump and the pressure gauge of the test machine. b. Read the transfer pressure directly from the gauge. 6-26.4.10 Transfer Pump Pressure Adjustment. Transfer pressure is controlled by the regulating valve in the end plate. To adjust the transfer pressure, the operation of the regulating valve can be modified according to the following steps. a. On certain pumps with aluminum end plates, the transfer pressure can be adjusted within the limits of an individual specification in one or both of two ways: by changing the end plate sleeve plug and by adjustment of the screw passing through the plug. b. Several plugs with different step thicknesses are available; the stepped portion in contact with the regulating spring determining the spring compression. The screwed transfer pressure adjuster limits the movement of the regulating piston and so controls the maximum uncovered area of the sleeve port. The first method above modifies transfer pressure characteristics over the lower and middle speed ranges and the second method controls the pressure rise over the upper speed range. 6-60

S9233-C9-MMA-010 NOTE Additional information is given in the individual pump test data. NOTE Tools are available for setting the screwed adjuster in the end plate while the pump is running. If a change of the end plate sleeve plug is necessary to comply with the test plan, the appropriate numbers and the item designation are given in the parts list. c. There is a third type of transfer pressure adjuster that varies the pre-loading of the regulating spring and maximum lift of the piston. It has a spring peg fitted between the adjusting screw and regulating spring. This has the same effect as the first method, but allows more variation and gives easier adjustment. 6-26.4.11 Pressurized Cam Boxes. a. Install the test pressure gauge to the governor housing vent screw hole. On self-venting pumps, this must allow the pressure to be read without restricting the permanent bleeding operation. This can be carried out by using tools from service kit number HF-531. NOTE On some pumps, the cam box is pressurized during running by a spring-loaded ball pressurizing valve located in the back leakage connection in the inspection cover. On pumps designed to provide excess fuel, this operation is carried out by the proportional pressurizing valve. b. Pressure limits are given in the appropriate test data. If pressure is incorrect, ensure the pump is not leaking and there is no reaction in the back leakage passages. If the pressurizing valve is faulty, a new inspection cover complete with valve must be fitted, or on pumps with excess fuel facility, a new proportional valve must be fitted. 6-26.4.12 Advance Device Test. The appropriate test plan for the individual pump specifies the type of advance device fitted and details the tests for the particular unit. All advance devices are tested using special tool number 7244-59 which consists of a gauge with a scale covering 0 to 18 degrees and a feeler pin tool number 724470. Install this tool according to the following steps. NOTE The pump must be re-primed after installing the tool. After priming, operate the throttle and press inward; release the advance gauge pin a few times with the pump running at 100 rpm. a. Remove the small screw from the piston spring cap on the advance device. b. Pass the threaded bushing of the feeler pin assembly through the hole in the tool bracket. c. Insert the end of the plunger into the hole in the spring cap and screw the bushing into the spring cap hole. This will clamp the bracket between the spring cap and the shoulder on the threaded bushing (figure 6-38). 6-61

S9233-C9-MMA-010 d. Zero the gauge by moving the scale relative to the pointer. NOTE The tests outlined in the test data must be applied to ensure that the degree of advance obtained is within the stated limits at the speeds specified. e. To adjust the degree of advance, increase or decrease the thickness of the shims between the piston spring and the spring cap.

Figure 6-38. Advancing Device Test Gauge NOTE On completion of all tests, the drive shaft screw must be slackened and re-torqued three times to the correct value. f. When the tests are satisfactory, remove the special tool and prime the pump. 6-26.4.13 Timing.

Time the fuel injection pump according to the following steps.

a. After completion of tests, remove the pump from the test machine and drain by loosening the inspection cover screws. Remove the inspection cover. b. For internal or external timing, connect the stirrup pipe tool number 7144-262A to the fuel outlet X and to the 6-62

S9233-C9-MMA-010 outlet directly opposite. Install the relief valve tool number 7144-155 to the stirrup pipe and connect the complete tool through a high-pressure pipe to a nozzle testing unit. CAUTION

Do not exceed the specified pressure. Excess pressure can cause damage to the shoe assemblies and adjusting plates. NOTE Normally a pressure of 440 psi (30 atm) rating is installed in the system. However, a higher pressure may be required. To obtain the higher pressures, connect the stirrup pipe directly to the nozzle testing unit, omitting the relief valve. c. Turn the pump drive shaft in the direction indicated on the nameplate until resistance to further movement is felt. This is the timing position. d. Access to the timing ring may be obtained through the inspection cover. Move the timing ring until the straight edge of the timing retaining ring aligns with the mark on the drive plate. Retaining ring with two straight ears are only for spacing; the retaining ring ends are positioned remote from the inspection opening. After carrying out this operation, reinstall the inspection cover and tighten screws securely. 6-26.5 TEST PARAMETERS. 6-26.5.1 Test Conditions. The following figures, for service use only, have been compiled on, and must only be used on, a test machine conforming to the following ISO 400S standards. a. Test oil:

ISO 4113 at temperature 100°35°F (40°2°C).

b. Nozzles:

ISO 4010.

c. Nozzle opening pressure: d. HP outlet connections: e. HP pipes:

2494 psi + 43.5-0 psi (172 + 3, -0 bar). Original.

ISO 4093.2.

f. Test bench drive:

ADC 103.

6-26.5.2 Test Procedure and Conditions. a. Install auto-advance gauge and set to zero before commencing test. b. Electric solenoid to be energized for all tests unless otherwise stated. c. Screw transfer pressure adjuster fully out and then three turns in before commencing test. d. Pump to be free from leaks both when stationary or running. e. Throttle and shutoff levers to be set fully open unless otherwise stated. f. Where marked, use 30 seconds glass draining time and allow fuel to settle for 15 seconds before taking readings unless stated otherwise by the test bench manufacturer’s instructions. 6-63

S9233-C9-MMA-010 g. A .019-inch (0.5-mm) shim is fitted to the piston spring cap on assembly. Do not remove the shim. No additional shimming is required.

NOTE Critical fuel deliveries are given in mm3 /stroke. Hence, the tester must determine the number of stakes applicable in accordance with the manufacturer’s instructions. h. Conduct test procedures according to table 6-5.

Table 6-5. Fuel Injection Pump Test Procedures Test Operation 1. 2. 3. 4. 5. 6.

Requirements

Obtain delivery from all nozzles. Set to 95 lbf/in2 (6.6 bar) using P adjuster 10 lbf/in2 (0.7 bar) minimum 1° 4-3/4° to 5-1/4° 10 to 100 cm3 per 100 strokes time cycle (flow rate 120 to 1200 cm3 /min) 7. Max delivery setting Set to code on Delivery tolerance 0.7 mm3 /stroke. Spread between nameplate. lines not to exceed 7.0 mm3 /stroke. 8. Delivery check 100 Minimum delivery to be as at test (7) minus 25 mm3 /stroke. 9. Cutoff operation 200 Average delivery not to exceed 0.8 cm3 . Shutoff lever closed. 10. Throttle operation 200 Average delivery not to exceed 0.8 cm3 . Throttle lever closed. 11. Delivery check 1300 Record average delivery in cm3 . 12. Governor setting 1430 Set throttle by max. speed adjusting screw to give max. average delivery of 2.0 cm3 . No line to exceed 3.0 cm3 . No stop screw. 13. Delivery check 1300 With throttle set at 200 rpm, average delivery not to be less than at test (11), minus 0.4 cm3 . 14. Governor setting Set half speed on Set throttle to give average delivery of 2.0 cm3 . nameplate. Lock stop screw. Prior to performing test 15, run machine down to 100 rpm and stop. Disconnect transfer pressure gauge and replace head locking bolt. Start machine and prime as at (1). 15. Solenoid shutoff operation 325 De-energize solenoid and wait for 5 seconds before operating trip gear. Average delivery not to exceed 0.5 cm3 .

6-64

Priming Transfer pressure Transfer pressure Low load advance check Full advance Back leakage

RPM 100 1300 100 100 300 1200

S9233-C9-MMA-010 Table 6-5. Fuel Injection Pump Test Procedures - Continued Test Operation

RPM

Requirements

16. Timing internal and external.

Before commencing timing operation, loosen locknut and ease splined drive hub from shaft. Remove pressure end plug 7123-473B and replace with a spring cap plug. Install a suitable length adjusting screw and turn the screw to lock the advance piston in a fully advanced position. Using outlet X pressurized to 795 psi (55 bar) and with pump in this position and indexing tool set to 280 degrees, scribe a line on pump housing flange (use insert 7244-30). Depressurize outlet, then rotate drive a further 18 degrees until indexing tool reads 262 degrees against housing scribe line. Slide shaft locking screw washer into position with large hole diameter located around shoulder diameter of screw, then torque to 60 lb-inch. With pump drive locked in this position, set internal timing retaining ring to plate letter C. Remove the spring cap plug and install the original pressure end plug 7123-473B. 17. Attach appropriate labels to pump housing and drive shaft on completion of testing.

6-26.6 REINSTALLATION. Reinstall the fuel injection pump according to the following steps. Unless otherwise noted, callouts refer to figure 7-28. a. Check to ensure the number 1 cylinder is at TDC. b. Install a new gasket (41) and spacer (42) on the pump mounting flange. c. Ensure key (38) is securely in position on the pump shaft. d. Reinstall the pump onto the mounting studs; take care not to dislodge the key while guiding the shaft through the drive gear. e. Finger-tighten the mounting nuts. The pump must remain free to move within the flange slots. f. Attach pump drive shaft nut (40) and lock washer (39); torque 11 to 15 lb-ft. The pump may rotate slightly due to the gear helix and clearance. This is acceptable providing the pump is free to move on the flange slots and the crankshaft does not move. Do not overtighten; this is not the final torque. g. Loosen the pump lock screw and position the special washer behind the lock screw head. Torque the lock screw to 15 lb-ft. h. Rotate the pump to align the scribe marks and torque the mounting nuts to 18 lb-ft. i. Disengage the timing pin. j. Reinstall the pump support bracket. Finger-tighten all cap screws, before the final torque. NOTE Tighten the bracket-to-block mounting cap screw before tightening the bracketto-injection pump cap screws. Torque all the cap screws to 18 lb-ft. k. Torque the drive gear mounting nut to 48 lb-ft. 6-65

S9233-C9-MMA-010 l. Reinstall the access cap. m. Reinstall the solenoid wiring and all fuel lines. n. Reinstall the coolant recovery tank, if removed. o. Reconnect and adjust the throttle linkage to obtain full stop-to-stop movement. p. Bleed all air from the fuel system. q. Test operate the engine without a load to ensure proper operation and control. 6-27.

INTAKE MANIFOLD COVER.

6-27.1 REMOVAL. Remove the intake manifold cover according to the following steps. Unless otherwise noted, callouts refer to figure 7-18. a. Remove the high-pressure fuel supply lines. Refer to paragraph 6-22.1. b. For the model 6BT5.9-M engine: loosen two hose clamps (1) and disconnect hose section (2) from air intake manifold cover (24). c. For the model 6B5.9-M engine: loosen and remove the air cleaner/silencer prior to removing the intake manifold cover (24). Refer to paragraph 6-11.1. d. Loosen and remove hex head cap screws (23), intake manifold cover (24), and gasket (22). Discard the gasket. e. Clean and inspect parts according to paragraph 6-7.1 and paragraph 6-7.2. 6-27.2 REINSTALLATION. Reinstall the intake manifold cover according to the following steps. Unless otherwise noted, callouts refer to figure 7-18. CAUTION

Loose connections or cracks in the suction side of the intake pipe on turbocharged engines can allow debris to be ingested into the turbocharger compressor and forced into the engine. CAUTION

Leaks at the intake manifold, unsealed bolt holes, or manifold cover gasket can allow dust and dirt to be ingested into naturally aspirated engines. a. Replace gasket (22) and position manifold cover (24) in its proper location. NOTE The hex head cap screws nearest the valve covers must be coated with liquid Teflon. 6-66

S9233-C9-MMA-010 b. Apply liquid Teflon on hex head cap screws and reinstall. Torque cap screws to 18 lb-ft. c. Reinstall the air cleaner/silencer on the model 6B5.9-M engine; refer to paragraph 6-11.2. Then reinstall hose clamps (1) on the intake piping and air tube (3). Also reinstall hose section (2) and tighten the hose clamps. d. Reinstall and bleed the high-pressure fuel supply tubes. Refer to paragraph 6-22.2. e. On the model 6BT5.9-M, test the turbocharger supply air discharge to the intake manifold and flexible hose connections using a liquid soap solution. f. Test the intake manifold cover and pipe fittings for air leaks (figure 6-39).

Figure 6-39. Checking Intake Manifold for Air Leaks 6-28.

TURBOCHARGER.

6-28.1 REMOVAL. to figure 7-18.

Remove the turbocharger according to the following steps. Unless otherwise noted, refer

a. Remove the oil supply line, hose clamps, and drain line with gasket from the turbocharger (figure 6-40). Discard the gasket. b. Loosen and remove hose clamps and hose (4 and 5). c. Drain at least two gallons of coolant from the engine; refer to paragraph 6-14.1. d. Loosen upper hose clamp (7) and disconnect hose (8) from the turbocharger. Remove the hose clamp. NOTE Ensure the sea water supply valve is shut. e. Drain the oil cooler (figure 7-17). Loosen and remove pipe plug (2, figure 7-19) from the exhaust elbow. f. Loosen and remove hose clamps (3, figure 7-19) and elbow hose (1, figure 7-19). g. Loosen and remove four cap screws (4, figure 7-19) and disconnect the exhaust elbow from the turbocharger and the exhaust piping. 6-67

S9233-C9-MMA-010 h. Refer to paragraph 6-11.1 and remove the air cleaner/silencer. i. Loosen and remove four cap screws (6), the turbocharger, and gasket (9). Discard the gasket. j. Place the turbocharger on a clean work bench. k. Cover exhaust manifold (12) open end with a blank gasket/flange.

6-28.2 DISASSEMBLY. Disassemble the turbocharger according to the following steps. Unless otherwise noted, callouts refer to figure 7-20.

a. Scribe housings (3, 25, and 33) for reassembly in the same position as at disassembly.

CAUTION

To prevent damage to equipment, a soft-jawed vise, cloth, or cardboard should be used to protect parts. b. Clamp the turbocharger in a bench vise with soft jaws. c. Loosen V-band nut (4) and remove compressor housing V-band clamp (5). Remove and discard seal (6). d. Remove compressor housing (3) and check for impeller contact. e. Remove impeller lock nut (7). Turn the nut to the right to loosen. The nut and shaft have left-hand threads. f. Remove impeller (8) and inspect the blades for damage.

6-68

S9233-C9-MMA-010

Figure 6-40. Removing Supply Lines to the Turbocharger NOTE The wheel and shaft assembly is balanced as a unit. Both must be replaced if either is damaged. g. Remove diffuser cap screws (24) and lock plates (23). h. Remove diffuser (9) and rectangular ring seal (10). Discard the O-ring. i. Remove oil slinger (12) and split ring seal (11). Discard the seal. Check the diffuser for cracks or excessive wear. j. Remove oil baffle (13). 6-69

S9233-C9-MMA-010 NOTE The thrust bearing is a disposable item and is not be reused under any circumstance. k. Remove thrust bearing (15) and retaining screws (14). Discard the bearing. l. Remove thrust collar (16). Check the collar for excessive wear. m. Remove turbine housing screws (19), lock plates (20), and clamping plates (21). n. Remove bearing housing (25). NOTE The wheel and shaft assembly is balanced as a unit. If the turbine blades or shaft are damaged or exhibit excessive wear, the entire assembly must be replaced. o. Remove turbine shaft and wheel (28) and heat shield (26). Check the turbine blades and shaft for excessive wear. p. Remove and discard seal split ring (27).

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. q. Remove and discard outer retaining rings (17). r. Remove and discard shaft bearings (18). s. Remove and discard inner retaining rings (17). 6-28.3 CLEANING AND INSPECTION.

Clean and inspect the turbocharger according to the following steps.

a. Using a stiff bristled, nylon brush and solvent, thoroughly clean all parts. Do not use a wire brush to clean the compressor wheel. b. Remove carbon build-up from the housing with a scraper and a medium-grit emery cloth. c. Polish the bearing surfaces with a crocus cloth.

WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. d. Rinse all pans in a clean solvent and dry with compressed air. e. Inspect all parts after cleaning for cracks, excessive wear, and overheating. 6-70

S9233-C9-MMA-010 f. Measure the shaft bearing diameter, min. 0.432 inches. g. Inspect the exhaust manifold as follows: 1. Inspect the gasket surfaces for gouges, scratches, or burn out. 2. Place a straight-edge across the exhaust ports to measure warpage. Using a feeler gauge, measure between the straight-edge and the manifold surface. The maximum allowable warpage is 0.004 inch.

6-28.4 REASSEMBLY. Reassemble the turbocharger according to the following steps. Unless otherwise noted, callouts refer to figure 7-20.

a. Install seal split ring (27) and lubricate the groove with engine oil. b. Install heat shield (26).

CAUTION

To prevent damage to equipment, a soft-jawed vise, cloth, or cardboard should be used to protect parts. c. Clamp a 16-mm socket in a soft-jawed vise and position the shaft in the socket.

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. d. Reinstall inner retaining rings (17) into bearing housing (25). Ensure the beveled face is toward the bearing. e. Lubricate and install one turbocharger bearing (18) and outer retainer ring (17). Ensure the beveled face is toward the bearing. f. Lubricate and install the other turbocharger bearing (18) and outer retainer ring (17). Ensure the beveled face is toward the bearing. g. Reassemble turbine shaft and wheel (28) and heat shield (26) to bearing housing (25). Rotate the housing as downward pressure is applied to assist in properly seating seal ring (27). See figure 6-41.

6-71

S9233-C9-MMA-010

Figure 6-41. Seating Piston Ring NOTE All balance marks must be aligned during reassembly to ensure the wheel and shaft assembly remain balanced. h. Reinstall the thrust collar. Align the balance marks. Mark the top surfaces to ensure alignment can be verified after installing the thrust bearing. See figure 6-42.

Figure 6-42. Aligning Balance Marks i. Lubricate and install thrust bearing (15) and screws (14). Torque cap screws to 40 lb-inch. j. Reinstall oil baffle (13). Check the balance mark alignment. k. Reinstall seal ring (11) on oil slinger (12). l. Mark the top surface of the oil slinger in line with the balance mark. m. Lubricate and reinstall the oil slinger into diffuser (9). n. Install rectangular ring seal (10) on the diffuser. o. Reinstall the diffuser. Ensure the balance marks on the oil slinger and shaft are aligned. p. Align the balance marks and install impeller (8). Use care not to move the bearing housing. 6-72

S9233-C9-MMA-010 q. Reinstall locknut (7) onto shaft. Do not allow the impeller to turn when installing the nut. The impeller nut and shaft have left-hand threads. Torque to 120 lb-inch. r. Reinstall bearing housing (25) into turbine housing (33). s. Align the scribe marks of the housings (25 and 33). t. Apply antiseize compound to the cap screw threads (19 and 24). u. Reinstall clamping plates (21), lock plates (20), and cap screws (19). Torque cap screws to 100 lb-inch. v. Reinstall lock plates (23) and cap screws (24). Torque cap screws to 50 lb-inch and bend the lock plate tabs over the cap screws. w. Using a dial indicator, measure shaft end play (minimum 0.001 inch, maximum 0.003 inch). See figure 6-43. x. Using a dial indicator, measure radial clearance of the shaft (minimum 0.012 inch, maximum 0.018 inch). See figure 6-44. y. Reinstall compressor housing (3) with rectangular seal ring (6) and V-band clamp (5). Apply antiseize compound to the V-band bolt threads. Torque V-band clamp nut (4) to 120 lb-inch. Tap against the V-band clamp in four places around its circumference. Torque again to specified value.

Figure 6-43. Measuring Turbocharger Shaft End Play

6-73

S9233-C9-MMA-010

Figure 6-44. Measuring Radial Clearance 6-28.5 REINSTALLATION. Reinstall the turbocharger according to the following steps. Unless otherwise noted, callouts refer to figure 7-18. a. Remove exhaust manifold (12) end blank flange. b. Apply antiseize compound on mounting cap screws (6). c. Install new turbocharger gasket (9) and the turbocharger on exhaust manifold (12) using four mounting cap screws (6). Torque to 24 lb-ft. d. If necessary, loosen turbine housing cap screws (24, figure 7-20) and position bearing housing (25, figure 7-20) to the turbocharger oil drain tube and gasket (figure 6-40). Reinstall two cap screws into the oil drain tube flange, gasket, and bearing housing. Torque to 18 lb-ft. e. If the oil drain tube in the block was removed, apply sealant to the tube sealing surfaces and reinstall the tube in the block so it is aligned with the turbocharger drain tube. f. Position the oil drain hose to connect the oil drain tubes and torque the hose clamps (figure 6-40). g. If loosened, torque turbocharger turbine housing cap screws (24, figure 7-20) to 100 lb-inch. h. Reinstall upper hose clamp (4) and connect hose (5) onto air tube (3). Tighten the hose clamp. i. If required, loosen compressor housing V-band clamp (4, figure 7-20) and position the housing to align with air tube (3) and connector hose (5). j. Retighten V-band clamp after alignment and bend the tabs of lock plates (20, figure 7-20) over the cap screw heads. Torque the cap screws to 50 lb-inch. k. Reinstall lower hose clamp (4) and reconnect to the turbocharger; torque clamps to a value of 6 lb-ft. NOTE Turbocharger must be pre-lubricated. l. While spinning the turbocharger impeller to distribute oil in the bearings, pour two to three ounces of clean engine oil into the oil inlet fitting on top of the turbocharger. 6-74

S9233-C9-MMA-010 m. Reinstall the oil supply line and torque the fitting cap screws securely to 26 lb-ft (figure 6-40). n. Apply antiseize compound to four cap screws (4, figure 7-19). Position exhaust elbow (figure 7-19) in place against the turbocharger. Reinstall mounting cap screws (4, figure 7-19) and tighten. o. Apply liquid Teflon to pipe plug (2, figure 7-19). Reinstall and tighten. Reconnect exhaust piping to exhaust elbow. p. Reinstall lower elbow hose clamp and elbow hose (3 and 4, figure 7-19) on the exhaust outlet connection and tighten. q. Reinstall upper hose clamp (3, figure 7-19) and reconnect upper elbow hose end to the heat exchanger (1, figure 7-15) sea water discharge to the exhaust elbow connection. r. Shut the transmission’s oil cooler (figure 7-17) sea water drain plug. s. If required, open the sea water inlet valve. t. If required, refill the engine with fresh water. 6-29.

OIL PRESSURE REGULATOR VALVE.

6-29.1 DISASSEMBLY. Disassemble the oil pressure regulator valve according to the following steps. Unless otherwise noted, callouts refer to figure 7-23. a. Remove plug (8), washer (9), spring (10), and plunger (11). b. Clean and inspect the plunger and bore for nicks and scratches. Ensure the valve moves freely in the bore. NOTE The spring height limit for an open valve is 1.574 inches and 1.77 inches for assembled valve height. c. Check the spring height (figure 6-45).

Figure 6-45. Checking Spring Height 6-29.2 REASSEMBLY. Reassemble the oil pressure regulator valve in the reverse order of disassembly. Torque threaded plug to 74 lb-ft. 6-75

S9233-C9-MMA-010 6-30.

OIL COOLER.

6-30.1 REMOVAL. refer to figure 7-23.

Remove the oil cooler according to the following steps. Unless otherwise noted, callouts

a. Locate a suitable empty container under filter (1) and lube oil filter head (2). b. Remove oil filter cartridge (1) by turning the filter canister counterclockwise. Clean the filter head gasket surface. c. Refer to paragraph 6-12.1 and remove the alternator. d. Drain coolant from the engine; refer to paragraph 6-14.1, procedure step (a). e. Support water transfer tube (6, figure 7-15) and loosen water transfer tube forward hose clamp (7, figure 7-15). Loosen water transfer connection (18, figure 7-18) and hose (17, figure 7-18) from the inlet water connection. f. Disconnect water transfer tube hose (4, figure 7-15) from inlet water connection (1, figure 7-16). g. Loosen and remove three cap screws (4, figure 7-16) and remove the water inlet connection from the cylinder block. Remove and discard ring seal (2, figure 7-16). NOTE The model 6B5.9-M engine does not have an oil supply line to the turbocharger. The oil filter head outlet is plugged instead. h. Remove the turbocharger oil supply fitting from oil filter head (2) to gain access to oil cooler mounting screws (12). i. Remove oil filter head (2), gaskets (5 and 7), and cooler core (6). j. Clean all sealing surfaces. k. Using pressurized (70 psi) air, check the cooler core for leaks. l. If necessary, remove bypass valve (4) and install a new valve. Drive the new valve in until it bottoms against the step in the bore. 6-30.2 REINSTALLATION. callouts refer to figure 7-23.

Reinstall the oil cooler according to the following steps. Unless otherwise noted,

a. Install oil cooler gaskets (5 and 7), core (6), and oil filter head (2) using cap screws (12). Torque the cap screws securely. b. Lubricate the oil filter oil seal with clean oil and install a new oil filter cartridge (1) by turning the canister clockwise onto its mounting stud 1/4 turn past gasket contact. c. Reinstall the turbocharger oil supply fitting and line on the model 6BT5.9-M engine. d. Install a new ring seal (2, figure 7-16) and reinstall the water inlet connection. Reconnect the water inlet connection. e. Reinstall the alternator and reconnect the wiring in reverse order of removal. Refer to paragraph 6-12.1. f. Refill the coolant system and operate the engine to check for leaks. g. Operate the engine to check for front oil seal leakage. 6-76

S9233-C9-MMA-010 6-31.

CRANKSHAFT OIL SEALS.

6-31.1 FRONT CRANKSHAFT OIL SEAL. 6-31.1.1 Removal. Remove the front crankshaft oil seal (gear cover in place) according to the following steps. Unless otherwise noted, callouts refer to figure 7-13. a. Loosen and remove hex head cap screws and belt guard (2 and 1, figure 7-1) from engine. b. Using a 1/2-inch square drive ratchet handle, release V-belt (11, figure 7-3) tension and remove the V-belt. c. Loosen and remove four hex head cap screws (1, figure 7-12) and vibration damper (2 and 3, figure 7-12) from the crankshaft. d. Drill two, 1/8-inch holes into oil seal (15) casing 180 degrees apart. e. Using a slide hammer and a number 10 metal screw inserted in the holes, remove oil seal (15). f. Clean and dry the sealing surface of the oil seal. 6-31.1.2 Reinstallation. Reinstall the front crankshaft oil seal (gear cover in place) according to the following steps. Unless otherwise noted, callouts refer to figure 7-13. NOTE Teflon seals must be installed on a clean, dry sealing surface. a. Using the seal starter ring, install oil seal (15) over the crankshaft. Coat the O.D. of the seal casing with Loctite 277 or equivalent. b. Install oil seal (15) using the seal driver. c. Reinstall crankshaft pulley (2 and 3, figure 7-12) using cap screws (1, figure 7-12). Torque cap screws to 101 lb-ft. d. Reinstall the drive belt and front cover. Torque cap screws to 18 lb-ft. 6-31.2 REAR CRANKSHAFT OIL SEAL. 6-31.2.1 Removal. Remove the rear crankshaft oil seal (flywheel housing installed) according to the following steps. Unless otherwise noted, callouts refer to figure 7-30. a. Refer to paragraph 6-9.1 and remove the starting motor. NOTE Ensure the transmission has been removed from the engine and that the engine is adequately supported. b. Loosen and remove eight hex head cap screws (1). c. Remove flywheel (4, figure 7-29). 6-77

S9233-C9-MMA-010 d. Drill two, 1/8-inch holes in the oil seal casing 180 degrees apart. e. Using a slide hammer and a number 10 metal screw, remove oil seal (6). f. Clean and dry the sealing surface. 6-31.2.2 Reinstallation. Reinstall the rear crankshaft oil seal (flywheel housing installed) according to the following steps. Unless otherwise noted, callouts refer to figure 7-30. NOTE Do not use Loctite on the rear oil seal. a. Use the seal starter ring and install the seal over the crankshaft. Use a mild soap solution on the O.D. of the seal to ease installation. NOTE Teflon oil seals must be installed on a clean, dry surface. b. Install the oil seal with the oil seal driver. Alternately strike the driver at the 3-, 6-,9-, and 12-o’clock positions to prevent the oil seal from binding. c. Reinstall flywheel (4, figure 7-29) using cap screws (1). Torque the cap screws to 101 lb-ft in proper sequence (paragraph 6-43.1) d. Operate the engine to check for oil leaks. 6-32.

CAM FOLLOWER COVER.

6-32.1 REMOVAL. Remove the cam follower cover according to the following steps. Unless otherwise noted, callouts refer to figure 7-31. a. Loosen the fuel drain fittings. Refer to paragraph 6-24.1. b. Remove the fuel filter. Refer to paragraph 6-23.1. c. Slide spring hose clamp (4) down the hose (5) and slip the hose off breather baffle (2). d. Loosen and remove hex head cap screws (7), grommet seals (8), push rod cover (cam follower cover) (3), and gasket (1) from the cylinder block. e. Clean all gasket sealing surfaces. 6-32.2 REINSTALLATION. Reinstall the cam follower cover according to the following steps. Unless otherwise noted, callouts refer to figure 7-31. NOTE Some gaskets have an adhesive back. a. Pull off the protective cover on the gasket, if so equipped, to expose the adhesive surface. 6-78

S9233-C9-MMA-010 b. Attach cam follower cover gasket (1) to cover (3). Apply gasket sealant to the cylinder block side of the gasket. c. If a rubber cam follower cover gasket is used, it must be installed with the word FRONT toward the front of the cover and the word FORWARD on the bottom and pointing toward the front of the cover. d. Reinstall cam follower cover gasket and breather baffle (2) with mounting hex head cap screws (7) and grommet seals (8). When installing the cam follower cover, position the cap screw seals between the fuel drain lines and cam follower cover. See figure 6-46.

Figure 6-46. Positioning Fastener Devices e. Torque the mounting hex head cap screws to 18 lb-ft. f. Fill with clean fuel and reassemble the fuel filter to the fuel filter head. Refer to paragraph 6-23. g. Torque the fuel drain fitting and bleed the fuel system. Refer to paragraph 6-25.7. h. Reconnect hose (5) to cam follower cover and breather baffle (2). i. Test run the engine and check for leaks. 6-33.

OIL PRESSURE TRANSDUCER.

Replace the oil pressure transducer according to the following steps. Unless otherwise noted, callouts refer to figure 7-6. a. Tag and disconnect the wires from oil pressure transducer (5). b. Remove the oil pressure transducer by turning counterclockwise. c. Reinstall in the reverse order of removal. d. Test while running the engine. 6-34.

VALVE COVER.

Remove/reinstall the valve covers according to the following steps. Unless otherwise noted, callouts refer to figure 7-32. a. Remove special hex head cap screws (1), O-ring seals (2), valve covers (3), and gasket (4). Discard O-ring seals and gaskets. 6-79

S9233-C9-MMA-010 b. Reinstall in the reverse order of removal. Torque the cap screws to 18 lb-ft. 6-35.

ROCKER LEVER ASSEMBLY.

6-35.1 REMOVAL. Remove the rocker lever assembly according to the following steps. Unless otherwise noted, callouts refer to figure 7-33. a. Loosen nuts (5) on the rocker lever and setscrews (9). Back off on the screws until they stop. b. Remove hex head cap screws (2) from rocker lever support (1). c. Remove hex head cap screws (3) from the rocker lever supports and remove the support and rocker assemblies from head (9, figure 7-34). d. Remove push rods (10). 6-35.2 DISASSEMBLY. Disassemble the rocker lever assembly according to the following steps. Unless otherwise noted, callouts refer to figure 7-33.

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. a. Remove retaining rings (7) and washers (8). b. Remove rocker levers (4 and 11). NOTE The rocker shaft and pedestal is serviced as an assembly. Do not disassemble. c. Remove nut (5) and setscrew (9) from rocker levers (4 and 11). 6-35.3 CLEANING AND INSPECTION. lowing steps.

Clean and inspect the rocker lever assemblies according to the fol-

WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. a. Clean all parts in a strong solution of detergent and hot water. Rinse in clean hot water and dry with compressed air. 6-80

S9233-C9-MMA-010 b. Inspect the rocker levers for cracks and excessive wear in the bore and valve stem contact surface. c. Measure the rocker lever bore (minimum 0.7480 inch; maximum 0.7500 inch). d. Inspect the pedestal and shaft for cracks and excessive wear. e. Measure the shaft diameter (minimum 0.7456 inch; maximum 0.7470 inch). 6-35.4 REASSEMBLY. Reassemble the rocker lever assemblies according to the following steps. Unless otherwise noted, callouts refer to figure 7-33. a. Reinstall setscrew (9) and nut (5) in rocker levers (4 and 11). b. Lubricate the rocker lever shaft with clean engine oil. NOTE Ensure the intake and exhaust rocker levers are in the correct position as when removed. c. Position the levers on the rocker shaft. d. Reinstall plain washers (8).

WARNING

To prevent serious eye injury while removing/installing retailing ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. e. Install retaining rings (7). 6-35.5 REINSTALLATION. Reinstall the rocker lever assembly according to the following steps. Unless otherwise noted, callouts refer to figure 7-33. CAUTION

To prevent damage to equipment, the push rods must be correctly seated in the valve tappets. a. Insert push rods (10) into the engine block push rod bores; ensure the push rods are correctly and securely seated in valve tappets (6, figure 7-36). b. Position rocker lever support (1) complete with the valve rocker levers (4 and 11) installed on the engine head mount pad; position both rocker lever adjustment screws (9) in applicable push rod (10) socket, and ensure the valve rocker lever contact pad aligns with the stems of valves (7 and 8, figure 7-34). c. Insert hex head cap screws (2 and 3) through the rocker lever support assembly and tighten securely. d. Turn the intake valve adjustment screws, as required, to obtain 0.010-inch clearance between the valve rocker lever contact pads and valve stems; turn the exhaust valve adjustment screws as required to obtain 0.020-inch 6-81

S9233-C9-MMA-010 clearance between the rocker lever pads and the valve stems. Measure the clearance with standard feeler gauges. Lock adjustment screws by tightening the locking nuts while holding the adjustment screw with a screwdriver. Refer to paragraph 6-5 for the complete valve adjustment procedure. 6-36.

CYLINDER HEAD.

6-36.1 REMOVAL. Remove the cylinder head according to the following steps. Unless otherwise noted, callouts refer to figure 7-34. a. If necessary, remove fuel injection nozzles. Refer to paragraph 6-25.1. b. If necessary, remove the exhaust manifold (12, figure 7-18). c. If necessary, remove rocker lever assemblies. Refer to paragraph 6-35.1. d. Remove the remaining cylinder hex head cap screws (15 and 16) working from the center to each end of the head evenly.

WARNING

To prevent injury or death, ensure extreme care and proper lifting devices are used during handling. The equipment is heavy. e. Remove cylinder head (9) and gasket (4) from the cylinder block (figure 7-37). 6-36.2 DISASSEMBLY. Disassemble the cylinder head according to the following steps. Unless otherwise noted, callouts refer to figure 7-34. a. Identify and tag or mark the valves as to their location.

WARNING

To prevent serious eye injury, wear safety eye protection when removing springs under pressure. b. Using a valve spring compressor, compress valve springs (11) and remove collets (13). c. Slowly release the valve spring and remove retainer (12) and spring (11). d. Remove valves (7 or 8), whichever applies. Keep the valves in a labeled rack. e. Repeat step b and step c for the remaining collets, retainers, springs, and valves. f. Remove valve stem seals (14). 6-36.3 CLEANING AND INSPECTION.

Clean and inspect the cylinder head according to the following steps.

a. Clean carbon from the injection nozzle seat with a nylon or brass brush. 6-82

S9233-C9-MMA-010 b. Remove gasket residue from all gasket surfaces.

WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. c. Wash the cylinder head in hot soapy water solution. Rinse with clean water and dry with compressed air. d. Polish the head gasket sealing surfaces with a sanding block and 400-grit sand paper. Clean the head of all grit after sanding. e. Inspect the valve guides for scuffing or scoring. f. Inspect the valve guide bore (minimum 0.3157 inch; maximum 0.3185 inch). g. Inspect the head surface for nicks, erosion, etc. h. Inspect for head distortion using a straight-edge and a feeler gauge. Variations of 0.0039 inch within a 2 inch diameter area or 0.003 inch overall, end-to-end or side-to-side are acceptable. If these limits are exceeded, the head must be replaced. i. Clean and inspect the valves according to the following steps. 1. Clean the valve heads with a soft wire wheel. Remark valve locations, as necessary. 2. Polish the valve stem with a crocus cloth. Remark the valves according to cylinder head location. 3. Inspect for abnormal wear on the valve heads and stems. Measure the valve stem diameter (minimum 0.3126 inch; maximum 0.3142 inch). Mark the new valve(s), if required, for the replacement location. 4. Check for and replace bent valve(s). Mark new valve(s) if required, for replacement location. 5. Regrind valve faces, as necessary; intake valves at 30 degrees and exhaust valves at 45 degrees. 6. Measure valve face rim thickness; minimum thickness is 0.031 inch. 7. Inspect the valve stem tip for flatness. Resurface the tip, if necessary. j. Insert the valve springs as follows: 1. Measure the valve spring free length. The limit is 2.190 inches and maximum spring inclination is 0.039 inch. 2. Measure the valve spring tension. A minimum load of 65 to 72.2 lbs is required to compress the spring to a height of 1.94 inches. Replace any springs that do not pass this test. 6-36.4 VALVE SEAT GRINDING.

Grind the valve seats according to the following steps. NOTE

Previously re-ground seats can be replaced with new seats. a. Install the valves (one at a time) without springs, in the designated location. b. Measure the depth of each valve (minimum 0.039 inch; maximum 0.060 inch). c. Grind valve seats to remove scores, scratches, and burns. Seat angles are 30 degrees for intake and 45 degrees for exhaust. 6-83

S9233-C9-MMA-010 d. Install the valves in their respective bores and re-measure valve depth. Record the depth of each valve. Subtract the recorded depth before grinding from the recorded depth after grinding to obtain the grinding depth. Grinding depth limit is 0.010 inch. Mark an X on the cylinder head to indicate reground valve seats. Replace valves if the valve depth is not within specifications. e. Apply a light coat of lapping compound to each valve. Lap each valve to its respective valve seat. f. Clean the valve and seat after lapping. Measure the valve seat width (minimum 0.060 inch; maximum 0.080 inch). g. If required, grind the valve seat with a 60-degree stone then a 15-degree stone to center the seat of the valve face. Maintain the valve seat width limits (minimum 0.060 inch; maximum 0.080 inch). 6-36.5 REASSEMBLY. Reassemble the cylinder head according to the following steps. Unless otherwise noted, callouts refer to figure 7-34. NOTE Ensure all cylinder head components are cleaned prior to reassembly. a. Reinstall valve stem seals (14). b. Before reinstalling the valve, lubricate the valve stems with 90-weight engine oil.

WARNING

To prevent serious eye injury, wear safety eye protection when removing springs under pressure. c. Using a spring compressor, reinstall and compress valve spring (11) and retainer (12) and reinstall collets (13). Release the spring tension after reassembly; tap the valve stems to ensure the collets are seated. 6-36.6 REINSTALLATION. Reinstall the cylinder head according to the following steps. Unless otherwise noted, callouts refer to figure 7-34. a. If removed, reinstall the two cylinder head dowels. Drive the dowels to the bottom of the dowel bore. b. Ensure the cylinder head is clean and free of surface imperfections on the gasket surface. c. Ensure head gasket (4) is correctly aligned with the holes in the block and position the head over the dowels. d. Carefully place cylinder head (9) on the block and seat it on the dowels. e. Position the push rods into the valve tappets. f. Lubricate the push rod sockets with clean engine oil. g. Lubricate the valve stems with clean engine oil. h. Completely loosen the rocker lever adjusting setscrews (9, figure 7-33). 6-84

S9233-C9-MMA-010 i. Reinstall rocker lever supports (1, figure 7-33). Ensure the supports are aligned with the locating dowels in the head. j. Using clean engine oil, lubricate the hex head cap screw threads and under the cap screw heads. k. Reinstall hex head cap screws (2, figure 7-33) finger-tight. l. Using clean engine oil, lubricate the hex head cap screw threads and under the cap screw heads. m. Reinstall hex head cap screws (3, figure 7-33) finger-tight. n. Using clean engine oil, lubricate the remaining hex head cap screws threads and under the heads. o. Reinstall hex head cap screws (15 and 16) finger-tight. p. Torque the cylinder head hex head cap screws (figure 6-47) as follows: 29 lb-ft; 62 lb-ft; 92 lb-ft. q. Torque pedestal hex head cap screws (2 and 3, figure 7-33) at 18 lb-ft.

Figure 6-47. Cylinder Torque Sequence r. Adjust the valve clearance. Refer to paragraph 6-5. s. Reinstall the valve covers in reverse order of removal, paragraph 6-34. t. Reinstall the exhaust manifold and any other accessories removed. 6-37.

OIL PAN.

Remove/reinstall the oil pan according to the following steps. Unless otherwise noted, callouts refer to figure 7-35. NOTE Ensure all oil has been drained from the engine sump. a. Rotate the engine on the overhaul stand so oil pan (9) is on top. b. Remove hex head cap screws (3), the oil pan, and gasket (16). Discard the gasket. c. Reinstall the oil pan in the reverse order of removal. Use a new gasket. 6-38.

SUCTION TUBE.

Remove/reinstall the suction tube according to the following steps. Unless otherwise noted, callouts refer to figure 7-35. 6-85

S9233-C9-MMA-010 a. Remove oil pan (9). b. Remove hex head cap screws (12 and 13), suction connection (11), and gasket (10). Discard the gasket. c. Reinstall the suction tube in the reverse order of removal. Use a new gasket. Torque cap screws to 18 lb-ft. d. Reinstall the oil pan.

6-39.

VALVE TAPPET.

6-39.1 REMOVAL.

Remove the valve tappet (head installed) according to the following steps.

a. Insert wooden dowels of sufficient diameter and length into the push rod tube holes and into the top of each tappet securely. When properly installed, the dowels can be used to pull the tappets up and should not be able to be pulled out without considerable force. NOTE Remove only one tappet at a time. b. Pull tappets up and wrap a rubber band around the top of the dowel rods (figure 6-48). This will prevent the tappets from dropping down when the camshaft is removed. c. Remove the camshaft; refer to paragraph 6-40.1. d. Insert a trough made out of plastic half pipe (PVC) to the full length of the cam bore (figure 6-49). e. Remove the rubber band from two companion tappets. Secure the dowel for the tappet not being removed to the nearest adjoining dowel.

Figure 6-48. Retaining Valve Tappets 6-86

S9233-C9-MMA-010

Figure 6-49. Valve Tappet Removal f. Pull the wooden dowel from the tappet bore; allow the tappet to fall into the trough. g. Ensure the tappet is laying over (figure 6-49) in the trough before the trough is removed. Carefully pull the trough and tappet from the cam bore and remove the tappet. h. Repeat step d through step f until all tappets are removed.

6-39.2 CLEANING AND INSPECTION.

Clean and inspect the valve tappets according to the following steps.

a. Inspect the socket, stem, and face for pitting, cracks, or excessive wear. If excessive wear is noted on the face contact surface, replace the tappet. b. Measure the valve tappet stem diameter (minimum 0.627 inch; maximum 0.629 inch).

6-39.3 REINSTALLATION.

Reinstall the valve tappets (head installed) according to the following steps.

a. Insert the plastic trough the full length of the cam bore. b. Feed the installation tool down the tappet bore and into the plastic trough (figure 6-50). c. Feed the installation tool through the cam bores by carefully pulling the plastic trough and installation tool out of the cam bore. d. Lubricate the tappets with Lubriplate 105. e. Insert the installation tool into the tappet. 6-87

S9233-C9-MMA-010

Figure 6-50. Inserting Installation Tool into Tappet Bore NOTE To aid in removing the installation tool after the tappet is installed, work the tool in and out of the tappet several times prior to installation. f. Slide the trough back into the cam bore. g. Pull the tool and tappet through the cam bore and up into the tappet bore (figure 6-51). If difficulty is experienced in getting the tappet to make the bend from the trough up into the tappet bore, due to the webbing of the block, pull the trough out just enough to allow the tappet to drop down and align itself, then pull the tappet up into the bore. h. After the tappet has been pulled into position, slide the trough back into the cam bore and rotate it 1/2 turn. This will position the round side of the trough up, which will hold the tappet in place. i. Remove the installation tool from the tappet.

Figure 6-51. Pulling Installation Tool/Tappet through Cam Bore j. Install a wooden dowel into the top of the tappet and wrap a rubber band around the dowel to secure the tappet in place. 6-88

S9233-C9-MMA-010 k. Repeat step b through step j for all tappets. l. Reinstall the camshaft. Refer to paragraph 6-40.5. 6-40.

CAMSHAFT.

6-40.1 REMOVAL. refer to figure 7-36.

Remove the camshaft according to the following steps. Unless otherwise noted, callouts

a. Remove the cylinder head. Refer to paragraph 6-36.1. b. Rotate engine on stand and remove the oil pan. Refer to paragraph 6-37. NOTE Keep the adjoining gear from moving when checking the camshaft backlash or the readings will be the total of both gears. c. Prior to removing camshaft (5), measure the camshaft backlash as follows: 1. Position a dial indicator on a tooth of camshaft gear (1). 2. When checking the backlash, hold the adjoining gear (fuel pump drive) from moving. 3. Record the camshaft gear backlash. Mark the camshaft gear and crankshaft gear for further analysis if the backlash exceeds limits; gear backlash limit A is 0.003 inch to 0.013 inch. See figure 6-52.

Figure 6-52. Measuring Camshaft Gear Backlash 4. Repeat steps 2 and 3 while holding the crankshaft gear in position. d. Remove hex head cap screws (2). e. Remove camshaft (5) and thrust support (3) from the cylinder block. Do not drop the thrust support. f. Remove valve tappets (6). 6-40.2 CLEANING AND INSPECTION.

Clean and inspect the camshaft according to the following steps.

a. Clean the camshaft and gear with an approved solvent and a clean, lint-free rag. 6-89

S9233-C9-MMA-010 b. Inspect the fuel transfer pump lobe, valve lobes, and bearing journals for cracking, pitting, or scoring. c. Inspect the gear teeth for pitting and cracks at the root of the teeth. d. Measure the bearing journals and valve lobes. Lobe diameters at peak: intake (minimum 1.861 inch; maximum 1.866 inch); exhaust (minimum 1.850 inch; maximum 1.855 inch); transfer pump (minimum 1.410 inch; maximum 1.422 inch); and journal diameter (minimum 2.1245 inches; maximum 2.1265 inches). 6-40.3 CAMSHAFT GEAR. Replace the camshaft gear according to the following steps. Unless otherwise noted, callouts refer to figure 7-36. a. Using a hydraulic press, remove gear (1) and key (4) from camshaft (5). b. Remove any burrs and smooth rough surfaces caused by removing the gear from the camshaft. c. Reinstall key (4) in the camshaft keyway. d. Lubricate the camshaft gear surface with Lubriplate 105. e. Heat the gear in a 250°F oven at for 45 minutes.

WARNING

To prevent injury, exercise extreme care and wear insulated gloves when handling heated solutions or metal. f. Reinstall gear (1) onto the camshaft. Ensure the timing marks are facing away from the camshaft and the gear is seated against the camshaft shoulder. 6-40.4 CAMSHAFT BUSHING. Replace the camshaft bushing according to the following steps. Unless otherwise noted, callouts refer to figure 7-37. NOTE The limit of wear on the number 1 bushing is the same as for the other bores without bushings. NOTE If the bores without the bushing are worn beyond the limit, the cylinder block must be replaced. a. Replace the camshaft bushing if it exceeds the wear limit. The limit is 2.1324 inches. b. Remove camshaft bushing (14) with a bushing remover and hammer. NOTE Mark the cylinder block so the oil hole in the block and bushing can be aligned when the bushing is installed. 6-90

S9233-C9-MMA-010 c. Install new camshaft bushing (14) so it is even with the front face of the cylinder block. Ensure the oil holes align. d. Measure the installed camshaft bushing. The limit is minimum 2.1295, maximum 2.1314 inches. 6-40.5 REINSTALLATION. callouts refer to figure 7-36.

Reinstall the camshaft according to the following steps. Unless otherwise noted,

a. Lubricate the camshaft bores with Lubriplate 105. b. Lubricate the camshaft journals and lobes with Lubriplate 105. c. Install the camshaft and gear assembly into the cylinder block up to the last journal. Ensure the timing marks are aligned. d. Lubricate thrust plate (3) with Lubriplate 105 and install the thrust plate. e. Push camshaft (5) fully into the cylinder block. f. Install thrust plate hex head cap screws (2). Torque the cap screws to 18 lb-ft. NOTE The end play is controlled by the thickness of the thrust plate and the groove in the camshaft. g. Using a dial indicator, measure the camshaft end play. The end play limits are 0.007 to 0.011 inch. h. Ensure the gear backlash is correct for any replaced gears. Measure the gear backlash with a dial indicator. The limits are 0.003 to 0.013 inch. 6-41.

LUBE OIL PUMP.

6-41.1 REMOVAL. Remove the lube oil pump according to the following steps. Unless otherwise noted, callouts refer to figure 7-22. a. Refer to paragraph 6-13.1 and remove the belt guard, drive belt, and vibration damper. b. Loosen and remove sixteen hex head cap screws (12, figure 7-13). Remove oil seal (15, figure 7-13). Discard the gear cover gasket and oil seal. c. Position a dial indicator on a tooth of the oil pump and measure the backlash of the crankshaft and pump gears. The backlash limits are 0.003 to 0.013 inch. If the limits are exceeded, mark the lube oil pump gear and idler gear for additional analysis. NOTE When checking the backlash, keep the adjoining gear from moving d. Position the indicator on a tooth of the oil pump idler gear. Record the idler gear backlash. The backlash limit is 0.003 to 0.013 inch. Mark the idler gear and crankshaft gear for additional analysis if the limits are exceeded. e. Remove hex head cap screws (2) and oil pump (1). 6-91

S9233-C9-MMA-010 f. Visually inspect the oil pump gears for chips, cracks, or excessive wear. 6-41.2 DISASSEMBLY. Disassemble the lube oil pump according to the following steps. Unless otherwise noted, refer to figure 6-53. a. Remove the sealing plate. b. Mark TOP on the gerotor planetary. c. Remove the gerotor planetary. d. Inspect the gerotor for excessive wear or scoring.

Figure 6-53. Lube Oil Pump Disassembly WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. e. Clean all parts in an approved solvent and dry with compressed air. f. Inspect the pump housing and gerotor drive for damage and excessive wear. 6-41.3 REASSEMBLY. Reassemble the lube oil pump according to the following steps. Unless otherwise noted, refer to figure 6-54. a. Reinstall the gerotor planetary in the oil pump. Ensure the gerotor planetary is installed in its original position. b. Measure the gerotor tip clearance (maximum 0.007 inch). See figure 6-54. c. Measure the clearance of the gerotor drive to gerotor planetary to port plate (maximum 0.005 inch). See figure 6-55. d. Measure the clearance of the gerotor planetary to the body bore (maximum 0.015 inch). See figure 6-56. 6-92

S9233-C9-MMA-010 e. Measure the pump gear backlash. The limit for a used pump is 0.003 - 0.015 inch.

Figure 6-54. Measuring Gerotor Tip Clearance

Figure 6-55. Measuring Gerotor Drive/Gerotor Planetary-to-Port Plate Clearance

f. Reinstall the sealing plate on the oil pump housing.

6-93

S9233-C9-MMA-010

Figure 6-56. Measuring Gerotor Planetary-to-Body Bore Clearance 6-41.4 REINSTALLATION. Reinstall the lube oil pump according to the following steps. Unless otherwise noted, callouts refer to figure 7-22. a. Lubricate the pump with clean engine oil. NOTE Ensure when replacing the pump the correct size pump is used. The six-cylinder pump gerotor size is 0.715 inch. b. Install pump (1). Ensure the idler gear pin fits into the locating bore in the cylinder block. c. Reinstall hex head cap screws (2). Torque hex head cap screws to 18 lb-ft. d. Install new gear cover gasket and gear cover (19 and 16, figure 7-13) with hex head cap screws (12, figure 7-13). e. Reinstall new front oil seal (15, figure 7-13). Refer to paragraph 6-32.2. f. Reinstall the vibration damper, drive belt, and belt guard; refer to paragraph 6-13.2. Torque the belt guard mounting cap screws to 18 lb-ft. Torque vibration damper cap screws to 101 lb-ft. 6-42.

GEAR HOUSING.

6-42.1 REMOVAL. Remove the gear housing according to the following steps. Unless otherwise noted, callouts refer to figure 7-13. a. Refer to paragraph 6-13.1 and remove the belt guard, drive belt, and vibration damper. 6-94

S9233-C9-MMA-010 NOTE Do not remove the timing pin assembly unless the gear housing is being replaced. b. Remove hex head cap screws (12 and 14), belt retainer (13), cover (16), and gasket (19). Discard the gasket and oil seal (15). c. Remove hex head cap screws (11 and 12), gear housing (20), and gasket (1). Discard the gasket.

6-42.2 REINSTALLATION. Reinstall the gear housing according to the following steps. Unless otherwise noted, callouts refer to figure 7-13.

a. If removed, reinstall the gear housing dowel pins. b. Install new gasket (1). c. Reinstall gear housing (20) and hex head cap screws (11 and 12). Torque the cap screws to 18 lb-ft. d. Install gasket (19), cover (16), and hex head cap screws (12 and 14) and belt retainer (13). Torque the cap screws to 18 lb-ft. e. Reinstall crankshaft from oil seal (15). Refer to paragraph 6-31.1.2. f. Reinstall the vibration damper, drive belt, and belt guard. Refer to paragraph 6-13.2.

6-43.

FLYWHEEL/FLYWHEEL HOUSING.

6-43.1 FLYWHEEL. Remove/reinstall the flywheel according to the following steps. Unless otherwise noted, callouts refer to figure 7-29.

a. Lock the crankshaft. b. Remove hex head cap screws (1), plain washers (2), and flywheel (4). c. Reinstall flywheel (4) on the crankshaft end boss. d. Ensure the crankshaft is locked. e. Reinstall hex head cap screws (1) and plain washers (2). Torque the cap screws, in sequence, to 101 lb-ft (figure 6-57). 6-95

S9233-C9-MMA-010

Figure 6-57. Flywheel Cap Screw Torque Sequence 6-43.2 FLYWHEEL RING GEAR.

Replace the flywheel ring gear according to the following steps.

a. Remove flywheel (4). Refer to paragraph 6-43.1.

WARNING

Wear eye protection when removing the ring gear from the flywheel. Do not use a steel drift pin. b. Using a brass drift pin, drive ring gear (3) off the flywheel. c. Heat the new ring gear in a 260 °F oven for 20 minutes.

WARNING

To prevent injury, exercise extreme care and wear insulated gloves when handling heated solutions or metal. NOTE The ring gear is properly positioned for installation when the bevel on the teeth is toward the crankshaft side of the flywheel. d. Position the ring gear and install on the flywheel. e. Reinstall the flywheel. 6-43.3 FLYWHEEL HOUSING. Remove/reinstall the flywheel housing according to the following steps. Unless otherwise noted, callouts refer to figure 7-30. 6-96

S9233-C9-MMA-010 a. Remove starter motor. Refer to paragraph 6-9.1. b. Remove the flywheel. Refer to paragraph 6-43.1. c. Remove hex head cap screws (1) and flywheel housing (12). d. Remove and discard O-ring seal (5) and oil seal (6). e. If necessary, install new ring dowels. Drive the dowels in until they are against the bottom of the bore. f. Install new oil seal (6) and O-ring seal (5). g. Reinstall flywheel housing (12); ensure the housing sits squarely on the ring dowels. h. Reinstall hex head cap screws (1). Torque the hex head cap screws in sequence to 57 lb-ft (figure 6-58). i. Refer to paragraph 6-9.6 to reinstall starter motor.

Figure 6-58. Flywheel Housing Torque Sequence 6-44.

PISTON AND CONNECTING ROD.

6-44.1 REMOVAL. Remove the pistons and connecting rods according to the following steps. Unless otherwise noted, callouts refer to figure 7-38. a. Place the engine in a horizontal position with the pistons facing up. b. Using a ridge reamer, remove the ridge from the top of all cylinders. Remove only enough metal to eliminate the ridge. Do not gouge the cylinder bore. c. Metal stamp each correcting rod (1) and rod cap according to the cylinder. d. Metal stamp each piston (6) according to the cylinder. NOTE The rod cap, cap screws, and rod bearing should be kept together with the rod it was from which it was removed. e. Reposition the cylinder block until it is vertical to the deck and remove hex head cap screws (3), the rod cap, and rod bearings (2). 6-97

S9233-C9-MMA-010 CAUTION

To prevent damage to the connecting rod and bearing, avoid the use of metal objects during removal. f. Push the rod and piston assembly out of the top of the cylinder bore. Do not drop the assembly.

6-44.2 DISASSEMBLY. Disassemble the pistons and connecting rods according to the following steps. Unless otherwise noted, callouts refer to figure 7-38.

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove.

a. Remove retaining rings (4). b. Remove piston pin (5). c. Remove piston rings (9, 8, and 7).

6-44.3 CLEANING AND INSPECTION. following steps.

Clean and inspect the pistons and connecting rods according to the

a. Soak the pistons in cold parts cleaner overnight, if possible. CAUTION

Do not bead blast the pistons. b. After soaking in parts cleaner, wash the pistons and rods in a strong solution of laundry detergent and hot water. CAUTION

Do not clean the pistons and rods in an acid tank. c. Clean the remaining deposits from the ring grooves with the square end of a broken ring. Do not use a ring groove cleaner. Do not scratch the ring sealing surface in the piston groove. 6-98

S9233-C9-MMA-010

WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. d. Wash the pistons again in detergent or solvent; rinse and dry with compressed air. e. Inspect the piston for damage and excessive wear in the areas of the piston top, ring grooves, skirt, and pin bore. f. Measure the piston skirt diameter (minimum 4.0088 inches; maximum 4.0117 inches). g. Using a new piston ring and feeler gauge, measure the clearance in the ring groove top ring: (turbocharged, use Keystone gauge; N.A.; minimum 0.003 inch; maximum 0.0059 inch); all intermediate rings (minimum 0.003 inch; maximum 0.0059 inch); and all oil control rings (minimum 0.0016 inch; maximum 0.0051 inch). h. Measure the piston pin bore (minimum 1.5750 inch; maximum 1.5758 inch). i. Inspect the piston pin for nicks, gouges, and excessive wear. Measure the pin diameter (minimum 1.5744 inch, maximum 1.5749 inch). j. Inspect the connecting rod for damage and wear. The I-beam section cannot have dents. k. Measure the connecting rod pin bore diameter (minimum 1.5769 inch; maximum 1.5784 inch).

6-44.4 MEASURE ROD BEARING CLEARANCE. lowing steps.

Measure the rod bearing clearance according to the fol-

a. Measure the connecting rod bore with the bearings installed and the cap screws torqued to 73 lb-ft. Record the smallest diameter. b. Measure the mean diameter of the rod journal on the crankshaft (minimum 2.7150 inches, maximum 2.7170 inches; maximum out-of-round 0.002 inch; maximum taper 0.0005 inch; bearing clearance 0.0035 inch).

NOTE The bearing clearance is the rod bearing inside diameter minus the crankshaft journal diameter. c. The bearing clearance can also be determined using plastigauge (figure 6-59).

6-99

S9233-C9-MMA-010

Figure 6-59. Using Plastigauge to Measure Clearance 6-44.5 REASSEMBLY. Reassemble the pistons and connecting rods according to the following steps. Unless otherwise noted, callouts refer to figure 7-38. a. Align the piston and connecting rod pin bores. Ensure the FRONT marking on the piston and the number on the connecting rod are properly positioned.

WARNING

To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. b. Install a retaining ring (4) in the pin bore groove on the front side of piston (6). c. Lubricate piston pin (5) and pin bores with clean engine oil. d. Install the piston pin and second retaining ring (4). 6-44.6 CHECKING PISTON RING GAP.

Check the piston ring gap according to the following steps.

a. Position each ring, one at a time, in the cylinder where it is being used. Use a piston to square the ring in the cylinder bore about 3-1/2 inches from the top of the bore. b. Using a feeler gauge, measure the gap of the ring (turbocharged, top minimum 0.0160; maximum 0.0275; N.A. top, and all other rings: minimum 0.0100 inch; maximum 0.0215 inch). 6-44.7 PISTON RING INSTALLATION. 6-100

Install the piston rings according to the following steps.

S9233-C9-MMA-010 NOTE Install all rings with the word TOP facing up. a. Position the oil ring expander in the lower oil control ring groove. b. Install oil control ring (7) over the oil ring expander with the end gap 180 degrees from the ends of the oil ring expander. c. Install intermediate middle ring (8). d. Install top ring (9). 6-44.8 REINSTALLATION. Reinstall the pistons and connecting rods according to the following steps. Unless otherwise noted, callouts refer to figure 7-38. a. Rotate the engine on the overhaul stand until the crankshaft is vertical. b. Install bearing shells (2) into rods (1) and cap. Ensure the tang on the shells is in the slot of the cap and rod. c. Lubricate the rod bearings with a light film of Lubriplate 105. d. Lubricate the rings and piston skirts with clean engine oil. e. Position the ring gaps about 120 degrees from each other. CAUTION

If a strap-type ring compressor is used to install the piston and connecting rod assembly into the block, ensure the inside end of the strap does not hook on a ring gap and break the ring. f. Compress the rings using a suitable ring compressor. g. Lubricate the cylinder bore with clean engine oil. h. Position the crankshaft rod journal for the piston to be installed at bottom dead center (BDC). NOTE Ensure the four-digit number stamped on the rod and cap at the parting line match and are installed on the oil cooler side of the engine. i. Reinstall the piston/rod assembly in the cylinder bore and seat the rod bearing shell on the crankshaft. j. Reinstall rod cap and hex head cap screws (3) to the connecting rod (1). k. Alternately torque the hex head cap screws as follows: 26 lb-ft; 51 lb-ft; 73 lb-ft. l. Measure the side clearance between the connecting rod and crankshaft. The limits are 0.004 inch to 0.012 inch. m. Check the crankshaft for freedom of rotation as the pistons are installed. If the crankshaft does not rotate freely, check the installation of the rod bearings and bearing size. 6-101

S9233-C9-MMA-010 6-45.

CRANKSHAFT.

6-45.1 REMOVAL. to figure 7-39.

Remove crankshaft according to the following steps. Unless otherwise noted, callouts refer

a. Rotate the engine to a horizontal position (crankshaft up) and remove main bearing cap bolts (10, figure 7-37). NOTE The main caps should be numbered. If they are not, be sure to metal stamp the caps and upper bearing saddles with the correct numbers. Number 1 is the main cap closest to the vibration damper. b. Remove main bearing caps (11, figure 7-37). Do not pry on the main bearing caps to free, but use two of the main cap bolts to wiggle the main cap loose.

WARNING

To prevent injury or death, ensure extreme care and proper lifting devices are used during handling. The equipment is heavy. c. Lift crankshaft (2) and gear (1) from the cylinder block. d. Remove lower main bearings (6) from the caps and upper main bearings (4 and 5) from the bearing saddles in the block. e. Using a 3/16-inch pin punch, remove piston cooling nozzles (13, figure 7-37). f. Reinstall the main caps in their original position so they will not be misplaced. 6-45.2 CLEANING AND INSPECTION.

Clean and inspect the crankshaft according to the following steps.

WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. a. Clean the crankshaft oil passages with a nylon bore brush. Rinse with a clean solvent and dry with compressed air. b. Inspect the crankshaft seal wear surfaces for scratches or grooving. c. Inspect the rod and main journals for deep scoring and overheating. NOTE The main bearing clearance is the main bore diameter with the bearing installed, minus the crank main journal diameter. 6-102

S9233-C9-MMA-010 d. Measure the main journal diameters and determine the main bearing clearance (minimum 3.2662 inches, maximum 3.2682 inches; out-of-roundness maximum 0.002 inch; taper maximum 0.0005 inch; bearing clearance maximum 0.00475 inch). 6-45.3 CRANKSHAFT GEAR REPLACEMENT. Replace the crankshaft gear according to the following steps. Unless otherwise noted, callouts refer to figure 7-39. a. Using a heavy-duty bearing puller, remove the crankshaft gear. Use a flat nose center stud. Do not use a pointed center stud; it may damage the threads in the end of the crankshaft. b. Remove all burrs and ensure the gear surface on the end of the crankshaft is smooth. c. If removed, reinstall roll pin (3) until it bottoms. d. Heat the new crankshaft gear (1) for 45 minutes at 250°F. If heated longer, the gear will be permanently distorted.

WARNING

To prevent injury, exercise extreme care and wear insulated gloves when handling heated solutions or metal. e. Install the hot gear, timing mark facing out, up to the shoulder on crankshaft (2). 6-45.4 REINSTALLATION. callouts refer to figure 7-39.

Reinstall the crankshaft according to the following steps. Unless otherwise noted,

a. Remove main bearing caps (11, figure 7-37). b. Using a 1/2-inch center punch, install piston cooling nozzles (13, figure 7-37) even with or below the bearing saddle surface. Ensure the spray holes are clean and open. c. Install upper main bearings (4). d. Install the thrust/main bearing (5) in the second journal from the rear. e. Lubricate the bearings with Lubriplate 105. f. Reinstall crankshaft (2). g. Install lower main bearings (6) into the main bearing caps. Lubricate the bearings with Lubriplate 105. h. Ensure dowel rings (12, figure 7-37) have been installed into the caps figure 7-30. i. Position the main bearings and caps over the crankshaft. j. Using clean engine oil, lubricate the main bearing cap screw threads and the underside of the heads. k. Install hex head cap screws (10, figure 7-37) and torque (figure 6-60) as follows: 44 lb-ft; 88 lb-ft; 129 lb-ft.

6-103

S9233-C9-MMA-010

Figure 6-60. Main Bearing Cap Torque Sequence l. Rotate the crankshaft after the main bearing caps have been properly torqued. The crankshaft must rotate freely. m. Using a dial indicator positioned against the face of the crankshaft gear, measure the crankshaft end play. The limits are 0.005 inch to 0.010 inch. 6-46.

CYLINDER BLOCK.

6-46.1 REMOVAL. Remove the cylinder block components according to the following steps. Unless otherwise noted, callouts refer to figure 7-37. a. Remove pipe plugs (8 and 16). b. Remove expansion plugs (2) from the oil passages and expansion plugs (1, 4, 6, and 7) from the coolant passages. c. Drive expansion plug (3) from the camshaft bore. Use care not to damage the camshaft bore. d. Drive the turbocharger drain tube from the inside of cylinder block (9). e. Remove front mounting supports (1 and 3, figure 7-4). 6-46.2 CLEANING AND INSPECTION. following steps.

Clean and inspect the cylinder block (figure 7-37) according to the

a. If excessive deposits of scale are present in the coolant passages, the block may be cleaned in an acid bath. Otherwise, clean the block in a hot tank using a soap and water solution. b. After the block is clean, it will be necessary to deglaze the cylinders to aid the seating of the piston rings. A correctly de-glazed surface will have a cross-hatched appearance with the lines at 15- to 25-degree angles with the top of the cylinder block; 30- to 50-degree angles on the cross-hatch. Use a fine grit flexi-hone drill, a 50-50 mixture of diesel fuel, and 30W engine oil to deglaze the bores. 6-104

S9233-C9-MMA-010

WARNING

Never turn a stream of compressed air on anyone. Severe injury or death could result. c. After deglazing, clean the block in a strong solution of laundry detergent and hot water, then rinse the block and dry with compressed air. Wipe the bores with a white, lint-free, lightly oiled cloth. If grit is still present, re-clean the block. d. Wash the block in solvent. Clean all the oil passages with a nylon bore brush. Rinse with a clean solvent and dry with compressed air. e. Inspect the cylinder bores for damage or excessive wear. Measure the bore diameter with a bore gauge (minimum 4.0157 inches; maximum 4.0203 inches) and measure 1 inch and 4-1/2 inches from the top surface of the block at two places, each measurement 180 degrees apart (out-of-roundness maximum 0.0015 inch; taper maximum 0.003 inch). f. Check the top surface of the block for flatness between the cylinders. The variance is 0.002 inch. g. Inspect the main bearing bores for damage or abnormal wear. Measure the main bearing bore with the bearings installed and the bearing caps torqued to 130 lb-ft. Measure it at two points, 180 degrees apart and near both sides of the bearing (maximum 2.2720 inches). 6-46.3 REINSTALLATION. Reinstall the cylinder block components according to the following steps. Unless otherwise noted, callouts refer to figure 7-37. a. Apply a bead of Loctite 277 around the outside diameter of the oil passage expansion plugs (2). b. Drive the expansion plugs in until they are even with the countersink in the block. c. Apply a bead of Loctite 277 to the coolant passage expansion plugs (1, 4, and 6). d. Drive the plugs in until the outer edge is flush with the countersink in the block. e. Apply a bead of liquid Teflon sealant to pipe plugs (8 and 16). Reinstall the plugs. Refer to table 6-9 for correct torques. f. Apply a bead of Loctite 277 around the outside diameter of the camshaft expansion plug (3). Position the plug with the convex side out. Drive the plug flush with the cylinder block. g. Reinstall front mounting supports (1 and 3, figure 7-4). 6-47.

OIL PAN HEATER.

Replace the oil pan heater according to the following steps. Unless otherwise noted, callouts refer to figure 7-35. a. Disconnect the oil heater electrical cord. b. Loosen and remove plug (7) and sealing washer (6). Drain the engine oil sump. c. Remove the heater element and washer. d. Reinstall a new heater element and copper washer. Torque the element to 60 lb-ft. 6-105

S9233-C9-MMA-010 e. If further repairs to the diesel engine are not required, replace plug and sealing washer and refill the oil sump with correct oil. Refer to table 2-3. f. Reconnect oil heater electrical cord. 6-48.

START-UP.

Following engine reinstallation, proceed as follows:

WARNING

To prevent injury or death, ensure extreme care and proper lifting devices are used during handling. The equipment is heavy. a. Using a spreader bar and engine lifting device, set the engine on a suitable test stand. b. Connect the engine to all necessary piping and electrical systems. c. After the engine is secured in position, follow pre-operational checks listed in chapter 2, paragraph 2-3.1. Check for proper connection of all systems. Ensure engine operating fluids are at proper levels; refer to table 1-1 or table 1-2, as applicable. d. Start the engine and run at idle speed for a sufficient time to check for leaks, proper connection of controls, and for the engine to warm-up to operating temperatures. Ensure the engine is ready for further testing. Complete testing as per PMS instructions. Table 6-6. Clearance Measurements Item

Dimension

Cylinder Bores

Min. 4.0157-in. Max. 4.0203-in. .0015-in. .003-in. Max. 2.2720-in. Min. 2.1324-in. Min. 0.630-in. Max. 0.632-in. Min. 2.1295-in. Max. 2.1314-in. Min. 3.2662-in. Max. 3.2682-in. Max 0.00475-in. 0.002-in. 0.0005-in. Min 4.0088-in. Max 4.0117-in.

Out-of-Roundness Taper Limit Main Bearing Bores Camshaft Bore Tappet Bores Installed Cam Bushing Main Journal Diameter Main Bearing Clearance Out-of-Roundness Taper Piston Skirt Diameter Piston Ring Top Turbocharged Naturally Aspirated

6-106

Use Keystone Gauge Min 0.003-in. Max 0.0059-in.

S9233-C9-MMA-010 Table 6-6. Clearance Measurements - Continued Item

Dimension

Piston Ring Intermediate

Min 0.003-in. Max 0.0059-in. Min 0.0016-in. Max 0.0051-in. Min 1.5750-in. Max 1.5758-in. Min 1.5744-in. Max 1.5784-in. Min 2.7150-in. Max 2.7170-in. 0.002-in. 0.0005-in. Min 0.3157-in. Max 0.3185-in. Min 0.3126-in. Max 0.3142-in.

Oil Control Piston Pin Bore Piston Pin Diameter Mean Diameter of on the Crankshaft Out-of-Roundness Taper Valve Guide Bore Valve Stem Diameter Valve Seat Angle Intake Exhaust Valve Rim Thickness Valve Depth Valve Seat Width Limit Valve Spring Free Length Max Inclination Turbocharger Shaft Diameter (bearing) * Shaft End Play **

Shaft End Play

Radial Clearance Oil Pump Tip Clearance Body Bore Clearance Port Plate Clearance Gear Backlash Limits for a Used Pump Starter Motor Brush Replacement Cable Size *

30° 45° Min 0.031-in. Min 0.039-in. Max 0.060-in. Min 0.060-in. Max 0.080-in. 2.190-in. 0.039-in. Min 0.432-in. Min 0.004-in. Max 0.006-in. Min 0.001-in. Max 0.003-in. Min 0.012-in. Max 0.018-in. Max 0.007-in. Max 0.015-in. Max 0.005-in. 0.003 to 0.015-in. Min 0.5-in. Min.012-in.

For turbochargers with a serial number before 840638.

**

For turbochargers with a serial number after and including 840638.

6-107

S9233-C9-MMA-010 Table 6-7. Torque Specifications Item Alternator Pulley Alternator Link Alternator Mtg Bolt Alternator Support (upper) Belt Tensioner Mtg Cam Thrust Plate Connecting Rod (then rotate 60°) Crankshaft Damper and Pulley Crossover Clamp Exhaust Manifold Exhaust Outlet Pipe Brkt Mtg Exhaust Outlet Pipe, Flanged Exhaust Outlet Pipe, V Band Clamp Flywheel Flywheel Housing Flywheel Housing Plug Front Cover Cap Front Engine support Fuel Banjo Screw (in head) Fuel Vent Screw (in banjo) Fuel Filter Fuel Low-Pressure Supply Fuel Low-Pressure Return Fuel Filter Adapter Nut Fuel Line Fitting (HP) Fuel Pump Drive Gear Fuel Pump Lock Fuel Pump Mtg Nut Fuel Pump Support Bracket Gear Cover Gear Housing-to-Block Head Mtg Step 1 Step 2 (retorque) Step 3 Head Thread Plug (front) Injection Nozzle Banjo Screw Injection Nozzle Retaining Nut Intake Manifold Cover/After Cooler Intake Heater Plug Lift Pump Mtg/Cover Plate Lifting Bracket (rear) Main Bearing Cap Step 1 Step 2 Step 3 Oil Fill Tube Mtg Oil Filter

6-108

lb-ft 59 32 57 18 32 18 45 101 4 32 32 18 6 101 45 32 Hand-tighten 57 24 4 1/2 turn after contact 18 11 24 18 48 22 18 18 18 18 26 70 73 90 6 44 18 45 18 57 44 88 129 32 1/2 turn after contact

S9233-C9-MMA-010 Table 6-7. Torque Specifications - Continued Oil Filter Head Mtg Oil Pan Drain Plug Oil Pan Heater Plug Oil Pan Mtg Oil Pressure Regulator Plug Oil Pump Mtg Oil Suction Tube (flange) Rear Seal Mtg Rocker Support Rocker Lever Nut 12 Point Starter Mtg Tach Drive Retainer Tappet Cover Thermostat Housing Timing Pin Flange Mtg Turbine Housing Turbocharger Compressor Housing Clamp Turbocharger Mounting Nuts Turbocharger Oil Drain Tube Turbocharger Oil Supply Tubes (both ends) Water Hose Water Inlet (lower) Water Inlet Plugs Water Pump Mtg Water Pump Pulley Valve Cover Valve Cover Oil Fill FUEL INJECTION PUMP Item AUTO ADVANCE ARRANGEMENT Cap Screw Advance Housing Cap Nut Advance Housing Cold Advance Plug Advance Housing Spring Cap Assembly Cold Advance Shaft Locknut Head Locating Fitting END PLATE, BRACKETS, HEAD, AND ROTOR End Plate Securing Screws Fuel Inlet Connection Pressure-Relief Valve Assembly High-Pressure Banjo Bolts Delivery Valve Holders Distributor Rotor Plug Screw Solenoid Solenoid Terminal Screw Hydraulic Head Bracket Throttle Lever Stop Screw Locknut Latch Valve Body

18 55 90 18 90 18 18 7 18 18 32 2 18 18 4 8 5 24 18 18 4 32 25 18 18 18 Hand-tighten lb-in

Head Type

450 250 250 250 40 350

Special 1/2 in. AF 27 mm 15/16-in. AF 10 mm 3/4 in. AF

45 520 180 320 360 28 130 30 120 40 170

5/16-in. AF 15/16-in. AF 24 mm 14 mm 17 mm 3/32-in. Allen 24 mm 8 mm 5 mm Allen 10 mm 22 mm

6-109

S9233-C9-MMA-010 Table 6-7. Torque Specifications - Continued Latch Valve Sleeve Nut Latch Valve Locknut Rotor Vent Switch Valve Body RotorVent Switch Valve Plug GOVERNOR AND HOUSING ASSEMBLIES Torque Trimmer Locking Plate Screws Governor Control Housing Screws Governor Control Bracket Studs Governor Control Bracket Screw Governor Control Bracket-Pivot Screw Cambox Pressuring Valve Holder Cambox Valve Adapter Vent Screw Body Vent Screw Anti-Stall Screw Locknut Idle Adjustment Screw Locknut Idling Shaft Screw Throttle Shaft Locknut Indexing Plate Vernier Set Bolt Face Cam Setting Screw Max Speed Screw Locknut Aux. Idle Spring Locknut PUMP BODY, DRIVE SHAFT, AND THROTTLE BRACKET Idle Actuator Bracket Screws Cover Plate Screws Drive Shaft Catch Plate Screws Drive Shaft Timing Disc Screws Timing Adapter Screws Pivot (Rocker lever) Light-Load Advance Roller Assembly Locknut Grub Screw (Rocker lever) Drive Shaft Nut

140 40 170 140

5/8-in. AF 1/2-in. AF 22 mm 5/8-in. AF

30 35 60 20 20 250 200 40 40 30 20 20 40 50 30 20 10

4 mm Allen 4 mm Allen 8 mm 7 mm 7 mm 5/8-in. AF 17 mm 7/16-in. AF 5/16-in. AF 10 mm 8 mm 7 mm 10 mm 10 mm 8 mm 8 mm 5.5 mm

15 20 35 25 20 80 40

3 mm Allen 8 mm TORX T15 TORX T10 3 mm Allen 13 mm 10 mm

10 720

1.5 mm Allen 22 mm

Table 6-8. Roller-to-Roller Dimensions Service Setting Code A105L-1000-2-2860 A94L-900-2-2725

Roller to Roller (mm)

Test 11 RPM

Test 12 RPM

1300 1250

1430 1360

50.5 50.3

Test 13 RPM 1300 1250

Table 6-9. Torque for Pipe Plugs

6-110

Pipe Plug Size

In Aluminum or Brass (lb-ft)

In Iron (lb-ft)

1/8 inch 1/4 inch 1/2 inch

7 10 20

10 15 35

S9233-C9-MMA-010 Table 6-9. Torque for Pipe Plugs - Continued Pipe Plug Size

In Aluminum or Brass (lb-ft)

In Iron (lb-ft)

3/4 inch

30

50

6-111 / (6-112 Blank)

6-112 @@FIpgtype@@BLANK@@!FIpgtype@@

S9233-C9-MMA-010 CHAPTER 7 ILLUSTRATED PARTS BREAKDOWN 7-1.

INTRODUCTION.

This chapter contains illustrations and parts lists for the major components used in the diesel engines. Each illustration has a corresponding table that identifies component parts. Illustration reference numbers cross over to component parts in the appropriate table which lists the following: a. Figure and Index Number b. Description. c. Quantity. d. Commercial and Government Entity (CAGE) Code. e. Manufacturer’s Part Number. The following is a listing of major components/systems present in this chapter. Major Components List Figure/Table Number

Page Number

7-1 7-2 7-3

7-3 7-4 7-8

7-4 7-5 7-6 7-7 7-8 7-9 7-10 7-11 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21 7-22 7-23 7-24 7-25 7-26

7-10 7-11 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21 7-22 7-23 7-25 7-26 7-28 7-30 7-31 7-34 7-35 7-36 7-37 7-38 7-40

Description Belt Guard Starter Motor V-Belt Tensioner/Alternator Mounting Front Engine Support Alternator Instrument Panel Air Cleaner Expansion Tank Bracket Lifting Bracket Fresh Water Pump Thermostat Housing Vibration Damper Front Gear Cover/Gear Housing Sea Water Pump Heat Exchanger Water Inlet Connection Marine Transmission Oil Cooler Exhaust Manifold/Intake Cover Exhaust Outlet Connection Turbocharger Oil Level Gauge Lube Oil Pump Lube Oil Cooler Fuel Lift Pump Fuel Piping Fuel Filter

7-1

S9233-C9-MMA-010

Figure/Table Number

Page Number

7-27 7-28 7-29 7-30 7-31 7-32 7-33 7-34 7-35 7-36 7-37 7-38 7-39 7-40 7-41 7-42

7-41 7-43 7-48 7-49 7-50 7-51 7-52 7-54 7-56 7-58 7-59 7-61 7-62 7-63 7-64 7-65

Description Fuel Injection Nozzle Fuel Injection Pump Flywheel Flywheel Housing Cam Follower Cover Valve Covers Rocker Lever Cylinder Head Oil Pan Camshaft Cylinder Block Piston and Connecting Rod Crankshaft and Main Bearings Transmission Mounting Bracket Vibration Isolator Fuel/Water Separator

Figure 7-1. Belt Guard 7-2

S9233-C9-MMA-010 Table 7-1. Belt Guard Figure and Index No. 7-1-1 7-1-2

Description Guard, Belt (front) Screw, Hex Flange Head (M8-1.25 x 20 mm)

Qty.

CAGE Code

1 3

15434 15434

Model 6B5.9-M Mfg. Part No. 3916028 3900630

Model 6BT5.9-M Mfg. Part No. 3916028 3900630

7-3

S9233-C9-MMA-010

Figure 7-2. Starter Motor

7-4

S9233-C9-MMA-010 Table 7-2. Starter Motor Figure and Index No. 7-2-0 7-2-1 7-2-2 7-2-3 7-2-4 7-2-5 7-2-6 7-2-7 7-2-8 7-2-9 7-2-10 7-2-11 7-2-12 7-2-13 7-2-14 7-2-15 7-2-16 7-2-17 7-2 7-2-19 7-2-20 7-2-21 7-2-22 7-2-23 7-2-24 7-2-25 7-2-26 7-2-27 7-2-28 7-2-29 7-2-30 7-2-31 7-2-32 7-2-33 7-2-34 7-2-35 7-2-36 7-2-37 7-2-38 7-2-39 7-2-40 7-2-41 7-2-42 7-2-43 7-2-44 7-2-45

Description Motor, Starter (24Vdc) Plug, Lubricator Core Spring Seal, Oil Pad, Lubrication Wick Bushing, Bearing Endshield, Drive End Terminal, Main Support Insulator, Terminal Bushing, Insulating Ring, Sealing Washer Washer Washer, Lock Nut, Hex Washer, Lock Screw, Phillips Head * Terminal, Solenoid * Bushing, Insulating * Bushing, Insulating * Washer * Washer, Lock * Nut Plug Screw, Twelve Point Solenoid Assembly Stop, Contact Rivet Screw, Self-Tapping Washer Screw (hex hd) Spring, Plunger Segments Spring Plunger Contact, Moving Spring and Trigger Guide, Trigger Spring Washer Nut Spacer Bushing, Insulating Resistor

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

7E658

CA45G24125M

CA45G24125M

1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 2 2 2 2 13 4 2 3 1 1 3 2 2 2 1 1 1 1 1 1 1 1 1 1 2 1 1

7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 15434 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658

6211-500 6211-479 5933-906 593345 6410-19 593344 6211-6836 6211-514 6211-276 6211-275 5587-77 5855-30CZ 5936-129 NW1-23Z1 5001-31 5330-262C 5936-102 NS85-8Z1 5335-833 6211-273A 5587-140 NW2-3221 5244-22 NU9-871 6211-648 3903834 6211-546 5933-520 5366-255 5335-774 NW1-10Z1 5334-325 6211-468 6211-3768 6211-385 6211-373 6010-148 6010-201X 6010-201 5933-636 NW2-28Z1 NU9-8Z1 5936-374 5587-117A 6211-526

6211-500 6211-479 5933-906 5933-45 6410-19 593344 6211-6836 6211-514 6211-276 6211-275 5587-77 5855-30CZ 5936-129 NW1-23Z1 5001-31 5330-262C 5936-102 NS85-8Z1 5335-833 6211-273A 5587-140 NW2-3221 5244-22 NU9-871 6211-648 3903834 6211-546 5933-520 5366-255 5335-774 NW1-10Z1 5334-325 6211-468 6211-3768 6211-385 6211-373 6010-148 6010-201X 6010-201 5933-636 NW2-28Z1 NU9-8Z1 5936-374 5587-117A 6211-526

7-5

S9233-C9-MMA-010 Table 7-2. Starter Motor - Continued Figure and Index No. 7-2-46 7-2-47 7-2-48 7-2-49 7-2-50 7-2-51 7-2-52 7-2-53 7-2-54 7-2-55 7-2-56 7-2-57 7-2-58 7-2-59 7-2-60 7-2-61 7-2-62 7-2-63 7-2-64 7-2-65 7-2-66 7-2-67 7-2-68 7-2-69 7-2-70 7-2-71 7-2-72 7-2-73 7-2-74 7-2-75 7-2-76 7-2-77 7-2-78 7-2-79 7-2-80 7-2-81 7-2-82 7-2-83 7-2-84 7-2-85 7-2-86 7-2-87

7-6

Description Screw (hex hd) Rivet Collar Spring Washer Plate, Trip Ring, Retaining (external) Nut, Square Screw, Phillips Head Cover, Commutator Lining Cap, End Pad, Retaining Ball, Steel Spring, Recoil Nut, Hex Washer, Lock Washer Washer Bushing, Insulating Ring, Retaining (internal) Shim, Washer Bushing, Bearing Bolt Washer, Lock Screw, Phillips Head Brushes Kit Endshield, Commutator Spring, Bushing Insulator, Terminal Terminal Yoke Screw, Pole Shoe Insulator Field Coil Set Kit Dowel Ball, Lock Ring/ Overspeed Pinion Assembly Ring, Sealing Armature Spring Washer, Thrust

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 2 1 1 1 1 1

7E658 7E658 7E658 7E658 7E658 7E658 7E658

5334-325 5336-256 6211-372 6211-437 5936-456 6211-600 NW1-9

5334-325 5336-256 6211-372 6211-437 5936-456 6211-600 NW1-9

1 1 1 1 1 1 1 1 2 2 1 2 1 1

7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658

5388-1 5336-804 6211-128 6211-129 6211-368 6211-369 NC7-7 5933-509 5338-262C 6001-31 NW2-81T1 5936-129 5587-81 6211-367

5388-1 5336-804 6211-128 6211-129 6211-368 6211-369 NC7-7 5933-509 5338-262C 6001-31 NW2-81T1 5936-129 5587-81 6211-367

AR 1 2 2 4 1 1

7E658 7E658 7E658 7E658 7E658 7E658 7E658

NW1-70 6211-303 5933-147 5001-53 NS37-14ZI 6063-42 6211-336E

NW1-70 6211-303 5933-147 5001-53 NS37-14ZI 6063-42 6211-336E

4 1 1 1 4 1 1 1 12

7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658

S933-336 6211-329 6211-327 5933-183 5933-190 5933-183B 5933-602G 6211-662 NC7-17

S933-336 6211-329 6211-327 5933-183 5333-190 5933-183B 5933-602G 6211-662 NC7-17

1 1 1 1 1

7E658 7E658 7E658 7E658 7E658

6211-700Z 6211-660 6332-A1441 6211-710 6265-710

6211-700Z 6211-660 6332-A1441 6211-710 6265-710

S9233-C9-MMA-010 Table 7-2. Starter Motor - Continued Figure and Index No. 7-2-88 NS NS NS *

Description Nut, Stop Overhaul Kit Washer, Shim Washer, Shim

Qty. 1 1 AR AR

CAGE Code 7E658 7E658 7E658 7E658

Model 6B5.9-M Mfg. Part No. 5330-539 6010-127 NW1-69Y1 5936-163

Model 6BT5.9-M Mfg. Part No. 5330-539 6010-127 NW1-69Y1 5936-163

Includes relay (R) terminal parts

7-7

S9233-C9-MMA-010

Figure 7-3. V-Belt Tensioner/Alternating Mounting

7-8

S9233-C9-MMA-010

Table 7-3. V-Belt Tensioner/Alternating Mounting Figure and Index No. 7-3-1 7-3-2 7-3-3 7-3-4 7-3-5 7-3-6 7-3-7 7-3-8 7-3-9 7-3-10 7-3-11

Description

Qty.

Brace, Alternator Screw, Cap (hex hd, M8-1.25 x 20 mm) Screw, Cap (hex hd, M10-1.50 x 90 mm) Screw, Cap (hex hd, M8-1.25 x 25 mm) Support, Alternator Spacer, Mounting Screw (flat hd, M8-1.25 x 21 mm) Screw, Cap (hex hd, M10-1.50 x 62 mm) Tensioner, Belt Bracket, Belt Tensioner Belt, Drive

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 2

15434 15434

3903089 3900620

3903089 3900620

1

15434

3910527

3910527

3

15434

3900621

3900621

1 1 2

15434 15434 15434

3910713 3910715 3903095

3910713 3910715 3903095

1

15434

3905426

3905426

1 1

15434 15434

3911315 3905888

3911315 3905888

1

15434

3908564

3908564

Figure 7-4. Front Engine Support

Table 7-4. Front Engine Support Figure and Index No. 7-4-1 7-4-2 7-4-3

Description Support, Front Engine Screw, Cap (hex hd, M12-1.75 x 35 mm) Support, Front Engine

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 6

15434 15434

3917095 3900637

3917095 3900637

1

15434

3917096

3917096

7-9

S9233-C9-MMA-010

Figure 7-5. Alternator

7-10

S9233-C9-MMA-010 Table 7-5. Alternator Figure and Index No. 7-5-0 7-5-1 7-5-2 7-5-3 7-5-4 7-5-5 7-5-6 7-5-7 7-5-8 7-5-9 7-5-10 7-5-11 7-5-12 7-5-13 7-5-14 7-5-15 7-5-16 7-5-17 7-5-18 7-5-19 7-5-20 7-5-21 7-5-22 7-5-23 7-5-24 7-5-25 7-5-26 7-5-27 7-5-28 7-5-29 7-5-30 7-5-31 7-5-32 7-5-33 7-5-34 7-5-35 7-5-36 7-5-37 7-5-38

Description Alternator (24 vdc, 55 amp) Stator Ring, Retaining (sealing) Ring, Slip Ring, Retaining (external) Bearing, Ball (rear) Spacer Rotor Key Screw, Machine Washer, Lock Spacer Plate, Clamp (bearing retainer) Bearing, Ball (front) Shield, Drive End (front housing) Washer, Lock Thru-bolt Fan Washer Nut Screw, Recess Head Tag Terminal, Positive Guide (locator) Lead Grommet Washer, Insulating Connector, Spade (Lucar blade) Gasket Assembly, Holder and Brush Washer, Flat Washer, Lock Screw Insulator Connector, Spade (Lucar blade) Screw Screw, Self-Tapping Bushing, Insulating Washer

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

7E658

AC5RS1268650M

AC5RS1268650M

1 1

7E658 7E658

6332-A1422 6220-481

6332-A1422 6220-481

1 1

7E658 7E658

6220-104 NM2-4

6220-104 NM2-4

1 1 1 1 1 1 1 1

7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658

6220-693 6220-496 6220-321E NK1-8 NS37-14Z1 5244-22 6220-307A 6220-242

6220-693 6220-496 6220-321E NK1-8 NS37-14Z1 5244-22 6220-307A 6220-242

1 1

7E658 7E658

6220-694 6220-898C

6220-694 6220-898C

1 3 1 1 1 2 2 1 4 1 1 6 1

7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658

5293-57 5335-807 6220-911 NW1-39Z1 5330-423 6332-47 5469-417 6220-923A 6220-828 6220-501A 6220-296 6220-141 5459-920

5293-57 5335-807 6220-911 NW1-39Z1 5330-423 6332-47 5469-417 6220-923A 6220-828 6220-501A 6220-296 6220-141 5459-920

1 1

7E658 7E658

6220-75 6220-477

6220-75 6220-477

2 2 2 1 2

7E658 7E658 7E658 7E658 7E658

NW1-10T1 5244-22 5332-49 6220-922 5459-736

NW1-10T1 5244-22 5332-49 6220-922 5459-736

2 2 1 4

7E658 7E658 7E658 7E658

5332-47 5332-81 5587-180 NW1-14T1

5332-47 5332-81 5587-180 NW1-14T1

7-11

S9233-C9-MMA-010 Table 7-5. Alternator - Continued Figure and Index No. 7-5-39 7-5-40 7-5-41 7-5-42 7-5-43 7-5-44 7-5-45 7-5-46 7-5-47 7-5-48 7-5-49 7-5-50 7-5-51 7-5-52 7-5-53 7-5-54 7-5-55 7-5-56 7-5-57 7-5-58 7-5-59

7-12

Description Nut Plate Cowl, End Cover Washer, Lock Washer, Flat Screw Ferrule Ferrule Nut, Round Plug, Gland Screw Gland Connector, Spade (Lucar blade) Lead Regulator, Voltage Shield, Slip Ring End (rear housing) Band, Insulating Assembly, Heat Sink and Diode Screw, Machine Terminal, Negative Tie

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

4 1 1 2 2 2 1 1 1 1 4 1 1

7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658 7E658

NU10-11T1 5668-2720 6220-351K 5293-57 NW1-15Z1 5337-64F 5998-22M 5998-22N 5658-339 5658-310 5335-700C 6220-428 6220-478

NU10-11T1 5668-2720 6220-351K 5293-57 NW1-15Z1 5337-64F 5998-22M 5998-22N 5658-339 5658-310 5335-700C 6220-428 6220-478

1 1 1

7E658 7E658 7E658

6220-917 1861542 6220-923A

6220-917 1861542 6220-923A

1 3

7E658 7E658

6220-143 6010-107

6220-143 6010-107

2 1 6

7E658 7E658 7E658

5337-64 5334-502A 6220-366

5337-64 5334-502A 6220-366

S9233-C9-MMA-010

Figure 7-6. Instrument Panel Table 7-6. Instrument Panel Figure and Index No. 7-6-1 7-6-2 7-6-3 7-6-4 7-6-5 7-6-6 7-6-7 7-6-8 7-6-9 7-6-10 7-6-11 7-6-12

Description Panel, Instrument Light, Indicator Switch, Start Transducer (water temp.) Transducer (oil pressure) Adapter (plain) Pickup, Magnetic Sending Unit (pressure) Tachometer Gauge, Oil Pressure (transmission) Gauge, Voltmeter (24 Vdc) Gauge (engine fault light)

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 1 1 1

15434 15434 88140 15434

3905329 3022279 MS35059-21 3015238

3905329 3022279 MS35059-21 3015238

1

15434

3015237

3015237

1 1 1

15434 15434 15434

187368 3039524 208603

187368 3039524 208603

1 1

15434 15434

3031734 3032800

3031734 3032800

1

15434

3015235

3015235

1

15434

NPN

NPN

7-13

S9233-C9-MMA-010 Table 7-6. Instrument Panel - Continued Figure and Index No. 7-6-13 7-6-14

Description

Qty.

Gauge, Oil Pressure (engine) Gauge, Temperature (engine fresh water)

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

15434

3015232

3015232

1

15434

3015234

3015234

Figure 7-7. Air Cleaner

Table 7-7. Air Cleaner Figure and Index No. 7-7-1 7-7-2

7-14

Description Clamp, T Bolt Silencer, Air (light duty)

Qty.

CAGE Code 1 1

15434 15434

Model 6B5.9-M Mfg. Part No. 135144 9310559

Model 6BT5.9-M Mfg. Part No. 135144 3905326

S9233-C9-MMA-010

Figure 7-8. Expansion Tank Bracket Table 7-8. Expansion Tank Bracket Figure and Index No. 7-8-1

7-8-2 7-8-3 7-8-4 7-8-5 7-8-6

Description Bracket, Heat Exchanger/Air Cleaner Screw, Cap (hex hd, M8-1.25 x 16 mm) Screw, Cap (hex hd, M12-1.75 x 25 mm) Screw, Cap (hex hd, M12-1.75 x 25 mm) Brace, Air Cleaner Washer, Plain

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

15434

3905097

3905097

4

15434

3900629

3900629

2

15434

3901249

3901249

1

15434

3903200

3903200

1 1

15434 15434

3905099 3011610

3905099 3011610

7-15

S9233-C9-MMA-010

Figure 7-9. Lifting Bracket Table 7-9. Lifting Bracket Figure and Index No. 7-9-1 7-9-2

Description Bracket, Lifting Screw, Cap (hex hd, M12-1.75 x 25 mm)

Qty.

CAGE Code 1 2

Model 6B5.9-M Mfg. Part No.

15434 15434

Figure 7-10. Fresh Water Pump

7-16

3908118 3903200

Model 6BT5.9-M Mfg. Part No. 3908118 3903200

S9233-C9-MMA-010 Table 7-10. Fresh Water Pump Figure and Index No. 7-10-1 7-10-2 7-10-3

Description

Qty.

Pump, Water Seal, Rectangular Ring Screw, Cap (hex hd) (M8-1.25 x 22 mm)

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 1

15434 15434

3903749 3906698

3903749 3906698

2

15434

3900227

3900227

Figure 7-11. Thermostat Housing

Table 7-11. Thermostat Housing Figure and Index No. 7-11-1 7-11-2 7-11-3 7-11-4 7-11-5 7-11-6

Description Screw, Cap (hex hd, M8-1.25 x 70 mm) Screw, Cap (hex hd, M8-1.25 x 35 mm) Housing, Thermostat Thermostat Gasket Bracket, Lifting

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

2

15434

3903096

3903096

1

15434

3900632

3900632

1 1 1 1

15434 15434 15434 15434

3903756 3912587 3903301 3903757

3903756 3912587 3903301 3903757

7-17

S9233-C9-MMA-010

Figure 7-12. Vibration Damper Table 7-12. Vibration Damper Figure and Index No. 7-12-1 7-12-2 7-12-3

7-18

Description Screw, Cap (hex hd, M12-1.25 x 36 mm) Pulley, Crankshaft Damper, Vibration

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Pan No.

4

15434

3903857

3903857

1 1

15434 15434

3907982 3911422

3907982 3911422

S9233-C9-MMA-010

Figure 7-13. Front Gear Cover/Gear Housing Table 7-13. Front Gear Cover/Gear Housing Figure and Index No. 7-13-1 7-13-2 7-13-3 7-13-4 7-13-5 7-13-6 7-13-7 7-13-8 7-13-9 7-13-10 7-13-11 7-13-12 7-13-13 7-13-14 7-13-15

Description Gasket, Gear Housing Seal, Rectangular Ring Housing, Timing Seal, O-Ring Ring, Retaining Pin, Timing Screw, Cap (rdhd, M5-.8 x 17 mm) Screw, Cap (hex hd, M12-1.75 x 25 mm) Plate, Cover Gasket, Accessory Drive Cover Screw, Cap (hex hd, M8-1.25 x 50 mm) Screw, Cap (hex hd; M8-1.25 x 16 mm) Retainer, Belt Screw, Cap (hex hd; M8-1.25 x 60 mm) Seal, Oil

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 1

15434 15434

3914384 3906693

3914384 3906693

1 1 1 1 2

15434 15434 15434 15434 15434

3905933 3903927 3904849 3903924 3907998

3905933 3903927 3904849 3903924 3907998

2

15434

3901249

3901249

1 1

15434 15434

3214868 3913192

3914868 3913192

10

15434

3900633

3900633

16

15434

3900629

3900629

1 1

15434 15434

3912772 3901446

3912772 3901446

1

15434

3904343

3900709

7-19

S9233-C9-MMA-010 Table 7-13. Front Gear Cover/Gear Housing - Continued Figure and Index No. 7-13-16 7-13-17 7-13-18 7-13-19 7-13-20 NS NS NS

Description

Qty.

Cover, Gear Cover, Access Hole Seal, Rectangular Ring Gasket, Gear Cover Housing, Gear Dataplate Screw, Drive Dataplate

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 1 1

15434 15434 15434

3903794 3903463 3903475

3903794 3903463 3903475

1 1 1 4 1

15434 15434 15434 15434 15434

3910500 3910411 391027 3908612 3906610

3924375 3911712 391027 3908612 3906610

Figure 7-14. Sea Water Pump Table 7-14. Sea Water Pump Figure and Index No. 7-14-1 7-14-2 7-14-3 7-14-4 7-14-5 7-14-6

7-20

Description Tube, Sea Water Pump Hose, Elbow Screw, Cap (hex hd, M12-1.75 x 30 mm) Pump, Sea Water Gasket, Hydraulic Pump Clamp, Hose

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

15434

3905062

3905062

1 2

15434 15434

188580 3910495

188580 3910495

1 1

15434 15434

3907458 3009400

3907458 3009400

2

15434

209773

209773

S9233-C9-MMA-010 Table 7-14. Sea Water Pump - Continued Figure and Index No. NS

Description

Qty.

Sea Water Pump Repair Kit

CAGE Code 1

Model 6B5.9-M Mfg. Part No.

15434

3908220

Model 6BT5.9-M Mfg. Part No. 3908220

Figure 7-15. Heat Exchanger Table 7-15. Heat Exchanger Figure and Index No. 7-15-1 7-15-2 7-15-3 7-15-4 7-15-5 7-15-6 7-15-7 7-15-8

Description Exchanger, Heat Isolator, Vibration Bracket, Heat Exchanger Hose, Plain Plug, Pipe Tube, Water Transfer Clamp, Hose Plug, Zinc

Qty.

CAGE Code

Model 6B5.9-M Mfg. Pan No.

Model 6BT5.9-M Mfg. Part No.

1 2 2

15434 15434 15434

391-583 3905048 3905344

391-583 3905048 3905344

2 1 1 4 1

15434 15434 15434 15434 15434

63549 S-949-B 3905052 43828-D 68241

63549 S-949-B 3905052 43828-D 68241

7-21

S9233-C9-MMA-010 Table 7-15. Heat Exchanger - Continued Figure and Index No. 7-15-9 7-15-10 7-15-11 7-15-12 7-15-13 7-15-14 7-15-15 7-15-16 7-15-17 7-15-18 7-15-19 7-15-20 7-15-21 7-15-22

Description

Qty.

Gasket, End Cover, End Washer, Fiber Screw (hex hd) Hose Hose Elbow, Male Adapter Clamp, Hose Cock, Drain Tank, Expansion Cap, Filler Hose, Plain Screw, Cap (hex hd) Clamp, Retaining

CAGE Code 2 2 2 2 1 1 2 4 1 1 1 1 4 2

Model 6B5.9-M Mfg. Pan No.

15434 15434 15434 15434 15434 15434 15434 15434 15434 15434 15434 15434 15434 15434

3910343 3910344 3910556 3910345 AS400960M9 555538 68139 43828-C S-962-E 391-1399 3907022 3275209 3908226 3905057

Model 6BT5.9-M Mfg. Part No. 3910343 3910344 3910556 3910345 AS400960M9 555538 68139 43828-C S-962-E 391-1399 3907022 3275209 3908226 3905057

Figure 7-16. Water Inlet Connection

Table 7-16. Water Inlet Connection Figure and Index No. 7-16-1 7-16-2 7-16-3 7-16-4

7-22

Description Connection, Water Inlet Seal, Ring (Rectangular) Plug, Pipe Screw, Cap (hex hd)

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

15434

3907007

3907007

1

15434

3906697

3906697

1 3

15434 15434

3008468 3902460

3008468 3902460

S9233-C9-MMA-010

Figure 7-17. Marine Transmission Oil Cooler Table 7-17. Marine Transmission Oil Cooler Figure and Index No. 7-17-1 7-17-2 7-17-3 7-17-4 7-17-5 7-17-6 7-17-7 7-17-8 7-17-9

Description Elbow, Male Adaptor Cooler, Oil Clamp, Hose Hose, Elbow U-Bolt Isolator, Noise Screw, Cap (hex hd, M10-1.50 x 30 mm) Nut, Hex (heavy) Bracket, Oil Cooler

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

2 1 6 1 2 1 2

15434 15434 15434 15434 15434 15434 15434

3005945 3910594 43828-A 188580 3905049 3905055 3903112

3005845 3910584 43828-A 188580 3905049 3905055 3903112

4 1

15434 15434

S-224 3911734

S-224 3911734

7-23

S9233-C9-MMA-010 Table 7-17. Marine Transmission Oil Cooler - Continued Figure and Index No. 7-17-10 7-17-11 7-17-12 NS NS NS

7-24

Description Hose, Elbow Tube, Sea Water Pump Hose, Plain Hose, Flexible Hose, Flexible Elbow, Street

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 1

15434 15434

3275391 3905059

3275391 3905059

1 1 1 1

15434 15434 15434 15434

9539-A AM8012SS AM8023MS 70470

9539-A AM8012SS AM8023MS 70470

S9233-C9-MMA-010

Figure 7-18. Exhaust Manifold/Intake Cover

7-25

S9233-C9-MMA-010 Table 7-18. Exhaust Manifold/Intake Cover Figure and Index No. 7-18-1 7-18-2 7-18-3 7-18-4 7-18-5 7-18-6 7-18-7 7-18-8 7-18-9 7-18-10 7-18-11 7-18-12 7-18-13 7-18-14 7-18-15 7-18-16 7-18-17 7-18-18 7-18-19 7-18-20 7-18-21 7-18-22 7-18-23 7-18-24

7-26

Description Clamp, Hose Hose, Plain Tube, Air Clamp, Hose Hose, Plain Screw, Cap (hex hd, M10-1.50 x 30 mm) Clamp, Hose Hose, Plain Gasket, Turbocharger Plug, Expansion Gasket, Manifold Manifold, Exhaust Washer, Plain Screw, Cap (hex hd, M10-1.5 x 123 mm) Stud Clamp, Hose Hose, Plain Connection, Water Transfer Coupling, Elbow Hose (90°) Nut, Flange (hex) Plug, Expansion Gasket, Intake Manifold Cover Screw, Cap (hex hd, M8-1.25 x 26 mm) Cover, Intake Manifold

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

2 1 1 2 1 4

15434 15434 15434 15434 15434 15434

NA NA NA NA NA 3903112

3026396 3904422 3910331 3008690 3901804 3903112

2 1 2 4 6 1 8 12

15434 15434 15434 15434 15434 15434 15434 15434

NA NA 3905033 3908092 3905443 3905322 3009330 3907789

43828-A 3910578 3905033 3908092 3905443 3905322 3009330 3907789

4 2 1 1

15434 15434 15434 15434

3907978 21073 3905089 3907165

3907978 21073 3905089 3907165

1

15434

3908221

3908221

4 1 1

15434 15434 15434

3818824 3007636 3902002

3818824 3007636 3902002

12

15434

3904341

3904341

1

15434

3910333

3910333

S9233-C9-MMA-010

Figure 7-19. Exhaust Outlet Connection Table 7-19. Exhaust Outlet Connection Figure and Index No. 7-19-0 7-19-1 7-19-2 7-19-3 7-19-4

Description Connection, Exhaust Outlet Hose, Elbow Plug, Pipe Clamp, Hose Screw, Cap (hex hd, M8-1.25 x 20 mm)

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

15434

3913460

3910894

1 1 2 4

15434 15434 15434 15434

3910777 3906619 43828-B 3900630

3910777 3906619 43828-B 3900630

7-27

S9233-C9-MMA-010

Figure 7-20. Turbocharger

7-28

S9233-C9-MMA-010 Table 7-20. Turbocharger Figure and Index No. 7-20-0 7-20-1 7-20-2 7-20-3 7-20-4 7-20-5 7-20-6 7-20-7 7-20-8 7-20-9 7-20-10 7-20-11 7-20-12 7-20-13 7-20-14 7-20-15 7-20-16 7-20-17 7-20-18 7-20-19 7-20-20 7-20-21 7-20-22 7-20-23 7-20-24 7-20-25 7-20-26 7-20-27 7-20-28 7-20-29 7-20-30 7-20-31 7-20-32 7-20-33 7-20-34 7-20-35 NS NS

Description Assembly, Turbocharger Dataplate Screw, Drive Housing, Compressor Nut, V-band (regular hex) Clamp, V-band Seal, Rectangular Ring Locknut Impeller Diffuser Seal, Rectangular Ring Seal, Split Ring Slinger, Oil Baffle, Oil Screw (flat hd; M8-1.25 x 12 mm) Bearing, Thrust Collar, Thrust Ring, Retaining Bearing Screw, Cap (hex hd; M8-1.25 x 12 mm) Lockplate Plate, Clamping Gasket, Oil Drain Lockplate Screw, Cap (hex hd; M6-1.0 x 18 mm) Housing, Bearing Shield, Heat Seal, Split Ring Shaft and Wheel Screw, Banjo Connector Washer, Plain Union, Banjo Connector Adapter, Reducing Housing, Turbine Plug, Threaded Gasket Rotor Assembly Turbo Repair Kit

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No. Mfg. NA

Model 6BT5.9-M MFG. Part No.

1

15434

3524424

1 2 1 1

15434 15434 15434 15434

3519905 3519163 3522389 3503335

1 1

15434 15434

3521832 3523958

1 1 1 1

15434 15434 15434 15434

3503562 3521711 3522801 3502449

1 1 1 3

15434 15434 15434 15434

3758848 3503662 3503668 3503347

1 1 4 2 4

15434 15434 15434 15434 15434

3518987 3518980 3762259 3503100 3759917

2 1 1 2 4

15434 15434 15434 15434 15434

3501102 3501188 3901805 3502066 3522827

1 1 1 1 1

15434 15434 15434 15434 15434

3520702 3519302 3756754 3510336 3523050

4 1

15434 15434

3910339 3523049

1 1 1 1 1 1

15434 15434 15434 15434 15434 15434

3503678 3520730 3503677 3905033 3523755 3802067

7-29

S9233-C9-MMA-010 Table 7-20. Turbocharger - Continued Figure and Index No. NS NS NS NS NS NS NS NS NS NS

Description

Qty.

Connector, Female Clamp, Hose Clip Screw, Cap (hex hd) Gasket, Oil Drain Tube, Oil Drain Hose, Plain Hose, flexible Connection, Oil Drain Tube, Oil Drain

CAGE Code 1 4 2 2 1 1 2 1 1 1

Model 6B5.9-M Mfg. Part No. Mfg.

15434 15434 15434 15434 15434 15434 15434 15434 15434 15434

NA

Model 6BT5.9-M MFG. Part No. S-1008-1 43828-A 108722 3900630 3901850 3903744 3903745 3905084 3910322 3912941

Figure 7-21. Oil Level Gauge Table 7-21. Oil Level Gauge Figure and Index No. 7-21-1

7-30

Description Dipstick

Qty.

CAGE Code 1

15434

Model 6B5.9-M Mfg. Part No. 3907012

Model 6BT5.9-M Mfg. Part No. 3907012

S9233-C9-MMA-010 Table 7-21. Oil Level Gauge - Continued Figure and Index No. 7-21-2 7-21-3 7-21-4 7-21-5 7-21-6 7-21-7 7-21-8 7-21-9 7-21-10

Description

Qty.

End, Oil Gauge Tube Clamp, Spring Brace, Tube Screw, Cap (hex hd, M8-1.25 x 16 mm) Tube, Oil Gauge Tube, Oil Gauge Plug, Expansion Clip Nut, Hex (regular)

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 2 1 1

15434 15434 15434 15434

3905802 3909395 3905803 3900629

3905802 3909395 3905803 3900629

1 1 2 1 1

15434 15434 15434 15434 15434

3905800 3905425 3900955 108722 3900240

3905800 3905425 3900955 108722 3900240

Figure 7-22. Lube Oil Pump

Table 7-22. Lube Oil Pump Figure and Index No. 7-22-1 7-22-2

Description Screw, Cap (hex hd, M8-1.25 x 30 mm) Pump, Lube Oil

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

4

15434

3900677

3900677

1

15434

3906414

3906414

7-31

S9233-C9-MMA-010

Figure 7-23. Lube Oil Cooler Table 7-23. Lube Oil Cooler Figure and Index No. 7-23-1 7-23-2 7-23-3 7-23-4 7-23-5 7-23-6 7-23-7 7-23-8 7-23-9 7-23-10 7-23-11 7-23-12

7-32

Description Cartridge, Lube Oil Filter Head, Lube Oil Filter Plug, Pipe (1/8-27 NPT) Valve, Pressure-Relief Gasket, Filter Head Core, Cooler Gasket, Oil Cooler Core Plug, Threaded (M221.5 x 14 mm) Washer, Sealing Spring, Compression Plunger, PressureRegulator Screw, Cap (hex hd, M8-1.25 x 35 mm)

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

15434

3908615

3908615

1 1

15434 15434

3902295 3906619

3902295 3906619

1 1 1 1

15434 15434 15434 15434

3902338 3912638 3911940 3904427

3902338 3912638 3911940 3904427

1

15434

3904386

3904386

1 1 1

15434 15434 15434

3902425 3903261 3909376

3902425 3903261 3909376

14

15434

3900632

3900632

S9233-C9-MMA-010

Figure 7-24. Fuel Lift Pump Table 7-24. Fuel Lift Pump Figure and Index No. 7-24-1 7-24-2 7-24-3

7-24-4 7-24-5 7-24-6

Description Washer, Plain Tube, Fuel Supply Screw, Banjo Connector (M12-1.5 x 24 mm) Pump, Fuel Lift Screw, Cap (hex hd; M8-1.25 x 25 mm) Gasket, Cover Plate

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

2 1 1

15434 15434 15434

3903037 3907582 3903035

3903037 3907582 3903035

1 2

15434 15434

3904374 3900631

3904374 3900631

1

15434

3904044

3904044

7-33

S9233-C9-MMA-010

Figure 7-25. Fuel Piping

7-34

S9233-C9-MMA-010 Table 7-25. Fuel Piping Figure and Index No. 7-25-1 7-25-2 7-25-3 7-25-4 7-25-5 7-25-6 7-25-7 7-25-8 7-25-9 7-25-10 7-25-11 7-25-12 7-25-13 7-25-14 7-25-15 7-25-16 7-25-17 7-25-18 7-25-19 7-25-20 7-25-21 7-25-22

Description Isolator, Vibration Brace, Tube Washer, Plain Screw, Cap (hex hd, M5-.8 x 20 mm) Manifold, Fuel Seal, Grommet Tee, Male Union Tube, Fuel Drain Screw, Cap (hex hd, M8-1.25 x 20 mm) Seal, O-ring Tube, Fuel Drain Seal, Banjo Connector Screw, Banjo Connector (M6-1.0 x 15 mm) Brace, Tube Screw (hex hd, M8-1.25 x 26 mm) Tube, Fuel Supply Tube, Fuel Supply Tube, Fuel Supply Brace, Tube Tube, Fuel Supply Tube, Fuel Supply Tube, Fuel Supply

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

6 3 6 6

15434 15434 15434 15434

3904520 3904519 3903723 3903609

3904520 3904519 3903723 3903609

1 3 1 1 2

15434 15434 15434 15434 15434

3909696 3905391 3905388 3905692 3900630

3909696 3905391 3905388 3905692 3900630

2 1 6 6

15434 15434 15434 15434

3900267 3905709 3903380 3905307

3900267 3905709 3903380 3905307

2 2

15434 15434

3906894 3904341

3906584 3904341

1 1 1 1 1 1 1

15434 15434 15434 15434 15434 15434 15434

3906033 3906034 3906035 3906651 3906036 3906037 3906038

3906033 3906034 3906035 3906651 3906036 3906037 3906038

7-35

S9233-C9-MMA-010

Figure 7-26. Fuel Filter Table 7-26. Fuel Filter Figure and Index No. 7-26-1 7-26-2 7-26-3 7-26-4 7-26-5 7-26-6 7-26-7 7-26-8 7-26-9

7-36

Description Adapter, Filter Head Filter, Fuel Washer, Plain Screw, Banjo Connector Tube, Fuel Supply Seal Grommet Tube, Fuel Supply Tee, Male Union Tube, Fuel Supply

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 1 2 1

15434 15434 15434 15434

3903845 3903640 3903037 3905860

3903845 3903640 3903037 3905860

1 3 1 1 1

15434 15434 15434 15434 15434

3905375 3905351 3905364 3905353 3905363

3905375 3905351 3905364 3905353 3905363

S9233-C9-MMA-010

Figure 7-27. Fuel Injection Nozzle Table 7-27. Fuel Injection Nozzle Figure and Index No. 7-27-0 7-27-1 7-27-2

Description Assembly, Fuel Injection Nozzle Seal, Rectangular Ring Shim (1.00 mm thick) Shim (1.04 mm thick) Shim (1.08 mm thick) Shim (1.10 mm thick) Shim (1.14 mm thick) Shim (1.18 mm thick) Shim (1.20 mm thick) Shim (1.24 mm thick) Shim (1.28 mm thick) Shim (1.30 mm thick) Shim (1.34 mm thick) Shim (1.38 mm thick) Shim (1.40 mm thick)

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

6

OHD22

3919304

3908238

1

OHD22

3909356

3909356

AR AR AR AR AR AR AR AR AR AR AR AR AR

OHD22 ORD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22

3905156 3905157 3905158 3905159 3905160 3895161 3905162 3905163 3905164 3905165 3905166 3905167 3905168

3905156 3905157 3905158 3905159 3905160 3905161 3905162 3905163 3905164 3905165 3905166 3905167 3905168

7-37

S9233-C9-MMA-010 Table 7-27. Fuel Injection Nozzle - Continued Figure and Index No.

7-27-3 7-27-4 7-27-5 7-27-6 7-27-7 7-27-8 7-27-9 7-27-10 NS

7-38

Description Shim (1.44 mm thick) Shim (1.48 mm thick) Shim (1.50 mm thick) Shim (1.54 mm thick) Shim (1.58 mm thick) Shim (1.60 mm thick) Shim (1.64 mm thick) Shim (1.68 mm thick) Shim (1.70 mm thick) Shim (1.74 mm thick) Shim (1.76 mm thick) Shim (1.78 mm thick) Shim (1.80 mm thick) Shim (1.84 mm thick) Shim (1.88 mm thick) Shim (1.90 mm thick) Shim (1.94 mm thick) Shim (1.98 mm thick) Spring, Compression Spindle Washer, Sealing Nut, Injection Nozzle Nozzle Valve, Needle Disc, Intermediate Seal, Banjo Connector Kit, Injection Nozzle

Qty. AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 1 1 1 1 1 1 1 1 1

CAGE Code OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22 OHD22

Model 6B5.9-M Mfg. Part No. 3905169 3905170 3905171 3905172 3905173 3905174 3905175 3905176 3905177 3905178 3905179 3905180 3905181 3905182 3905183 3905184 3905185 3905186 3905125 3905153 3900808 3905155 NPN NPN 3905154 3903380 3802058

Model 6BT5.9-M Mfg. Part No. 3905169 305170 3905171 3905172 3905173 3905174 3905175 3905176 3905177 3905178 3905179 3905180 3905181 3904182 3905183 3905184 3905185 3905186 3905125 3905153 3900808 3905155 NPN NPN 3905154 3903380 3802058

S9233-C9-MMA-010

Figure 7-28. Fuel Injection Pump (Sheet 1 of 2)

7-39 / (7-40 Blank)

7-40 @@FIpgtype@@BLANK@@!FIpgtype@@

S9233-C9-MMA-010

Figure 7-28. Fuel Injection Pump (Sheet 2 of 2)

7-41 / (7-42 Blank)

7-42 @@FIpgtype@@BLANK@@!FIpgtype@@

S9233-C9-MMA-010 Table 7-28. Fuel Injection Pump Figure and Index No. 7-28-1 7-28-2 7-28-3 7-28-4 7-28-5 7-28-6 7-28-7 7-28-8 7-28-9 7-28-10 7-28-11 7-28-12 7-28-13 7-28-14 7-28-15 7-28-16 7-28-17 7-28-18 7-28-19 7-28-20 7-28-21 7-28-22 7-28-23 7-28-24 7-28-25 7-28-26 7-28-27 7-28-28 7-28-29 7-28-30 7-28-31 7-28-32 7-28-33 7-28-34 7-28-35 7-28-36 7-28-37 7-28-38 7-28-39 7-28-40 7-28-41 7-28-42 7-28-43

Description Plug, Protection Connection, Fuel Washer Filter Spring Piston Sleeve and Piston Washer Spring Spring, Guide Adjuster, Pressure Screw Bracket Spring, Single Link Seal, Lead Nameplate Screw, Hex Head Washer, Lock Plate, Cover Screw, Socket Head Washer Ring, Sealing Shoes and Roller Assembly Gasket Ring, Cam Ring, Retaining, Internal Nameplate Rivet, Drive Washer Screw, Vent Vent, Screw Valve, Metering (size A) Screw, Hex Head Washer, Tab Washer Washer, Thrust Ring, Retaining, External Key, Drive Washer, Lock Nut Gasket Spacer Screw

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 1 1 1 1 1 1 1 1 1 1 4 1 1 3 1 2 2 1 1 1 1 1

63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632

9120-012 9120-007 NW5-77W4 7123-620 7123-551 7123-15G 7135-74BS 5936-177 7123-439 7167-183F 7139-650G 7167-667 9120-020 7123-453B 5606-62 9120-028 5334-274 NP1-5 7180-55A 5335-694 5339-964 5855-30BC 7135-72N

9120-012 9120-007 NW5-77W4 7123-620 7123-551 7123-15G 7135-74BS 5936-177 7123-439 7167-183F 7139-650G 7167-667 9120-020 7123-453B 5606-62 9120-028 5334-274 NP1-5 7180-55A 5335-684 5339-964 5855-30BC 7135-72N

1 1 1

63632 63632 63632

9045-137 7139-687E 5950-64A

9045-137 7139-687E 5950-64A

1 2 2 1 1 AR

63632 63632 63632 63632 63632 63632

7180-54B NR21-4 NW5-18W4 5334-332 7123-352B 7139-559D

7180-54B NR21-4 NW5-18W4 5334-332 7123-352B 7139-559D

1 1 2 AR 1

63632 63632 63632 63632 63632

5334-277 7167-331 NW5-18W4 7139-955 NM1-9

5334-277 7167-331 NW5-18W4 7139-955 NM1-9

1 1 1 1 1 2

63632 63632 63632 63632 63632 63632

NK1-22 5001-40 7182-189 9120-003 9120-002 9120-008

NK1-22 5001-40 7182-189 9120-003 9120-002 9120-008

7-43

S9233-C9-MMA-010 Table 7-28. Fuel Injection Pump - Continued Figure and Index No. 7-28-44 7-28-45 7-28-46 7-28-47 7-28-48 7-28-49 7-28-50 7-28-51 7-28-52 7-28-53 7-28-54 7-28-55 7-28-56 7-28-57 7-13-58 7-28-59 7-28-60 7-28-61 7-28-62 7-28-63 7-28-64 7-28-65 7-28-66 7-28-67 7-28-68 7-28-69 7-28-70 7-28-71 7-28-72 7-28-73 7-28-74 7-28-75 7-28-76 7-28-77 7-28-78 7-28-79 7-28-80 7-28-81 7-28-82 7-28-83 7-28-84 7-28-85 7-28-86 7-28-87

7-44

Description Housing Assembly Seal, Oil Retaining Ring, Internal Washer, Thrust Drive, Shaft Weights, Governor Sleeve, Thrust Ring, Spring Screw, Hex Head Washer Ring, Sealing Screw, Locking Plate, Adjusting Assembly, Head and Rotor Ring, Seal Liner, Transfer Pump Rotor, Transfer Pump Blade, Transfer Pump Plate, End Plate, Clamping Screw Cap, Sealing Screw, Hex Head Nut Washer Screw, Vent Vent, Screw Washer Washer Connection, Fuel Plug, Protection Guide, Spring Washer Spring Nut, Self-Locking Lever, Break Back Nut, Cap Washer Nut, Cap Washer, Lock Lever Cover, Control Gasket Stud

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 2 1

63632 63632 63632

7123-454CF 5393-252R5 5950-137

7123-454CF 393-252R 5950-137

1 1 4 1 1 1 1 1 1 AR 1

63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632

5936-124 7180-173B 7123-914G 7123-618 5921-16 5334-280 9120-004 5855-30BR 9120-009 NPN 7180-158L

5936-124 7180-173B 7123-914G 7123-618 5921-16 5334-280 9120-004 5855-30BR 9120-009 NPN 7180-158L

1 1 1 2 1 2 4 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2

63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632

7139-43 7139-540 7123-18 7123-19 7123-576P 7139-267 5334-315F 7139-184 5334-267E NU9-8Y1 NW1-65Y1 5334-332 7123-351B NW5-15W 5936-332C 9120-005 9120-011 7139-441 5936-291 7139-442 5330-406 7135-75E 5330-344 5339-970 5330-406 NP1-5 7123-725B 7123-888N 7123-287 7123-527

7139-43 7139-540 7123-18 7123-19 7123-576P 7139-267 5334-315F 7139-184 5334-276E NU9-8Y1 NW1-65Y1 5334-332 7132-351B 4NW5-15W4 5936-332C 9120-005 9120-011 7139-441 5936-291 7139-442 5330-406 7135-75E 5330-344 5339-970 5330-406 NP1-5 7123-725B 7123-888N 7123-287 7123-527

S9233-C9-MMA-010 Table 7-28. Fuel Injection Pump - Continued Figure and Index No. 7-28-88 7-28-89 7-28-90 7-28-91 7-28-92 7-28-93 7-28-94 7-28-95 7-28-96 7-28-97 7-28-98 7-28-99 7-28-100 7-28-101 7-28-102 7-28-103 7-28-104 7-28-105 7-28-106 7-28-107 7-28-108 7-28-109 7-28-110 7-28-111 7-28-112 7-28-113 7-28-114 7-28-115 7-28-116 7-28-117 7-28-118 7-28-119 7-28-120 7-28-121 7-28-122 7-28-123 NS NS NS NS

Description Ring, Sealing Shaft, Throttle Plate, Keep Spring Washer, Lock Bar, Shut-Off Arm, Governor Spring Spring, Idling Guide, Spring Shaft, Shutoff Tube, Fuel Injection (high-pressure banjo) Valve, Pressure Plug, Piston Washer Nut, Cap Ball, Steel Fitting, Head Locating Ring, Sealing Gasket Ring, Sealing Spring Shim Screw, Hex Head Washer Cap, Spring Screw, Cam Stud Housing and Piston (A.A.) Blade, Lucar Screw, Socket Head Washer Solenoid (complete) Ring, Sealing Spring, Solenoid Cap, Protection Screw, Drive Plate Dowel Gear, Drive Ring, Backing

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

4 1 1 1 2 1 1 1 1 1 1 6

63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632

5855-30 7123-770A 7123-355 7123-898X 7123-600 7123-304B 7135-76X 7123-89 7123-92D 7123-93 7123-726 7167-978

5855-30 7123-770A 7123-355 7123-898X 7123-600 7123-304B 7135-76X 7123-89 7123-92D 7123-93 7123-726 7167-978

6 1 1 1 1 1

63632 63632 63632 63632 63632 63632

7139-177G 7123-473 7022-160D 5330-362 NC7-8 7123-261B

7139-177G 7123-473 7022-160D 5330-362 NC7-8 7123-261B

2 1 2 1 1 1 1 1 1 1 1

63632 63632 63632 63632 63632 63632 63632 63632 63632 63632 63632

7139-821 7123-937 5855-308D 7123-294T NW2-80Y1 7167-299 5936-355C 7167-358Z 7123-975 5335-694A 7123-819CB

7139-821 7123-937 5855-308D 7123-294T NW2-80Y1 7167-299 5936-355C 7167-358Z 7123-975 5335-694A 7123-819CB

1 1 1 1 1 1 1 2 2 1 1

63632 63632 63632 63632 63632 63632 63632 63632 63632 15434 63632

9120-017 7167-78 7167-786 7180-49A 5855-30DT 7167-787 7098-109B 5334-245 7167-386 3914912 7182-423

9120-017 57167-785 7167-786 7180-49A 5855-30DT 7167-787 7098-109B 5334-245 7167-386 3914912 7182-423

7-45

S9233-C9-MMA-010

Figure 7-29. Flywheel Table 7-29. Flywheel Figure and Index No. 7-29-1 7-29-2 7-29-3 7-29-4 NS

7-46

Description Screw, Cap (hex hd, M12-1.25 x 32 mm) Washer, Plain Gear, Flywheel Ring Flywheel Flywheel Assembly

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

8

15434

3901395

3901395

8 1 1 1

15434 15434 15434 15434

3900269 3901774 3905616 3905831

3900269 2901774 3905616 3905831

S9233-C9-MMA-010

Figure 7-30. Flywheel Housing Table 7-30. Flywheel Housing Figure and Index No. 7-30-1 7-30-2 7-30-3 7-30-4 7-30-5 7-30-6 7-30-7 7-30-8 7-30-9 7-30-10 7-30-11 7-30-12 NS

Description Screw, Cap (hex hd, M12-1.25 x 40 mm) Plug, Threaded Plate, Cover Screw, Cap (hex hd, M8-1.25 x 21 mm) Seal, O-Ring Seal, Oil Screw, Cap (hex hd, M6-1.00 x 14 mm) Gasket, Rear Cover, Rear Plug, O-Ring Seal, O-Ring Housing, Flywheel Seal Kit

Qty.

CAGE Code

Model 6135.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

8

15434

3910540

3910540

1 1 2

15434 15434 15434

3904181 3908095 3912072

3904181 3908095 3912072

1 1 6

15434 15434 15434

3912473 3904089 3900627

3912473 3904089 3900627

1 1 1 1 1 1

15434 15434 15434 15434 15434 15434

3901019 3906526 3910248 3910260 3903282 3909410

3901019 3906526 3910428 3910260 3903282 3909410

7-47

S9233-C9-MMA-010

Figure 7-31. Cam Follower Cover Table 7-31. Cam Follower Cover Figure and Index No. 7-31-1 7-31-2 7-31-3 7-31-4 7-31-5 7-31-6 7-31-7 7-31-8

7-48

Description Gasket, Push Rod (cam follower) Cover Baffle, Breather Cover, Push Rod (cam follower) Clamp, Spring Hose Hose, Plain Clip Screw, Cap (hex hd) Seal, Grommet

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

15434

3904776

3904776

1 1

15434 15434

3907586 3911822

3907586 3911822

1 1 1 5 5

15434 15434 15434 15434 15434

3904230 3909049 3909670 3900629 3900267

3904230 3908049 3909670 3900629 3900267

S9233-C9-MMA-010

Figure 7-32. Valve Covers Table 7-32. Valve Covers Figure and Index No. 7-32-1 7-32-2 7-32-3 7-32-4 7-32-5 7-32-6 7-32-7

Description Screw, Cap (hex hd, M8-1.25 x 25.5 mm) Seal, O-Ring Cover, Valve Gasket, Valve Cover Cover, Valve Seal, Rectangular Ring Cap, Filler

Qty

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

6

15434

3907049

3907049

6 5 6 1 1

15434 15434 15434 15434 15434

3910824 3902604 3902666 3902605 3902363

3910824 3902604 3902666 3902605 3902363

1

15434

3901895

3901895

7-49

S9233-C9-MMA-010

Figure 7-33. Rocker Lever

7-50

S9233-C9-MMA-010 Table 7-33. Rocker Lever Figure and Index No. 7-33-1 7-33-2 7-33-3 7-33-4 7-33-5 7-33-6 7-33-7 7-33-8 7-33-9 7-33-10 7-33-11 NS NS NS NS NS

Description Support, Rocker Lever Screw, Cap (hex hd, M8-1.25 x 75 mm) Screw, Cap (hex hd, M12-1.75 x 180 mm) Lever, Rocker (exhaust) Nut, Regular (hex) Plug, Expansion Ring, Retaining Washer, Plain Setscrew (slotted) Rod, Push Lever, Rocker (intake) Support, Rocker Lever Support, Rocker Lever Shaft, Rocker Lever Lever, Rocker (intake) Assembly Lever, Rocker (exhaust) Assembly

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

6

15434

3910814

3910814

6

15434

3901221

3901221

6

15434

3903940

3903940

6

15434

3910810

3910810

12 12 12 12 12 12 6 1

15434 15434 15434 15434 15434 15434 15434 15434

S-205 3907555 3900242 3900245 3900706 3904679 3910811 3910815

S-205 3907555 3900242 3900245 3900706 3904679 3910811 3910815

6

15434

3910816

3910816

6 6

15434 15434

3910813 3910809

3910813 3910809

6

15434

3910808

3910808

7-51

S9233-C9-MMA-010

Figure 7-34. Cylinder Head

7-52

S9233-C9-MMA-010 Table 7-34. Cylinder Head Figure and Index No. 7-34-0 7-34-1 7-34-2 7-34-3 7-34-4 7-34-5 7-34-6 7-34-7 7-34-8 7-34-9 7-34-10 7-34-11 7-34-12 7-34-13 7-34-14 7-34-15 7-34-16 7-34-17

NS NS NS NS

Description Assembly, Cylinder Head Plug, Pipe Plug, Pipe Plug, Pipe Gasket, Cylinder Head Insert, Valve (exhaust) Insert, Valve (intake) Valve, Exhaust Valve, Intake Head, Cylinder (bare) Plug, Expansion Spring, Valve Retainer, Valve Spring Collet, Valve Seal, Valve Stem Screw, Cap (hex hd, M12-1.75 x 120 mm) Screw, Cap (hex hd, M12-1.75 x 70 mm) Guide, Valve Stem (thin wall intake and exhaust) Guide, Valve Stem (thick wall intake) Guide, Valve Stem (thick wall exhaust) Intake Valve Kit Exhaust Valve Kit

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

15434

3910276

3910276

1 5 2 1

15434 15434 15434 15434

3008469 3908468 3908465 3907057

3008469 3909468 3908465 3907057

1 1 6 6 1 5 12 12 12 12 14

15434 15434 15434 15434 15434 15434 15434 15434 15434 15434 15434

3904105 3906854 3901607 3901117 3909974 3902606 3900276 3900299 3900250 3901097 3903939

3904105 3906854 3901607 3901117 3909974 3902606 3900276 3900299 3900250 3901097 3903939

6

15434

3903938

3903938

12

15434

3906206

3906206

6

15434

3904408

3904408

6

15434

3904409

3904409

6 6

15434 15434

3802005 3802006

3802005 3802006

7-53

S9233-C9-MMA-010

Figure 7-35. Oil Pan

7-54

S9233-C9-MMA-010 Table 7-35. Oil Pan Figure and Index No. 7-35-1 7-35-2 7-35-3 7-35-4 7-35-5 7-35-6 7-35-7 7-35-8 7-35-9 7-35-10 7-35-11 7-35-12 7-35-13 7-35-14 7-35-15 7-35-16

Description Plug, Threaded Seal, O-ring Screw, Cap (hex hd, M8-1.25 x 25 mm) Washer, Sealing Plug, Threaded Washer, Sealing Plug, Threaded Screw, Cap (hex hd, M8-1.25 x 80 mm) Pan, Oil Gasket, Flange Connection, Oil Suction Screw, Cap (hex hd, M8-1.25 x 16 mm) Screw, Cap (hex hd, M8-1.25 x 16 mm) Baffle, Oil Pan Screw, Cap (hex hd, M8-1.25 x 20 mm) Gasket, Oil Pan

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 2 36

15434 15434 15434

3040995 3037537 3900631

3040995 3037537 3900631

1 1 1 1 2

15434 15434 15434 15434 15434

3902425 3904386 3900216 3900215 3902112

3902425 3904386 3900216 3900215 3902112

1 1 1

15434 15434 15434

3911405 3905468 3911407

3911405 3905468 3911407

2

15434

3900225

3900225

1

15434

3900629

3900629

1 4

15434 15434

3911411 3900630

3911411 3900630

1

15434

3911410

3911410

7-55

S9233-C9-MMA-010

Figure 7-36. Camshaft Table 7-36. Camshaft Figure and Index No. 7-36-1 7-36-2 7-36-3 7-36-4 7-36-5 7-36-6

7-56

Description Gear, Camshaft Screw, Cap (hex hd, M8-1.25 x 20 mm) Support, Camshaft Thrust Key, Woodruff (plain, 4.0 mm) Camshaft Tappet, Valve

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 2

15434 15434

3907431 3900620

3907431 3900620

1

15434

3901761

3901761

1

15434

3902332

3902332

1 12

15434 15434

3907824 3907240

3907824 3907240

S9233-C9-MMA-010

Figure 7-37. Cylinder Block

7-57

S9233-C9-MMA-010 Table 7-37. Cylinder Block Figure and Index No. 7-37-1 7-37-2 7-37-3 7-37-4 7-37-5 7-37-6 7-37-7 7-37-8 7-37-9 7-37-10 7-37-11 7-37-12 7-37-13 7-37-14 7-37-15 7-37-16 7-37-17 7-37-18 NS

7-58

Description Plug, Expansion (58.06 mm) Plug, Expansion (17.73 mm) Plug, Expansion Plug, Expansion (1-in.) Dowel, Ring Plug, Expansion Plug, Expansion Plug, Pipe (1/8-27 in.) Block, Cylinder Screw, Cap (hex hd, M14-2.00 x 119 mm) Cap, Main Bearing Dowel, Ring Nozzle, Piston Cooling Bushing, Camshaft Dowel, Pin Plug, Pipe Plug, Expansion Dowel, Ring Block Hardware Kit

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

6

15434

3900965

3900965

3

15434

3900956

3900956

1 4

15434 15434

3900687 3007635

3900687 3007635

2 2 1 2 1 14

15434 15434 15434 15434 15434 15434

3900068 3900955 3900958 3906619 3901204 3904217

3900068 3900955 3900958 3906619 3901204 3904217

7 14 6

15434 15434 15434

3900967 3900068 3901020

3900967 3900068 3901020

1 2 1 1 2 1

15434 15434 15434 15434 15434 15434

3901306 3900257 3008468 3027646 3902343 3905813

3901306 3900257 3008468 NA 3902343 3905813

S9233-C9-MMA-010

Figure 7-38. Piston and Connecting Rod Table 7-38. Piston and Connecting Rod Figure and Index No. 7-38-1 7-38-2 7-38-3

7-38-4 7-38-5 7-38-6 7-38-7 7-38-8 7-38-9 NS NS +

*

Description Rod, Connecting (with cap) Bearing, Connecting Rod Screw, Connecting Rod (M11-1.25 x 59 mm) + Ring, Retaining Pin, Piston + Piston + * Ring, Oil Control + * Ring, Lower Compression + * Ring, Upper Compression Piston Kit Piston Ring Set

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

6

15434

3901569

3901569

12

15434

3901170

3901170

12

15434

3900919

3900919

12 6 6 6 6

15434 15434 15434 15434 15434

3901706 3901793 3906223 NPN NPN

3901706 3901793 3907156 NPN NPN

6

15434

NPN

NPN

6 6

15434 15434

3802060 3802040

3802100 3902050

Part of 3802060 or 3802100.

Part of 3802040 or 3802050. 7-59

S9233-C9-MMA-010

Figure 7-39. Crankshaft and Main Bearings

Table 7-39. Crankshaft and Main Bearings Figure and Index No. 7-39-1 7-39-2 7-39-3 7-39-4 7-39-5 7-39-6 NS NS NS NS

7-60

Description Gear, Crankshaft Crankshaft, Engine Pin, Roll Bearing, Main (upper) Bearing, Crankshaft, Thrust Bearing, Main (lower) Sleeve, Wear (front) Sleeve, Wear (rear) Crankshaft, Engine w/gear Main Bearing Set

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No

1 1 1 6 1

15434 15434 15434 15434 15434

3901258 3907804 3904483 3901090 3906230

3901258 3907804 3904483 3901090 3906230

7 1 1 1

15434 15434 15434 15434

3901150 3906080 3906081 3908032

3901150 3906080 3906081 3908032

1

15434

3802070

3802070

S9233-C9-MMA-010

Figure 7-40. Transmission Mounting Bracket Table 7-40. Transmission Mounting Bracket Figure and Index No. 7-40-1 7-40-2

Description Bracket, Transmission (mount) Screw, Cap (captive washer)

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

2

15434

3907003

3005186

4

15434

103023

3029620

Figure 7-41. Vibration Isolator 7-61

S9233-C9-MMA-010 Table 7-41. Vibration Isolator Figure and Index No. 7-41-0 7-41-1 7-41-2 7-41-3 7-41-4 7-41-5 7-41-6 7-41-7 7-41-8 7-41-9

7-62

Description Isolator, Vibration Stud (3/4-in. UNF, Stl) Nut, Jam (hex hd, stl) Nut (hex hd, stl, grade 5) Washer (stl concave) Insert, Flexible (Buna-N) Washer (stl) Screw (hex hd, grade 5) Pad, Flexible (syn Buna-N) Casting (alum alloy; 556-T6)

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 1

96867 96867

DF-237-MI NPN

DF-237-MI NPN

2 1

96867 96867

NPN NPN

NPN NPN

1 1

96867 96867

NPN 3BG725BME014

NPN 3BG725BME014

1 1

96867 96867

NPN NPN

NPN NPN

1

96967

3BG725BME

3BG725BME

1

96867

NPN

NPN

S9233-C9-MMA-010

Figure 7-42. Fuel/Water Separator Table 7-42. Fuel/Water Separator Figure and Index No. 7-42-0 7-42-1 7-42-2 7-42-3 7-42-4 7-42-5 7-42-6 7-42-7

Description Separator, Fuel/Water Pump, Primer Pump, Vent Head (w/plugs, SAE 9/16-18 ports) Element (30 micron; vacuum) O-ring, Bowl Bowl (metal; w/plugs and drain) Knob, Drain

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1 1 1 1

55752 55752 55752 55752

225 RK20025 RK20027 RK20002

225 RK20025 RK20027 RK20002

1

55752

R26S-UL

R26S-UL

1 1

55752 55752

20016 RK20026

20016 RK20026

1

55752

RK20017

RK20017

7-63

S9233-C9-MMA-010 Table 7-42. Fuel/Water Separator - Continued Figure and Index No. 7-42-8

7-42-9 NS NS

7-64

Description Probe, Water Sensor (w/O-rings and connector) Check, Ball and Cup Kit, Seal Service Kit, Primer Knob and Seal Service

Qty.

CAGE Code

Model 6B5.9-M Mfg. Part No.

Model 6BT5.9-M Mfg. Part No.

1

55752

RK20726

RK20726

1 1 1

55752 55752 55752

RK20011 RK20075 RK20076

RK20011 RK20075 RK20076

S9233-C9-MMA-010 CHAPTER 8 INSTALLATION 8-1.

INTRODUCTION. This chapter provides installation procedures for the diesel engine.

8-2.

INSTALLATION. Install the diesel engine according to the following steps and the manufacturer’s specifications.

WARNING

To prevent injury or death, ensure extreme care and proper lifting devices are used during handling. The equipment is heavy. CAUTION

Prior to installing the engine, ensure that all engine mounts and system interfaces are rust-free, clean, complete, and in good working order. CAUTION

When installing the diesel engine, care must be taken to ensure proper alignment of rotating components. a. Set engine in place using a spreader bar and engine lifting device. b. Install the engine using slings capable of supporting the weight of the engine. c. Install all bedplate holddown bolts to structural foundation supports. The installation angle, flywheel down, is three degrees minimum. d. Uncap and connect the fuel oil return and supply lines, sea water lines, coolant lines, hydraulic piping systems, and lube oil lines. e. Connect the control panel wiring harness. f. Connect the exhaust line to the exhaust manifold. g. Open the fuel line valves. h. Recheck all bolts and connections for tightness. i. Fill all fluids, lube oil, and coolant to proper levels. 8-1

S9233-C9-MMA-010 8-3.

START-UP AND CHECKOUT.

After the engine has been installed, follow the prestart checks listed in chapter 2 and check for proper operation of the following systems: oil, fuel, fresh water, sea water, and electrical and all the engine controls and indicators. 8-4.

ENGINE OPTION LISTS:

The specific engine option lists for each boat listed on the Approval and Procurement Record Page are listed below for future reference. 10 Meter Utility Contract Number: N00024-90-C-2219 Engine Configuration Number: D401015MM12 Engine Description 10 Meter Utility Boat OPTION NO.

OPTION DESCRIPTION

AC 9026 AF 9026 EE 9928 EG 9071 EG 9040 EM 9066 FS 9050 HX 9944 LG 9151 MG 9911 SE 9025 ST 9913 TR 9006 WI 9005 XM 9014

Cleaner, Air Adapter, Front Drive Alternator Instrumentation Engine Instrument Panel, 24V, 6 Cyl. Support, Front Engine Separator, Fuel Water Heat Exchanger Gauge, Oil Level 6B Marine Base Package, Guard Starting Motor Transmission Connection, Water Inlet Mainfold, Exhaust

15 Meter Utility Boat Contract Number: N00024-90-C-2220 Engine Configuration Number: D402013MM22 Engine Description 15 Meter Utility Boat

8-2

Option No.

Option Description

AC 9016 AF 9026 EE 9928 EG 9071 EG 9940 EM 9066 HX 9923 LG 9151 MB 9915

Cleaner, Air Adapter, Front Drive Alternator Instrumentation, Engine Instrument Panel, 24V, 6 Cyl. Support, Front Engine Heat Exchanger Gauge, Oil Level 6BT Marine Base

S9233-C9-MMA-010

Option No.

Option Description

SG 9025 ST 9913 TB 9079 WI 9005

Package, Guard Starting Motor Location, Tubercharger Connection, Water Inlet

26-Foot Personnel Boat Contract Number: N00024-90-C-2222 Engine Configuration Number: D402013MS12 Engine Description 26 Foot Personnel Boat OPTION NO.

OPTION DESCRIPTION

AC 9016 AF 9026 EE 9928 EG 9940 EM 9066 FS 9050 HX 9923 LG 9150 MG 9915 SG 9025 ST 9913 TB 9079 TR 9006 WI 9005 XS 9034

Cleaner, Air Adapter, Front Drive Alternator Instrument Panel 24V, 6 Cyl. Support, Front Engine Separator, Fuel Water Heat Exchanger Gauge, Oil 6BT Marine Base Package, Guard Starting Motor Location, Turbocharger Transmission Connection, Water Inlet Connection, Exhaust

24-Foot Rigid Inflatable Boat (RIB) Contract Number: N00024-91-C-2314 Engine Configuration Number: D402013MM22 Engine Description 24 Foot Rigid Inflatable Boat Option No.

Option Description

AC 9016 EE 9928 EG 9069 EG 9940 EM 9066 HX 9923 LG 9150 MB 9915 PS 9005 RG 9027 SA 9010 SG 9025 TB 9079

Cleaner, Air Alternator Instrumentation, Engine Instrument Panel, 24V, 6 Cyl. Support, Front Engine Heat Exchanger Gauge, Oil Level 6BT Marine Base Pump, Oil Sump Gear Marine Support, Marine Gear Package, Guard Location, Turbocharger

8-3

S9233-C9-MMA-010

8-4

Option No.

Option Description

TR 9004 VB 9009 WI 9010 XS 9042

Transmission Isolator, Vibration Connection, Water Inlet Connection, Exhaust