Deisel Engines

[SGML Version See Change Record ]TECHNICAL MANUAL

DESCRIPTION, OPERATION,MAINTENANCE

AND ILLUSTRATED PARTSBREAKDOWN

DIESEL ENGINES

DISTRIBUTION STATEMENT B: DISTRIBUTION AUTHORIZED TO U. S. GOVERNMENTAGENCIES ONLY; ADMINISTRATIVE/OPERATIVE USE OTHER REQUESTS FOR THISDOCUMENT MUST ME REFERRED TO NAVAL SEA SYSTEMS COMMAND (SEA-09T).

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT ISRESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC. 2751 ETSEQ.) OR THE EXPORT ADMINISTRATION ACT OF 1979, AS AMENDED, TITLE 50U.S.C., APP 2401, ET SEQ. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TOSEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH PROVISIONSOF OPNAVINST 5510.161, REFERENCE (JJ).

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO-SURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT.

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PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

30 OCT 1990

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RECORD OF CHANGESCHANGE DATE DESCRIPTION OF CHANGE CHANGE NO.

NOTE

THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONICSOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NOLOEP. ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOTMATCH THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE CONTENT ISEXACTLY THE SAME. ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TM WILL ONLY FITIN THIS PAGINATED VERSION.

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FOREWORD

This Technical Manual is intended to provide operation, maintenance, and repair information for the mod-els 6B5.9-M and 6BT5.9-M diesel engines. The manual contains descriptive and functional information, operat-ing instructions, and maintenance and repair instructions for this system. This manual is one volume subdividedinto 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 arerequested 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 toCommanding Officer, Naval Ship Weapon Systems Engineering Station (Code 5H00), Port Hueneme, CA 93043-5007 on NAVSEA Technical Manual Deficiency/Evaluation Report, Form NAVSEA 9086/10. To facilitate suchreporting, three copies of Form 9086/10 are included at the end of this technical manual. All feedback commentsshall be thoroughly investigated and originators will be advised of action resulting therefrom. Extra copies ofNAVSEA Form 9086/10 may be requisitioned from the Naval Publications and Forms Center, Philadelphia, PA19120.

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TABLE OF CONTENTS

Chapter/Paragraph Page

1 GENERAL INFORMATION AND SAFETY PRECAUTIONS . . . . . . . . . . . 1-1

1-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11-1.1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11-1.2 SAFETY PRECAUTIONS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2 EQUIPMENT DESCRIPTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2 NORMAL OPERATING RANGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-3 OPERATING PROCEDURES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22-3.1 PRE-OPERATIONAL CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . 2-22-3.2 NORMAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32-3.3 SHUTDOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52-3.4 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3.4.1 Low Oil Pressure.. . . . . . . . . . . . . . . . . . . . . . . . . . 2-62-3.4.2 High Engine Coolant Temperature.. . . . . . . . . . . . . . . . . 2-72-3.4.3 Runaway Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

3 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2 GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-3 DETAILED DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13-3.1 DIESEL ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13-3.2 ELECTRICAL STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . 3-13-3.3 AIR INTAKE AND EXHAUST SYSTEMS. . . . . . . . . . . . . . . . . . . 3-2

3-3.3.1 Air Intake System.. . . . . . . . . . . . . . . . . . . . . . . . . . 3-23-3.3.2 Exhaust System.. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-3.4 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73-3.4.1 Fuel Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73-3.4.2 Fuel Injection Nozzles.. . . . . . . . . . . . . . . . . . . . . . . 3-73-3.4.3 Fuel Drain Manifold. . . . . . . . . . . . . . . . . . . . . . . . . 3-73-3.4.4 Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73-3.4.5 Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-3.5 LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73-3.6 COOLING WATER SYSTEMS.. . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-3.6.1 Fresh Water Cooling System.. . . . . . . . . . . . . . . . . . . . 3-73-3.6.2 Sea Water Cooling System.. . . . . . . . . . . . . . . . . . . . . 3-8

3-3.7 CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . 3-8

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TABLE OF CONTENTS - Continued


3-3.7.1 Starter Switch.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83-3.7.2 Electrical Fuel Shutoff. . . . . . . . . . . . . . . . . . . . . . . . 3-83-3.7.3 Tachometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83-3.7.4 Lube Oil Pressure Switch.. . . . . . . . . . . . . . . . . . . . . 3-83-3.7.5 Water Temperature Switch.. . . . . . . . . . . . . . . . . . . . . 3-8

4 SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2 TROUBLESHOOTING GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-3 TROUBLESHOOTING PROCEDURES.. . . . . . . . . . . . . . . . . . . . . . . . 5-105-3.1 ENGINE WILL NOT CRANK. . . . . . . . . . . . . . . . . . . . . . . . . . 5-105-3.2 ENGINE CRANKS BUT WILL NOT START (SMOKE FROM

EXHAUST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105-3.3 ENGINE STARTS BUT WILL NOT KEEP RUNNING. . . . . . . . . . . . 5-105-3.4 ENGINE RUNNING HOT.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

SECTION 2. REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-6 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-7 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56-7.1 CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66-7.2 INSPECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-8 REPAIR/REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76-8.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76-8.2 PRELIMINARY PROCEDURES AND SAFETY INFORMATION. . . . . . 6-8

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6-9 STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96-9.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96-9.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96-9.3 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6-116-9.4 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-166-9.5 TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-9.5.1 Solenoid Engagement Mechanism.. . . . . . . . . . . . . . . . . 6-206-9.5.2 Performance Tests.. . . . . . . . . . . . . . . . . . . . . . . . . . 6-216-9.5.3 Relay Test.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-9.6 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-10 GAUGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-11 AIR CLEANER/SILENCER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236-11.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236-11.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

6-12 ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236-12.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-236-12.2 REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246-12.3 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6-13 DRIVE BELT AND BELT TENSIONER. . . . . . . . . . . . . . . . . . . . . . . . . 6-246-13.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246-13.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-14 FRESH WATER PUMP.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-256-14.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-256-14.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6-15 THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6-16 SEA WATER PUMP.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-276-16.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-276-16.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-276-16.3 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-286-16.4 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6-17 HEAT EXCHANGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-306-17.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-306-17.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-306-17.3 REASSEMBLY/REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 6-31

6-18 MARINE TRANSMISSION OIL COOLER. . . . . . . . . . . . . . . . . . . . . . . 6-326-18.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-326-18.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

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6-19 WATER TRANSFER CONNECTION.. . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

6-20 TEMPERATURE TRANSDUCER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6-21 FUEL LEFT PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-346-21.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-346-21.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6-22 FUEL PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-346-22.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-346-22.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

6-23 FUEL FILTER AND FUEL/WATER SEPARATOR. . . . . . . . . . . . . . . . . . . 6-356-23.1 FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-356-23.2 FUEL/WATER SEPARATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

6-24 FUEL DRAIN MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-366-24.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-366-24.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6-25 FUEL INJECTION NOZZLES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-366-25.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-366-25.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-376-25.3 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6-376-25.4 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-386-25.5 FUEL INJECTION NOZZLE TEST. . . . . . . . . . . . . . . . . . . . . . . 6-386-25.6 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-406-25.7 BLEEDING THE FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 6-40

6-26 FUEL INJECTION PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-446-26.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-446-26.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-476-26.3 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-516-26.4 PRE-TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

6-26.4.1 Pressure Test.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-576-26.4.2 Seal Testing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-586-26.4.3 General Testing Procedures.. . . . . . . . . . . . . . . . . . . . 6-586-26.4.4 Priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-596-26.4.5 Pump Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-596-26.4.6 Shutoff Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-596-26.4.7 Maximum Fuel Setting.. . . . . . . . . . . . . . . . . . . . . . . 6-596-26.4.8 Governor Test.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-606-26.4.9 Transfer Pump Setting.. . . . . . . . . . . . . . . . . . . . . . . 6-60

6-26.4.10 Transfer Pump Pressure Adjustment.. . . . . . . . . . . . . . . . 6-606-26.4.11 Pressurized Cam Boxes.. . . . . . . . . . . . . . . . . . . . . . . 6-616-26.4.12 Advance Device Test.. . . . . . . . . . . . . . . . . . . . . . . . 6-616-26.4.13 Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

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6-26.5 TEST PARAMETERS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-636-26.5.1 Test Conditions.. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-636-26.5.2 Test Procedure and Conditions.. . . . . . . . . . . . . . . . . . . 6-63

6-26.6 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

6-27 INTAKE MANIFOLD COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-666-27.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-666-27.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66

6-28 TURBOCHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-676-28.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-676-28.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-686-28.3 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6-706-28.4 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-716-28.5 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74

6-29 OIL PRESSURE REGULATOR VALVE. . . . . . . . . . . . . . . . . . . . . . . . . 6-756-29.1 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-756-29.2 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75

6-30 OIL COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-766-30.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-766-30.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76

6-31 CRANKSHAFT OIL SEALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-776-31.1 FRONT CRANKSHAFT OIL SEAL. . . . . . . . . . . . . . . . . . . . . . . 6-77

6-31.1.1 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-776-31.1.2 Reinstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77

6-31.2 REAR CRANKSHAFT OIL SEAL. . . . . . . . . . . . . . . . . . . . . . . . 6-776-31.2.1 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-776-31.2.2 Reinstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78

6-32 CAM FOLLOWER COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-786-32.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-786-32.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78

6-33 OIL PRESSURE TRANSDUCER.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79

6-34 VALVE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79

6-35 ROCKER LEVER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-806-35.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-806-35.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-806-35.3 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6-806-35.4 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-816-35.5 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81

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6-36 CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-826-36.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-826-36.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-826-36.3 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6-826-36.4 VALVE SEAT GRINDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-836-36.5 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-846-36.6 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84

6-37 OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85

6-38 SUCTION TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85

6-39 VALVE TAPPET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-866-39.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-866-39.2 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6-876-39.3 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87

6-40 CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-896-40.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-896-40.2 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6-896-40.3 CAMSHAFT GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-906-40.4 CAMSHAFT BUSHING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-906-40.5 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91

6-41 LUBE OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-916-41.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-916-41.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-926-41.3 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-926-41.4 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94

6-42 GEAR HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-946-42.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-946-42.2 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95

6-43 FLYWHEEL/FLYWHEEL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-956-43.1 FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-956-43.2 FLYWHEEL RING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-966-43.3 FLYWHEEL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96

6-44 PISTON AND CONNECTING ROD. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-976-44.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-976-44.2 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-986-44.3 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6-986-44.4 MEASURE ROD BEARING CLEARANCE. . . . . . . . . . . . . . . . . . 6-996-44.5 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1006-44.6 CHECKING PISTON RING GAP. . . . . . . . . . . . . . . . . . . . . . . . 6-1006-44.7 PISTON RING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 6-100

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6-44.8 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101

6-45 CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1026-45.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1026-45.2 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6-1026-45.3 CRANKSHAFT GEAR REPLACEMENT.. . . . . . . . . . . . . . . . . . . 6-1036-45.4 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103

6-46 CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1046-46.1 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1046-46.2 CLEANING AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6-1046-46.3 REINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-3 START-UP AND CHECKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-4 ENGINE OPTION LISTS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

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LIST OF TABLES

Table Title Page

1-1. 6B5.9-M Principal Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-106

6-7. Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

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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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LIST OF TABLES - Continued

Table Title Page

7-39. Crankshaft and Main Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

7-40. Transmission Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61

7-41. Vibration Isolator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62

7-42. Fuel/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63

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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. . . . . . . . . . . . . . 6-43

6-22. Venting High-Pressure Fuel Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

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LIST OF ILLUSTRATIONS - Continued

Figure 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

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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

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Figure 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

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Figure Title Page

7-40. Transmission Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61

7-41. Vibration Isolator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61

7-42. Fuel/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63

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xv

SAFETY SUMMARY

GENERAL SAFETY NOTICES The following general safety notices supplement specific warnings andcautions appearing elsewhere in this manual. General and specific precautions must be understood and appliedduring operation and maintenance. The Commanding Officer or other authority will issue orders as deemed nec-essary 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 alltimes. Do not replace components, make adjustments, or perform internal equipment maintenance without firstsecuring electrical power. Dangerous potential may exist when the electrical power is in the OFF position becauseof charges retained by capacitors. Before touching, always secure electrical power and discharge the circuit byshorting through a load to ground with a shorting probe.

DO NOT REPAIR OR ADJUST ALONE Under no circumstances should any person reach into or enterequipment enclosures for the purpose of servicing or adjusting equipment except in the presence of personnelcapable of rendering aid.

FIRST AID An injury, no matter how slight, should never go unattended. Always obtain first aid ormedical attention immediately.

ENERGIZED EQUIPMENT Before working on energized equipment, ensure against grounding. If pos-sible, 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 shallbe posted. The safety watch must have a full view of the repair/adjustment operation and immediate access tocontrols that can stop the equipment in motion.

SPECIFIC SAFETY NOTICES The specific safety warnings and cautions summarized below appear inappropriate 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 notstrictly observed, could result in injury or death to personnel.

A CAUTION is an operating or maintenance procedure, practice, condition or statement which, if notstrictly 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 empha-sis.

WARNING

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

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WARNING

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

WARNING

To prevent injury or death, control all oil and fuel leakage immediately. Oilor 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 capfrom the expansion tank. Steam formed by the sudden release of pressurefrom a heated cooling system may force hot coolant through the system’sopenings. (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 deathcouldresult. (Page6-5,page6-14,page6-37,page6-70,page6-80,page6-83,page6-92, page 6-99, page 6-102, page 6-105)

WARNING

Rotating machinery can cause injury or death. Ensure the engine is shutdown before working on equipment and that the starter is tagged OUT-OF-SERVICE. (Page 6-8)

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WARNING

To prevent injury or death, ensure extreme care and proper lifting devicesare used during handling. The equipment is heavy. (Page 6-8, page 6-82, page6-102, page 6-106, page 8-1)

WARNING

To prevent injury or death, ensure the engine is securely mounted to theoverhaul stand before releasing the lifting sling; engine damage may resultif 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 ringgroove.(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), wearsafety 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, underno circumstances should both main terminals be connected to the supplyvoltage source. Otherwise the pinion will rotate at high speed when pulledforward and present extreme danger to the operator. (Page 6-20)

WARNING

To prevent serious hand injury while removing/installing the drive belt, keephands out of the path of the spring-loaded belt tensioner. (Page 6-24, page6-24)

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WARNING

To prevent injury, exercise extreme care and wear insulated gloves whenhandling 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 seriousinjury. Use the proper equipment and keep hands clear when testing thenozzles. (Page 6-39)

WARNING

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

WARNING

Do not bleed a hot engine. This action could cause fuel to spill onto a hotexhaust 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 ringgroove. (Page 6-81)

WARNING

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

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WARNING

To prevent injury, exercise extreme care and wear insulated gloves whenhandling 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 notuse a steel drift pin. (Page 6-96)

CAUTION

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

CAUTION

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

CAUTION

To prevent damage to equipment, this entire procedure and the emergencyoperating procedures must be understood before starting the engine. Rapidautomatic sequence of some events without proper operator actions maydamage the equipment. (Page 2-4)

CAUTION

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

CAUTION

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

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CAUTION

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

CAUTION

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

CAUTION

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

CAUTION

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

CAUTION

Do not allow machined or lapped mating surfaces to contact any surfacewithout protection against nicks, scratches, burrs, etc. (Page 6-6)

CAUTION

Avoid scratching and nicking critical surfaces of balls and rollers in bear-ings; 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. Mois-ture in an air line can cause rust. (Page 6-6)

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CAUTION

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

CAUTION

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

CAUTION

To prevent damage to equipment, a soft-jawed vise, cloth, or cardboardshould be used to protect parts. (Page 6-10, page 6-16, page 6-17, page 6-37, page6-38, page 6-68, page 6-71)

CAUTION

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

CAUTION

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

CAUTION

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

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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, usetwo wrenches. (Page 6-35)

CAUTION

To prevent serious damage to the injection nozzle, ensure the interior of thesocket 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 asuitable 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 thefuel 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 tothe shoe assemblies and adjusting plates. (Page 6-63)

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CAUTION

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

CAUTION

Leaks at the intake manifold, unsealed bolt holes, or manifold cover gasketcan allow dust and dirt to be ingested into naturally aspirated engines. (Page6-66)

CAUTION

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

CAUTION

To prevent damage to the connecting rod and bearing, avoid the use of metalobjects 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 connectingrod assembly into the block, ensure the inside end of the strap does not hookon a ring gap and break the ring. (Page 6-101)

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CAUTION

Prior to installing the engine, ensure that all engine mounts and systeminterfaces are rust-free, clean, complete, and in good working order. (Page8-1)

CAUTION

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

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

CHAPTER 1

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1-1. INTRODUCTION.

1-1.1 GENERAL INFORMATION. This manual provides the necessary information to install, maintain, oper-ate, and repair the models 6B5.9-M and 6BT5.9-M diesel engines. The engines are manufactured by the Cum-mins 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 dieselengine shall comply with U.S. Navy Safety Precautions for Operations Afloat, OPNAV 5100 Series. Specificsafety precautions are included in the appropriate chapters of this manual. General and specific warnings andcautions are contained in theSafety 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 six-cylinder, turbocharged, diesel engine (figure 1-2). Each engine is provided with an instrument panel that moni-tors engine pressures and temperatures.Table 1-1lists the principal characteristics of the 6B5.9-M diesel engineandtable 1-2lists the principal characteristics of the 6BT5.9-M diesel engine.

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

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1-1

Table 1-1. 6B5.9-M Principal Characteristics

Item Data

Diesel EngineModel 6B5.9-MManufacturer Cummins Engine Co.Type 4-cycle, in-line, 6-cylinderAspiration NaturalBore x Stroke 4.02 in. x 4.72 in.Engine Weight (dry) 855 lbsDisplacement 359 cu. in.Duty Cycle Medium continuousHorsepowerShaft (at 2500 rpm) 112 shpBrake (at 2500 rpm) 115 bhpFiring Order 1-5-3-6-2-4Compression Ratio 18.5:1Rotation (as viewed from front of engine) ClockwiseNormal Idle Speed 750 rpmTorque Capacity of Front of Crankshaft (max) 210 lb-ft

Figure 1-2. Model 6BT5.9-M Diesel Engine

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1-2

Table 1-1. 6B5.9-M Principal Characteristics - Continued

Item Data

Crankshaft End Clearance (range) .0054 to.0104 in.Engine Speed 2500 rpmPiston Speed 1969 ft/minBrake Mean Effective Pressure 101 psiStandard Flywheel Housing Size SAE No. 3Lubrication SystemHigh Oil Level Capacity 15 qtsLow Oil Level Capacity 13 qtsOil Temperature (max) 250° FOil Pressure at Idle (min allowable) 10 psiOil Pressure at Rated (min allowable) 40-60 psiOil Regulating Valve Opening Pressure 60 psiDifferential Pressure to Open Bypass Valve 20 psiContinuous Operational Angularity of Oil Pan(max)Front down 45 degreesFront Up 45 degreesSide-to-Side 45 degreesCooling SystemCoolant Capacity (engine only) 13.6 galsEngine w/Heat Exchange 21.8 galsThermostat RangeStarting 180° FFully Open 203° FPressure 15 psiExternal Pressure Loss in Cooling System (max) 5 psiAllowable Coolant Expansion Space of SystemCapacity (min)

5 percent

Coolant Make-up Capacity (min) 2.7 galsEngine Water Flow 55 gpmFuel Oil SystemFuel Consumption (max) 6.3 gphFuel Flow to Pump (max) 8 gphAllowable Pressure Drop Across Fuel Filter (max) 3 psiAllowable Return Line Restriction (max) 5.0-inHgRestriction to Fuel Pump with Dirty Filter (max) 3.75-inHgFuel Supply Hose Size 6Fuel Return Hose Size 4Air Supply SystemIntake Air Flow 210 cfmAllowable Intake Restriction at Rated Speed andLoad with Dirty Air Filter Element (max)

20-inH2 O

Allowable Return Line Restriction (max) 20.4-inHgIntake Air Restriction (naturally aspirated) 20-inH2 OVentilation Area (min) 57 sq. in.Exhaust SystemExhaust Gas Flow 600 cfm

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1-3

Table 1-1. 6B5.9-M Principal Characteristics - Continued

Item Data

Exhaust Gas Temperature 1150°FExhaust Diameter (min)Dry 3.0-in.Wet 3.5-in.Heat Rejection to Coolant 4500 Btu/minHeat Rejection to Ambient 800 Btu/minSea Water SystemSea Water Flow 23 gpmSea Water Pressure (max) 15 psiSea Water Pump Inlet Restriction (max) 5 inHgSea Water Strainer Open Area (min) 6.0-in.Sea Water Pump Initial Suction Lift (max) 10 ftElectrical SystemRecommended Battery Capacity (min) Cold soak at0°F or Above (min/CCA) w/24-Vdc Starter

475

Reserve Capacity Allowable Resistance of StartingCircuit w/24 volt Starteralign=″right″ (max)

.0020 ohms

Table 1-2. 6BT5.9-M Principal Characteristics

Item Data

Diesel EngineManufacturer Cummins Engine Co.Model 6BT5.9-MType 4-cycle, in-line, 6-cylinderAspiration TurbochargedInstallation Angle (max; up front) 15 degreesBore x Stroke 4.02-in. x 4.72-in.Engine Weight Dry 880 lbs,Displacement 359 cu. in.Duty Cycle Medium continuousFiring Order 1-5-3-6-2-4Fuel Injection DirectEngine Torque 378 lb-ftValve Clearance (intake) .010-in.Valve Clearance (exhaust) .020-in.HorsepowerShaft (at 2500 rpm) 175 shpBrake (at 2500 rpm) 180 bhpShaft PowerHigh Output 204 shp at 2600 rpmIntermittent 175 shp at 2500 rpmCompression Ratio 17.5:1Rotation Viewed from Front of Engine ClockwiseRated SpeedHigh Output 2600 rpmIntermittent 2500 rpm

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Table 1-2. 6BT5.9-M Principal Characteristics - Continued

Item Data

Standard Flywheel Housing Size SAE No. 3Normal Idle Speed 750 rpmPiston Displacement 359 cu. in.Fuel SystemFuel ConsumptionHigh Output 11.2 gph at 2600 rpmIntermittent 9.7 gph at 2500 rpmFuel Flow to Pump 12 gphAllowable Restriction to Pump with Dirty Filter(max)

3.75 inHg

Allowable Injector Return Line Restriction (max) 5.0 inHgAllowable Pressure Drop Across Fuel Filter(max)

3.0 psi

Fuel Supply Hose Diameter 25-inFuel Supply Hose Size 6Fuel Return Hose Diameter 19-inFuel Return Hose Size 4Air Supply SystemIntake Manifold Pressure 43 inHgInlet Restriction Filter (max/clean) 15-inH2 OInlet Restriction Filter (max/dirty) 25-inH2 OAllowable dirt Holding Capacity of Air Cleaner(min)

3.0 gpm/cfm

Intake Air Flow 510 cfmVentilation Area (min) 138 sq. in.Heat Rejection to Ambient 7100 BTU/minLubrication SystemAllowable Oil Pressure at Idle (min) 10 psiAllowable Oil Pressure at Rated Speed (min) 40-60 psiRegulating Valve Opening Pressure 60 psiDifferential Pressure to Open Bypass Valve 20 psiOil CapacityHigh 15 qtsLow 13 qtsTotal System Capacity 16 qtsContinuous Operational Angularity of Oil Pan(Max)Front down 45 degreesFront Up 45 degreesSide-to-Side 45 degreesCooling SystemEngine Water FlowHigh Output 56 gpmIntermittent 55 gpmCoolant Capacity (engine only) 13.6 galsThermostat Standard Modulating RangeStarting 180°F

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Table 1-2. 6BT5.9-M Principal Characteristics - Continued

Item Data

Fully Open 203°FCoolant Temperature (max) 210°FExternal Pressure Loss in Cooling System (max) 5 psiStatic Pressure of Coolant (max; exclusive ofpressure cap)

15 psi

Allowable Coolant expansion Space of SystemCapacity (min)

5 percent

Coolant Make-up Capacity (min) 2.7 galsSea Water SystemSea Water FlowHigh Output 25.5 gpmIntermediate 23.5 gpmSea Water Pressure (max) 15 psiSea Water Strainer Open Area (min) 6.0-in.Sea Water Pump Inlet Restriction (max) 5 inHgSea Water Pump Initial Suction Lift (max) 10 ftHeat Rejection to Coolant 6900 Btu/minSea Water Pipe Size (min) 1.25-in.Exhaust SystemExhaust Gas FlowHigh Output 1230 cfmIntermittent 777 cfmExhaust Gas TemperatureHigh Output 835°FIntermittent 750°FHeat Rejection to CoolantHigh Output 7100Intermittent 5594Exhaust Diameter (min; dry) 4.0-in.Exhaust Diameter (min; wet) 5.0-in.Electrical SystemRecommended Battery Capacity Cold Soak at0°F or above (min/CCA)

475

Reserve Capacity Allowable Resistance of Start-ing Circuit w/24-Volt Starter (max)

.0020 ohms

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CHAPTER 2

OPERATION

2-1. INTRODUCTION.

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

2-2. NORMAL OPERATING RANGES.

Table 2-1lists the normal operating ranges for the models 6B5.9-M and 6BTS.9-M. Indicator readings out-side the normal operating range may require corrective maintenance to prevent equipment damage. Operating theengine below minimum values or above maximum values will damage the equipment.

Table 2-1. Normal Operating Ranges

Indication Range

6B5.9-MAir Inlet Restriction (max at rated speed and load)With Clean Filter Element 20 inH2 OWith Dirty Filter Element 20.4 inH2 OBlowby (max; 0.221 in diameter orifice) 4.9 inHg at 2200 rpm; 7.0 at 2500

rpmCoolant TemperatureStandard Thermostat (modulating range) 175 to 195°FTemperature (max) 210°FExhaust Back Pressure at Rated Load and Speed (max) 3 inHgFuel Inlet Restriction With Clean Filter Element (max) 3.5 inHgIdle Speed 750 rpmInjector Return Line Restriction 5.0 inHgOil Pressure - Main Oil PassageMax at rated rpm 60 psiMin at rated rpm 30 psiMin at idle rpm 10 psiOil Temperature (max) 250°F6BT5.9-MAir Inlet Restriction (max at rated speed and load)With Clean Filter Element 15 inH2 OWith Dirty Filter Element 25 inH2 OBlow By (max; 0.221 in. dia. orifice) 4.9 inHg at 2200 rpm 7.0 at 2500

rpmCoolant TemperatureStandard Thermostat (modulating range) 175 to 195°FTemperature (max) 210°FExhaust Back Pressure at Rated Load and Speed (max) 3 inHgFuel Wet Restriction With Clean Filter Element (max) 3.5 inH2 OIdle Speed 750 rpm

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Table 2-1. Normal Operating Ranges - Continued

Indication Range

Injector Return Line Restriction 5.0 inHgOH Pressure-Main Oil PassageMax at rated rpm 60 psiMin at rated rpm 30 psiMin at idle rpm 10 psiOil Temperature (max) 250°F

2-3. OPERATING PROCEDURES.

2-3.1 PRE-OPERATIONAL CHECKS. The following steps shall be used to check and prepare the engine foroperation

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 cor-rectly.

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 totable 2-2and refuel in accordance with the NSTM, Chapter 541, and the appro-priate 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-servicefuel tank only.

h. Check the fuel piping, hoses, fittings, and valves for leaks. If leaks are found, refer tochapter 5and trouble-shooting.

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 tempera-ture, the coolant level should be about two inches below the top of the filler neck; add engine coolant, asrequired. Replace the cap.

m. Check the fresh water pipes, hoses, and fittings for leaks. If leaks are found, refer tochapter 5and trouble-shoot.

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

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Table 2-2. Fuel and Lubricating Oil

Type Usage

PrimaryFuel, Naval Distillate (MIL-F-168834) Use when ambient temperature is consistently

above 30°F.SecondaryTurbine Fuel, Aviation, Grade JP-5 (MIL-T-5624) Use when ambient temperature is consistently

below 30°F.PrimaryLubricating Oil, Internal Combustion Engine,Diesel (MIL-9000G, Sym 9250)

Use with ambient temperature above 20°F.

SecondaryLubricating Oil, Internal Combustion Engine,Diesel (MIL-L-2104)

Ambient temperature consistently below 20°F.

CAUTION

To prevent damage to equipment, prime the sea water pumps prior to opera-tion.

q. If necessary, prime the sea water pump.

CAUTION

To prevent damage to equipment, ensure that oil in the engine is at theproper 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 totable 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 inaccordance 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 coverselectrical starting for cold and warm weather.

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CAUTION

To prevent damage to equipment, this entire procedure and the emergencyoperating procedures must be understood before starting the engine. Rapidautomatic sequence of some events without proper operator actions maydamage the equipment.

a. Review this entire procedure and the emergency engineering operating procedures (EEOP) before performingany steps. This will ensure undemanding of required actions during rapid automatic sequence of events. Whereconflicts exist, the EEOP takes precedence.

b. Ensure the pre-operational checks have been performed. Refer toparagraph 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 pro-cedures contained in the BIB.

e. When the ambient temperature is greater than 40°F or the engine is warm, start the engine with the electricalstarting system.

WARNING

To prevent injury or death, exercise extreme caution when working on oraround 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 arecontinuous 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 warninglights should be lit.

3. Place and hold the switch in the START position to activate the starter motor and crank the engine. Pro-ceed to step f.

4. If the engine does not start after 30 seconds, return the switch to the OFF position. Wait two minutesbetween unsuccessful attempts.

5. Repeat steps 1 through 4. If the engine does not start after four attempts, refer tochapter 5and trouble-shoot.

WARNING

To prevent injury or death, shut down the engine when unusual noise orvibration occurs. Unusual noise or vibrations may be an indication of equip-ment failure.

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f. Within 10 to 15 seconds after the engine starts, the alternator warning light and the low oil pressure warninglight should go out, and the oil pressure gauge should indicate at least 10 psi. If this does not occur, place theswitch in the OFF position and shut down the engine. Refer tochapter 5and troubleshoot.

g. If abnormal noises or vibrations are present in the engine or any driven equipment, shut down the engineaccording to the EEOP.

WARNING

To prevent injury or death, control all oil and fuel leakage immediately. Oilor 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 thetemperature 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 withinoperating limits. Refer totable 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 greaterthan 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 dur-ing extended idle periods. Running the engine at idle speed for prolongedperiods 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 theclutches 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 stopswitch. Stopping the engine before it cools down may cause damage toequipment.

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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 shutdownlever does riot stop the engine, determine and correct the cause. Refer tochapter 5and troubleshoot.

d. If the engine does not stop, actuate the emergency fuel shutdown lever for the on-service fuel tank. Ensurethe engine stops in about 10 seconds. Determine and correct the cause of the stop switch not stopping theengine.

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 bringlevel to full mark. (Refer totable 2-2.) Reinstall the oil fill cap on the cover.

CAUTION

If excessive oil must be repeatedly drained from the engine, troubleshoot thecause 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 inaccordance with the NSTM, Chapter 593.

4. Reinstall the dipstick in the dipstick tube.

k. Refer totable 2-2and 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. Ifthe equipment malfunctions, refer tochapter 5and troubleshoot. Ensure equipment repair/replacement is per-formed 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 malfunctioningwarning light. Refer tochapter 5and 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 toparagraph 2-3.3.).

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e. If the engine operation is required and low oil pressure is due to oil leakage, operate the engine while per-forming 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 levelto 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 pressurecannot be maintained greater than 10 psi, shut down the engine according toparagraph 2-3.3.

f. Determine and correct the cause of low oil pressure. Refer tochapter 5and 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 correctthe malfunction. Refer tochapter 5and troubleshoot.

2. If the water temperature gauge indicates 200°F or greater, decrease engine speed to attempt cooling of theengine. Refer tochapter 5and troubleshoot.

b. If engine operation is required and high engine coolant temperature is due to coolant leakage, operate theengine as follows:

1. Allow the engine to cool as long as possible.

WARNING

To prevent injury or death, use extreme caution when removing the capfrom the expansion tank. Steam formed by the sudden release of pressurefrom a heated cooling system may force hot coolant through the system’sopenings.

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 toparagraph 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 tochapter 5and troubleshoot.

2-3.4.3 Runaway Engine. If oil is introduced into the cylinders, the engine will become uncontrollable and mayoverspeed. Excessive oil level in the oil pan will cause a runaway engine. If a runaway engine is suspected, pro-ceed as follows:

a. Shut down the engine according to the EEOP.

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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 tochapter 5and troubleshoot.

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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 pro-vide power for boat accessories. The model 6B5.9-M diesel engine is a six-cylinder, four-cycle internal combus-tion 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 startingsystem, an air intake and exhaust system, a fuel system, lubrication system, cooling system, and various controlsand indicators.

3-3. DETAILED DESCRIPTION.

3-3.1 DIESEL ENGINE. The engine is a four-cycle, internal combustion engine that includes an intake aircleaner/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 connectingrod assemblies convert the heat energy released by fuel combustion into mechanical energy to rotate the crank-shaft assembly. Crankshaft assembly rotation is then transmitted by the idler gear to the camshaft assembliesthrough a gear train. The camshaft assemblies actuate the cylinder head assemblies to inject fuel into and con-duct exhaust gases out of the cylinders in the required timed sequence. The cylinder head assembly forms the topenclosure for the cylinders and provides for cooling, lubrication, fuel injection, and exhaust gas removal. (Themodel 6BT5.9-M includes a turbocharger to increase intake air volume and pressure.) The cylinder block assem-bly 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-voltbattery bank, starting motor, and an alternator. A deposition toggle switch (OFF, RUN, START) is included forengine control. The OFF position closes the fuel supply to the injection pump. The RUN position energizes theengine gauges, instruments, warning lights, and control devices, and also opens the fuel supply valve. The STARTposition is a momentary contact. When held closed, the solenoid switch on the starter motor is closed to supplyfull battery power to the starter motor for cranking the engine. When released the switch returns to the RUNposition where it remains until it is moved to the OFF position. An electrical interlock, which is included in theengine 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 ini-tial excitation of the alternator field. An alternator failure warning light is fed by the same line. As soon as thealternator begins to generate voltage, that voltage matches the battery voltage to the regulator and turns out thealternator failure warning light, and the alternator becomes self-excited. The voltage regulator senses battery con-dition and maintains alternator output voltage at an appropriate level throughout the full range of engine runningspeeds. When the alternator output stops, battery power returns to the warning light.

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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 forthe model 6135.9-M, and above atmospheric pressure for the model 6BT5.9-M. The model 6B5.9-M intake sys-tem includes air cleaner/ silencer piping and an intake manifold and intake valves, through which clean, cool airis 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.

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

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

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

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3-3.3.2 Exhaust System. The exhaust system includes those components used to expel the engine’s exhaustgasses. It starts with the exhaust valves, one valve for each of the six cylinders. Each cylinder expels its exhaustgas into the manifold: in the model 6B5.9-M, the exhaust passes through a sea water-cooled exhaust elbow fit-ting, through a 2-1/2-inch to 3-inch piping, a muffler, and more piping to the atmosphere. The path of the exhaustgasses for the model 6BT5.9-M is the same from the cylinder exhaust valve to the exhaust manifold, but in thismodel, the exhaust gasses are used to drive the turbocharger. From the turbocharger, the exhaust gas passesthrough the sea water-cooled elbow, piping, muffler, and additional piping before it is discharged to the atmo-sphere.

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 fuelfrom the supply tank and supplies low-pressure fuel (3 to 5 psi) to the fuel filter head, through the filter, then tothe fuel injection pump. The fuel injection pump increases fuel pressure and routes the high-pressure fuel to eachInjection nozzle.

3-3.4.2 Fuel Injection Nozzles. Fuel is supplied through the high-pressure lines to the fuel injection nozzles inthe cylinder head. When the high-pressure fuel reaches the injection nozzles, the pressure lifts the needle valveagainst spring tension and allows fuel to enter the combustion chamber. A common drain line returns unused fuelto 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 tothe 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 solenoid-operated valve blocks the supply of fuel to the high-pressure pumping and distribution components. The valve isdesigned 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 bythe front crankshaft gear located in the oil pan at the front of the engine. A pressure regulator is mounted in theblock to control pressure. Filters and screens are provided in the lubricating system to remove impurities in theoil. A bypass valve is provided in the full-flow oil filter head to continue lubrication if the element becomesclogged. 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 freshwater and antifreeze. The engine fresh water cooling system includes an engine block, cylinder head, heatexchanger, 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 (2500rpm) by the fresh water pump. Coolant output from the fresh water pump empties into the oil cooler cavity of

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the cylinder block. The coolant circulates around each cylinder and crosses the cylinder block to the fuel injec-tion 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 thermo-stat is closed and coolant flow bypasses the heat exchanger, trapped air goes to the water pump inlet via drilledpassages in the block and head. When the operating temperature is reached, the thermostat opens, thereby block-ing the bypass passage to the fresh water pump and opening the outlet to the heat exchanger. Coolant flowingthrough the heat exchanger to the fresh water pump is cooled by a counterflow of sea water pumped through theheat exchanger. Sea water exits from the heat exchanger via a sea water connection at the upper rear end of theheat exchanger. The expansion tank provides make-up coolant for the closed coolant system and provides a placefor 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 oilpassing through the transmission’s oil cooler, fresh water coolant passing through the heat exchanger, and exhaustgas passing through the exhaust manifold elbow to the muffler. The water pump, which has a maximum suctionlift of 10 feet, draws sea water through a strainer with a minimum open area of six square inches. The sea waterpump discharges coolant at a maximum pressure of 15 psi.

3-3.7 CONTROLS AND INDICATORS. Various controls and indicators are provided with the diesel engineinstallation to start, operate, and shut down the diesel engine and to monitor diesel engine parameters duringoperation. Seefigure 3-1for 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 thecircuit 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 stopthe engine under normal operating conditions by stopping the fuel flow to the nozzles when the start switch ismoved to the OFF position.

3-3.7.3 Tachometer. The tachometer is electrically connected to a sender attached to the engine. It convertsmechanical 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 thelube oil pressure drops to eight psi. This completes the low lube oil alarm circuit to the control panel to activatethe 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, isoperated by a high cooling water temperature condition. When the cooling water temperature exceeds 225°F, theswitch closes a set of contacts that causes the engine warning light at the control panel to activate.

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CHAPTER 4

SCHEDULED MAINTENANCE

4-1. INTRODUCTION.

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

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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 per-sonnel in maintenance facilities. However, some of the diagnostic and corrective action procedures may requirepersonnel 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 die-sel engines. At the first sign of trouble, isolate the problem and evaluate before removing any components.Table5-1 represents a list of potential problems, their probable causes, and suggested corrective actions.

Table 5-1. Troubleshooting Guide

Problem/Malfunction Probable Cause Corrective Action

Engine will not crank. a. Loose or corroded batterycables.

a. Clean and tighten batteryconnections.

b. Loose or corroded connectionsin the starting circuit

b. Clean and tighten connec-tions.

c. Battery charge low. c. (1) Inspect battery for deadcell. Replace defective battery.(2) Inspect alternator output.Replace defective alternator.

d. Faulty solenoid or startingmotor.

d. Temporarily cross-connectthe starter solenoid terminals Ifthe starter does not crank,replace the starter motor.

e. Faulty auxiliary magnetic switch. e. Temporarily connect startersolenoid terminal P to S. if theengine does not crank, replacethe switch.

f. Faulty starter switch. f. Temporarily connect termi-nals I to S on the start switch.If the starter cranks, replacethe switch.

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5-1

Table 5-1. Troubleshooting Guide - Continued


2. Engine cranks but will notstart (no smoke from exhaust).

a. No fuel in supply tank. a. Replenish fuel supply.b. Electrical or manual fuel shut-down not open.

b. Inspect for loose wires;ensure the valve is operating.The manual shutoff valve mustbe in the run position.

c. Air intake or exhaust plugged. c. Remove obstruction.d. Fuel filter plugged or water con-taminated.

d. Drain fuel/water separatorand replace fuel filter.

e. Injection pump not receivingfuel or air in fuel.

e. Inspect fuel flow and bleedair from fuel system.

f. Worn or faulty injection pump. f. Check fuel delivery. Replacepump, 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 notstart (smoke from exhaust).

a. Incorrect starting procedure. a. Ensure the EEOP is used tostan engine.

b. No fuel in supply tank. b. Check fuel supply; replenishas necessary.

c. Electric or manual fuel shutdownnot open.

c. Ensure solenoid is energized.If no voltage, inspect for bro-ken wires. If voltage is present,inspect shutdown solenoidoperation. Replace defectiveparts.

d. Exhaust restriction. d. Locate and correct anyexhaust restriction.

e. Fuel filter plugged or contami-nated.

e. Drain fuel/water separatorand renew fuel filter element.

f. Injection pump not receiving fuelor air in fuel.

f. Inspect fuel flow and bleedair from fuel system.

g. Worn or faulty pump. g. Replace injection pump.4. Engine hard to start or willnot start (smoke from exhaust).

a. Engine under load. a. Ensure clutch or transmis-sion is disengaged.

b. Incorrect starting procedure. b. Refer tochapter 2.c. Cranking speed too low/slow. c. (1) Inspect battery, starting

motor for loose or corrodedwiring connections. Clean andtighten connections.(2) Bar engine over to checkfor excessive resistance.

d. Crankcase heater not working. d. Check power source, ther-mostat and heater to ensureheater is operating properly.Replace defective parts.

e. Insufficient intake air. e. Inspect/replace air filter andcheck for obstructions.

f. Air in fuel system. f. Bleed air from fuel system.Determine cause of air in sys-tem and correct.

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5-2



g. External pump timing incorrect g. Ensure pump timing marksare in alignment and timing iscorrect.

h. Contaminated fuel. h. Drain and flush fuel supplytanks. Refill with clean fuel oil.

i. Injection nozzles worn or faulty. i. Inspect and replace injectionnozzles, as necessary.

j. Valves incorrectly adjusted. j. Adjust valves.k. Worn or faulty injection pump. k. Replace injection pump.

5. Engine starts but will notkeep running.

a. Low fuel level in supply tank. a. Replenish fuel supply, asnecessary.

b. Broken or loose correction toshutdown.

b. Inspect shutdown wiring andrepair, as necessary.

c. Restricted exhaust. c. Inspect and correct exhaustrestriction

d. Fuel restriction in the suctionside of the fuel system.

d. Remove restriction,

e. Restricted fuel drain manifold orreturn line.

e. Remove restriction.

f. Fuel system leak/air in fuel sys-tem.

f. Visually inspect fuel systemfor leak and correct leakage.Bleed air from fuel system.

g. Contaminated fuel. g. Drain and flush the fuel sup-ply tank. Refill with clean fueloil.

h. Injection nozzles worn or faulty. h. Inspect and replace nozzles,as necessary.

i. Worn or faulty injection pump. i. Replace injection pump.6. Surging (speed change). a. If at idle, idle speed is set too

low.a. Adjust idle speed.

b. High-pressure fuel leak. b. Inspect and correct leaks inhigh-pressure fuel lines, fit-tings, nozzle sealing washers,or delivery valves.

c. Worn or faulty injection nozzles. c. Replace nozzles, as neces-sary.

d. Faulty delivery valve. d. Replace delivery valve.e. Faulty injection pump. e. Replace injection pump.

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5-3



7. Rough idle. a. Cold engine. a. Refer to Coolant Tempera-ture Below Normal.

b. Idle speed too low. b. Adjust low idle screw.c. Engine mounts overtightened,damaged, or loose.

c. Inspect condition of mounts.Replace, as necessary.

d. High-pressure fuel leak. d. Correct leaks in high-pressure lines, fittings, injectionsealing washers, or delivery ofvalve seals.

e. Air in fuel system. e. Locate and correct source ofair in fuel system. Bleed airfrom 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 losingcompression.

i. Perform compression checkand repair, as necessary.

8. Engine runs rough or misfir-ing.

a. Fuel injection lines leaking. a. Repair leaks in high-pressurelines, fittings, nozzle sealwashers, or delivery valves.

b. Air in the fuel or the fuel supplyis inadequate.

b. Inspect flow rate and bleedair from the system.

c. Contaminated fuel. c. Drain and flush fuel supplytanks. Refill with clean fuel oil.

d. Incorrect valve adjustment. d. Inspect for bent push rodand 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.

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9. Engine will not reach ratedspeed.

a. Engine overloaded. a. Verify high-idle speed with-out load. Reduce engine load.

b. Faulty tachometer. b. Ensure correct engine speedwith hand tachometer. Replacetachometer or sending unit, ifnecessary.

c. Throttle linkage worn or improp-erly adjusted.

c. Replace or adjust linkage forstop fuel control lever travel.

d. High-speed stop screw incor-rectly adjusted.

d. Reset high-speed stop screw.

e. Mechanical shutdown lever par-tially engaged.

e. Reposition shutdown leverin run position

f. Inadequate fuel supply. f. Inspect the fuel flow. Locateand correct the source of therestriction.

g. Restricted manifold drain line, ifcondition is intermittent

g. Remove restriction.

h. Faulty injection pump. h. Replace pump.10. Low power. a. Fuel control lever not moving to

full speed.a. Ensure throttle travel is fromstop-to-stop.

b. Mechanical shutdown lever par-tially engaged.

b. Place shutdown lever in runposition.

c. High oil level. c. Reduce oil level to correctmark on dipstick.

d. Engine overloaded. d. Inspect for added loadingfrom faulty accessories ormarine gear. Repair, as neces-sary.

e. Incorrect external injection pumptiming.

e. Ensure pump timing marksare aligned.

f. Air intake air inadequate or toohigh or low in temperature.

f. Replace air cleaner element.Correct any restrictions.

g. High-pressure fuel leak. g. Correct leaks in high-pressure lines, fittings, nozzlesealing washers, or deliveryvalve seals.

h. Inadequate fuel supply. h. Inspect the fuel flow throughthe filter to locate the source ofthe restriction.

i. High fuel temperature. i. Ensure fuel heater is off inwarm weather.

j. Restricted fuel drain manifold (iflow power is intermittent).

j. Correct restriction.

k. Poor quality fuel. k. Operate engine from a fueltank known to have good fuel.

l. Valve clearances incorrect. l. Adjust valves.m. Injection pump internal fault. m. Time pump.

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n. Low compression. n. Perform compression checkto determine faulty cylinders.Repair as necessary.

o. Worn or faulty injection nozzles. o. Inspect nozzles. Repair orreplace, 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 malfunctioningturbocharger.

r. Inspect/replace, as necessary.

11. Excessive exhaust smoke(white smoke).

a. Engine running too cold a. Refer to Coolant Tempera-ture Below Normal,

b. Inadequate air intake. b. Change air cleaner element;inspect and repair any otherrestrictions.

c. Model 6BT5.9-M air leak at tur-bocharger.

c. Locate/correct turbochargerair leak(s).

d. More than one sealing washerunder nozzle.

d. Remove extra washer.

e. Model 6BT5.9-M malfunctioningturbocharger.

e. Replace turbocharger.

f. Faulty injection nozzles. f. Replace nozzles.g. Faulty or overfueled injectionfuel pump.

g. Replace injection pump.

h. Piston rings not sealing (bluesmoke).

h. Perform compression checkand correct any deficiency dis-covered.

12. Coolant temperature abovenormal.

a. Low coolant level. a. Replenish coolant as neces-sary. 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 toheat exchanger.

e. (1) Inspect sea water suctionfor debris. Clean, as necessary.(2) Check sea water pump out-put. Rebuild or replace pump,as necessary.

f. Heat exchanger plugged. f. Clean heat exchanger.g. Faulty temperature gauge. g. Ensure the gauge is accu-

rate; if not, replace the gauge.h. Faulty, incorrect, or no thermo-stat

h. Replace thermostat.

i. Air in cooling system. i. (1) Ensure correct thermostatinstalled.(2) Inspect for head gasketleak.

j. Faulty water pump. j. Replace water pump.

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k. Incorrect injection pump timing. k. Time injection pump.l. Incorrect external injection pumptiming.

l. Ensure pump timing marksare aligned.

m. Plugged cooling passages inhead, head gasket, or block.

m. Flush the system and fillwith clear coolant.

n. Engine overloaded. n. Reduce engine load andspeed.

13. Coolant temperature belownormal.

a. Incorrect thermostat, brokenjiggle pin, or contamination in thethermostat.

a. Replace thermostat.

b. Temperature sensor or gaugefaulty.

b. Ensure the gauge and sensoram accurate. Replace as neces-sary.

c. Coolant not flowing by tempera-ture sensor.

c. Clean coolant passages inblock.

14. Coolant loss. a. External leak. a. Inspect engine and compo-nents for leaking hoses or gas-kets. Repair all leaks.

b. Transmission cooler leak. b. Inspect transmission sumpfor coolant. Replace cooler ifleaking.

c. Lube oil cooler leak. c. Inspect for coolant in oilsump. Replace cooler.

d. Head gasket leak. d. Replace head gasket.e. Cracked or porous head. e. Replace head.f. Leak in cylinder block coolantpassages.

f. Replace the cylinder block.

15. Lubricating oil pressurelow.

a. Low oil level. a. Replenish oil to proper levelon dipstick. Repair oil leaks.

b. Oil viscosity thin, diluted, orwrong specification.

b. Ensure correct oil is beingused. Refer totable 2-2.

c. Faulty pressure switch or gauge. c. Ensure the pressure switchand gauge are functioning cor-rectly. Replace faulty switch orgauge.

d. Relief valve stuck open. d. Replace valve.e. Plugged oil filter. e. Change oil filter.f. Shipping plugs left in cooler (ifcooler was replaced).

f. Remove plugs.

g. incorrect lube oil pump installed(if replaced).

g. Replace with correct pump.

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.

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5-7



16. Lube oil pressure too high. a. Faulty pressure switch or gauge. a. Ensure pressure switch andgauge are functioning correctly.Replace if necessary.

b. Engine running too cold. b. Refer to Coolant tempera-ture below normal.

c. Oil viscosity too thick. c. Ensure correct oil is beingused.

d. Relief valve stuck closed. d. Replace valve.e. Incorrect lube oil pump installed(if replaced).

e. Replace with correct lube oilpump.

17. Loss of lube oil. a. External leaks. a. Inspect for leaks and correctas necessary.

b. Crankcase overfilled. b. Drain oil to correct level ondipstick.

c. Incorrect oil. c. Ensure oil is correct viscos-ity. Test oil for fuel dilution.

d. Oil cooler leak. d. Inspect for oil in coolant.Replace cooler.

e. Excessive blow-by forcing oilout of the breather.

e. Measure blow-by and cor-rect as necessary.

f. Worn valve seals. f. Replace valve seals.g. Worn piston rings. g. Perform compression check.

Replace piston, rings, as neces-sary.

h. Model 6BT5.9-M turbochargerleaking oil into the air intake.

h. Inspect model 6BT5.9-Mturbocharger for faulty seals.Replace seals, as necessary.

18. Contaminated coolant. a. Rusty coolant. a. Drain and flush cooling sys-tem. Fill with correct coolantmixture.

b. Leaking marine gear oil cooler. b. Replace cooler.c. Oil leaks from oil cooler, headgasket, head, and cylinder block.

c. Refer to Loss of lube oil.

19. Contaminated lube oil. a. Coolant in oil (internal leakage). a. Refer to Coolant loss.b. Excessive oil sludge. b. Decrease oil change inter-

vals. Ensure correct oil viscos-ity in use.

c. Fuel in oil (engine operating toocold).

c. Avoid excessive idling.Ensure engine comes up totemperature.

d. Fuel pump seal leaking. d. Replace pump.e. Injection nozzle needle valvesriot sealing.

e. Locate and replace nozzles,as necessary.

20. Fuel or oil leaking fromexhaust manifold.

a. Intake air restriction. a. Replace filter element Avoidexcessive idling.

b. Injection nozzle needle valvestuck open.

b. Locate and replace nozzles,as necessary.

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21. Compression knock. a. Air in fuel system. a. Bleed fuel system.b. Poor quality fuel. b. Clean and flush fuel supply

tanks. Refill with clean fuel oil.c. Engine overloaded. c. Reduce engine load and

speed.d. Incorrect injection pump timing. d. Time injection pump.

22. Excessive fuel consump-tion.

a. Overloading from faulty accesso-ries.

a. Repair/replace accessories,as necessary.

b. Poor quality fuel. b. Ensure proper grade of fuelis in use.

c. Inadequate intake air or exhaustrestriction.

a. Refer to Excessive exhaustsmoke.

d. Fuel pump timing. d. Time the pump.e. Worn or faulty nozzles. e. Replace nozzles.f. Valves not seating. f. Adjust valves.

23. Engine will not shut off. a. Fuel shutoff valve inoperative. a. Secure engine mechanicallywith lever on fuel pump.Replace sealing washer, piston,and spring.

b. Engine running on fumes drawninto the air intake.

b. Inspect air intake ducts forsource of fumes, and correct.

24. Excessive vibration. a. Engine not running smoothly. a. Refer to Engine runs toughor is misfiring.

b. Loose or broken engine mounts. b. Replace engine mounts.c. Faulty accessories. c. Replace vibrating compo-

nents.d. Worn or damaged alternatorbearing.

d. Replace the alternator.

e. Flywheel housing misaligned. e. Realign flywheel housing.f. Loose or broken component inengine.

f. Inspect internal engine com-ponents. Replace as necessary.

g. Unbalanced shaft gear(s) or fly-wheel.

g. Balance shaft or flywheel, asnecessary.

25. Excessive engine noises. a. Drive belt squeal, insufficienttension, or excessive loading.

a. Ensure all belt drive compo-nents are properly adjusted.

b. Intake air or exhaust leaks. b. Refer to Excessive exhaustsmoke.

c. Excessive valve lash. c. Ensure valves and pushrodsare not bent and rocker armsare not excessively worn.Adjust valves.

d. Gear train noise. d. Inspect and measure geartrain back lash. Replace gears,as necessary.

e. Internal engine componentsknocking.

e. Replace rod and main bear-ings.

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26. Alternator not charging. a. Loose or corroded battery con-nections.

a. Clean and tighten batteryconnections

b. Alternator belt slipping. b. Replace belt tensioner ortighten belt, as necessary.

c. Alternator pulley loose on shaft. c. Tighten pulley.d. Faulty alternator. d. Replace alternator.

5-3. 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 positivebattery 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, replacethe 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 wiresnot 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 temperatureis above 225°F.

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5-10

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

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5-11 / (5-12 Blank)


CHAPTER 6

CORRECTIVE MAINTENANCE

6-1. INTRODUCTION.

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

6-2. TOOLS AND EQUIPMENT.

Most of the tools and equipment recommended for use in the maintenance procedures are standard shop itemsand 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 intable 6-1.

Table 6-1. Special Tools

Tool Part Number

Starter MotorSetting Gauge (for motors with pinion face to mounting flange dimension of 1.875-inch)

5693-222

Setting Gauge (for motors with pinion face to mounting flange dimension of 0.8125-inch)

5693-222A

Setting Gauge (for motors with pinion face to mounting flange dimension of 1.000inch)

5693-222B

Extraction and Replacement Tool (for commutator end bearing) 5693-240Plug Gauge (for drive end bearing) 5693-267Extractor, Drive End Bearing 5693-266Plug Gauge (for commutator end bearing) 5693-275Fitting Tool (for inspection hole core plugs) 5693-298Fitting Tool (for dust scraper ring on drive end shield) 5693-299Fitting Tool (for lubricator core plug) 5693-300End Float Gauge 6244-4Check Gauge (for retaining ring on trip collar) 6244-3Split Collar (for dust seal protection) 6244-6Compression Spring Balance Scale (0 to 50 lb capacity in 1-lb units) NPNFuel Injection PumpTool Kit 7144-1580Socket, Torque Spanner (cam advance screw) 7244-125ATorque Adapter, Drive Plate Screw (fused with 7144-511A) 7144-482Gauge, Auto Advance 7244-59Pin, Feeler 7244-70Tool, Adjusting Max Fuel and Extractor End Plate Sleeve (steel plate only) 7144-875Spanner Box, Transfer Pump Rotor 7044-889Spanner, Drive Plate (slotted type) 7144-744Spanner, Rotor Plug 7144-220Protection CapsCap and Plug Seals (auto advance) 7044-898

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6-1

Table 6-1. Special Tools - Continued

Tool Part Number

Head Locating Fitting Seal (nearest bolt head) 7044-897Head Locating Fitting Sleeve (top seal) 7144-18End Plate Sleeve Seal (steel plates only) 7144-11Throttle and Shut-off Shaft Upper Seal 7144-459AThrottle and Shut-off Shaft Lower Seal 7144-458ADrive Shaft Seal 7144-900Metering Valve Pinion Seals 7144-88Idling Stop and Maximum Speed Stop Seals 7144-124Drive Shaft Seal, Standard 7144-820Drive Shaft Seals (uprated type drive) 7244-15Single Piece Drive (shaft seal) 7244-23AAdapter, Assembly Timing 7144-262Valve, Relief 7144-155Pipe, Stirrup 7144-262ABolt, Blank-off 7144-558Guide, Drive Hub Oil Seal 7144-260AAssembly Fixture, Governor Weight 7144-894Tool, Drive Shaft Holding 7144-773Extractor, Drive Hub Oil Seal 7044-893ATorque Adapter, Drive Shaft Screw 7144-261Alignment Tool, Metering Valve 7144-508BAlignment Tool, Oversize Metering Valve 7144-508CSpanner, Drive Plate Screw 7144-511AAssembly Rod, Metering Valve 7044-895Adapter, Transfer Pressure Gauge 7044-892Testing Tool, Outer Seal 7144-760Inspection Plug 7144-13Plate, Pump Mounting 7244-155Adjustment Tool, Shutoff Lever 7144-559AKey, Regulator Plug (steel end plates only) 7144-465Gasket (for 7144-760) 7144-763Gauge Flange Marking 7244-26Insert 7244-30Insert 7244-31Insert 7244-32Extractor 7244-105Guide, Drive Hub Oil Seal 7244-154Spanner, Slotted Nut 7244-25Spanner, Holding Drive Nut 7244-24Fixture, Fuel Pump Mounting 7044-888FRachet Adapter 7144-14

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6-2

SECTION 1.

ADJUSTMENT AND ALIGNMENT

6-3. INTRODUCTION.

This section provides procedures necessary to perform adjustments and alignments to the diesel engine. Someadjustment 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).

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 rpmcan 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).

Figure 6-1. Adjusting Tachometer

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6-3

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 tim-ing pin before rotating the crankshaft.

c. Using the timing pin (figure 6-3), locate top dead center (TDC) for the number 1 cylinder.

d. Disengage the timing pin.

NOTE

The clearance is correct when some friction is felt when the feeler gauge ismoved 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 num-

Figure 6-2. Adjusting Valve Clearance

Figure 6-3. Using Timing Pin to Locate TDC

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6-4

ber 1 exhaust valve clearance to 0.020 inch. By turning the adjusting screw clockwise or counterclockwise, asnecessary, 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 thenumber 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 thenumber 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 alsoprovides specific procedures (including removal, disassembly, reassembly, and reinstallation) for the variouscomponents used on the diesel engine.

6-7. CLEANING AND INSPECTION.

General cleaning and inspection procedures that must be performed during component repair are provided inthe 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 deathcould result.

CAUTION

Do not use harsh abrasives that might scratch, score, or otherwise mar sur-face finishes.

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6-5

CAUTION

Do not allow machined or lapped mating surfaces to contact any surfacewithout protection against nicks, scratches, burrs, etc.

CAUTION

Avoid scratching and nicking critical surfaces of balls and rollers in bear-ings; 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. Mois-ture in an air line can cause rust.

CAUTION

If polishing is required, avoid leaving deposits of metal dust in and aroundbearings.

6-7.1 CLEANING. Observing all applicable warnings and cautions, clean components in accordance with thefollowing steps.

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 toremove 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-freecloth.

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 pos-sible.

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6-6

g. Valves, pistons, sleeves, and other internal parts that have close tolerance fits in mating bores should be indi-vidually cleaned to prevent scoring and marring of surfaces.

6-7.2 INSPECTION. Inspect all disassembled parts for excessive wear and damage according to the followingsteps.

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 con-taminants.

c. Inspect a threaded areas for stripped threads and evidence of cross-threading; examine area adjacent to threadsfor 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 origi-nal 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 toapply.

g. Refer tochapter 7for 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 levelmaintenance.

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6-8.2 PRELIMINARY PROCEDURES AND SAFETY INFORMATION. Prior to performing any work on thediesel engine, proceed as follows:

WARNING

Rotating machinery can cause injury or death. Ensure the engine is shutdown before working on equipment and that the starter is tagged OUT-OF-SERVICE.

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 toproceed 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 devicesare used during handling. The equipment is heavy.

CAUTION

To prevent damage to equipment, the diesel engine lifting device should beadjusted so the lifting hooks are vertical.

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6-8

o. Using a spreader bar with a suitable sling and adequate chain, lift the engine from its base. Mount the engineon 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 theoverhaul stand before releasing the lifting sling; engine damage may resultif 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. Remove the starter motor according to the following steps. Unless otherwise noted, calloutsrefer tofigure 7-2.

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 tofigure 7-2.

a. Using a scribe or similar sharp-pointed tool, remove two core plugs (25) from drive end shield (7), exposingtwo 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 removebrushes (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).

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WARNING

To prevent serious eye injury while removing/installing retaining ring(s),wear safety eye protection. Ensure retaining ring(s) is secure in the ringgroove.

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; endfloat 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 arma-ture (85). Remove and discard sealing ring (84).

CAUTION

To prevent damage to equipment, a soft-jawed vise, cloth, or cardboardshould 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 directionof 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 col-lar (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 andoverspeed balls (82). Remove the armature from the clamp or vise.

WARNING

To prevent serious eye injury while removing/installing refining ring(s), wearsafety 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 thedrive end shield.

p. Remove any burrs from the pinion and withdraw pinion assembly (83) from the drive end shield.

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q. Detach the flexible lead from moving contact (37); remove the link to the binding post on the moving con-tact.

r. Using a suitable punch, remove securing rivets (47) to free resistor (45) from the drive end shield; removeresistor bushing (44) and spacers (43).

s. Remove main terminal nuts (16), lock washers (15), screw (18) and lock washer (17). Remove washers (13and 14), sealing ring (12) and insulator bushing (11). Rotate main terminal (8), 180 degrees axially andremove 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 termi-nals (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 termi-nal 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 mustride on the commutator to provide Proper performance. Check by hand to ensure the brush springs providefirm contact between the brushes and commutator. If the springs are distorted or discolored, they should bereplaced.

NOTE

Do not turn the commutator or undercut the insulation on the motor. Use 240-grit 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 aresometimes 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 amjoined to the commutator. Loose or poor connections cause arcing and burning of the commutator. If thebars are not badly burned, leads originally soldered to the riser bars can be re-soldered. Check for insula-tion to ground by means of a 500-volt megger type tester between any commutator segment and the arma-ture 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 probeis placed on the commutator and the other test probe on the armature core or shaft, the armature isgrounded and must be replaced.

c. Field coils. Using a test lamp, check the field coils for grounds and open circuits according to the follow-ing steps.

1. Grounds. Disconnect the field coil ground connections. Connect one test probe to the field frame andthe 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. thefield coils are open. If the field coils need to be removed for repair or replacement, a pole shoe spreaderand pole shoe screwdriver should be used. Care should be exercised in replacing the field coils to prevent

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6-11

grounding or shorting as they are tightened in place. Where the pole shoe has a long lip on one side, itshould 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 con-sumption at nominal voltage. A link should be made between the green lead and the terminal lug, refer totable 6-2andfigure 6-4.

Table 6-2. Solenoid Test Data

Starter Type Ammeter in Supply Circuit Read Ammeter

CA4524 InsulatedReturn

Apply 24 volts to black and greenleads*

Check current consumption is approxi-mately 16 amperes.

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

CAUTION

To prevent overheating, do not leave the pull-in winding energized morethan 15 seconds. The current draw will decrease as the winding temperatureincreases. The purpose of the R terminal is to short out the ignition resistorduring cranking, thereby providing high ignition coil output.

1. With all leads disconnected from the solenoid, make test connections to the solenoid switch terminal andto ground or to the second switch terminal (if present) to check the hold-in winding. Compare the amme-

Figure 6-4. Starter Motor Solenoid

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6-12

ter reading with the specifications. A high reading indicates a shorted or grounded hold-in winding and alow reading indicates excessive resistance. To check the pull-in winding, connect from the solenoid switchterminal to the solenoid motor terminal.

2. Examine the contacts and, if necessary, clean them with white spirit or very fine carborundum paper. Thefirst stage gap should be 0.083 inch (2.1 mm) with a bottom limit of 0.076 inch (1.93 mm) and a maxi-mum of 0.098 inch (2.5 mm). Press down the plunger and ensure the second stage contacts make, but onlyafter the trigger is tripped. If the contacts are badly burned, the gap excessive, or the coils appear to haveoverheated, the solenoid should be replaced as a complete unit.

e. Dismantling the solenoid. To replace defective components, dismantle the solenoid according to the follow-ing steps. Unless otherwise noted, callouts refer tofigure 7-2.

1. Remove rivets (29) securing trigger guide (39) and the rivets securing contact stop (28); remove the con-tact stop and trigger guide. Examine the trigger guide for wear on the pivot points; replace the triggerguide, 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 thefollowing steps.

1. Locate the fixed contact assembly on the solenoid; ensure the contact plate rivet holes align with those inthe solenoid coil plate.

2. Replace plunger (36), moving contact (37), and springs (33 and 35). The rectangular-shaped extension onone 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) andtrigger 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 obtainedby bending the brass contact stop.

g. Commutator end bearing. Ensure commutator end bearing bushing (68) is tight in its housing. Check theside play between the armature shaft and bearing. If the side play is excessive, replace the end bearing bush-ing 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 bearingafter assembly. On new drive end shields, the retaining pad is fitted in theoil way.

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6-13

1. Check the internal diameter of the drive end shield (7). If bearing bushing (6) is worn, the drive end shieldmust 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 newpinion has the same number of teeth and is a free-sliding fit on the armature shaft. If necessary, lightly lapthe pinion bore and shaft with a fine lapping paste. Remove all traces of lapping paste using a bottle brushto ensure absolute cleanliness of the pinion helix. If the pinion is fitted with an oil seal in the bore, all burrsor sharp, edges must be removed or the seal will tear. Install a new oil seal with the U-channel facing towardthe pinion teeth end (figure 6-5).

j. Springs. Ensure the starter motor springs are not damaged, discolored, or deformed and retain their ten-sion. Refer totable 6-3.

Table 6-3. Spring Tension

Spring Compressed Length Tension

Lock Spring 0.375 in. (9.53 mm) 1.69 to 1.94 lbsRecoil Spring 1.313 in. (33.35 mm) 26.50 to 29.50 lbsPinion Spring 1.250 in. (31.75 mm) 7.75 to 8.50 lbsPinion Spring (oilsealed starter)

1.469 in. (37.3 mm) 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 commu-tator. With a rough cut, remove just enough copper to clear traces of the damage. After this, a very lightcut should be taken using a diamond or tungsten carbide tip to obtain a high quality surface finish.

WARNING


3. Remove all traces of dust using dry, compressed air. The minimum diameter to which the commutator can

Figure 6-5. Installing Oil Seal

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6-14

be machined is 1.56 inch (392 mm). Radius at the juncture of the risers and commutator must not exceed0.040 inch (1.0 mm). The risers should not be skimmed and the commutator must not be undercut, as car-bon 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 heliceswith 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 otherwisenoted, callouts refer tofigure 7-2.

1. Using a pole shoe screwdriver, unscrew pole shoe screws (78). Remove the pole shoes and windings; notetheir original positions within the starter housing (figure 6-6). Mark number 1 position with tape or scribemark on housing.

NOTE

As an aid to correct assembly, the pole shoes are numbered and must be replacedin the same positions as original. Otherwise, they might foul the armature duringoperation.

2. Fit the replacement windings into the housing and replace the pole shoes in their original positions (figure6-6).

3. Carefully align the pole shoes in the housing; insert and torque the pole shoe screws (78) 25 to 30 lb-ftusing a pole shoe screwdriver. When completed, ensure no space exists between the mating surfaces ofthe pole shoes and the housing.

n. Brush gear. Using a 10-volt megger-type tester, check the insulation between all brush holders and thestarter motor frame. The insulation resistance must be not less than one megohm. Ensure all brush holdersam 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:

Figure 6-6. Positions of Pole Shoes and Windings

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6-15

CAUTION


1. Place the armature in an armature clamping device or a vise with protected jaws. Wrap a strip of fine glasspaper (not emery cloth or carborundum) around the commutator with the abrasive side outward; securethe 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 springsin position.

3. Rotate the end shield in the opposite direction to the normal direction of rotation of the armature until thebrushes 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 springbalance hooked under the lip of the spring, remove the brushes from the holder, raise the lip to the height ofthe 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 tofigure 7-2. Refer totable 6-1for 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 thefour segments inside the spring so they lie end-to-end in a circle; install the spring in the outer groove of thesegments.

b. Place the solenoid switch on the workbench, coil end facing upward. Gently push the spring and segmentassembly 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 pinionassembly (83). Remove the split protection collar.

d. Place terminal insulator (10) under main terminal (8) of the assembled solenoid switch (figure 6-4); the endwith the hole must be upright.

e. Insert the solenoid assembly in the drive end shield and secure with self-tapping screws (30) and lock wash-ers (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), lockwasher (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 theanodized 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.

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6-16

k. Reinstall collar (48) to the pinion assembly (83) pinion sleeve; ensure the 45-degree chamfer inside the col-lar is facing the solenoid assembly.

WARNING


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 retainingring (52). Ensure the external retaining ring locates properly in the ring groove; check with gauge 6244-3 toensure 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 withwasher (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 andscrew; 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 frominside the bore. Use a small screwdriver blade with a spot of grease to feed the balls and apply a small amountof 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 itsspring 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 todislodge the lock ring balls.

4. Engage the pinion with the shaft helix and release the pinion. Screw the pinion onto the shaft and ensurethe pinion assembly locking mechanism engages.

5. Support the weight of the drive end shield and rotate the pinion in both directions to ensure freedom ofmovement and that the locking mechanism functions correctly. The locking mechanism can be released bypulling the lock collar back against its spring.

CAUTION


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6-17

NOTE

On oil sealed starters only, use Loctite grade D on the threads when installing thepinion 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 directionof 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) andensuring 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 endshield (73). Reinstall two thru-bolts (69), lock washers (70), and torque securely 7 to 7-1/2 lb-ft.

WARNING


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 totable 6-1to determine the correctgauge (5693-222, 5693-222A, or 5693-222B) to be used according to the required mounting flange dimen-sion.

1. Bolt the appropriate gauge on the starter motor mounting flange with the arm marked CHECK toward thepinion (figure 6-7); push the armature toward the drive end of the motor until the pinion face just touchesthe gauge. With the armature held in this position and using standard feeler gauges, measure gap Xbetween the thrust washer and the commutator end shield. Shim washers having a total thickness equal tothe measurement should then be fitted between the thrust washer and the retaining ring. Ensure the shimwashers are well greased before use.

Figure 6-7. Adjusting Forward Movement

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6-18

NOTE

Example: If gap X is now 0.120 inch, shim washers having a total thickness of0.020 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. Thegap should now be within the limits of 0.079 inch, + 0.020 inch, - 0.00 inch. If the gap is beyond thislimit, remove the commutator end shield (73) and reinstall the shim washers (67) on the armature shaft tothe value of the excess.

WARNING


3. Replace the commutator end shield, thrust washers, shim washers, and the retaining ring as determined instep 1.

NOTE

If a screwed end cap is installed in place of a bayonet type, the starter must beheld vertically (commutator end up) and the thrust pad attached to the cap withgrease. The cap must be torqued 7 to 10 lb-ft and the two thin corners of thehexagon locked to slots in the bearing collar with a punch.

4. Apply grease to steel ball (59) and spring (60); refer totable 6-3. Insert spring, then the steel ball in thearmature shaft bore. Replace end cap (57) turning it in the direction of starter motor rotation to lock it inplace.

5. Ensure that any variation in the relationship of the pinion position to the check gauge is within the limitsof 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) usingtool number 5693-300.

Figure 6-8. Adjusting Rear Movement

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6-19

x. Connect the field windings and the free end of the resistor to the solenoid switch lugs with screws (30) andwashers (23).

y. Install brush kit (72) and trigger and springs (38). Connect the brush leads and the field winding leads to thebrush 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. Test the solenoid engagement mechanism’s operation according tothe following steps.

Table 6-4. 24-Vdc Starter Test Data

Nominal Voltage ofStarter Type of Test

MinimumBatteryCapacity

Torque Val-ues

CurrentAmpere

Terminal Volt-age

Speed(rpm)

24 Vdc LT 78 Ah 38.0 lb-ft 910 max 9.2 --RT 78 Ah 17.0 lb-ft 555 max

min.15.2 1550

LR 78 Ah N/A 60-100 24.0 7000Brush spring tension: 6 to 7.5 lbs. LT = Locked TorqueBrush grade: DM100. RT = Running TorqueBrush length (new): 19 mm. LR = Light Running (no load)

WARNING

To prevent injury or death when testing the engagement mechanism, underno circumstances should both main terminals be connected to the supplyvoltage source. Otherwise the pinion will rotate at high speed when pulledforward 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 performingany starter motor performance tests.

b. Connect the battery solenoid terminal S and solenoid terminal R. With the solenoid energized, the pinionshould move forward approximately 1.25 inch.

c. With the solenoid still energized, pull the pinion forward by rotating it opposite to normal rotation. The lock-ing 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 sharpmovement.

e. Check the recoil spring action by applying a compression spring balance to the driving end of the armatureshaft. The force required before backward movement of the shaft occurs should be 30 to 38 lbs.

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6-20

6-9.5.2 Performance Tests.

a. Prior to performing any starter performance tests, ensure the brushes are thoroughly bedded on the commuta-tor. Refer toparagraph 6-9.3, step o.

CAUTION

To prevent damage to equipment, the starter should always be run in con-junction with a flywheel. If this is not possible, do not operate the starter formore than five seconds. If the starter is allowed to run without a load, thepinion will not be restrained from rotating in the initial stages and will notcomplete the forward movement necessary to trip the second stage contacts.Under these conditions, the resistor will remain in the circuit and may bedamaged by overheating. Prolonged operation on first stage contacts maycause 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 faceof the flywheel.

c. Connect starter terminals as shown infigure 6-9to a fully charged 24-volt battery. Refer totable 6-4for startermotor test values.

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 atthe bottom of the starter in relation to mounting on the engine.

Figure 6-9. Connecting Starter Terminals

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6-21

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 therelay winding, B+ to 5W + terminal, B- to junction of capacitor positive and the black relay winding startlead. Increase the variable resistance and set the relay by adjusting the armature spring tension so the contactsopen between 32 and 34 milliamperes.

d. Connect a voltage source not exceeding 20 volts to terminals SW+ and E; observe that the relay momentarilycloses. Failure to close indicates a faulty capacitor, loose or broken connections, or an excessive core gap set-ting.

e. Connect a 24-volt lamp and battery in series with the relay contacts, SW+ and SOL terminals. Press armatureto coil to close contacts and observe if lamp lights. Failure to light indicates dirty contacts or loose or brokenconnections.

6-9.6 REINSTALLATION. Reinstall the starting motor in reverse order of removal, refer toparagraph 6-9.1.Ensure the commutator cover (55), Phillips head screw (54) is at the bottom when the starter motor is mountedon the engine. This is important, as fuel and water may enter the motor if the commutator cover is not correctlypositioned. 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 tofigure 7-6.

a. Identify, tag, and disconnect the wiring to the gauge to be removed.

b. Remove the mounting nuts and bracket

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6-22

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 tofigure 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 pipingon the model 6B5.9-M engine.

6-11.2 REINSTALLATION. Reinstall the air cleaner/ silencer according to the following steps. Unless other-wise noted, callouts refer tofigure 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. Remove the alternator according to the following steps. Unless otherwise noted, calloutsrefer tofigure 7-3.

Figure 6-10. Relay Test

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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, keephands 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 alter-nator with alternator brace (1).

f. Remove mounting spacer (6).

6-12.2 REPAIR. For repair procedures to the alternator, refer to the NAVSEA technical manual S9313-A5-MMA-010.

6-12.3 REINSTALLATION. Reinstall the alternator on alternator support (5) in the reverse order of removal;refer toparagraph 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 other-wise noted, callouts refer tofigure 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, keephands 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 toparagraph 6-7.1andparagraph 6-7.2.

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6-13.2 REINSTALLATION. Reinstall the drive belt and belt tensioner according to the following steps. Unlessotherwise noted, callouts refer tofigure 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 thethumb 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) to92 lb-ft.

e. Reinstall the remaining pans and belt guard in the reverse order of removal. Refer toparagraph 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 tofigure 7-10.

a. Remove filler cap (19,figure 7-15) from the expansion tank and pipe plug (5,figure 7-15) from water trans-fer tube (6,figure 7-15). Drain the coolant into a suitable drain pan. Reinstall the pipe plug upon completionof drainage.

b. Refer toparagraph 6-13.1and 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 toparagraph 6-7.1andparagraph 6-7.2.

6-14.2 REINSTALLATION. Reinstall the fresh water pump according to the following steps. Unless otherwisenoted, callouts refer tofigure 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 toparagraph 6-13.2and 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.

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f. If required, refill the coolant system with a 50-percent mixture of fresh water and ethylene glycol-based anti-freeze.

6-15. THERMOSTAT.

Replace the thermostat according to the following steps. Unless otherwise noted, callouts refer tofigure 7-11.

a. Remove filler cap (19,figure 7-15) from the expansion tank and pipe plug (5,figure 7-15) from fresh watertransfer tube (6,figure 7-15). Drain the coolant into a suitable drain pan. Reinstall the pipe plug and tightenupon 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 thealternator pulley.

d. Loosen lower hose clamp (16,figure 7-18) and disconnect thermostat housing upper plain hose (17,figure7-18).

e. Loosen alternator brace (1,figure 7-3), hex head cap screw (2,figure 7-3), and alternator mounting hex headcap 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). Dis-card the gasket.

g. Clean and inspect parts according toparagraph 6-7.1andparagraph 6-7.2.

h. Install a new thermostat into the housing. Ensure the jiggle pin is in its notch and the tang on the thermostatis in the notch on the thermostat housing. Seefigure 6-11.

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.

Figure 6-11. Installing Thermostat in Housing

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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 tofigure 7-14.

NOTE

If repairs are being made with the engine in the craft, ensure the sea water sys-tem’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 hoseconnection and lower hose clamp (6) at sea water pump (4) discharge hose. Loosen suction hose to allow seawater 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 otherwisenoted, refer tofigure 7-14.

NOTE

The sea water pump and flange assembly consists of the sea water pump, whichis attached to the flange by two hex head cap screws, with the pump’s drive gearon 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 waterpump 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 installedin the same direction as removed.

f. Remove the impeller and rubber bushing from the housing.

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g. Remove the spacer plate.

h. Remove the key.

WARNING


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 removethe 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 toparagraph 6-7.1andparagraph 6-7.2. If the impeller requires replac-ing due to rips, tears, or chunks of material missing, then the heat exchanger and marine transmission oilcooler 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


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 con-tacts 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 atool 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 bear-ing, 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 andon the shaft at the same time. Press the bearing in until the second bearing has contacted the spacer.

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WARNING


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 whenhandling 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 gearis 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 thehousing over the impeller. Rotate the housing until the water connections are in the correct position and rein-stall 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 otherwisenoted, callouts refer tofigure 7-14.

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a. Reinstall the pump assembly (4) and gasket (5) on the engine using hex head cap screws (3). Torque the hexhead 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, call-outs refer tofigure 7-15.

a. Remove filler cap (19) from expansion tank (18). Remove pipe plug (5) from transfer tube (6) and drain cool-ant. Open expansion tank drain cock (17). Check for coolant in the system. Reinstall pipe plug (5) into thewater 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 theheat exchanger and fresh water pump outlet to the heat exchanger. Place the water transfer tube on wood sur-face.

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 dis-charge 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 theengine.

h. Support the heat exchanger while loosening and removing cap screws (21), retaining clamps (22), heatexchanger (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 otherwisenoted, callouts refer tofigure 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 therelative 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).

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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 brassrod from the rear to the front. This will push the debris out where it can be flushed out of the zinc plughole. Seefigure 6-12.

2. Flush the heat exchanger tubes from the rear with clean water. Make sure the end cavities are cleared ofall debris. Seefigure 6-13.

h. Clean and inspect parts according toparagraph 6-7.1andparagraph 6-7.2.

6-17.3 REASSEMBLY/REINSTALLATION. Reassemble/reinstall the heat exchanger in the reverse order ofdisassembly/removal; refer toparagraph 6-17.1and paragraph 6-17.2respectively . Use new gaskets (9), newfiber 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.

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

Figure 6-13. Flushing Heat Exchanger

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6-18. MARINE TRANSMISSION OIL COOLER.

6-18.1 REMOVAL. Remove the marine transmission oil cooler according to the following steps. Unless other-wise noted, callouts refer tofigure 7-17.

NOTE

If repairs are being made with the engine in the craft, ensure the sea water sys-tem’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 theelbows 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. Seefigure 6-14.

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

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NOTE

When back flushing the cooler, apply water pressure from the cooler dischargeside.

g. Flush all debris from the cooler with clean pressurized water. Seefigure 6-15.

h. Clean and inspect pans according toparagraph 6-7.1andparagraph 6-7.2.

6-18.2 REINSTALLATION. Reinstall the marine transmission oil cooler in the reverse order of removal; referto paragraph 6-18.1. Apply liquid Teflon sealant to the threads of male adapter elbows (1) before securing thesupply 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 referto figure 7-18.

a. Drain coolant level down; refer toparagraph 6-14.1.

b. Loosen hose clamps (16) and disconnect plain hose (17) from elbow coupling (19) and upper thermostathousing (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 plastichammer.

f. Remove gasket (9) and any gasket material from the water transfer connection plate and exhaust manifold. Donot 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 thermo-stat housing (3,figure 7-11); tighten hose clamps securely.

j. If required, refill the engine with coolant.

Figure 6-15. Flushing Marine Transmission Oil Cooler

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6-20. TEMPERATURE TRANSDUCER.

Replace the temperature transducer according to the following steps. Unless otherwise noted, callouts referto 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, call-outs refer tofigure 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 toparagraph 6-7.1andparagraph 6-7.2.

6-21.2 REINSTALLATION. Reinstall the fuel transfer pump in the reverse order of removal; refer toparagraph6-21.1. Use new sealing washers (1) and cover plate gasket (6).

6-22. FUEL PIPING.

6-22.1 REMOVAL. Remove the fuel piping according to the following steps. Unless otherwise noted, calloutsrefer tofigure 7-25.

NOTE

Individual high-pressure fuel line(s) can be removed without removing the com-plete 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.

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CAUTION

To prevent the fuel injection pump delivery valve holder from turning, usetwo wrenches.

c. Using two wrenches, loosen and remove high-pressure fuel lines (16, 17, 18, 20, 21. and 22) from the fuelinjection pump.

d. Loosen and remove cap screws (4), plain washer (3), tube brace (2), and vibration isolators from the high-pressure fuel lines.

6-22.2 REINSTALLATION. Reinstall the fuel piping in the reverse order of removal; refer toparagraph 6-22.1Torque to 18 lb-ft.

6-23. FUEL FILTER AND FUEL/WATER SEPARATOR.

6-23.1 FUEL FILTER. Replace the fuel filter according to the following steps. Unless otherwise noted, call-outs refer tofigure 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 replace-ment 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 andturn clockwise until the gasket contacts the filter head; turn the canister an additional 1/2 turn after the gas-ket contacts the filter head.

6-23.2 FUEL/WATER SEPARATOR. Replace the fuel/water separator element according to the followingsteps. Unless otherwise noted, callouts refer tofigure 7-42.

NOTE

Use a suitable container to catch any fuel/water drained from the fuel/separatorbowl.

a. Loosen the separator vent plug (2) mid open the separator bowl drain knob (7) to drain all fuel/water from theseparator 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 thebowl O-ring gland.

e. Spin the bowl (6) onto a new element (4). Do not overtighten.

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f. Lubricate the element gasket with fresh, clean engine oil; fill the bowl/element assembly with fresh, clean die-sel 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 tofigure 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, andfuel drain tube (8) from the cylinder block.

6-24.2 REINSTALLATION. Reinstall the fuel drain manifold in the reverse order of removal; refer toparagraph 6-24.1. Use liquid Teflon sealant on the fuel manifold and fuel drain tube end fittings. Use new banjoseal 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 otherwisenoted, callouts refer tofigure 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 thesocket 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 nozzlewith the cylinder number from which it was removed.

g. Place the fuel injection nozzle(s) on a clean working surface.

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6-25.2 DISASSEMBLY. Disassemble the fuel injection nozzles according to the following steps. Unless other-wise noted, callouts refer tofigure 7-27.

a. Remove and discard copper sealing washer (5).

CAUTION


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 asuitable bath of clean fuel oil.

NOTE

Hold the needle valve by the stem; skin oils will corrode the finely lapped sur-faces. Also, the needle valve and nozzle tip are matched to fit and should not beintermixed.

c. Remove nozzle needle valve (8), nozzle (7), and intermediate disc (9). Place the needle valve and nozzle ina 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 toparagraph 6-25.3.

6-25.3 CLEANING AND INSPECTION. Clean and inspect the fuel injection nozzles according to the follow-ing steps.

WARNING


a. Clean the edge filter in the nozzle by applying clean, dry, compressed air to the fuel passage from the nozzleside 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 intest oil.

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c. Clean the interior of the nozzle ring groove with the scraper. Rinse in an approved solvent to remove all dirtand carbon residue and dip in clean test oil. Refer toparagraph 6-7.1.

d. Clean the spray holes in the injection nozzles with an appropriate size cleaning needle. Remove burned ondeposits 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 shoulderwill 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 pullthe needle valve one-third of the way out of the nozzle body. The needle valve must slide all the way backinto the nozzle body under its own weight. If the nozzle fails the slide test, re-clean and re-test. Any nozzlebody 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 other-wise noted, callouts refer tofigure 7-27.

NOTE

Prior to reassembly, ensure all mating surfaces and pressure faces are absolutelyclean 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


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 valveand 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. Test the fuel injection nozzles according to the following steps.

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WARNING

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

NOTE

All injection nozzles must be tested for opening pressure, chatter, and spray pat-tern.

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. Ifthe 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

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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. Aused nozzle can generally be placed in service if it passes the leakage test, chat-ters 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 atomizethe 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 oth-erwise noted, callouts refer tofigure 7-27.

a. Apply a coat of antiseize compound to the threads of the fuel injection nozzle nozzle hold-down nut andbetween 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 ori-ent the nozzle.

d. Using a deep-well, 24-mm socket that will not damage the sealing surface of the fuel drain outlet, torque fuelinjection nozzle nut (6) to 44 lb-ft.

6-25.7 BLEEDING THE FUEL SYSTEM. Bleed the fuel system according to the following procedure. Unlessotherwise noted, callouts refer tofigure 7-25.

NOTE

Manual bleeding of the fuel system is required if the fuel filter is not filled priorto 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.

Figure 6-17. Leakage Test

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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 fuelinjection 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 ofair (figure 6-19).

6. Torque the bleed screw to 6 lb-ft.

NOTE

Control venting is provided at the fuel injection pump through the fuel drainmanifold. Small amounts of air introduced while changing the fuel oil filter/fuel

Figure 6-18. Energizing Solenoid

Figure 6-19. Venting Fuel Filter and Hand Lever

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injection pump supply line will be automatically vented if the fuel oil filter ischanged in accordance with the instructions.

b. Vent the fuel injection pump at the bleed screw (figure 6-20) as follows.

NOTE

The fuel injection pump can be vented both manually and through the use of thestarting 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 fuelinjection 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 startingmotor (figure 6-21).

c. Vent the high-pressure fuel lines as follows:

1. Loosen the high-pressure fuel tube fittings at the nozzle.

Figure 6-20. Venting Fuel Injection Pump

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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).

WARNING

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

4. Crank the engine to allow air to bleed from the high-pressure fuel tubes (figure 6-22). Torque the high-pressure fuel tube fittings at the nozzle.

Figure 6-21. Venting Fuel Injection Pump through Fuel Drain Manifold

Figure 6-22. Venting High-Pressure Fuel Tubes

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WARNING

Do not bleed a hot engine. This action could cause fuel to spill onto a hotexhaust 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 enginerunning, vent one high-pressure tube at a time until the engine runs smoothly (figure 6-23).

6. Stop the engine when the fuel system has been bled.

6-26. FUEL INJECTION PUMP.

6-26.1 REMOVAL. Remove the fuel injection pump according to the following steps. Unless otherwise noted,refer tofigure 6-24.

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 dur-ing pump calibration.

f. Using a 13-mm wrench, loosen the hex head adjustment cap screw and the mount brace cap screws; removethe 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.

Figure 6-23. Venting High-Pressure Fuel Lines with Engine Idling

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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 pinafter locating TDC.

j. Loosen the fuel pump lock screw (figure 6-26); position the special washer as shown, then tighten the lockscrew against the pump shaft. Torque the lock screw to 5 lb-ft.

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

Figure 6-24. Fuel Injection Pump Disassembly

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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

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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 ensurecorrect alignment and gear backlash when reinstalled.

CAUTION

To prevent damage to equipment and excessive teardown, do not drop thefuel 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 other-wise noted, callouts refer tofigure 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 suit-able 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 tocomplete repairs. The throttle is indexed to the lever. Note the location of indexmarks 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 pumpand connected to the governor spring.

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

i. Unhook and remove spring (91).

j. Remove idling spring (96) and spring guide (97).

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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 thelinkage 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 springretainer 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).

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 identifica-tion against the outer holes.

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

Figure 6-28. Governor Linkage Spring Removal

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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 thetransfer pump liner (59), i.e., 3 or 9 o’clock when viewed from the transfer rotor end, then remove transferpump liner.

y. Hold the drive hub with a wrench and loosen the transfer pump rotor with tool number 7044-889 (figure6-29). The direction in which the transfer pump rotor is loosened is indicated by an arrow marked on theface of the rotor. Unmarked rotors are loosened in the direction of pump rotation. Remove tools, then finger-tighten the transfer pump rotor.

z. Note the location of socket head screw (20), and remove the screw and washer (21). Remove head and rotorassembly (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 7144-744and 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).

Figure 6-29. Loosening Transfer Pump Rotor

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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 posi-tion with the transfer pump rotor finger-tightened.

Figure 6-30. Loosening Drive Plate Screws

Figure 6-31. Fitting Corks to Retain Plungers

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WARNING


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), thrustwasher (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 anddiscard oil seal (45) using tool number 7044-893A (figure 6-32). Remove housing retaining ring (46) withretaining ring pliers. Also remove and discard second oil seal (45).

ii. Clean and inspect all parts according toparagraph 6-7.1andparagraph 6-7.2.

6-26.3 REASSEMBLY. Reassemble the fuel injection pump according to the following steps. Unless otherwisenoted, callouts refer tofigure 7-28.

a. Immerse the two new replacement oil seals (45) in clean test oil. The oil seals must be inserted in the sameposition noted prior to disassembly. Use tool number 7244-154. Install inner oil seal (45). Next, reassemblehousing retaining ring (46) with its open end adjacent to tell-tale holes where provided, then install outeroil 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 governorcontrol machined face upwards.

Figure 6-32. Removing the Drive Hub Seal

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

d. Assemble thrust washer (47) and thrust sleeve (50) over drive shaft (48). Press down the thrust sleeve andinstall 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 cleantest oil and insert the drive shaft with a rotating action through the oil seals. When the drive shaft is securelyhome, remove the protection cap.

f. Install retaining ring (26) against the shoulder in the pump housing bore, positioning the square ear of theretaining 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 thesame 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 usingtool number 7144-14. Remove the tool and lightly tap the cam advance screw to ensure the cam ring is notbinding in the pump body.

NOTE

If the distributor head rotor screw has been removed or is loose, a new screw andwasher must be installed.

i. Unscrew and remove transfer pump rotor (60). Detach the distributor rotor from hydraulic head (57). Screwthe two drive plate screws fully home into the distributor rotor. Position the rotor so the heads of the screwsare gripped lightly by the jaws of a vise. Thoroughly de-grease the threads of the rotor and screw and lightlycoat 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 pumpinto service.

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

Figure 6-33. Rotor Screw Installation

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(56) on the hydraulic head with its chamfered edges upward. Insert the distributor rotor and line up theguide 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. Insertroller and shoe assemblies (23) with the ears in the roller shoe guides. The projecting ears on the shoes mustbe placed in the eccentric slots of the bottom adjusting plate so the contour of the ears match the contourof the slots.

l. Reinstall the top adjusting plate (figure 6-34) with its chamfered edges downward and engage the legs ofthe plate in the guide slots of the bottom adjusting plate. Locate the two plates so the fuel adjusting slot inthe top plate coincides with the scribed line on the distributor rotor head. Reassemble the drive platemachined 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.

m. Lift head and rotor assembly (57) and screw transfer pump rotor (60) finger-tight into the distributor rotorbody.

NOTE

Relief valve number 7144-155 must be fitted in the fuel line to ensure that thetest pressure of 440 psi (30 atm) is not exceeded. When other test pressures arestated on test plans, this relief valve can be omitted but care must be taken notto exceed the specified pressure. Excess pressure can cause damage to shoeassemblies and adjusting plates.

Figure 6-34. Reinstalling Top Adjusting Plate

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

o. Turn the pump rotor until the pumping plungers and rollers are forced outwards to the maximum fuel posi-tion. Using a micrometer, measure the overall roller-to-roller dimension. The roller-to-roller dimension mustbe 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 adapterfitted in a torque wrench. In use, the torque wrench handle and spanner mustform a straight line with the handle extending away from the spanner. The dis-tance between the center of the adapter and the center of the ring spanner is 5inches (127 mm). If the tools used are not kept in a straight line, the appliedtorque will be incorrect.

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

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

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

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

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oil feed drilling end of the piston housing. Reassemble the housing and piston assembly (116) to the pumphousing, 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 fitsinto the pump with clean test oil and install the hydraulic head into the pump housing. Insert the head intoposition, with a rotating motion, so the splines on the inner end of the drive shaft engage with the splinesin 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 inposition, 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. Progressivelyand 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 tothe correct value. (Refer totable 6-7for all torque values.)

NOTE

The transfer pump rotor must be tightened in the opposite direction of pumprotation.

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

y. Insert transfer pump liner (59) into the pump housing with the slot in the same position (3 o’clock viewedfrom 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 pis-ton 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 dowelon 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 tothe correct values.

ee. Reassemble governor arm (94) to the control bracket and reinstall the spring (95). Refer tofigure 6-28andreassemble 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 gov-ernor 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

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end of the governor arm on top of the step of the thrust sleeve and at the same time insert the meteringvalve 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 assem-bly. Position two new lock washers (92) with the lips positioned nearest to the metering valve and engag-ing the long edge of the keep plate. Screw in two studs (87) and finger-tighten. Place a new bracket screwtab washer with the tail bent down over that edge of the control bracket lying under the hook of the link-age assembly. Insert new hex head screw (33) with lock washer (34) and torque the hex head screw andstuds to the correct torque value; refer totable 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 themetering valve lever pin. Adjustment is made by slackening the linkage locking nut and tightening or loos-ening the linkage nut on the end of the hook linkage. When setting, apply light pressure to the governorcontrol arm to hold the metering valve in the fully open position. Ensure the vernier gauge is held parallelto 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 con-trol bracket. Slide shutoff bar (93) into the cutout in the control bracket.

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 gover-nor 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). Posi-tion 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 controlcover onto the two studs (87). While lowering the governor control cover into position onto the pumphousing, engage the shutoff shaft peg in the crook of the shutoff bar (93).

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

Figure 6-36. Adjusting Link Length

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

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

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

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 correctvalues.

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 oflocking wire with an unclenched seal, is loosely attached to the pump for sealing the throttle adjusting screwafter 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.

Figure 6-37. Attaching Governor Spring

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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 isclean and free from water.

b. Seal off the low-pressure outlet connection on the pump and completely immerse pump in a bath of clean testoil.

c. Raise the air pressure in the pump to 20 lb-in2 (1.41 kg cm2 ). Leave the pump immersed in oil for 10 min-utes 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 airpressure 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 oilseals. The gap in the retaining ring between the seals lines up with a tell-tale holein the pump body. The inner seal, nearest to the governor sleeve, is checked bythe 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 flangedcylinder 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 20seconds. Bubbles at the tell-tale hole normally indicate an oil seal failure, but first ensure that these are notcaused by a faulty gasket.

6-26.4.3 General Testing Procedures. When testing the fuel injection pump, ensure the following precautionsare observed.

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 apump with 46-mm spigot.

e. Unless otherwise stated, standard radial high-pressure connections must be fitted prior to testing.

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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 accord-ing 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, openthe 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 theconnections or close the bleeder valves.

f. Examine the pump after priming for oil leaks at all jointing faces, connections, and oil seals. The pump mustbe 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 bymeasuring the volume passing through each nozzle during 200 pump cycles. The pump test data outlines themaximum fuel delivery, overall tolerance, and the maximum permissible delivery variation spread between thenozzles.

6-26.4.6 Shutoff Control. The shutoff control is checked by running the pump at 325 rpm with the shutoff con-trol 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 aspecified speed with the throttle and shutoff controls fully open; refer to the injection pump nameplate. If outputis 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 turnedto 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 toolnumber 7144-511A, and a torque wrench. When using the recommended spanner tool, the distance betweenthe spanner and the adapter centers is 5 inches (127 mm). The torque spanner and the ring spanner must forma straight line when tightening the screws and care must be taken to ensure the spanner does not contact theside of the inspection aperture.

g. Replace and secure the inspection cover, refill the pump, vent as necessary, and re-check the maximum fueldelivery. Repeat until the volumes are within the specified limits.

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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 engineand 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 andadjust the maximum speed stop until the specified fuel delivery is obtained. This specified volume is less thanthat at the maximum fuel setting.

b. Reduce the speed of rotation, whereupon the fuel delivery should increase to a specified volume approximatelyequal to the maximum fuel delivery.

6-26.4.9 Transfer Pump Setting. Check the fuel injection pump’s transfer setting according to the followingsteps.

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 offthe fuel supply and connects the pump inlet to the vacuum gauge. A givendepression 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 install-ing adapter tool number 7044-892 into the hydraulic head, and a pipe fitted between the pump and the pres-sure 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 theend plate. To adjust the transfer pressure, the operation of the regulating valve can be modified according to thefollowing steps.

a. On certain pumps with aluminum end plates, the transfer pressure can be adjusted within the limits of an indi-vidual specification in one or both of two ways: by changing the end plate sleeve plug and by adjustment ofthe screw passing through the plug.

b. Several plugs with different step thicknesses are available; the stepped portion in contact with the regulatingspring determining the spring compression. The screwed transfer pressure adjuster limits the movement of theregulating piston and so controls the maximum uncovered area of the sleeve port. The first method abovemodifies transfer pressure characteristics over the lower and middle speed ranges and the second method con-trols the pressure rise over the upper speed range.

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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 thepump is running. If a change of the end plate sleeve plug is necessary to com-ply with the test plan, the appropriate numbers and the item designation are givenin the parts list.

c. There is a third type of transfer pressure adjuster that varies the pre-loading of the regulating spring and maxi-mum lift of the piston. It has a spring peg fitted between the adjusting screw and regulating spring. This hasthe 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 allowthe pressure to be read without restricting the permanent bleeding operation. This can be carried out by usingtools from service kit number HF-531.

NOTE

On some pumps, the cam box is pressurized during running by a spring-loadedball pressurizing valve located in the back leakage connection in the inspectioncover. On pumps designed to provide excess fuel, this operation is carried out bythe proportional pressurizing valve.

b. Pressure limits are given in the appropriate test data. If pressure is incorrect, ensure the pump is not leakingand there is no reaction in the back leakage passages. If the pressurizing valve is faulty, a new inspection covercomplete with valve must be fitted, or on pumps with excess fuel facility, a new proportional valve must befitted.

6-26.4.12 Advance Device Test. The appropriate test plan for the individual pump specifies the type of advancedevice fitted and details the tests for the particular unit. All advance devices are tested using special tool num-ber 7244-59 which consists of a gauge with a scale covering 0 to 18 degrees and a feeler pin tool number 7244-70. Install this tool according to the following steps.

NOTE

The pump must be re-primed after installing the tool. After priming, operate thethrottle and press inward; release the advance gauge pin a few times with thepump 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).

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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 ofadvance 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 andthe spring cap.

NOTE

On completion of all tests, the drive shaft screw must be slackened andre-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 coverscrews. 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

Figure 6-38. Advancing Device Test Gauge

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outlet directly opposite. Install the relief valve tool number 7144-155 to the stirrup pipe and connect the com-plete tool through a high-pressure pipe to a nozzle testing unit.

CAUTION

Do not exceed the specified pressure. Excess pressure can cause damage tothe shoe assemblies and adjusting plates.

NOTE

Normally a pressure of 440 psi (30 atm) rating is installed in the system. How-ever, a higher pressure may be required. To obtain the higher pressures, connectthe 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 isfelt. This is the timing position.

d. Access to the timing ring may be obtained through the inspection cover. Move the timing ring until the straightedge of the timing retaining ring aligns with the mark on the drive plate. Retaining ring with two straight earsare only for spacing; the retaining ring ends are positioned remote from the inspection opening. After carry-ing 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 onlybe 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: 2494 psi + 43.5-0 psi (172 + 3, -0 bar).

d. HP outlet connections: Original.

e. HP pipes: 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 read-ings unless stated otherwise by the test bench manufacturer’s instructions.

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g. A .019-inch (0.5-mm) shim is fitted to the piston spring cap on assembly. Do not remove the shim. No addi-tional shimming is required.

NOTE

Critical fuel deliveries are given in mm3 /stroke. Hence, the tester must deter-mine the number of stakes applicable in accordance with the manufacturer’sinstructions.

h. Conduct test procedures according totable 6-5.

Table 6-5. Fuel Injection Pump Test Procedures

Test Operation RPM Requirements

1. Priming 100 Obtain delivery from all nozzles.2. Transfer pressure 1300 Set to 95 lbf/in2 (6.6 bar) using P adjuster3. Transfer pressure 100 10 lbf/in2 (0.7 bar) minimum4. Low load advance check 100 1°5. Full advance 300 4-3/4° to 5-1/4°6. Back leakage 1200 10 to 100 cm3 per 100 strokes time cycle (flow rate

120 to 1200 cm3 /min)7. Max delivery setting Set to code on

nameplate.Delivery tolerance 0.7 mm3 /stroke. Spread betweenlines 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 exceed3.0 cm3 . No stop screw.

13. Delivery check 1300 With throttle set at 200 rpm, average delivery not tobe less than at test (11), minus 0.4 cm3 .

14. Governor setting Set half speed onnameplate.

Set throttle to give average delivery of 2.0 cm3 .Lock stop screw.

Prior to performing test 15, run machine down to 100 rpm and stop. Disconnect transfer pressure gauge andreplace 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 exceed0.5 cm3 .

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Table 6-5. Fuel Injection Pump Test Procedures - Continued

Test Operation RPM Requirements

16. Timing internal and exter-nal.

Before commencing timing operation, loosen locknutand ease splined drive hub from shaft. Remove pres-sure end plug 7123-473B and replace with a springcap plug. Install a suitable length adjusting screw andturn the screw to lock the advance piston in a fullyadvanced position. Using outlet X pressurized to 795psi (55 bar) and with pump in this position andindexing tool set to 280 degrees, scribe a line onpump housing flange (use insert 7244-30). Depressur-ize outlet, then rotate drive a further 18 degrees untilindexing tool reads 262 degrees against housingscribe line.Slide shaft locking screw washer into position withlarge hole diameter located around shoulder diameterof screw, then torque to 60 lb-inch. With pump drivelocked in this position, set internal timing retainingring to plate letter C. Remove the spring cap plugand 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 other-wise noted, callouts refer tofigure 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 throughthe 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 slightlydue to the gear helix and clearance. This is acceptable providing the pump is free to move on the flange slotsand 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 lockscrew 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 bracket-to-injection pump cap screws. Torque all the cap screws to 18 lb-ft.

k. Torque the drive gear mounting nut to 48 lb-ft.

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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 otherwisenoted, callouts refer tofigure 7-18.

a. Remove the high-pressure fuel supply lines. Refer toparagraph 6-22.1.

b. For the model 6BT5.9-M engine: loosen two hose clamps (1) and disconnect hose section (2) from air intakemanifold cover (24).

c. For the model 6B5.9-M engine: loosen and remove the air cleaner/silencer prior to removing the intake mani-fold cover (24). Refer toparagraph 6-11.1.

d. Loosen and remove hex head cap screws (23), intake manifold cover (24), and gasket (22). Discard the gas-ket.

e. Clean and inspect parts according toparagraph 6-7.1andparagraph 6-7.2.

6-27.2 REINSTALLATION. Reinstall the intake manifold cover according to the following steps. Unless oth-erwise noted, callouts refer tofigure 7-18.

CAUTION

Loose connections or cracks in the suction side of the intake pipe on turbo-charged engines can allow debris to be ingested into the turbocharger com-pressor and forced into the engine.

CAUTION

Leaks at the intake manifold, unsealed bolt holes, or manifold cover gasketcan 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 liquidTeflon.

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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 toparagraph 6-11.2. Then reinstall hoseclamps (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 toparagraph 6-22.2.

e. On the model 6BT5.9-M, test the turbocharger supply air discharge to the intake manifold and flexible hoseconnections using a liquid soap solution.

f. Test the intake manifold cover and pipe fittings for air leaks (figure 6-39).

6-28. TURBOCHARGER.

6-28.1 REMOVAL. Remove the turbocharger according to the following steps. Unless otherwise noted, referto figure 7-18.

a. Remove the oil supply line, hose clamps, and drain line with gasket from the turbocharger (figure 6-40). Dis-card 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 toparagraph 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 turbochargerand the exhaust piping.

Figure 6-39. Checking Intake Manifold for Air Leaks

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h. Refer toparagraph 6-11.1and 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 otherwisenoted, callouts refer tofigure 7-20.

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

CAUTION


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.

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NOTE

The wheel and shaft assembly is balanced as a unit. Both must be replaced ifeither 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 excessivewear.

j. Remove oil baffle (13).

Figure 6-40. Removing Supply Lines to the Turbocharger

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NOTE

The thrust bearing is a disposable item and is not be reused under any circum-stance.

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 shaftare 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 excessivewear.

p. Remove and discard seal split ring (27).

WARNING


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 thecompressor 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


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.

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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 betweenthe 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 tofigure 7-20.

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

b. Install heat shield (26).

CAUTION


c. Clamp a 16-mm socket in a soft-jawed vise and position the shaft in the socket.

WARNING


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 istoward the bearing.

f. Lubricate and install the other turbocharger bearing (18) and outer retainer ring (17). Ensure the beveled faceis toward the bearing.

g. Reassemble turbine shaft and wheel (28) and heat shield (26) to bearing housing (25). Rotate the housing asdownward pressure is applied to assist in properly seating seal ring (27). Seefigure 6-41.

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NOTE

All balance marks must be aligned during reassembly to ensure the wheel andshaft assembly remain balanced.

h. Reinstall the thrust collar. Align the balance marks. Mark the top surfaces to ensure alignment can be veri-fied after installing the thrust bearing. Seefigure 6-42.

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.

Figure 6-41. Seating Piston Ring

Figure 6-42. Aligning Balance Marks

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q. Reinstall locknut (7) onto shaft. Do not allow the impeller to turn when installing the nut. The impeller nutand 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 tabsover the cap screws.

w. Using a dial indicator, measure shaft end play (minimum 0.001 inch, maximum 0.003 inch). Seefigure 6-43.

x. Using a dial indicator, measure radial clearance of the shaft (minimum 0.012 inch, maximum 0.018 inch). Seefigure 6-44.

y. Reinstall compressor housing (3) with rectangular seal ring (6) and V-band clamp (5). Apply antiseize com-pound to the V-band bolt threads. Torque V-band clamp nut (4) to 120 lb-inch. Tap against the V-band clampin four places around its circumference. Torque again to specified value.

Figure 6-43. Measuring Turbocharger Shaft End Play

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6-28.5 REINSTALLATION. Reinstall the turbocharger according to the following steps. Unless otherwisenoted, callouts refer tofigure 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 capscrews (6). Torque to 24 lb-ft.

d. If necessary, loosen turbine housing cap screws (24,figure 7-20) and position bearing housing (25,figure7-20) to the turbocharger oil drain tube and gasket (figure 6-40). Reinstall two cap screws into the oil draintube 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 tubein 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 withair 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 screwheads. 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 cleanengine oil into the oil inlet fitting on top of the turbocharger.

Figure 6-44. Measuring Radial Clearance

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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 placeagainst 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 exhaustelbow.

p. Reinstall lower elbow hose clamp and elbow hose (3 and 4,figure 7-19) on the exhaust outlet connection andtighten.

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. Unlessotherwise noted, callouts refer tofigure 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 forassembled valve height.

c. Check the spring height (figure 6-45).

6-29.2 REASSEMBLY. Reassemble the oil pressure regulator valve in the reverse order of disassembly. Torquethreaded plug to 74 lb-ft.

Figure 6-45. Checking Spring Height

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6-30. OIL COOLER.

6-30.1 REMOVAL. Remove the oil cooler according to the following steps. Unless otherwise noted, calloutsrefer tofigure 7-23.

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 sur-face.

c. Refer toparagraph 6-12.1and remove the alternator.

d. Drain coolant from the engine; refer toparagraph 6-14.1, procedurestep (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 cylin-der 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 againstthe step in the bore.

6-30.2 REINSTALLATION. Reinstall the oil cooler according to the following steps. Unless otherwise noted,callouts refer tofigure 7-23.

a. Install oil cooler gaskets (5 and 7), core (6), and oil filter head (2) using cap screws (12). Torque the capscrews securely.

b. Lubricate the oil filter oil seal with clean oil and install a new oil filter cartridge (1) by turning the canisterclockwise 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 con-nection.

e. Reinstall the alternator and reconnect the wiring in reverse order of removal. Refer toparagraph 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.

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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 tofigure 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 followingsteps. Unless otherwise noted, callouts refer tofigure 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 Loc-tite 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 101lb-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 followingsteps. Unless otherwise noted, callouts refer tofigure 7-30.

a. Refer toparagraph 6-9.1and remove the starting motor.

NOTE

Ensure the transmission has been removed from the engine and that the engineis adequately supported.

b. Loosen and remove eight hex head cap screws (1).

c. Remove flywheel (4,figure 7-29).

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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 fol-lowing steps. Unless otherwise noted, callouts refer tofigure 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 theseal 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 posi-tions 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 tofigure 7-31.

a. Loosen the fuel drain fittings. Refer toparagraph 6-24.1.

b. Remove the fuel filter. Refer toparagraph 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), andgasket (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 other-wise noted, callouts refer tofigure 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.

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b. Attach cam follower cover gasket (1) to cover (3). Apply gasket sealant to the cylinder block side of the gas-ket.

c. If a rubber cam follower cover gasket is used, it must be installed with the word FRONT toward the front ofthe 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 grom-met seals (8). When installing the cam follower cover, position the cap screw seals between the fuel drain linesand cam follower cover. Seefigure 6-46.

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 toparagraph 6-23.

g. Torque the fuel drain fitting and bleed the fuel system. Refer toparagraph 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 referto 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 tofigure 7-32.

a. Remove special hex head cap screws (1), O-ring seals (2), valve covers (3), and gasket (4). Discard O-ringseals and gaskets.

Figure 6-46. Positioning Fastener Devices

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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 otherwisenoted, callouts refer tofigure 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 assem-blies 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 oth-erwise noted, callouts refer tofigure 7-33.

WARNING


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. Clean and inspect the rocker lever assemblies according to the fol-lowing steps.

WARNING


a. Clean all parts in a strong solution of detergent and hot water. Rinse in clean hot water and dry with com-pressed air.

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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 oth-erwise noted, callouts refer tofigure 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 whenremoved.

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 ringgroove.

e. Install retaining rings (7).

6-35.5 REINSTALLATION. Reinstall the rocker lever assembly according to the following steps. Unless oth-erwise noted, callouts refer tofigure 7-33.

CAUTION

To prevent damage to equipment, the push rods must be correctly seated inthe valve tappets.

a. Insert push rods (10) into the engine block push rod bores; ensure the push rods are correctly and securelyseated 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 headmount pad; position both rocker lever adjustment screws (9) in applicable push rod (10) socket, and ensurethe 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 rockerlever contact pads and valve stems; turn the exhaust valve adjustment screws as required to obtain 0.020-inch

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clearance between the rocker lever pads and the valve stems. Measure the clearance with standard feelergauges. Lock adjustment screws by tightening the locking nuts while holding the adjustment screw with ascrewdriver. Refer toparagraph 6-5for 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, call-outs refer tofigure 7-34.

a. If necessary, remove fuel injection nozzles. Refer toparagraph 6-25.1.

b. If necessary, remove the exhaust manifold (12,figure 7-18).

c. If necessary, remove rocker lever assemblies. Refer toparagraph 6-35.1.

d. Remove the remaining cylinder hex head cap screws (15 and 16) working from the center to each end of thehead evenly.

WARNING


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 otherwisenoted, callouts refer tofigure 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 removingsprings 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.

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b. Remove gasket residue from all gasket surfaces.

WARNING


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 allgrit 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 inchdiameter area or 0.003 inch overall, end-to-end or side-to-side are acceptable. If these limits are exceeded, thehead 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 (minimum0.3126 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 0.039inch.

2. Measure the valve spring tension. A minimum load of 65 to 72.2 lbs is required to compress the spring toa 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 degreesfor exhaust.

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d. Install the valves in their respective bores and re-measure valve depth. Record the depth of each valve. Sub-tract 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. Replacevalves 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 0.080inch).

g. If required, grind the valve seat with a 60-degree stone then a 15-degree stone to center the seat of the valveface. 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 otherwisenoted, callouts refer tofigure 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 removingsprings 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 otherwisenoted, callouts refer tofigure 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 dow-els.

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).

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i. Reinstall rocker lever supports (1,figure 7-33). Ensure the supports are aligned with the locating dowels inthe 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.

r. Adjust the valve clearance. Refer toparagraph 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 tofigure7-35.

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 tofigure 7-35.

Figure 6-47. Cylinder Torque Sequence

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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 eachtappet securely. When properly installed, the dowels can be used to pull the tappets up and should not be ableto 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 thetappets from dropping down when the camshaft is removed.

c. Remove the camshaft; refer toparagraph 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 tothe nearest adjoining dowel.

Figure 6-48. Retaining Valve Tappets

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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 thetrough 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 facecontact 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 toolout of the cam bore.

d. Lubricate the tappets with Lubriplate 105.

e. Insert the installation tool into the tappet.

Figure 6-49. Valve Tappet Removal

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NOTE

To aid in removing the installation tool after the tappet is installed, work the toolin 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 expe-rienced in getting the tappet to make the bend from the trough up into the tappet bore, due to the webbing ofthe block, pull the trough out just enough to allow the tappet to drop down and align itself, then pull the tap-pet 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.

j. Install a wooden dowel into the top of the tappet and wrap a rubber band around the dowel to secure the tap-pet in place.

Figure 6-50. Inserting Installation Tool into Tappet Bore

Figure 6-51. Pulling Installation Tool/Tappet through Cam Bore

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k. Repeat step b through step j for all tappets.

l. Reinstall the camshaft. Refer toparagraph 6-40.5.

6-40. CAMSHAFT.

6-40.1 REMOVAL. Remove the camshaft according to the following steps. Unless otherwise noted, calloutsrefer tofigure 7-36.

a. Remove the cylinder head. Refer toparagraph 6-36.1.

b. Rotate engine on stand and remove the oil pan. Refer toparagraph 6-37.

NOTE

Keep the adjoining gear from moving when checking the camshaft backlash orthe 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 thebacklash exceeds limits; gear backlash limit A is 0.003 inch to 0.013 inch. Seefigure 6-52.

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.

Figure 6-52. Measuring Camshaft Gear Backlash

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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; maxi-mum 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 otherwisenoted, callouts refer tofigure 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 whenhandling heated solutions or metal.

f. Reinstall gear (1) onto the camshaft. Ensure the timing marks are facing away from the camshaft and the gearis seated against the camshaft shoulder.

6-40.4 CAMSHAFT BUSHING. Replace the camshaft bushing according to the following steps. Unless other-wise noted, callouts refer tofigure 7-37.

NOTE

The limit of wear on the number 1 bushing is the same as for the other boreswithout bushings.

NOTE

If the bores without the bushing are worn beyond the limit, the cylinder blockmust 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 alignedwhen the bushing is installed.

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c. Install new camshaft bushing (14) so it is even with the front face of the cylinder block. Ensure the oil holesalign.

d. Measure the installed camshaft bushing. The limit is minimum 2.1295, maximum 2.1314 inches.

6-40.5 REINSTALLATION. Reinstall the camshaft according to the following steps. Unless otherwise noted,callouts refer tofigure 7-36.

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 marksare 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 inthe 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, call-outs refer tofigure 7-22.

a. Refer toparagraph 6-13.1and 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). Discardthe 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 pumpgears. The backlash limits are 0.003 to 0.013 inch. If the limits are exceeded, mark the lube oil pump gear andidler 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 limitis 0.003 to 0.013 inch. Mark the idler gear and crankshaft gear for additional analysis if the limits areexceeded.

e. Remove hex head cap screws (2) and oil pump (1).

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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 otherwisenoted, refer tofigure 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.

WARNING


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 otherwisenoted, refer tofigure 6-54.

a. Reinstall the gerotor planetary in the oil pump. Ensure the gerotor planetary is installed in its original posi-tion.

b. Measure the gerotor tip clearance (maximum 0.007 inch). Seefigure 6-54.

c. Measure the clearance of the gerotor drive to gerotor planetary to port plate (maximum 0.005 inch). Seefigure6-55.

d. Measure the clearance of the gerotor planetary to the body bore (maximum 0.015 inch). Seefigure 6-56.

Figure 6-53. Lube Oil Pump Disassembly

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

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

Figure 6-54. Measuring Gerotor Tip Clearance

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

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6-41.4 REINSTALLATION. Reinstall the lube oil pump according to the following steps. Unless otherwisenoted, callouts refer tofigure 7-22.

a. Lubricate the pump with clean engine oil.

NOTE

Ensure when replacing the pump the correct size pump is used. The six-cylinderpump 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,figure7-13).

e. Reinstall new front oil seal (15,figure 7-13). Refer toparagraph 6-32.2.

f. Reinstall the vibration damper, drive belt, and belt guard; refer toparagraph 6-13.2. Torque the belt guardmounting 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, call-outs refer tofigure 7-13.

a. Refer toparagraph 6-13.1and remove the belt guard, drive belt, and vibration damper.

Figure 6-56. Measuring Gerotor Planetary-to-Body Bore Clearance

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NOTE

Do not remove the timing pin assembly unless the gear housing is beingreplaced.

b. Remove hex head cap screws (12 and 14), belt retainer (13), cover (16), and gasket (19). Discard the gasketand 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 otherwisenoted, callouts refer tofigure 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 capscrews to 18 lb-ft.

e. Reinstall crankshaft from oil seal (15). Refer toparagraph 6-31.1.2.

f. Reinstall the vibration damper, drive belt, and belt guard. Refer toparagraph 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 tofigure 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).

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6-43.2 FLYWHEEL RING GEAR. Replace the flywheel ring gear according to the following steps.

a. Remove flywheel (4). Refer toparagraph 6-43.1.

WARNING

Wear eye protection when removing the ring gear from the flywheel. Do notuse 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


NOTE

The ring gear is properly positioned for installation when the bevel on the teethis 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 tofigure 7-30.

Figure 6-57. Flywheel Cap Screw Torque Sequence

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6-96

a. Remove starter motor. Refer toparagraph 6-9.1.

b. Remove the flywheel. Refer toparagraph 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 toparagraph 6-9.6to reinstall starter motor.

6-44. PISTON AND CONNECTING ROD.

6-44.1 REMOVAL. Remove the pistons and connecting rods according to the following steps. Unless other-wise noted, callouts refer tofigure 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 eliminatethe 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 itwas 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).

Figure 6-58. Flywheel Housing Torque Sequence

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6-97

CAUTION

To prevent damage to the connecting rod and bearing, avoid the use of metalobjects 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. Unlessotherwise noted, callouts refer tofigure 7-38.

WARNING


a. Remove retaining rings (4).

b. Remove piston pin (5).

c. Remove piston rings (9, 8, and 7).

6-44.3 CLEANING AND INSPECTION. Clean and inspect the pistons and connecting rods according to thefollowing steps.

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 hotwater.

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 ringgroove cleaner. Do not scratch the ring sealing surface in the piston groove.

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6-98

WARNING


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 pinbore.

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 (minimum0.003 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. Measure the rod bearing clearance according to the fol-lowing steps.

a. Measure the connecting rod bore with the bearings installed and the cap screws torqued to 73 lb-ft. Recordthe smallest diameter.

b. Measure the mean diameter of the rod journal on the crankshaft (minimum 2.7150 inches, maximum 2.7170inches; 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 crankshaftjournal diameter.

c. The bearing clearance can also be determined using plastigauge (figure 6-59).

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6-99

6-44.5 REASSEMBLY. Reassemble the pistons and connecting rods according to the following steps. Unlessotherwise noted, callouts refer tofigure 7-38.

a. Align the piston and connecting rod pin bores. Ensure the FRONT marking on the piston and the number onthe connecting rod are properly positioned.

WARNING


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 thecylinder 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. Install the piston rings according to the following steps.

Figure 6-59. Using Plastigauge to Measure Clearance

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6-100

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 oilring 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. Unlessotherwise noted, callouts refer tofigure 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 connectingrod assembly into the block, ensure the inside end of the strap does not hookon 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 linematch 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 0.012inch.

m. Check the crankshaft for freedom of rotation as the pistons are installed. If the crankshaft does not rotatefreely, check the installation of the rod bearings and bearing size.

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6-101

6-45. CRANKSHAFT.

6-45.1 REMOVAL. Remove crankshaft according to the following steps. Unless otherwise noted, callouts referto figure 7-39.

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 thecaps and upper bearing saddles with the correct numbers. Number 1 is the maincap 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 themain cap bolts to wiggle the main cap loose.

WARNING


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 saddlesin 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


a. Clean the crankshaft oil passages with a nylon bore brush. Rinse with a clean solvent and dry with compressedair.

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.

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6-102

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 clear-ance maximum 0.00475 inch).

6-45.3 CRANKSHAFT GEAR REPLACEMENT. Replace the crankshaft gear according to the followingsteps. Unless otherwise noted, callouts refer tofigure 7-39.

a. Using a heavy-duty bearing puller, remove the crankshaft gear. Use a flat nose center stud. Do not use apointed 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 dis-torted.

WARNING


e. Install the hot gear, timing mark facing out, up to the shoulder on crankshaft (2).

6-45.4 REINSTALLATION. Reinstall the crankshaft according to the following steps. Unless otherwise noted,callouts refer tofigure 7-39.

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 bear-ing 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 capsfigure 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.

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6-103

l. Rotate the crankshaft after the main bearing caps have been properly torqued. The crankshaft must rotatefreely.

m. Using a dial indicator positioned against the face of the crankshaft gear, measure the crankshaft end play. Thelimits 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 otherwisenoted, callouts refer tofigure 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 pas-sages.

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. Clean and inspect the cylinder block (figure 7-37) according to thefollowing steps.

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. Acorrectly de-glazed surface will have a cross-hatched appearance with the lines at 15- to 25-degree angles withthe top of the cylinder block; 30- to 50-degree angles on the cross-hatch. Use a fine grit flexi-hone drill, a50-50 mixture of diesel fuel, and 30W engine oil to deglaze the bores.

Figure 6-60. Main Bearing Cap Torque Sequence

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6-104

WARNING


c. After deglazing, clean the block in a strong solution of laundry detergent and hot water, then rinse the blockand 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 anddry with compressed air.

e. Inspect the cylinder bores for damage or excessive wear. Measure the bore diameter with a bore gauge (mini-mum 4.0157 inches; maximum 4.0203 inches) and measure 1 inch and 4-1/2 inches from the top surface ofthe block at two places, each measurement 180 degrees apart (out-of-roundness maximum 0.0015 inch; tapermaximum 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 bear-ings installed and the bearing caps torqued to 130 lb-ft. Measure it at two points, 180 degrees apart and nearboth sides of the bearing (maximum 2.2720 inches).

6-46.3 REINSTALLATION. Reinstall the cylinder block components according to the following steps. Unlessotherwise noted, callouts refer tofigure 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 totable 6-9for cor-rect torques.

f. Apply a bead of Loctite 277 around the outside diameter of the camshaft expansion plug (3). Position the plugwith 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 tofigure7-35.

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.

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6-105

e. If further repairs to the diesel engine are not required, replace plug and sealing washer and refill the oil sumpwith correct oil. Refer to table 2-3.

f. Reconnect oil heater electrical cord.

6-48. START-UP.

Following engine reinstallation, proceed as follows:

WARNING


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 inchapter 2, paragraph 2-3.1.Check for proper connection of all systems. Ensure engine operating fluids are at proper levels; refer totable1-1 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. Com-plete testing as per PMS instructions.

Table 6-6. Clearance Measurements

Item Dimension

Cylinder Bores Min. 4.0157-in.Max. 4.0203-in.

Out-of-Roundness .0015-in.Taper Limit .003-in.Main Bearing Bores Max. 2.2720-in.Camshaft Bore Min. 2.1324-in.Tappet Bores Min. 0.630-in.

Max. 0.632-in.Installed Cam Bushing Min. 2.1295-in.

Max. 2.1314-in.Main Journal Diameter Min. 3.2662-in.

Max. 3.2682-in.Main Bearing Clearance Max 0.00475-in.Out-of-Roundness 0.002-in.Taper 0.0005-in.Piston Skirt Diameter Min 4.0088-in.

Max 4.0117-in.Piston Ring TopTurbocharged Use Keystone GaugeNaturally Aspirated Min 0.003-in.

Max 0.0059-in.

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6-106

Table 6-6. Clearance Measurements - Continued

Item Dimension

Piston Ring Intermediate Min 0.003-in.Max 0.0059-in.

Oil Control Min 0.0016-in.Max 0.0051-in.

Piston Pin Bore Min 1.5750-in.Max 1.5758-in.

Piston Pin Diameter Min 1.5744-in.Max 1.5784-in.

Mean Diameter of on the Crankshaft Min 2.7150-in. Max 2.7170-in.Out-of-Roundness 0.002-in.Taper 0.0005-in.Valve Guide Bore Min 0.3157-in.

Max 0.3185-in.Valve Stem Diameter Min 0.3126-in.

Max 0.3142-in.Valve Seat AngleIntake 30°Exhaust 45°Valve Rim Thickness Min 0.031-in.Valve Depth Min 0.039-in.

Max 0.060-in.Valve Seat Width Limit Min 0.060-in.

Max 0.080-in.Valve SpringFree Length 2.190-in.Max Inclination 0.039-in.Turbocharger Shaft Diameter (bearing) Min 0.432-in.* Shaft End Play Min 0.004-in.

Max 0.006-in.** Shaft End Play Min 0.001-in.

Max 0.003-in.Radial Clearance Min 0.012-in.

Max 0.018-in.Oil PumpTip Clearance Max 0.007-in.Body Bore Clearance Max 0.015-in.Port Plate Clearance Max 0.005-in.Gear Backlash Limits for a Used Pump 0.003 to 0.015-in.Starter MotorBrush Replacement Min 0.5-in.Cable Size Min.012-in.

*For turbochargers with a serial number before 840638.

** For turbochargers with a serial number after and including 840638.

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6-107

Table 6-7. Torque Specifications

Item lb-ft

Alternator Pulley 59Alternator Link 32Alternator Mtg Bolt 57Alternator Support (upper) 18Belt Tensioner Mtg 32Cam Thrust Plate 18Connecting Rod (then rotate 60°) 45Crankshaft Damper and Pulley 101Crossover Clamp 4Exhaust Manifold 32Exhaust Outlet Pipe Brkt Mtg 32Exhaust Outlet Pipe, Flanged 18Exhaust Outlet Pipe, V Band Clamp 6Flywheel 101Flywheel Housing 45Flywheel Housing Plug 32Front Cover Cap Hand-tightenFront Engine support 57Fuel Banjo Screw (in head) 24Fuel Vent Screw (in banjo) 4Fuel Filter 1/2 turn after contactFuel Low-Pressure Supply 18Fuel Low-Pressure Return 11Fuel Filter Adapter Nut 24Fuel Line Fitting (HP) 18Fuel Pump Drive Gear 48Fuel Pump Lock 22Fuel Pump Mtg Nut 18Fuel Pump Support Bracket 18Gear Cover 18Gear Housing-to-Block 18Head MtgStep 1 26Step 2 (retorque) 70Step 3 73Head Thread Plug (front) 90Injection Nozzle Banjo Screw 6Injection Nozzle Retaining Nut 44Intake Manifold Cover/After Cooler 18Intake Heater Plug 45Lift Pump Mtg/Cover Plate 18Lifting Bracket (rear) 57Main Bearing CapStep 1 44Step 2 88Step 3 129Oil Fill Tube Mtg 32Oil Filter 1/2 turn after contact

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6-108

Table 6-7. Torque Specifications - Continued

Oil Filter Head Mtg 18Oil Pan Drain Plug 55Oil Pan Heater Plug 90Oil Pan Mtg 18Oil Pressure Regulator Plug 90Oil Pump Mtg 18Oil Suction Tube (flange) 18Rear Seal Mtg 7Rocker Support 18Rocker Lever Nut 1812 Point Starter Mtg 32Tach Drive Retainer 2Tappet Cover 18Thermostat Housing 18Timing Pin Flange Mtg 4Turbine Housing 8Turbocharger Compressor Housing Clamp 5Turbocharger Mounting Nuts 24Turbocharger Oil Drain Tube 18Turbocharger Oil Supply Tubes (both ends) 18Water Hose 4Water Inlet (lower) 32Water Inlet Plugs 25Water Pump Mtg 18Water Pump Pulley 18Valve Cover 18Valve Cover Oil Fill Hand-tightenFUEL INJECTION PUMP

Item lb-in Head TypeAUTO ADVANCE ARRANGEMENTCap Screw 450 SpecialAdvance Housing Cap Nut 250 1/2 in. AFAdvance Housing Cold Advance Plug 250 27 mmAdvance Housing Spring Cap Assembly 250 15/16-in. AFCold Advance Shaft Locknut 40 10 mmHead Locating Fitting 350 3/4 in. AFEND PLATE, BRACKETS, HEAD, ANDROTOREnd Plate Securing Screws 45 5/16-in. AFFuel Inlet Connection 520 15/16-in. AFPressure-Relief Valve Assembly 180 24 mmHigh-Pressure Banjo Bolts 320 14 mmDelivery Valve Holders 360 17 mmDistributor Rotor Plug Screw 28 3/32-in. AllenSolenoid 130 24 mmSolenoid Terminal Screw 30 8 mmHydraulic Head Bracket 120 5 mm AllenThrottle Lever Stop Screw Locknut 40 10 mmLatch Valve Body 170 22 mm

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6-109

Table 6-7. Torque Specifications - Continued

Latch Valve Sleeve Nut 140 5/8-in. AFLatch Valve Locknut 40 1/2-in. AFRotor Vent Switch Valve Body 170 22 mmRotorVent Switch Valve Plug 140 5/8-in. AFGOVERNOR AND HOUSING ASSEM-BLIESTorque Trimmer Locking Plate Screws 30 4 mm AllenGovernor Control Housing Screws 35 4 mm AllenGovernor Control Bracket Studs 60 8 mmGovernor Control Bracket Screw 20 7 mmGovernor Control Bracket-Pivot Screw 20 7 mmCambox Pressuring Valve Holder 250 5/8-in. AFCambox Valve Adapter 200 17 mmVent Screw Body 40 7/16-in. AFVent Screw 40 5/16-in. AFAnti-Stall Screw Locknut 30 10 mmIdle Adjustment Screw Locknut 20 8 mmIdling Shaft Screw 20 7 mmThrottle Shaft Locknut 40 10 mmIndexing Plate Vernier Set Bolt 50 10 mmFace Cam Setting Screw 30 8 mmMax Speed Screw Locknut 20 8 mmAux. Idle Spring Locknut 10 5.5 mmPUMP BODY, DRIVE SHAFT, ANDTHROTTLE BRACKETIdle Actuator Bracket Screws 15 3 mm AllenCover Plate Screws 20 8 mmDrive Shaft Catch Plate Screws 35 TORX T15Drive Shaft Timing Disc Screws 25 TORX T10Timing Adapter Screws 20 3 mm AllenPivot (Rocker lever) 80 13 mmLight-Load Advance Roller AssemblyLocknut

40 10 mm

Grub Screw (Rocker lever) 10 1.5 mm AllenDrive Shaft Nut 720 22 mm

Table 6-8. Roller-to-Roller Dimensions

Service Setting Code Roller to Roller (mm) Test 11 RPM Test 12 RPMTest 13RPM

A105L-1000-2-2860 50.5 1300 1430 1300A94L-900-2-2725 50.3 1250 1360 1250

Table 6-9. Torque for Pipe Plugs

Pipe Plug Size In Aluminum or Brass (lb-ft) In Iron (lb-ft)

1/8 inch 7 101/4 inch 10 151/2 inch 20 35

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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

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6-111 / (6-112 Blank)


CHAPTER 7

ILLUSTRATED PARTS BREAKDOWN

7-1. INTRODUCTION.

This chapter contains illustrations and parts lists for the major components used in the diesel engines. Eachillustration has a corresponding table that identifies component parts. Illustration reference numbers cross over tocomponent 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 Description

7-1 7-3 Belt Guard7-2 7-4 Starter Motor7-3 7-8 V-Belt Tensioner/Alternator

Mounting7-4 7-10 Front Engine Support7-5 7-11 Alternator7-6 7-14 Instrument Panel7-7 7-15 Air Cleaner7-8 7-16 Expansion Tank Bracket7-9 7-17 Lifting Bracket7-10 7-18 Fresh Water Pump7-11 7-19 Thermostat Housing7-12 7-20 Vibration Damper7-13 7-21 Front Gear Cover/Gear Housing7-14 7-22 Sea Water Pump7-15 7-23 Heat Exchanger7-16 7-25 Water Inlet Connection7-17 7-26 Marine Transmission Oil Cooler7-18 7-28 Exhaust Manifold/Intake Cover7-19 7-30 Exhaust Outlet Connection7-20 7-31 Turbocharger7-21 7-34 Oil Level Gauge7-22 7-35 Lube Oil Pump7-23 7-36 Lube Oil Cooler7-24 7-37 Fuel Lift Pump7-25 7-38 Fuel Piping7-26 7-40 Fuel Filter

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7-1

Figure/Table Number Page Number Description

7-27 7-41 Fuel Injection Nozzle7-28 7-43 Fuel Injection Pump7-29 7-48 Flywheel7-30 7-49 Flywheel Housing7-31 7-50 Cam Follower Cover7-32 7-51 Valve Covers7-33 7-52 Rocker Lever7-34 7-54 Cylinder Head7-35 7-56 Oil Pan7-36 7-58 Camshaft7-37 7-59 Cylinder Block7-38 7-61 Piston and Connecting Rod7-39 7-62 Crankshaft and Main Bearings7-40 7-63 Transmission Mounting Bracket7-41 7-64 Vibration Isolator7-42 7-65 Fuel/Water Separator

Figure 7-1. Belt Guard

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7-2

Table 7-1. Belt Guard

Figure andIndex No. Description Qty. CAGE Code

Model 6B5.9-MMfg. Part No.

Model 6BT5.9-MMfg. Part No.

7-1-1 Guard, Belt (front) 1 15434 3916028 39160287-1-2 Screw, Hex Flange

Head (M8-1.25 x 20mm)

3 15434 3900630 3900630

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7-3

Figure 7-2. Starter Motor

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7-4

Table 7-2. Starter Motor


Model 6B5.9-M Mfg.Part No.


7-2-0 Motor, Starter (24-Vdc)

1 7E658 CA45G24125M CA45G24125M

7-2-1 Plug, Lubricator Core 1 7E658 6211-500 6211-5007-2-2 Spring 1 7E658 6211-479 6211-4797-2-3 Seal, Oil 1 7E658 5933-906 5933-9067-2-4 Pad, Lubrication 1 7E658 593345 5933-457-2-5 Wick 1 7E658 6410-19 6410-197-2-6 Bushing, Bearing 1 7E658 593344 5933447-2-7 Endshield, Drive End 1 7E658 6211-6836 6211-68367-2-8 Terminal, Main 1 7E658 6211-514 6211-5147-2-9 Support 1 7E658 6211-276 6211-2767-2-10 Insulator, Terminal 1 7E658 6211-275 6211-2757-2-11 Bushing, Insulating 1 7E658 5587-77 5587-777-2-12 Ring, Sealing 1 7E658 5855-30CZ 5855-30CZ7-2-13 Washer 2 7E658 5936-129 5936-1297-2-14 Washer 1 7E658 NW1-23Z1 NW1-23Z17-2-15 Washer, Lock 2 7E658 5001-31 5001-317-2-16 Nut, Hex 2 7E658 5330-262C 5330-262C7-2-17 Washer, Lock 1 7E658 5936-102 5936-1027-2 Screw, Phillips Head 1 7E658 NS85-8Z1 NS85-8Z17-2-19 * Terminal, Solenoid 2 7E658 5335-833 5335-8337-2-20 * Bushing, Insulating 2 7E658 6211-273A 6211-273A7-2-21 * Bushing, Insulating 2 7E658 5587-140 5587-1407-2-22 * Washer 2 7E658 NW2-3221 NW2-32217-2-23 * Washer, Lock 13 7E658 5244-22 5244-227-2-24 * Nut 4 7E658 NU9-871 NU9-8717-2-25 Plug 2 7E658 6211-648 6211-6487-2-26 Screw, Twelve Point 3 15434 3903834 39038347-2-27 Solenoid Assembly 1 7E658 6211-546 6211-5467-2-28 Stop, Contact 1 7E658 5933-520 5933-5207-2-29 Rivet 3 7E658 5366-255 5366-2557-2-30 Screw, Self-Tapping 2 7E658 5335-774 5335-7747-2-31 Washer 2 7E658 NW1-10Z1 NW1-10Z17-2-32 Screw (hex hd) 2 7E658 5334-325 5334-3257-2-33 Spring, Plunger 1 7E658 6211-468 6211-4687-2-34 Segments 1 7E658 6211-3768 6211-37687-2-35 Spring 1 7E658 6211-385 6211-3857-2-36 Plunger 1 7E658 6211-373 6211-3737-2-37 Contact, Moving 1 7E658 6010-148 6010-1487-2-38 Spring and Trigger 1 7E658 6010-201X 6010-201X7-2-39 Guide, Trigger 1 7E658 6010-201 6010-2017-2-40 Spring 1 7E658 5933-636 5933-6367-2-41 Washer 1 7E658 NW2-28Z1 NW2-28Z17-2-42 Nut 1 7E658 NU9-8Z1 NU9-8Z17-2-43 Spacer 2 7E658 5936-374 5936-3747-2-44 Bushing, Insulating 1 7E658 5587-117A 5587-117A7-2-45 Resistor 1 7E658 6211-526 6211-526

S9233-C9-MMA-010

7-5

Table 7-2. Starter Motor - Continued




7-2-46 Screw (hex hd) 1 7E658 5334-325 5334-3257-2-47 Rivet 2 7E658 5336-256 5336-2567-2-48 Collar 1 7E658 6211-372 6211-3727-2-49 Spring 1 7E658 6211-437 6211-4377-2-50 Washer 1 7E658 5936-456 5936-4567-2-51 Plate, Trip 1 7E658 6211-600 6211-6007-2-52 Ring, Retaining

(external)1 7E658 NW1-9 NW1-9

7-2-53 Nut, Square 1 7E658 5388-1 5388-17-2-54 Screw, Phillips Head 1 7E658 5336-804 5336-8047-2-55 Cover, Commutator 1 7E658 6211-128 6211-1287-2-56 Lining 1 7E658 6211-129 6211-1297-2-57 Cap, End 1 7E658 6211-368 6211-3687-2-58 Pad, Retaining 1 7E658 6211-369 6211-3697-2-59 Ball, Steel 1 7E658 NC7-7 NC7-77-2-60 Spring, Recoil 1 7E658 5933-509 5933-5097-2-61 Nut, Hex 2 7E658 5338-262C 5338-262C7-2-62 Washer, Lock 2 7E658 6001-31 6001-317-2-63 Washer 1 7E658 NW2-81T1 NW2-81T17-2-64 Washer 2 7E658 5936-129 5936-1297-2-65 Bushing, Insulating 1 7E658 5587-81 5587-817-2-66 Ring, Retaining

(internal)1 7E658 6211-367 6211-367

7-2-67 Shim, Washer AR 7E658 NW1-70 NW1-707-2-68 Bushing, Bearing 1 7E658 6211-303 6211-3037-2-69 Bolt 2 7E658 5933-147 5933-1477-2-70 Washer, Lock 2 7E658 5001-53 5001-537-2-71 Screw, Phillips Head 4 7E658 NS37-14ZI NS37-14ZI7-2-72 Brushes Kit 1 7E658 6063-42 6063-427-2-73 Endshield, Commuta-

tor1 7E658 6211-336E 6211-336E

7-2-74 Spring, Bushing 4 7E658 S933-336 S933-3367-2-75 Insulator, Terminal 1 7E658 6211-329 6211-3297-2-76 Terminal 1 7E658 6211-327 6211-3277-2-77 Yoke 1 7E658 5933-183 5933-1837-2-78 Screw, Pole Shoe 4 7E658 5933-190 5333-1907-2-79 Insulator 1 7E658 5933-183B 5933-183B7-2-80 Field Coil Set Kit 1 7E658 5933-602G 5933-602G7-2-81 Dowel 1 7E658 6211-662 6211-6627-2-82 Ball, Lock Ring/

Overspeed12 7E658 NC7-17 NC7-17

7-2-83 Pinion Assembly 1 7E658 6211-700Z 6211-700Z7-2-84 Ring, Sealing 1 7E658 6211-660 6211-6607-2-85 Armature 1 7E658 6332-A1441 6332-A14417-2-86 Spring 1 7E658 6211-710 6211-7107-2-87 Washer, Thrust 1 7E658 6265-710 6265-710

S9233-C9-MMA-010

7-6

Table 7-2. Starter Motor - Continued




7-2-88 Nut, Stop 1 7E658 5330-539 5330-539NS Overhaul Kit 1 7E658 6010-127 6010-127NS Washer, Shim AR 7E658 NW1-69Y1 NW1-69Y1NS Washer, Shim AR 7E658 5936-163 5936-163

*Includes relay (R) terminal parts

S9233-C9-MMA-010

7-7

Figure 7-3. V-Belt Tensioner/Alternating Mounting

S9233-C9-MMA-010

7-8

Table 7-3. V-Belt Tensioner/Alternating Mounting




7-3-1 Brace, Alternator 1 15434 3903089 39030897-3-2 Screw, Cap (hex hd,

M8-1.25 x 20 mm)2 15434 3900620 3900620

7-3-3 Screw, Cap (hex hd,M10-1.50 x 90 mm)

1 15434 3910527 3910527


3 15434 3900621 3900621

7-3-5 Support, Alternator 1 15434 3910713 39107137-3-6 Spacer, Mounting 1 15434 3910715 39107157-3-7 Screw (flat hd,

M8-1.25 x 21 mm)2 15434 3903095 3903095


1 15434 3905426 3905426

7-3-9 Tensioner, Belt 1 15434 3911315 39113157-3-10 Bracket, Belt

Tensioner1 15434 3905888 3905888

7-3-11 Belt, Drive 1 15434 3908564 3908564

Table 7-4. Front Engine Support




7-4-1 Support, Front Engine 1 15434 3917095 39170957-4-2 Screw, Cap (hex hd,

M12-1.75 x 35 mm)6 15434 3900637 3900637

7-4-3 Support, Front Engine 1 15434 3917096 3917096

Figure 7-4. Front Engine Support

S9233-C9-MMA-010

7-9

Figure 7-5. Alternator

S9233-C9-MMA-010

7-10

Table 7-5. Alternator




7-5-0 Alternator (24 vdc, 55amp)

1 7E658 AC5RS1268650M AC5RS1268650M

7-5-1 Stator 1 7E658 6332-A1422 6332-A14227-5-2 Ring, Retaining (seal-

ing)1 7E658 6220-481 6220-481

7-5-3 Ring, Slip 1 7E658 6220-104 6220-1047-5-4 Ring, Retaining

(external)1 7E658 NM2-4 NM2-4

7-5-5 Bearing, Ball (rear) 1 7E658 6220-693 6220-6937-5-6 Spacer 1 7E658 6220-496 6220-4967-5-7 Rotor 1 7E658 6220-321E 6220-321E7-5-8 Key 1 7E658 NK1-8 NK1-87-5-9 Screw, Machine 1 7E658 NS37-14Z1 NS37-14Z17-5-10 Washer, Lock 1 7E658 5244-22 5244-227-5-11 Spacer 1 7E658 6220-307A 6220-307A7-5-12 Plate, Clamp (bearing

retainer)1 7E658 6220-242 6220-242

7-5-13 Bearing, Ball (front) 1 7E658 6220-694 6220-6947-5-14 Shield, Drive End

(front housing)1 7E658 6220-898C 6220-898C

7-5-15 Washer, Lock 1 7E658 5293-57 5293-577-5-16 Thru-bolt 3 7E658 5335-807 5335-8077-5-17 Fan 1 7E658 6220-911 6220-9117-5-18 Washer 1 7E658 NW1-39Z1 NW1-39Z17-5-19 Nut 1 7E658 5330-423 5330-4237-5-20 Screw, Recess Head 2 7E658 6332-47 6332-477-5-21 Tag 2 7E658 5469-417 5469-4177-5-22 Terminal, Positive 1 7E658 6220-923A 6220-923A7-5-23 Guide (locator) 4 7E658 6220-828 6220-8287-5-24 Lead 1 7E658 6220-501A 6220-501A7-5-25 Grommet 1 7E658 6220-296 6220-2967-5-26 Washer, Insulating 6 7E658 6220-141 6220-1417-5-27 Connector, Spade

(Lucar blade)1 7E658 5459-920 5459-920

7-5-28 Gasket 1 7E658 6220-75 6220-757-5-29 Assembly, Holder and

Brush1 7E658 6220-477 6220-477

7-5-30 Washer, Flat 2 7E658 NW1-10T1 NW1-10T17-5-31 Washer, Lock 2 7E658 5244-22 5244-227-5-32 Screw 2 7E658 5332-49 5332-497-5-33 Insulator 1 7E658 6220-922 6220-9227-5-34 Connector, Spade

(Lucar blade)2 7E658 5459-736 5459-736

7-5-35 Screw 2 7E658 5332-47 5332-477-5-36 Screw, Self-Tapping 2 7E658 5332-81 5332-817-5-37 Bushing, Insulating 1 7E658 5587-180 5587-1807-5-38 Washer 4 7E658 NW1-14T1 NW1-14T1

S9233-C9-MMA-010

7-11

Table 7-5. Alternator - Continued




7-5-39 Nut 4 7E658 NU10-11T1 NU10-11T17-5-40 Plate 1 7E658 5668-2720 5668-27207-5-41 Cowl, End Cover 1 7E658 6220-351K 6220-351K7-5-42 Washer, Lock 2 7E658 5293-57 5293-577-5-43 Washer, Flat 2 7E658 NW1-15Z1 NW1-15Z17-5-44 Screw 2 7E658 5337-64F 5337-64F7-5-45 Ferrule 1 7E658 5998-22M 5998-22M7-5-46 Ferrule 1 7E658 5998-22N 5998-22N7-5-47 Nut, Round 1 7E658 5658-339 5658-3397-5-48 Plug, Gland 1 7E658 5658-310 5658-3107-5-49 Screw 4 7E658 5335-700C 5335-700C7-5-50 Gland 1 7E658 6220-428 6220-4287-5-51 Connector, Spade

(Lucar blade)1 7E658 6220-478 6220-478

7-5-52 Lead 1 7E658 6220-917 6220-9177-5-53 Regulator, Voltage 1 7E658 1861542 18615427-5-54 Shield, Slip Ring End

(rear housing)1 7E658 6220-923A 6220-923A

7-5-55 Band, Insulating 1 7E658 6220-143 6220-1437-5-56 Assembly, Heat Sink

and Diode3 7E658 6010-107 6010-107

7-5-57 Screw, Machine 2 7E658 5337-64 5337-647-5-58 Terminal, Negative 1 7E658 5334-502A 5334-502A7-5-59 Tie 6 7E658 6220-366 6220-366

S9233-C9-MMA-010

7-12

Table 7-6. Instrument Panel




7-6-1 Panel, Instrument 1 15434 3905329 39053297-6-2 Light, Indicator 1 15434 3022279 30222797-6-3 Switch, Start 1 88140 MS35059-21 MS35059-217-6-4 Transducer (water

temp.)1 15434 3015238 3015238

7-6-5 Transducer (oil pres-sure)

1 15434 3015237 3015237

7-6-6 Adapter (plain) 1 15434 187368 1873687-6-7 Pickup, Magnetic 1 15434 3039524 30395247-6-8 Sending Unit (pres-

sure)1 15434 208603 208603

7-6-9 Tachometer 1 15434 3031734 30317347-6-10 Gauge, Oil Pressure

(transmission)1 15434 3032800 3032800

7-6-11 Gauge, Voltmeter (24Vdc)

1 15434 3015235 3015235

7-6-12 Gauge (engine faultlight)

1 15434 NPN NPN

Figure 7-6. Instrument Panel

S9233-C9-MMA-010

7-13

Table 7-6. Instrument Panel - Continued




7-6-13 Gauge, Oil Pressure(engine)

1 15434 3015232 3015232

7-6-14 Gauge, Temperature(engine fresh water)

1 15434 3015234 3015234

Table 7-7. Air Cleaner




7-7-1 Clamp, T Bolt 1 15434 135144 1351447-7-2 Silencer, Air (light

duty)1 15434 9310559 3905326

Figure 7-7. Air Cleaner

S9233-C9-MMA-010

7-14

Table 7-8. Expansion Tank Bracket




7-8-1 Bracket, HeatExchanger/AirCleaner

1 15434 3905097 3905097


4 15434 3900629 3900629


2 15434 3901249 3901249


1 15434 3903200 3903200

7-8-5 Brace, Air Cleaner 1 15434 3905099 39050997-8-6 Washer, Plain 1 15434 3011610 3011610

Figure 7-8. Expansion Tank Bracket

S9233-C9-MMA-010

7-15

Table 7-9. Lifting Bracket




7-9-1 Bracket, Lifting 1 15434 3908118 39081187-9-2 Screw, Cap (hex hd,

M12-1.75 x 25 mm)2 15434 3903200 3903200

Figure 7-9. Lifting Bracket

Figure 7-10. Fresh Water Pump

S9233-C9-MMA-010

7-16

Table 7-10. Fresh Water Pump




7-10-1 Pump, Water 1 15434 3903749 39037497-10-2 Seal, Rectangular

Ring1 15434 3906698 3906698

7-10-3 Screw, Cap (hex hd)(M8-1.25 x 22 mm)

2 15434 3900227 3900227

Table 7-11. Thermostat Housing





2 15434 3903096 3903096


1 15434 3900632 3900632

7-11-3 Housing, Thermostat 1 15434 3903756 39037567-11-4 Thermostat 1 15434 3912587 39125877-11-5 Gasket 1 15434 3903301 39033017-11-6 Bracket, Lifting 1 15434 3903757 3903757

Figure 7-11. Thermostat Housing

S9233-C9-MMA-010

7-17

Table 7-12. Vibration Damper



Model 6BT5.9-MMfg. Pan No.


4 15434 3903857 3903857

7-12-2 Pulley, Crankshaft 1 15434 3907982 39079827-12-3 Damper, Vibration 1 15434 3911422 3911422

Figure 7-12. Vibration Damper

S9233-C9-MMA-010

7-18

Table 7-13. Front Gear Cover/Gear Housing




7-13-1 Gasket, Gear Housing 1 15434 3914384 39143847-13-2 Seal, Rectangular

Ring1 15434 3906693 3906693

7-13-3 Housing, Timing 1 15434 3905933 39059337-13-4 Seal, O-Ring 1 15434 3903927 39039277-13-5 Ring, Retaining 1 15434 3904849 39048497-13-6 Pin, Timing 1 15434 3903924 39039247-13-7 Screw, Cap (rdhd,

M5-.8 x 17 mm)2 15434 3907998 3907998


2 15434 3901249 3901249

7-13-9 Plate, Cover 1 15434 3214868 39148687-13-10 Gasket, Accessory

Drive Cover1 15434 3913192 3913192


10 15434 3900633 3900633

7-13-12 Screw, Cap (hex hd;M8-1.25 x 16 mm)

16 15434 3900629 3900629

7-13-13 Retainer, Belt 1 15434 3912772 39127727-13-14 Screw, Cap (hex hd;

M8-1.25 x 60 mm)1 15434 3901446 3901446

7-13-15 Seal, Oil 1 15434 3904343 3900709

Figure 7-13. Front Gear Cover/Gear Housing

S9233-C9-MMA-010

7-19

Table 7-13. Front Gear Cover/Gear Housing - Continued




7-13-16 Cover, Gear 1 15434 3903794 39037947-13-17 Cover, Access Hole 1 15434 3903463 39034637-13-18 Seal, Rectangular

Ring1 15434 3903475 3903475

7-13-19 Gasket, Gear Cover 1 15434 3910500 39243757-13-20 Housing, Gear 1 15434 3910411 3911712NS Dataplate 1 15434 391027 391027NS Screw, Drive 4 15434 3908612 3908612NS Dataplate 1 15434 3906610 3906610

Table 7-14. Sea Water Pump




7-14-1 Tube, Sea WaterPump

1 15434 3905062 3905062

7-14-2 Hose, Elbow 1 15434 188580 1885807-14-3 Screw, Cap (hex hd,

M12-1.75 x 30 mm)2 15434 3910495 3910495

7-14-4 Pump, Sea Water 1 15434 3907458 39074587-14-5 Gasket, Hydraulic

Pump1 15434 3009400 3009400

7-14-6 Clamp, Hose 2 15434 209773 209773

Figure 7-14. Sea Water Pump

S9233-C9-MMA-010

7-20

Table 7-14. Sea Water Pump - Continued




NS Sea Water PumpRepair Kit

1 15434 3908220 3908220

Table 7-15. Heat Exchanger


Model 6B5.9-M Mfg.Pan No.


7-15-1 Exchanger, Heat 1 15434 391-583 391-5837-15-2 Isolator, Vibration 2 15434 3905048 39050487-15-3 Bracket, Heat

Exchanger2 15434 3905344 3905344

7-15-4 Hose, Plain 2 15434 63549 635497-15-5 Plug, Pipe 1 15434 S-949-B S-949-B7-15-6 Tube, Water Transfer 1 15434 3905052 39050527-15-7 Clamp, Hose 4 15434 43828-D 43828-D7-15-8 Plug, Zinc 1 15434 68241 68241

Figure 7-15. Heat Exchanger

S9233-C9-MMA-010

7-21

Table 7-15. Heat Exchanger - Continued


Model 6B5.9-M Mfg.Pan No.


7-15-9 Gasket, End 2 15434 3910343 39103437-15-10 Cover, End 2 15434 3910344 39103447-15-11 Washer, Fiber 2 15434 3910556 39105567-15-12 Screw (hex hd) 2 15434 3910345 39103457-15-13 Hose 1 15434 AS400960M9 AS400960M97-15-14 Hose 1 15434 555538 5555387-15-15 Elbow, Male Adapter 2 15434 68139 681397-15-16 Clamp, Hose 4 15434 43828-C 43828-C7-15-17 Cock, Drain 1 15434 S-962-E S-962-E7-15-18 Tank, Expansion 1 15434 391-1399 391-13997-15-19 Cap, Filler 1 15434 3907022 39070227-15-20 Hose, Plain 1 15434 3275209 32752097-15-21 Screw, Cap (hex hd) 4 15434 3908226 39082267-15-22 Clamp, Retaining 2 15434 3905057 3905057

Table 7-16. Water Inlet Connection




7-16-1 Connection, WaterInlet

1 15434 3907007 3907007

7-16-2 Seal, Ring (Rectangu-lar)

1 15434 3906697 3906697

7-16-3 Plug, Pipe 1 15434 3008468 30084687-16-4 Screw, Cap (hex hd) 3 15434 3902460 3902460

Figure 7-16. Water Inlet Connection

S9233-C9-MMA-010

7-22

Table 7-17. Marine Transmission Oil Cooler




7-17-1 Elbow, Male Adaptor 2 15434 3005945 30058457-17-2 Cooler, Oil 1 15434 3910594 39105847-17-3 Clamp, Hose 6 15434 43828-A 43828-A7-17-4 Hose, Elbow 1 15434 188580 1885807-17-5 U-Bolt 2 15434 3905049 39050497-17-6 Isolator, Noise 1 15434 3905055 39050557-17-7 Screw, Cap (hex hd,

M10-1.50 x 30 mm)2 15434 3903112 3903112

7-17-8 Nut, Hex (heavy) 4 15434 S-224 S-2247-17-9 Bracket, Oil Cooler 1 15434 3911734 3911734

Figure 7-17. Marine Transmission Oil Cooler

S9233-C9-MMA-010

7-23

Table 7-17. Marine Transmission Oil Cooler - Continued




7-17-10 Hose, Elbow 1 15434 3275391 32753917-17-11 Tube, Sea Water

Pump1 15434 3905059 3905059

7-17-12 Hose, Plain 1 15434 9539-A 9539-ANS Hose, Flexible 1 15434 AM8012SS AM8012SSNS Hose, Flexible 1 15434 AM8023MS AM8023MSNS Elbow, Street 1 15434 70470 70470

S9233-C9-MMA-010

7-24

Figure 7-18. Exhaust Manifold/Intake Cover

S9233-C9-MMA-010

7-25

Table 7-18. Exhaust Manifold/Intake Cover




7-18-1 Clamp, Hose 2 15434 NA 30263967-18-2 Hose, Plain 1 15434 NA 39044227-18-3 Tube, Air 1 15434 NA 39103317-18-4 Clamp, Hose 2 15434 NA 30086907-18-5 Hose, Plain 1 15434 NA 39018047-18-6 Screw, Cap (hex hd,

M10-1.50 x 30 mm)4 15434 3903112 3903112

7-18-7 Clamp, Hose 2 15434 NA 43828-A7-18-8 Hose, Plain 1 15434 NA 39105787-18-9 Gasket, Turbocharger 2 15434 3905033 39050337-18-10 Plug, Expansion 4 15434 3908092 39080927-18-11 Gasket, Manifold 6 15434 3905443 39054437-18-12 Manifold, Exhaust 1 15434 3905322 39053227-18-13 Washer, Plain 8 15434 3009330 30093307-18-14 Screw, Cap (hex hd,

M10-1.5 x 123 mm)12 15434 3907789 3907789

7-18-15 Stud 4 15434 3907978 39079787-18-16 Clamp, Hose 2 15434 21073 210737-18-17 Hose, Plain 1 15434 3905089 39050897-18-18 Connection, Water

Transfer1 15434 3907165 3907165

7-18-19 Coupling, ElbowHose (90°)

1 15434 3908221 3908221

7-18-20 Nut, Flange (hex) 4 15434 3818824 38188247-18-21 Plug, Expansion 1 15434 3007636 30076367-18-22 Gasket, Intake Mani-

fold Cover1 15434 3902002 3902002


12 15434 3904341 3904341

7-18-24 Cover, Intake Mani-fold

1 15434 3910333 3910333

S9233-C9-MMA-010

7-26

Table 7-19. Exhaust Outlet Connection




7-19-0 Connection, ExhaustOutlet

1 15434 3913460 3910894

7-19-1 Hose, Elbow 1 15434 3910777 39107777-19-2 Plug, Pipe 1 15434 3906619 39066197-19-3 Clamp, Hose 2 15434 43828-B 43828-B7-19-4 Screw, Cap (hex hd,

M8-1.25 x 20 mm)4 15434 3900630 3900630

Figure 7-19. Exhaust Outlet Connection

S9233-C9-MMA-010

7-27

Figure 7-20. Turbocharger

S9233-C9-MMA-010

7-28

Table 7-20. Turbocharger


Model 6B5.9-M Mfg.Part No. Mfg.

Model 6BT5.9-MMFG. Part No.

7-20-0 Assembly, Turbo-charger

1 15434 NA 3524424

7-20-1 Dataplate 1 15434 35199057-20-2 Screw, Drive 2 15434 35191637-20-3 Housing, Compressor 1 15434 35223897-20-4 Nut, V-band (regular

hex)1 15434 3503335

7-20-5 Clamp, V-band 1 15434 35218327-20-6 Seal, Rectangular

Ring1 15434 3523958

7-20-7 Locknut 1 15434 35035627-20-8 Impeller 1 15434 35217117-20-9 Diffuser 1 15434 35228017-20-10 Seal, Rectangular

Ring1 15434 3502449

7-20-11 Seal, Split Ring 1 15434 37588487-20-12 Slinger, Oil 1 15434 35036627-20-13 Baffle, Oil 1 15434 35036687-20-14 Screw (flat hd;

M8-1.25 x 12 mm)3 15434 3503347

7-20-15 Bearing, Thrust 1 15434 35189877-20-16 Collar, Thrust 1 15434 35189807-20-17 Ring, Retaining 4 15434 37622597-20-18 Bearing 2 15434 35031007-20-19 Screw, Cap (hex hd;

M8-1.25 x 12 mm)4 15434 3759917

7-20-20 Lockplate 2 15434 35011027-20-21 Plate, Clamping 1 15434 35011887-20-22 Gasket, Oil Drain 1 15434 39018057-20-23 Lockplate 2 15434 35020667-20-24 Screw, Cap (hex hd;

M6-1.0 x 18 mm)4 15434 3522827

7-20-25 Housing, Bearing 1 15434 35207027-20-26 Shield, Heat 1 15434 35193027-20-27 Seal, Split Ring 1 15434 37567547-20-28 Shaft and Wheel 1 15434 35103367-20-29 Screw, Banjo Connec-

tor1 15434 3523050

7-20-30 Washer, Plain 4 15434 39103397-20-31 Union, Banjo Connec-

tor1 15434 3523049

7-20-32 Adapter, Reducing 1 15434 35036787-20-33 Housing, Turbine 1 15434 35207307-20-34 Plug, Threaded 1 15434 35036777-20-35 Gasket 1 15434 3905033NS Rotor Assembly 1 15434 3523755NS Turbo Repair Kit 1 15434 3802067

S9233-C9-MMA-010

7-29

Table 7-20. Turbocharger - Continued


Model 6B5.9-M Mfg.Part No. Mfg.

Model 6BT5.9-MMFG. Part No.

NS Connector, Female 1 15434 S-1008-1NS Clamp, Hose 4 15434 43828-ANS Clip 2 15434 108722NS Screw, Cap (hex hd) 2 15434 3900630NS Gasket, Oil Drain 1 15434 NA 3901850NS Tube, Oil Drain 1 15434 3903744NS Hose, Plain 2 15434 3903745NS Hose, flexible 1 15434 3905084NS Connection, Oil Drain 1 15434 3910322NS Tube, Oil Drain 1 15434 3912941

Table 7-21. Oil Level Gauge




7-21-1 Dipstick 1 15434 3907012 3907012

Figure 7-21. Oil Level Gauge

S9233-C9-MMA-010

7-30

Table 7-21. Oil Level Gauge - Continued




7-21-2 End, Oil Gauge Tube 1 15434 3905802 39058027-21-3 Clamp, Spring 2 15434 3909395 39093957-21-4 Brace, Tube 1 15434 3905803 39058037-21-5 Screw, Cap (hex hd,

M8-1.25 x 16 mm)1 15434 3900629 3900629

7-21-6 Tube, Oil Gauge 1 15434 3905800 39058007-21-7 Tube, Oil Gauge 1 15434 3905425 39054257-21-8 Plug, Expansion 2 15434 3900955 39009557-21-9 Clip 1 15434 108722 1087227-21-10 Nut, Hex (regular) 1 15434 3900240 3900240

Table 7-22. Lube Oil Pump





4 15434 3900677 3900677

7-22-2 Pump, Lube Oil 1 15434 3906414 3906414

Figure 7-22. Lube Oil Pump

S9233-C9-MMA-010

7-31

Table 7-23. Lube Oil Cooler




7-23-1 Cartridge, Lube OilFilter

1 15434 3908615 3908615

7-23-2 Head, Lube Oil Filter 1 15434 3902295 39022957-23-3 Plug, Pipe (1/8-27

NPT)1 15434 3906619 3906619

7-23-4 Valve, Pressure-Relief 1 15434 3902338 39023387-23-5 Gasket, Filter Head 1 15434 3912638 39126387-23-6 Core, Cooler 1 15434 3911940 39119407-23-7 Gasket, Oil Cooler

Core1 15434 3904427 3904427

7-23-8 Plug, Threaded (M22-1.5 x 14 mm)

1 15434 3904386 3904386

7-23-9 Washer, Sealing 1 15434 3902425 39024257-23-10 Spring, Compression 1 15434 3903261 39032617-23-11 Plunger, Pressure-

Regulator1 15434 3909376 3909376


14 15434 3900632 3900632

Figure 7-23. Lube Oil Cooler

S9233-C9-MMA-010

7-32

Table 7-24. Fuel Lift Pump




7-24-1 Washer, Plain 2 15434 3903037 39030377-24-2 Tube, Fuel Supply 1 15434 3907582 39075827-24-3 Screw, Banjo Connec-

tor (M12-1.5 x 24mm)

1 15434 3903035 3903035

7-24-4 Pump, Fuel Lift 1 15434 3904374 39043747-24-5 Screw, Cap (hex hd;

M8-1.25 x 25 mm)2 15434 3900631 3900631

7-24-6 Gasket, Cover Plate 1 15434 3904044 3904044

Figure 7-24. Fuel Lift Pump

S9233-C9-MMA-010

7-33

Figure 7-25. Fuel Piping

S9233-C9-MMA-010

7-34

Table 7-25. Fuel Piping




7-25-1 Isolator, Vibration 6 15434 3904520 39045207-25-2 Brace, Tube 3 15434 3904519 39045197-25-3 Washer, Plain 6 15434 3903723 39037237-25-4 Screw, Cap (hex hd,

M5-.8 x 20 mm)6 15434 3903609 3903609

7-25-5 Manifold, Fuel 1 15434 3909696 39096967-25-6 Seal, Grommet 3 15434 3905391 39053917-25-7 Tee, Male Union 1 15434 3905388 39053887-25-8 Tube, Fuel Drain 1 15434 3905692 39056927-25-9 Screw, Cap (hex hd,

M8-1.25 x 20 mm)2 15434 3900630 3900630

7-25-10 Seal, O-ring 2 15434 3900267 39002677-25-11 Tube, Fuel Drain 1 15434 3905709 39057097-25-12 Seal, Banjo Connector 6 15434 3903380 39033807-25-13 Screw, Banjo Connec-

tor (M6-1.0 x 15 mm)6 15434 3905307 3905307

7-25-14 Brace, Tube 2 15434 3906894 39065847-25-15 Screw (hex hd,

M8-1.25 x 26 mm)2 15434 3904341 3904341

7-25-16 Tube, Fuel Supply 1 15434 3906033 39060337-25-17 Tube, Fuel Supply 1 15434 3906034 39060347-25-18 Tube, Fuel Supply 1 15434 3906035 39060357-25-19 Brace, Tube 1 15434 3906651 39066517-25-20 Tube, Fuel Supply 1 15434 3906036 39060367-25-21 Tube, Fuel Supply 1 15434 3906037 39060377-25-22 Tube, Fuel Supply 1 15434 3906038 3906038

S9233-C9-MMA-010

7-35

Table 7-26. Fuel Filter




7-26-1 Adapter, Filter Head 1 15434 3903845 39038457-26-2 Filter, Fuel 1 15434 3903640 39036407-26-3 Washer, Plain 2 15434 3903037 39030377-26-4 Screw, Banjo Connec-

tor1 15434 3905860 3905860

7-26-5 Tube, Fuel Supply 1 15434 3905375 39053757-26-6 Seal Grommet 3 15434 3905351 39053517-26-7 Tube, Fuel Supply 1 15434 3905364 39053647-26-8 Tee, Male Union 1 15434 3905353 39053537-26-9 Tube, Fuel Supply 1 15434 3905363 3905363

Figure 7-26. Fuel Filter

S9233-C9-MMA-010

7-36

Table 7-27. Fuel Injection Nozzle




7-27-0 Assembly, Fuel Injec-tion Nozzle

6 OHD22 3919304 3908238

7-27-1 Seal, RectangularRing

1 OHD22 3909356 3909356

7-27-2 Shim (1.00 mm thick) AR OHD22 3905156 3905156Shim (1.04 mm thick) AR ORD22 3905157 3905157Shim (1.08 mm thick) AR OHD22 3905158 3905158Shim (1.10 mm thick) AR OHD22 3905159 3905159Shim (1.14 mm thick) AR OHD22 3905160 3905160Shim (1.18 mm thick) AR OHD22 3895161 3905161Shim (1.20 mm thick) AR OHD22 3905162 3905162Shim (1.24 mm thick) AR OHD22 3905163 3905163Shim (1.28 mm thick) AR OHD22 3905164 3905164Shim (1.30 mm thick) AR OHD22 3905165 3905165Shim (1.34 mm thick) AR OHD22 3905166 3905166Shim (1.38 mm thick) AR OHD22 3905167 3905167Shim (1.40 mm thick) AR OHD22 3905168 3905168

Figure 7-27. Fuel Injection Nozzle

S9233-C9-MMA-010

7-37

Table 7-27. Fuel Injection Nozzle - Continued




Shim (1.44 mm thick) AR OHD22 3905169 3905169Shim (1.48 mm thick) AR OHD22 3905170 305170Shim (1.50 mm thick) AR OHD22 3905171 3905171Shim (1.54 mm thick) AR OHD22 3905172 3905172Shim (1.58 mm thick) AR OHD22 3905173 3905173Shim (1.60 mm thick) AR OHD22 3905174 3905174Shim (1.64 mm thick) AR OHD22 3905175 3905175Shim (1.68 mm thick) AR OHD22 3905176 3905176Shim (1.70 mm thick) AR OHD22 3905177 3905177Shim (1.74 mm thick) AR OHD22 3905178 3905178Shim (1.76 mm thick) AR OHD22 3905179 3905179Shim (1.78 mm thick) AR OHD22 3905180 3905180Shim (1.80 mm thick) AR OHD22 3905181 3905181Shim (1.84 mm thick) AR OHD22 3905182 3904182Shim (1.88 mm thick) AR OHD22 3905183 3905183Shim (1.90 mm thick) AR OHD22 3905184 3905184Shim (1.94 mm thick) AR OHD22 3905185 3905185Shim (1.98 mm thick) AR OHD22 3905186 3905186

7-27-3 Spring, Compression 1 OHD22 3905125 39051257-27-4 Spindle 1 OHD22 3905153 39051537-27-5 Washer, Sealing 1 OHD22 3900808 39008087-27-6 Nut, Injection Nozzle 1 OHD22 3905155 39051557-27-7 Nozzle 1 OHD22 NPN NPN7-27-8 Valve, Needle 1 OHD22 NPN NPN7-27-9 Disc, Intermediate 1 OHD22 3905154 39051547-27-10 Seal, Banjo Connector 1 OHD22 3903380 3903380NS Kit, Injection Nozzle 1 OHD22 3802058 3802058

S9233-C9-MMA-010

7-38

Figure 7-28. Fuel Injection Pump (Sheet 1 of 2)

S9233-C9-MMA-010

7-39 / (7-40 Blank)


Figure 7-28. Fuel Injection Pump (Sheet 2 of 2)

S9233-C9-MMA-010

7-41 / (7-42 Blank)


Table 7-28. Fuel Injection Pump




7-28-1 Plug, Protection 1 63632 9120-012 9120-0127-28-2 Connection, Fuel 1 63632 9120-007 9120-0077-28-3 Washer 1 63632 NW5-77W4 NW5-77W47-28-4 Filter 1 63632 7123-620 7123-6207-28-5 Spring 1 63632 7123-551 7123-5517-28-6 Piston 1 63632 7123-15G 7123-15G7-28-7 Sleeve and Piston 1 63632 7135-74BS 7135-74BS7-28-8 Washer 1 63632 5936-177 5936-1777-28-9 Spring 1 63632 7123-439 7123-4397-28-10 Spring, Guide 1 63632 7167-183F 7167-183F7-28-11 Adjuster, Pressure 1 63632 7139-650G 7139-650G7-28-12 Screw 4 63632 7167-667 7167-6677-28-13 Bracket 1 63632 9120-020 9120-0207-28-14 Spring, Single Link 1 63632 7123-453B 7123-453B7-28-15 Seal, Lead 3 63632 5606-62 5606-627-28-16 Nameplate 1 63632 9120-028 9120-0287-28-17 Screw, Hex Head 2 63632 5334-274 5334-2747-28-18 Washer, Lock 2 63632 NP1-5 NP1-57-28-19 Plate, Cover 1 63632 7180-55A 7180-55A7-28-20 Screw, Socket Head 1 63632 5335-694 5335-6847-28-21 Washer 1 63632 5339-964 5339-9647-28-22 Ring, Sealing 1 63632 5855-30BC 5855-30BC7-28-23 Shoes and Roller

Assembly1 63632 7135-72N 7135-72N

7-28-24 Gasket 1 63632 9045-137 9045-1377-28-25 Ring, Cam 1 63632 7139-687E 7139-687E7-28-26 Ring, Retaining, Inter-

nal1 63632 5950-64A 5950-64A

7-28-27 Nameplate 1 63632 7180-54B 7180-54B7-28-28 Rivet, Drive 2 63632 NR21-4 NR21-47-28-29 Washer 2 63632 NW5-18W4 NW5-18W47-28-30 Screw, Vent 1 63632 5334-332 5334-3327-28-31 Vent, Screw 1 63632 7123-352B 7123-352B7-28-32 Valve, Metering (size

A)AR 63632 7139-559D 7139-559D

7-28-33 Screw, Hex Head 1 63632 5334-277 5334-2777-28-34 Washer, Tab 1 63632 7167-331 7167-3317-28-35 Washer 2 63632 NW5-18W4 NW5-18W47-28-36 Washer, Thrust AR 63632 7139-955 7139-9557-28-37 Ring, Retaining,

External1 63632 NM1-9 NM1-9

7-28-38 Key, Drive 1 63632 NK1-22 NK1-227-28-39 Washer, Lock 1 63632 5001-40 5001-407-28-40 Nut 1 63632 7182-189 7182-1897-28-41 Gasket 1 63632 9120-003 9120-0037-28-42 Spacer 1 63632 9120-002 9120-0027-28-43 Screw 2 63632 9120-008 9120-008

S9233-C9-MMA-010

7-43

Table 7-28. Fuel Injection Pump - Continued




7-28-44 Housing Assembly 1 63632 7123-454CF 7123-454CF7-28-45 Seal, Oil 2 63632 5393-252R5 393-252R7-28-46 Retaining Ring, Inter-

nal1 63632 5950-137 5950-137

7-28-47 Washer, Thrust 1 63632 5936-124 5936-1247-28-48 Drive, Shaft 1 63632 7180-173B 7180-173B7-28-49 Weights, Governor 4 63632 7123-914G 7123-914G7-28-50 Sleeve, Thrust 1 63632 7123-618 7123-6187-28-51 Ring, Spring 1 63632 5921-16 5921-167-28-52 Screw, Hex Head 1 63632 5334-280 5334-2807-28-53 Washer 1 63632 9120-004 9120-0047-28-54 Ring, Sealing 1 63632 5855-30BR 5855-30BR7-28-55 Screw, Locking 1 63632 9120-009 9120-0097-28-56 Plate, Adjusting AR 63632 NPN NPN7-28-57 Assembly, Head and

Rotor1 63632 7180-158L 7180-158L

7-13-58 Ring, Seal 1 63632 7139-43 7139-437-28-59 Liner, Transfer Pump 1 63632 7139-540 7139-5407-28-60 Rotor, Transfer Pump 1 63632 7123-18 7123-187-28-61 Blade, Transfer Pump 2 63632 7123-19 7123-197-28-62 Plate, End 1 63632 7123-576P 7123-576P7-28-63 Plate, Clamping 2 63632 7139-267 7139-2677-28-64 Screw 4 63632 5334-315F 5334-315F7-28-65 Cap, Sealing 1 63632 7139-184 7139-1847-28-66 Screw, Hex Head 2 63632 5334-267E 5334-276E7-28-67 Nut 2 63632 NU9-8Y1 NU9-8Y17-28-68 Washer 2 63632 NW1-65Y1 NW1-65Y17-28-69 Screw, Vent 1 63632 5334-332 5334-3327-28-70 Vent, Screw 1 63632 7123-351B 7132-351B7-28-71 Washer 1 63632 NW5-15W 4NW5-15W47-28-72 Washer 1 63632 5936-332C 5936-332C7-28-73 Connection, Fuel 1 63632 9120-005 9120-0057-28-74 Plug, Protection 1 63632 9120-011 9120-0117-28-75 Guide, Spring 1 63632 7139-441 7139-4417-28-76 Washer 1 63632 5936-291 5936-2917-28-77 Spring 1 63632 7139-442 7139-4427-28-78 Nut, Self-Locking 1 63632 5330-406 5330-4067-28-79 Lever, Break Back 1 63632 7135-75E 7135-75E7-28-80 Nut, Cap 2 63632 5330-344 5330-3447-28-81 Washer 2 63632 5339-970 5339-9707-28-82 Nut, Cap 1 63632 5330-406 5330-4067-28-83 Washer, Lock 1 63632 NP1-5 NP1-57-28-84 Lever 1 63632 7123-725B 7123-725B7-28-85 Cover, Control 1 63632 7123-888N 7123-888N7-28-86 Gasket 1 63632 7123-287 7123-2877-28-87 Stud 2 63632 7123-527 7123-527

S9233-C9-MMA-010

7-44

Table 7-28. Fuel Injection Pump - Continued




7-28-88 Ring, Sealing 4 63632 5855-30 5855-307-28-89 Shaft, Throttle 1 63632 7123-770A 7123-770A7-28-90 Plate, Keep 1 63632 7123-355 7123-3557-28-91 Spring 1 63632 7123-898X 7123-898X7-28-92 Washer, Lock 2 63632 7123-600 7123-6007-28-93 Bar, Shut-Off 1 63632 7123-304B 7123-304B7-28-94 Arm, Governor 1 63632 7135-76X 7135-76X7-28-95 Spring 1 63632 7123-89 7123-897-28-96 Spring, Idling 1 63632 7123-92D 7123-92D7-28-97 Guide, Spring 1 63632 7123-93 7123-937-28-98 Shaft, Shutoff 1 63632 7123-726 7123-7267-28-99 Tube, Fuel Injection

(high-pressure banjo)6 63632 7167-978 7167-978

7-28-100 Valve, Pressure 6 63632 7139-177G 7139-177G7-28-101 Plug, Piston 1 63632 7123-473 7123-4737-28-102 Washer 1 63632 7022-160D 7022-160D7-28-103 Nut, Cap 1 63632 5330-362 5330-3627-28-104 Ball, Steel 1 63632 NC7-8 NC7-87-28-105 Fitting, Head Locat-

ing1 63632 7123-261B 7123-261B

7-28-106 Ring, Sealing 2 63632 7139-821 7139-8217-28-107 Gasket 1 63632 7123-937 7123-9377-28-108 Ring, Sealing 2 63632 5855-308D 5855-308D7-28-109 Spring 1 63632 7123-294T 7123-294T7-28-110 Shim 1 63632 NW2-80Y1 NW2-80Y17-28-111 Screw, Hex Head 1 63632 7167-299 7167-2997-28-112 Washer 1 63632 5936-355C 5936-355C7-28-113 Cap, Spring 1 63632 7167-358Z 7167-358Z7-28-114 Screw, Cam 1 63632 7123-975 7123-9757-28-115 Stud 1 63632 5335-694A 5335-694A7-28-116 Housing and Piston

(A.A.)1 63632 7123-819CB 7123-819CB

7-28-117 Blade, Lucar 1 63632 9120-017 9120-0177-28-118 Screw, Socket Head 1 63632 7167-78 57167-7857-28-119 Washer 1 63632 7167-786 7167-7867-28-120 Solenoid (complete) 1 63632 7180-49A 7180-49A7-28-121 Ring, Sealing 1 63632 5855-30DT 5855-30DT7-28-122 Spring, Solenoid 1 63632 7167-787 7167-7877-28-123 Cap, Protection 1 63632 7098-109B 7098-109BNS Screw, Drive Plate 2 63632 5334-245 5334-245NS Dowel 2 63632 7167-386 7167-386NS Gear, Drive 1 15434 3914912 3914912NS Ring, Backing 1 63632 7182-423 7182-423

S9233-C9-MMA-010

7-45

Table 7-29. Flywheel





8 15434 3901395 3901395

7-29-2 Washer, Plain 8 15434 3900269 39002697-29-3 Gear, Flywheel Ring 1 15434 3901774 29017747-29-4 Flywheel 1 15434 3905616 3905616NS Flywheel Assembly 1 15434 3905831 3905831

Figure 7-29. Flywheel

S9233-C9-MMA-010

7-46

Table 7-30. Flywheel Housing


Model 6135.9-M Mfg.Part No.



8 15434 3910540 3910540

7-30-2 Plug, Threaded 1 15434 3904181 39041817-30-3 Plate, Cover 1 15434 3908095 39080957-30-4 Screw, Cap (hex hd,

M8-1.25 x 21 mm)2 15434 3912072 3912072

7-30-5 Seal, O-Ring 1 15434 3912473 39124737-30-6 Seal, Oil 1 15434 3904089 39040897-30-7 Screw, Cap (hex hd,

M6-1.00 x 14 mm)6 15434 3900627 3900627

7-30-8 Gasket, Rear 1 15434 3901019 39010197-30-9 Cover, Rear 1 15434 3906526 39065267-30-10 Plug, O-Ring 1 15434 3910248 39104287-30-11 Seal, O-Ring 1 15434 3910260 39102607-30-12 Housing, Flywheel 1 15434 3903282 3903282NS Seal Kit 1 15434 3909410 3909410

Figure 7-30. Flywheel Housing

S9233-C9-MMA-010

7-47

Table 7-31. Cam Follower Cover




7-31-1 Gasket, Push Rod(cam follower) Cover

1 15434 3904776 3904776

7-31-2 Baffle, Breather 1 15434 3907586 39075867-31-3 Cover, Push Rod

(cam follower)1 15434 3911822 3911822

7-31-4 Clamp, Spring Hose 1 15434 3904230 39042307-31-5 Hose, Plain 1 15434 3909049 39080497-31-6 Clip 1 15434 3909670 39096707-31-7 Screw, Cap (hex hd) 5 15434 3900629 39006297-31-8 Seal, Grommet 5 15434 3900267 3900267

Figure 7-31. Cam Follower Cover

S9233-C9-MMA-010

7-48

Table 7-32. Valve Covers

Figure andIndex No. Description Qty CAGE Code



7-32-1 Screw, Cap (hex hd,M8-1.25 x 25.5 mm)

6 15434 3907049 3907049

7-32-2 Seal, O-Ring 6 15434 3910824 39108247-32-3 Cover, Valve 5 15434 3902604 39026047-32-4 Gasket, Valve Cover 6 15434 3902666 39026667-32-5 Cover, Valve 1 15434 3902605 39026057-32-6 Seal, Rectangular

Ring1 15434 3902363 3902363

7-32-7 Cap, Filler 1 15434 3901895 3901895

Figure 7-32. Valve Covers

S9233-C9-MMA-010

7-49

Figure 7-33. Rocker Lever

S9233-C9-MMA-010

7-50

Table 7-33. Rocker Lever




7-33-1 Support, RockerLever

6 15434 3910814 3910814


6 15434 3901221 3901221


6 15434 3903940 3903940

7-33-4 Lever, Rocker(exhaust)

6 15434 3910810 3910810

7-33-5 Nut, Regular (hex) 12 15434 S-205 S-2057-33-6 Plug, Expansion 12 15434 3907555 39075557-33-7 Ring, Retaining 12 15434 3900242 39002427-33-8 Washer, Plain 12 15434 3900245 39002457-33-9 Setscrew (slotted) 12 15434 3900706 39007067-33-10 Rod, Push 12 15434 3904679 39046797-33-11 Lever, Rocker (intake) 6 15434 3910811 3910811NS Support, Rocker

Lever1 15434 3910815 3910815

NS Support, RockerLever

6 15434 3910816 3910816

NS Shaft, Rocker Lever 6 15434 3910813 3910813NS Lever, Rocker (intake)

Assembly6 15434 3910809 3910809

NS Lever, Rocker(exhaust) Assembly

6 15434 3910808 3910808

S9233-C9-MMA-010

7-51

Figure 7-34. Cylinder Head

S9233-C9-MMA-010

7-52

Table 7-34. Cylinder Head




7-34-0 Assembly, CylinderHead

1 15434 3910276 3910276

7-34-1 Plug, Pipe 1 15434 3008469 30084697-34-2 Plug, Pipe 5 15434 3908468 39094687-34-3 Plug, Pipe 2 15434 3908465 39084657-34-4 Gasket, Cylinder

Head1 15434 3907057 3907057

7-34-5 Insert, Valve (exhaust) 1 15434 3904105 39041057-34-6 Insert, Valve (intake) 1 15434 3906854 39068547-34-7 Valve, Exhaust 6 15434 3901607 39016077-34-8 Valve, Intake 6 15434 3901117 39011177-34-9 Head, Cylinder (bare) 1 15434 3909974 39099747-34-10 Plug, Expansion 5 15434 3902606 39026067-34-11 Spring, Valve 12 15434 3900276 39002767-34-12 Retainer, Valve Spring 12 15434 3900299 39002997-34-13 Collet, Valve 12 15434 3900250 39002507-34-14 Seal, Valve Stem 12 15434 3901097 39010977-34-15 Screw, Cap (hex hd,

M12-1.75 x 120 mm)14 15434 3903939 3903939


6 15434 3903938 3903938

7-34-17 Guide, Valve Stem(thin wall intake andexhaust)

12 15434 3906206 3906206

NS Guide, Valve Stem(thick wall intake)

6 15434 3904408 3904408

NS Guide, Valve Stem(thick wall exhaust)

6 15434 3904409 3904409

NS Intake Valve Kit 6 15434 3802005 3802005NS Exhaust Valve Kit 6 15434 3802006 3802006

S9233-C9-MMA-010

7-53

Figure 7-35. Oil Pan

S9233-C9-MMA-010

7-54

Table 7-35. Oil Pan




7-35-1 Plug, Threaded 1 15434 3040995 30409957-35-2 Seal, O-ring 2 15434 3037537 30375377-35-3 Screw, Cap (hex hd,

M8-1.25 x 25 mm)36 15434 3900631 3900631

7-35-4 Washer, Sealing 1 15434 3902425 39024257-35-5 Plug, Threaded 1 15434 3904386 39043867-35-6 Washer, Sealing 1 15434 3900216 39002167-35-7 Plug, Threaded 1 15434 3900215 39002157-35-8 Screw, Cap (hex hd,

M8-1.25 x 80 mm)2 15434 3902112 3902112

7-35-9 Pan, Oil 1 15434 3911405 39114057-35-10 Gasket, Flange 1 15434 3905468 39054687-35-11 Connection, Oil Suc-

tion1 15434 3911407 3911407


2 15434 3900225 3900225


1 15434 3900629 3900629

7-35-14 Baffle, Oil Pan 1 15434 3911411 39114117-35-15 Screw, Cap (hex hd,

M8-1.25 x 20 mm)4 15434 3900630 3900630

7-35-16 Gasket, Oil Pan 1 15434 3911410 3911410

S9233-C9-MMA-010

7-55

Table 7-36. Camshaft




7-36-1 Gear, Camshaft 1 15434 3907431 39074317-36-2 Screw, Cap (hex hd,

M8-1.25 x 20 mm)2 15434 3900620 3900620

7-36-3 Support, CamshaftThrust

1 15434 3901761 3901761

7-36-4 Key, Woodruff (plain,4.0 mm)

1 15434 3902332 3902332

7-36-5 Camshaft 1 15434 3907824 39078247-36-6 Tappet, Valve 12 15434 3907240 3907240

Figure 7-36. Camshaft

S9233-C9-MMA-010

7-56

Figure 7-37. Cylinder Block

S9233-C9-MMA-010

7-57

Table 7-37. Cylinder Block




7-37-1 Plug, Expansion(58.06 mm)

6 15434 3900965 3900965

7-37-2 Plug, Expansion(17.73 mm)

3 15434 3900956 3900956

7-37-3 Plug, Expansion 1 15434 3900687 39006877-37-4 Plug, Expansion

(1-in.)4 15434 3007635 3007635

7-37-5 Dowel, Ring 2 15434 3900068 39000687-37-6 Plug, Expansion 2 15434 3900955 39009557-37-7 Plug, Expansion 1 15434 3900958 39009587-37-8 Plug, Pipe (1/8-27 in.) 2 15434 3906619 39066197-37-9 Block, Cylinder 1 15434 3901204 39012047-37-10 Screw, Cap (hex hd,

M14-2.00 x 119 mm)14 15434 3904217 3904217

7-37-11 Cap, Main Bearing 7 15434 3900967 39009677-37-12 Dowel, Ring 14 15434 3900068 39000687-37-13 Nozzle, Piston Cool-

ing6 15434 3901020 3901020

7-37-14 Bushing, Camshaft 1 15434 3901306 39013067-37-15 Dowel, Pin 2 15434 3900257 39002577-37-16 Plug, Pipe 1 15434 3008468 30084687-37-17 Plug, Expansion 1 15434 3027646 NA7-37-18 Dowel, Ring 2 15434 3902343 3902343NS Block Hardware Kit 1 15434 3905813 3905813

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7-58

Table 7-38. Piston and Connecting Rod




7-38-1 Rod, Connecting(with cap)

6 15434 3901569 3901569

7-38-2 Bearing, ConnectingRod

12 15434 3901170 3901170

7-38-3 Screw, ConnectingRod (M11-1.25 x 59mm)

12 15434 3900919 3900919

7-38-4 + Ring, Retaining 12 15434 3901706 39017067-38-5 Pin, Piston 6 15434 3901793 39017937-38-6 + Piston 6 15434 3906223 39071567-38-7 + * Ring, Oil Control 6 15434 NPN NPN7-38-8 + * Ring, Lower Com-

pression6 15434 NPN NPN

7-38-9 + * Ring, Upper Com-pression

6 15434 NPN NPN

NS Piston Kit 6 15434 3802060 3802100NS Piston Ring Set 6 15434 3802040 3902050

+Part of 3802060 or 3802100.

*Part of 3802040 or 3802050.

Figure 7-38. Piston and Connecting Rod

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Table 7-39. Crankshaft and Main Bearings



Model 6BT5.9-MMfg. Part No

7-39-1 Gear, Crankshaft 1 15434 3901258 39012587-39-2 Crankshaft, Engine 1 15434 3907804 39078047-39-3 Pin, Roll 1 15434 3904483 39044837-39-4 Bearing, Main (upper) 6 15434 3901090 39010907-39-5 Bearing, Crankshaft,

Thrust1 15434 3906230 3906230

7-39-6 Bearing, Main (lower) 7 15434 3901150 3901150NS Sleeve, Wear (front) 1 15434 3906080 3906080NS Sleeve, Wear (rear) 1 15434 3906081 3906081NS Crankshaft, Engine

w/gear1 15434 3908032 3908032

NS Main Bearing Set 1 15434 3802070 3802070

Figure 7-39. Crankshaft and Main Bearings

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Table 7-40. Transmission Mounting Bracket




7-40-1 Bracket, Transmission(mount)

2 15434 3907003 3005186

7-40-2 Screw, Cap (captivewasher)

4 15434 103023 3029620

Figure 7-40. Transmission Mounting Bracket

Figure 7-41. Vibration Isolator

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Table 7-41. Vibration Isolator




7-41-0 Isolator, Vibration 1 96867 DF-237-MI DF-237-MI7-41-1 Stud (3/4-in. UNF,

Stl)1 96867 NPN NPN

7-41-2 Nut, Jam (hex hd, stl) 2 96867 NPN NPN7-41-3 Nut (hex hd, stl,

grade 5)1 96867 NPN NPN

7-41-4 Washer (stl concave) 1 96867 NPN NPN7-41-5 Insert, Flexible

(Buna-N)1 96867 3BG725BME014 3BG725BME014

7-41-6 Washer (stl) 1 96867 NPN NPN7-41-7 Screw (hex hd, grade

5)1 96867 NPN NPN

7-41-8 Pad, Flexible (synBuna-N)

1 96967 3BG725BME 3BG725BME

7-41-9 Casting (alum alloy;556-T6)

1 96867 NPN NPN

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Table 7-42. Fuel/Water Separator




7-42-0 Separator, Fuel/Water 1 55752 225 2257-42-1 Pump, Primer 1 55752 RK20025 RK200257-42-2 Pump, Vent 1 55752 RK20027 RK200277-42-3 Head (w/plugs, SAE

9/16-18 ports)1 55752 RK20002 RK20002

7-42-4 Element (30 micron;vacuum)

1 55752 R26S-UL R26S-UL

7-42-5 O-ring, Bowl 1 55752 20016 200167-42-6 Bowl (metal; w/plugs

and drain)1 55752 RK20026 RK20026

7-42-7 Knob, Drain 1 55752 RK20017 RK20017

Figure 7-42. Fuel/Water Separator

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Table 7-42. Fuel/Water Separator - Continued




7-42-8 Probe, Water Sensor(w/O-rings and con-nector)

1 55752 RK20726 RK20726

7-42-9 Check, Ball and Cup 1 55752 RK20011 RK20011NS Kit, Seal Service 1 55752 RK20075 RK20075NS Kit, Primer Knob and

Seal Service1 55752 RK20076 RK20076

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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


CAUTION

Prior to installing the engine, ensure that all engine mounts and systeminterfaces are rust-free, clean, complete, and in good working order.

CAUTION

When installing the diesel engine, care must be taken to ensure properalignment 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, isthree degrees minimum.

d. Uncap and connect the fuel oil return and supply lines, sea water lines, coolant lines, hydraulic piping sys-tems, 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.

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8-3. START-UP AND CHECKOUT.

After the engine has been installed, follow the prestart checks listed inchapter 2and check for proper opera-tion of the following systems: oil, fuel, fresh water, sea water, and electrical and all the engine controls and indi-cators.

8-4. ENGINE OPTION LISTS:

The specific engine option lists for each boat listed on the Approval and Procurement Record Page are listedbelow 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 Cleaner, AirAF 9026 Adapter, Front DriveEE 9928 AlternatorEG 9071 Instrumentation EngineEG 9040 Instrument Panel, 24V, 6 Cyl.EM 9066 Support, Front EngineFS 9050 Separator, Fuel WaterHX 9944 Heat ExchangerLG 9151 Gauge, Oil LevelMG 9911 6B Marine BaseSE 9025 Package, GuardST 9913 Starting MotorTR 9006 TransmissionWI 9005 Connection, Water InletXM 9014 Mainfold, Exhaust

15 Meter Utility Boat



Engine Description 15 Meter Utility Boat

Option No. Option Description

AC 9016 Cleaner, AirAF 9026 Adapter, Front DriveEE 9928 AlternatorEG 9071 Instrumentation, EngineEG 9940 Instrument Panel, 24V, 6 Cyl.EM 9066 Support, Front EngineHX 9923 Heat ExchangerLG 9151 Gauge, Oil LevelMB 9915 6BT Marine Base

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SG 9025 Package, GuardST 9913 Starting MotorTB 9079 Location, TuberchargerWI 9005 Connection, Water Inlet

26-Foot Personnel Boat


Engine Configuration Number: D402013MS12

Engine Description 26 Foot Personnel Boat

OPTION NO. OPTION DESCRIPTION

AC 9016 Cleaner, AirAF 9026 Adapter, Front DriveEE 9928 AlternatorEG 9940 Instrument Panel 24V, 6 Cyl.EM 9066 Support, Front EngineFS 9050 Separator, Fuel WaterHX 9923 Heat ExchangerLG 9150 Gauge, OilMG 9915 6BT Marine BaseSG 9025 Package, GuardST 9913 Starting MotorTB 9079 Location, TurbochargerTR 9006 TransmissionWI 9005 Connection, Water InletXS 9034 Connection, Exhaust

24-Foot Rigid Inflatable Boat (RIB)



Engine Description 24 Foot Rigid Inflatable Boat


AC 9016 Cleaner, AirEE 9928 AlternatorEG 9069 Instrumentation, EngineEG 9940 Instrument Panel, 24V, 6 Cyl.EM 9066 Support, Front EngineHX 9923 Heat ExchangerLG 9150 Gauge, Oil LevelMB 9915 6BT Marine BasePS 9005 Pump, Oil SumpRG 9027 Gear MarineSA 9010 Support, Marine GearSG 9025 Package, GuardTB 9079 Location, Turbocharger

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TR 9004 TransmissionVB 9009 Isolator, VibrationWI 9010 Connection, Water InletXS 9042 Connection, Exhaust

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Documents

Deisel Engines