Professional Documents
Culture Documents
30 OCT 1990
TITLE-1 / (TITLE-2 Blank)@@FIpgtype@@TITLE@@!FIpgtype@@
@@FIpgtype@@TITLE@@!FIpgtype@@
TITLE-2
@@FIpgtype@@BLANK@@!FIpgtype@@
S9233-C9-MMA-010
RECORD OF CHANGES
CHANGE DATE DESCRIPTION OF CHANGE CHANGE NO.
NOTE
THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONIC
SOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NO
LOEP. ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOT
MATCH THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE CONTENT IS
EXACTLY THE SAME. ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TM WILL ONLY FIT
IN THIS PAGINATED VERSION.
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 subdivided
into the following chapters:
Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are
requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors,
Omissions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be reported to
Commanding Officer, Naval Ship Weapon Systems Engineering Station (Code 5H00), Port Hueneme, CA 93043-
5007 on NAVSEA Technical Manual Deficiency/Evaluation Report, Form NAVSEA 9086/10. To facilitate such
reporting, three copies of Form 9086/10 are included at the end of this technical manual. All feedback comments
shall be thoroughly investigated and originators will be advised of action resulting therefrom. Extra copies of
NAVSEA Form 9086/10 may be requisitioned from the Naval Publications and Forms Center, Philadelphia, PA
19120.
TABLE OF CONTENTS
Chapter/Paragraph Page
2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
i
S9233-C9-MMA-010
Chapter/Paragraph Page
5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ii
S9233-C9-MMA-010
Chapter/Paragraph Page
iii
S9233-C9-MMA-010
Chapter/Paragraph Page
iv
S9233-C9-MMA-010
Chapter/Paragraph Page
v
S9233-C9-MMA-010
Chapter/Paragraph Page
vi
S9233-C9-MMA-010
Chapter/Paragraph Page
8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
vii
S9233-C9-MMA-010
LIST OF TABLES
viii
S9233-C9-MMA-010
ix
S9233-C9-MMA-010
x
S9233-C9-MMA-010
LIST OF ILLUSTRATIONS
6-21. Venting Fuel Injection Pump through Fuel Drain Manifold . . . . . . . . . . . . . . 6-43
xi
S9233-C9-MMA-010
xii
S9233-C9-MMA-010
xiii
S9233-C9-MMA-010
xiv
S9233-C9-MMA-010
xv
S9233-C9-MMA-010
SAFETY SUMMARY
GENERAL SAFETY NOTICES The following general safety notices supplement specific warnings and
cautions appearing elsewhere in this manual. General and specific precautions must be understood and applied
during operation and maintenance. The Commanding Officer or other authority will issue orders as deemed 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 all
times. Do not replace components, make adjustments, or perform internal equipment maintenance without first
securing electrical power. Dangerous potential may exist when the electrical power is in the OFF position because
of charges retained by capacitors. Before touching, always secure electrical power and discharge the circuit by
shorting through a load to ground with a shorting probe.
DO NOT REPAIR OR ADJUST ALONE Under no circumstances should any person reach into or enter
equipment enclosures for the purpose of servicing or adjusting equipment except in the presence of personnel
capable of rendering aid.
FIRST AID An injury, no matter how slight, should never go unattended. Always obtain first aid or
medical attention immediately.
ENERGIZED EQUIPMENT Before working on energized equipment, ensure against grounding. If 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 shall
be posted. The safety watch must have a full view of the repair/adjustment operation and immediate access to
controls that can stop the equipment in motion.
SPECIFIC SAFETY NOTICES The specific safety warnings and cautions summarized below appear in
appropriate chapters of this manual. Each is referenced to the text page on which it appears.
The following warnings and cautions appear in the text of this volume and are repeated here for empha-
sis.
WARNING
xvi
S9233-C9-MMA-010
WARNING
To prevent injury or death, shut down the engine when unusual noise or
vibration occurs. Unusual noise or vibrations may be an indication of equip-
ment failure. (Page 2-4)
WARNING
To prevent injury or death, control all oil and fuel leakage immediately. Oil
or fuel spraying on hot components is an extreme fire hazard. (Page 2-5)
WARNING
To prevent injury or death, use extreme caution when removing the cap
from the expansion tank. Steam formed by the sudden release of pressure
from a heated cooling system may force hot coolant through the system’s
openings. (Page 2-7)
WARNING
WARNING
WARNING
Rotating machinery can cause injury or death. Ensure the engine is shut
down before working on equipment and that the starter is tagged OUT-OF-
SERVICE. (Page 6-8)
xvii
S9233-C9-MMA-010
WARNING
To prevent injury or death, ensure extreme care and proper lifting devices
are used during handling. The equipment is heavy. (Page 6-8, page 6-82, page
6-102, page 6-106, page 8-1)
WARNING
WARNING
WARNING
WARNING
WARNING
To prevent serious hand injury while removing/installing the drive belt, keep
hands out of the path of the spring-loaded belt tensioner. (Page 6-24, page
6-24)
xviii
S9233-C9-MMA-010
WARNING
To prevent injury, exercise extreme care and wear insulated gloves when
handling heated components. Heated metal pans can cause serious burns.
(Page 6-29)
WARNING
Fuel spray from an injection nozzle can penetrate the skin and cause serious
injury. Use the proper equipment and keep hands clear when testing the
nozzles. (Page 6-39)
WARNING
Fuel spray from an injection nozzle can penetrate the skin and cause serious
injury. Use the proper equipment and keep hands clear when testing the
nozzle. (Page 6-43)
WARNING
Do not bleed a hot engine. This action could cause fuel to spill onto a hot
exhaust manifold thereby creating a danger from fire. (Page 6-44)
WARNING
WARNING
To prevent serious eye injury, wear safety eye protection when removing
springs under pressure. (Page 6-82, page 6-84)
xix
S9233-C9-MMA-010
WARNING
To prevent injury, exercise extreme care and wear insulated gloves when
handling heated solutions or metal. (Page 6-90, page 6-96, page 6-103)
WARNING
Wear eye protection when removing the ring gear from the flywheel. Do not
use a steel drift pin. (Page 6-96)
CAUTION
To prevent damage to equipment, prime the sea water pumps prior to opera-
tion. (Page 2-3)
CAUTION
CAUTION
CAUTION
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 prolonged
periods will dilute oil with fuel and cause sludge build-up. (Page 2-5)
xx
S9233-C9-MMA-010
CAUTION
To prevent damage to equipment, cool the engine before pressing the stop
switch. Stopping the engine before it cools down may cause damage to
equipment. (Page 2-5)
CAUTION
If excessive oil must be repeatedly drained from the engine, troubleshoot the
cause to prevent further damage to the engine. (Page 2-6)
CAUTION
To prevent damage to the timing pin and camshaft gear, disengage the 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
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)
xxi
S9233-C9-MMA-010
CAUTION
CAUTION
CAUTION
CAUTION
CAUTION
The retaining pad must be removed to prevent oil starvation of the bearing
after assembly. On new drive end shields, the retaining pad is fitted in the
oil way. (Page 6-13)
CAUTION
xxii
S9233-C9-MMA-010
CAUTION
Do not scratch the white ceramic surface of the seat. (Page 6-29)
CAUTION
To prevent the fuel injection pump delivery valve holder from turning, use
two wrenches. (Page 6-35)
CAUTION
To prevent serious damage to the injection nozzle, ensure the interior of the
socket does not come in contact with the fuel drain outlet sealing surface.
(Page 6-36)
CAUTION
To prevent damage to the injection nozzle and needle valve, place parts in a
suitable bath of clean fuel oil. (Page 6-37)
CAUTION
CAUTION
CAUTION
Do not exceed the specified pressure. Excess pressure can cause damage to
the shoe assemblies and adjusting plates. (Page 6-63)
xxiii
S9233-C9-MMA-010
CAUTION
Loose connections or cracks in the suction side of the intake pipe on 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 gasket
can allow dust and dirt to be ingested into naturally aspirated engines. (Page
6-66)
CAUTION
CAUTION
To prevent damage to the connecting rod and bearing, avoid the use of metal
objects during removal. (Page 6-98)
CAUTION
CAUTION
Do not clean the pistons and rods in an acid tank. (Page 6-98)
CAUTION
xxiv
S9233-C9-MMA-010
CAUTION
Prior to installing the engine, ensure that all engine mounts and system
interfaces are rust-free, clean, complete, and in good working order. (Page
8-1)
CAUTION
When installing the diesel engine, care must be taken to ensure proper
alignment of rotating components. (Page 8-1)
CHAPTER 1
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 diesel
engine shall comply with U.S. Navy Safety Precautions for Operations Afloat, OPNAV 5100 Series. Specific
safety precautions are included in the appropriate chapters of this manual. General and specific warnings and
cautions are contained in the Safety Summary, which is located in the front matter of this manual.
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 1-1 lists the principal characteristics of the 6B5.9-M diesel engine
and table 1-2 lists the principal characteristics of the 6BT5.9-M diesel engine.
1-1
S9233-C9-MMA-010
1-2
S9233-C9-MMA-010
Item Data
Crankshaft End Clearance (range) .0054 to.0104 in.
Engine Speed 2500 rpm
Piston Speed 1969 ft/min
Brake Mean Effective Pressure 101 psi
Standard Flywheel Housing Size SAE No. 3
Lubrication System
High Oil Level Capacity 15 qts
Low Oil Level Capacity 13 qts
Oil Temperature (max) 250° F
Oil Pressure at Idle (min allowable) 10 psi
Oil Pressure at Rated (min allowable) 40-60 psi
Oil Regulating Valve Opening Pressure 60 psi
Differential Pressure to Open Bypass Valve 20 psi
Continuous Operational Angularity of Oil Pan
(max)
Front down 45 degrees
Front Up 45 degrees
Side-to-Side 45 degrees
Cooling System
Coolant Capacity (engine only) 13.6 gals
Engine w/Heat Exchange 21.8 gals
Thermostat Range
Starting 180° F
Fully Open 203° F
Pressure 15 psi
External Pressure Loss in Cooling System (max) 5 psi
Allowable Coolant Expansion Space of System 5 percent
Capacity (min)
Coolant Make-up Capacity (min) 2.7 gals
Engine Water Flow 55 gpm
Fuel Oil System
Fuel Consumption (max) 6.3 gph
Fuel Flow to Pump (max) 8 gph
Allowable Pressure Drop Across Fuel Filter (max) 3 psi
Allowable Return Line Restriction (max) 5.0-inHg
Restriction to Fuel Pump with Dirty Filter (max) 3.75-inHg
Fuel Supply Hose Size 6
Fuel Return Hose Size 4
Air Supply System
Intake Air Flow 210 cfm
Allowable Intake Restriction at Rated Speed and 20-inH2 O
Load with Dirty Air Filter Element (max)
Allowable Return Line Restriction (max) 20.4-inHg
Intake Air Restriction (naturally aspirated) 20-inH2 O
Ventilation Area (min) 57 sq. in.
Exhaust System
Exhaust Gas Flow 600 cfm
1-3
S9233-C9-MMA-010
Item Data
Exhaust Gas Temperature 1150°F
Exhaust Diameter (min)
Dry 3.0-in.
Wet 3.5-in.
Heat Rejection to Coolant 4500 Btu/min
Heat Rejection to Ambient 800 Btu/min
Sea Water System
Sea Water Flow 23 gpm
Sea Water Pressure (max) 15 psi
Sea Water Pump Inlet Restriction (max) 5 inHg
Sea Water Strainer Open Area (min) 6.0-in.
Sea Water Pump Initial Suction Lift (max) 10 ft
Electrical System
Recommended Battery Capacity (min) Cold soak at 475
0°F or Above (min/CCA) w/24-Vdc Starter
Reserve Capacity Allowable Resistance of Starting .0020 ohms
Circuit w/24 volt Starteralign=″right″ (max)
1-4
S9233-C9-MMA-010
Item Data
Standard Flywheel Housing Size SAE No. 3
Normal Idle Speed 750 rpm
Piston Displacement 359 cu. in.
Fuel System
Fuel Consumption
High Output 11.2 gph at 2600 rpm
Intermittent 9.7 gph at 2500 rpm
Fuel Flow to Pump 12 gph
Allowable Restriction to Pump with Dirty Filter 3.75 inHg
(max)
Allowable Injector Return Line Restriction (max) 5.0 inHg
Allowable Pressure Drop Across Fuel Filter 3.0 psi
(max)
Fuel Supply Hose Diameter 25-in
Fuel Supply Hose Size 6
Fuel Return Hose Diameter 19-in
Fuel Return Hose Size 4
Air Supply System
Intake Manifold Pressure 43 inHg
Inlet Restriction Filter (max/clean) 15-inH2 O
Inlet Restriction Filter (max/dirty) 25-inH2 O
Allowable dirt Holding Capacity of Air Cleaner 3.0 gpm/cfm
(min)
Intake Air Flow 510 cfm
Ventilation Area (min) 138 sq. in.
Heat Rejection to Ambient 7100 BTU/min
Lubrication System
Allowable Oil Pressure at Idle (min) 10 psi
Allowable Oil Pressure at Rated Speed (min) 40-60 psi
Regulating Valve Opening Pressure 60 psi
Differential Pressure to Open Bypass Valve 20 psi
Oil Capacity
High 15 qts
Low 13 qts
Total System Capacity 16 qts
Continuous Operational Angularity of Oil Pan
(Max)
Front down 45 degrees
Front Up 45 degrees
Side-to-Side 45 degrees
Cooling System
Engine Water Flow
High Output 56 gpm
Intermittent 55 gpm
Coolant Capacity (engine only) 13.6 gals
Thermostat Standard Modulating Range
Starting 180°F
1-5
S9233-C9-MMA-010
Item Data
Fully Open 203°F
Coolant Temperature (max) 210°F
External Pressure Loss in Cooling System (max) 5 psi
Static Pressure of Coolant (max; exclusive of 15 psi
pressure cap)
Allowable Coolant expansion Space of System 5 percent
Capacity (min)
Coolant Make-up Capacity (min) 2.7 gals
Sea Water System
Sea Water Flow
High Output 25.5 gpm
Intermediate 23.5 gpm
Sea Water Pressure (max) 15 psi
Sea Water Strainer Open Area (min) 6.0-in.
Sea Water Pump Inlet Restriction (max) 5 inHg
Sea Water Pump Initial Suction Lift (max) 10 ft
Heat Rejection to Coolant 6900 Btu/min
Sea Water Pipe Size (min) 1.25-in.
Exhaust System
Exhaust Gas Flow
High Output 1230 cfm
Intermittent 777 cfm
Exhaust Gas Temperature
High Output 835°F
Intermittent 750°F
Heat Rejection to Coolant
High Output 7100
Intermittent 5594
Exhaust Diameter (min; dry) 4.0-in.
Exhaust Diameter (min; wet) 5.0-in.
Electrical System
Recommended Battery Capacity Cold Soak at 475
0°F or above (min/CCA)
Reserve Capacity Allowable Resistance of Start- .0020 ohms
ing Circuit w/24-Volt Starter (max)
1-6
S9233-C9-MMA-010
CHAPTER 2
OPERATION
2-1. INTRODUCTION.
This chapter provides procedures to check, prepare, operate, and shut down the diesel engine. These proce-
dures are sufficient to enable assigned personnel to operate the engine safely and efficiently. The applicable boat
information book (BIB) and the Naval Ship’s Technical Manual (NSTM), Chapters 233 and 541, provide addi-
tional information and procedures for various operation conditions.
2-1
S9233-C9-MMA-010
Indication Range
Injector Return Line Restriction 5.0 inHg
OH Pressure-Main Oil Passage
Max at rated rpm 60 psi
Min at rated rpm 30 psi
Min at idle rpm 10 psi
Oil Temperature (max) 250°F
2-3.1 PRE-OPERATIONAL CHECKS. The following steps shall be used to check and prepare the engine for
operation
2-2
S9233-C9-MMA-010
CAUTION
To prevent damage to equipment, prime the sea water pumps prior to opera-
tion.
q. If necessary, prime the sea water pump.
CAUTION
2-3.2 NORMAL OPERATION. The following steps shall be used for normal operation. This procedure covers
electrical starting for cold and warm weather.
2-3
S9233-C9-MMA-010
CAUTION
a. Review this entire procedure and the emergency engineering operating procedures (EEOP) before performing
any steps. This will ensure undemanding of required actions during rapid automatic sequence of events. Where
conflicts exist, the EEOP takes precedence.
b. Ensure the pre-operational checks have been performed. Refer to paragraph 2-3.1.
c. Place throttle in the idle position.
d. When the ambient temperature is 40°F or less and the engine is cold, start the engine using the cold start 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 electrical
starting system.
WARNING
NOTE
The start switch has three positions: OFF, RUN, and START. OFF and RUN are
continuous contact positions and START is a momentary contact position.
2. Place the switch in the RUN position and observe that the engine’s gauges and instruments are energized.
The temperature gauges should read normal temperatures and the alternator and low oil pressure warning
lights should be lit.
3. Place and hold the switch in the START position to activate the starter motor and crank the engine. Pro-
ceed to step f.
4. If the engine does not start after 30 seconds, return the switch to the OFF position. Wait two minutes
between unsuccessful attempts.
5. Repeat steps 1 through 4. If the engine does not start after four attempts, refer to chapter 5 and trouble-
shoot.
WARNING
To prevent injury or death, shut down the engine when unusual noise or
vibration occurs. Unusual noise or vibrations may be an indication of equip-
ment failure.
2-4
S9233-C9-MMA-010
f. Within 10 to 15 seconds after the engine starts, the alternator warning light and the low oil pressure warning
light should go out, and the oil pressure gauge should indicate at least 10 psi. If this does not occur, place the
switch in the OFF position and shut down the engine. Refer to chapter 5 and troubleshoot.
g. If abnormal noises or vibrations are present in the engine or any driven equipment, shut down the engine
according to the EEOP.
WARNING
To prevent injury or death, control all oil and fuel leakage immediately. Oil
or fuel spraying on hot components is an extreme fire hazard.
h. Periodically check the engine, attached piping, and hoses for oil, fuel, coolant, and sea water leakage.
1. If oil or fuel is spraying, shut down the engine according to the EEOP.
2. If the oil or coolant levels cannot be maintained, shut down the engine according to the EEOP.
3. If fuel is leaking, shut down the engine according to the EEOP.
4. If sea water is leaking and the coolant temperature is above 190°F and rising, shut down the engine. If the
temperature reaches 210°F, shut down the engine according to the EEOP.
i. Periodically monitor all engine indicators and record readings. Ensure the monitored parameters are within
operating limits. Refer to table 2-1.
j. Run the engine at idle speed for one minute.
CAUTION
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 prolonged
periods will dilute oil with fuel and cause sludge build-up.
l. Operate the engine, as required, for boat operations; maintain 800 rpm or greater when operating. Ensure the
clutches are not engaged at speeds greater than 850 rpm.
2-3.3 SHUTDOWN. Shut down the engine according to the following steps.
CAUTION
To prevent damage to equipment, cool the engine before pressing the stop
switch. Stopping the engine before it cools down may cause damage to
equipment.
2-5
S9233-C9-MMA-010
a. To cool down the engine, run the engine for five minutes at idle speed with the clutch disengaged.
b. Move the start switch to the OFF position; ensure the engine stops.
c. If the engine does not stop, actuate the emergency manual shutdown lever. If the emergency fuel shutdown
lever does riot stop the engine, determine and correct the cause. Refer to chapter 5 and troubleshoot.
d. If the engine does not stop, actuate the emergency fuel shutdown lever for the on-service fuel tank. Ensure
the engine stops in about 10 seconds. Determine and correct the cause of the stop switch not stopping the
engine.
e. If actuated, reset the emergency fuel shutdown lever and open the emergency fuel shutdown valve.
f. Close the fuel supply shutoff valve supplying fuel from the on-service fuel tank to the engine.
g. Close the fuel return shutoff valve which allows fuel spill to return to the on-service fuel tank.
h. Close the sea water manual valves that were opened for engine operations
i. Open the sea water vent and drain connections.
j. After the engine has been stopped for 20 minutes, ensure oil in the engine is at the proper level.
1. Remove the dipstick from the oil pan and check the level. The oil level should be at the full mark.
2. If the level is low, remove the oil fill cap from the valve cover and add lubricating oil, as required to bring
level to full mark. (Refer to table 2-2.) Reinstall the oil fill cap on the cover.
CAUTION
If excessive oil must be repeatedly drained from the engine, troubleshoot the
cause to prevent further damage to the engine.
3. If the level is high, pump oil from the oil pan into an appropriate disposal container. Dispose of oil in
accordance with the NSTM, Chapter 593.
4. Reinstall the dipstick in the dipstick tube.
k. Refer to table 2-2 and fill the fuel tanks with fuel in accordance with the NSTM, Chapter 541, and the BIB.
l. Perform required engine maintenance.
2-3.4 EMERGENCY OPERATION. Emergency operation is necessary when the equipment malfunctions. If
the equipment malfunctions, refer to chapter 5 and troubleshoot. Ensure equipment repair/replacement is per-
formed as soon as possible.
a. If the warning light indicating low oil pressure comes on, check the oil pressure gauge.
b. If the oil pressure gauge indicates greater than 10 psi, determine and correct the cause of the malfunctioning
warning light. Refer to chapter 5 and troubleshoot.
c. If the oil pressure gauge indicates 10 psi or less, stop the engine.
d. If operation of the engine is not absolutely required, shut down the engine (refer to paragraph 2-3.3.).
2-6
S9233-C9-MMA-010
e. If the engine operation is required and low oil pressure is due to oil leakage, operate the engine while 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 level
to the full mark. Reinstall the oil fill cap on the cover.
3. Reinstall the dipstick in the oil pan.
4. Continuously repeat steps 1 through 3 while the engine is running.
5. If the oil level cannot be maintained between the low and full marks on the dipstick or the oil pressure
cannot be maintained greater than 10 psi, shut down the engine according to paragraph 2-3.3.
f. Determine and correct the cause of low oil pressure. Refer to chapter 5 and troubleshoot.
a. If the warning light indicating high engine coolant temperature comes on, check the water temperature gauge.
1. If the water temperature gauge indicates 210°F or greater, shut down the engine to determine and correct
the malfunction. Refer to chapter 5 and troubleshoot.
2. If the water temperature gauge indicates 200°F or greater, decrease engine speed to attempt cooling of the
engine. Refer to chapter 5 and troubleshoot.
b. If engine operation is required and high engine coolant temperature is due to coolant leakage, operate the
engine as follows:
1. Allow the engine to cool as long as possible.
WARNING
To prevent injury or death, use extreme caution when removing the cap
from the expansion tank. Steam formed by the sudden release of pressure
from a heated cooling system may force hot coolant through the system’s
openings.
2. Using extreme caution, remove the cap from the expansion tank.
3. Add coolant, as required, to bring the tank to the proper level.
4. Operate the engine; refer to paragraph 2-3.2. Continuously monitor the tank and add coolant, as required,
to maintain the proper level.
5. If the coolant level cannot be maintained, shut down the engine according to the EEOP.
6. When engine operations are complete, reinstall the cap on the tank.
c. Determine and correct the cause of a high engine coolant temperature. Refer to chapter 5 and troubleshoot.
2-3.4.3 Runaway Engine. If oil is introduced into the cylinders, the engine will become uncontrollable and may
overspeed. Excessive oil level in the oil pan will cause a runaway engine. If a runaway engine is suspected, pro-
ceed as follows:
2-7
S9233-C9-MMA-010
b. If the engine speed is quickly approaching 2600 rpm, actuate the emergency manual shutdown lever.
c. Determine and correct the cause of a runaway engine. Refer to chapter 5 and troubleshoot.
2-8
S9233-C9-MMA-010
CHAPTER 3
FUNCTIONAL DESCRIPTION
3-1. INTRODUCTION.
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 starting
system, an air intake and exhaust system, a fuel system, lubrication system, cooling system, and various controls
and indicators.
3-3.1 DIESEL ENGINE. The engine is a four-cycle, internal combustion engine that includes an intake air
cleaner/silencer, six pistons and connecting rod assemblies, a crankshaft assembly, idler gear, camshaft assembly,
cylinder head assembly, cylinder block assembly, and an accessory drive assembly. The piston and connecting
rod assemblies convert the heat energy released by fuel combustion into mechanical energy to rotate the crank-
shaft assembly. Crankshaft assembly rotation is then transmitted by the idler gear to the camshaft assemblies
through a gear train. The camshaft assemblies actuate the cylinder head assemblies to inject fuel into and con-
duct exhaust gases out of the cylinders in the required timed sequence. The cylinder head assembly forms the top
enclosure for the cylinders and provides for cooling, lubrication, fuel injection, and exhaust gas removal. (The
model 6BT5.9-M includes a turbocharger to increase intake air volume and pressure.) The cylinder block 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-volt
battery bank, starting motor, and an alternator. A deposition toggle switch (OFF, RUN, START) is included for
engine control. The OFF position closes the fuel supply to the injection pump. The RUN position energizes the
engine gauges, instruments, warning lights, and control devices, and also opens the fuel supply valve. The START
position is a momentary contact. When held closed, the solenoid switch on the starter motor is closed to supply
full battery power to the starter motor for cranking the engine. When released the switch returns to the RUN
position where it remains until it is moved to the OFF position. An electrical interlock, which is included in the
engine throttle and clutch control, prevents starting the engine unless the transmission is in neutral.
The alternator includes a solid-state, integral voltage regulator. A positive battery lead supplies power for ini-
tial excitation of the alternator field. An alternator failure warning light is fed by the same line. As soon as the
alternator begins to generate voltage, that voltage matches the battery voltage to the regulator and turns out the
alternator failure warning light, and the alternator becomes self-excited. The voltage regulator senses battery con-
dition and maintains alternator output voltage at an appropriate level throughout the full range of engine running
speeds. When the alternator output stops, battery power returns to the warning light.
3-1
S9233-C9-MMA-010
3-3.3.1 Air Intake System. The air intake system provides clean air to the cylinders at atmospheric pressure for
the model 6135.9-M, and above atmospheric pressure for the model 6BT5.9-M. The model 6B5.9-M intake sys-
tem includes air cleaner/ silencer piping and an intake manifold and intake valves, through which clean, cool air
is admitted into the engine cylinders. The model 6BT5.9-M is equipped with an exhaust-driven turbocharger,
which increases the intake air volume and pressure to the cylinders via the intake manifold and intake valves.
3-2
S9233-C9-MMA-010
3-3.3.2 Exhaust System. The exhaust system includes those components used to expel the engine’s exhaust
gasses. It starts with the exhaust valves, one valve for each of the six cylinders. Each cylinder expels its exhaust
gas into the manifold: in the model 6B5.9-M, the exhaust passes through a sea water-cooled exhaust elbow fit-
ting, through a 2-1/2-inch to 3-inch piping, a muffler, and more piping to the atmosphere. The path of the exhaust
gasses for the model 6BT5.9-M is the same from the cylinder exhaust valve to the exhaust manifold, but in this
model, the exhaust gasses are used to drive the turbocharger. From the turbocharger, the exhaust gas passes
through the sea water-cooled elbow, piping, muffler, and additional piping before it is discharged to the 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 fuel
from the supply tank and supplies low-pressure fuel (3 to 5 psi) to the fuel filter head, through the filter, then to
the fuel injection pump. The fuel injection pump increases fuel pressure and routes the high-pressure fuel to each
Injection nozzle.
3-3.4.2 Fuel Injection Nozzles. Fuel is supplied through the high-pressure lines to the fuel injection nozzles in
the cylinder head. When the high-pressure fuel reaches the injection nozzles, the pressure lifts the needle valve
against spring tension and allows fuel to enter the combustion chamber. A common drain line returns unused fuel
to the supply tank.
3-3.4.3 Fuel Drain Manifold. Any leakage past the fuel injection needle valve enters the fuel drain manifold.
The fuel drain manifold routes controlled venting from the injection pump and leakage from the nozzles back to
the main fuel tank.
3-3.4.4 Throttle. The throttle provides a means for the operator to manually control engine speed above idle,
as required, by varying operating conditions of speed and load.
3-3.4.5 Fuel Shutoff Valve. The injection pump is equipped with an electrical shutoff valve. This solenoid-
operated valve blocks the supply of fuel to the high-pressure pumping and distribution components. The valve is
designed to be closed when there is no electrical power to the solenoid.
3-3.5 LUBRICATION SYSTEM. The engine is pressure-lubricated by a gerotor-type lube oil pump driven by
the front crankshaft gear located in the oil pan at the front of the engine. A pressure regulator is mounted in the
block to control pressure. Filters and screens are provided in the lubricating system to remove impurities in the
oil. A bypass valve is provided in the full-flow oil filter head to continue lubrication if the element becomes
clogged. The engines lube oil capacity at full level holds 15 quarts of oil.
3-3.6.1 Fresh Water Cooling System. Coolant in the fresh water cooling system consists of a mixture of fresh
water and antifreeze. The engine fresh water cooling system includes an engine block, cylinder head, heat
exchanger, fresh water pump, thermostat, expansion tank, and piping; it has a coolant capacity of 21.8 gallons.
The coolant is pressurized up to 15 pounds psi when the diesel engine is running at normal operating speed (2500
rpm) by the fresh water pump. Coolant output from the fresh water pump empties into the oil cooler cavity of
3-7
S9233-C9-MMA-010
the cylinder block. The coolant circulates around each cylinder and crosses the cylinder block to the fuel 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 drilled
passages 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 flowing
through the heat exchanger to the fresh water pump is cooled by a counterflow of sea water pumped through the
heat exchanger. Sea water exits from the heat exchanger via a sea water connection at the upper rear end of the
heat exchanger. The expansion tank provides make-up coolant for the closed coolant system and provides a place
for hot coolant to expand.
3-3.6.2 Sea Water Cooling System. The sea water cooling system furnishes sea water, which is used to cool oil
passing through the transmission’s oil cooler, fresh water coolant passing through the heat exchanger, and exhaust
gas passing through the exhaust manifold elbow to the muffler. The water pump, which has a maximum suction
lift of 10 feet, draws sea water through a strainer with a minimum open area of six square inches. The sea water
pump discharges coolant at a maximum pressure of 15 psi.
3-3.7 CONTROLS AND INDICATORS. Various controls and indicators are provided with the diesel engine
installation to start, operate, and shut down the diesel engine and to monitor diesel engine parameters during
operation. See figure 3-1 for an electrical schematic of the engine controls.
3-3.7.1 Starter Switch. When the starter switch is activated, 24-Vdc is supplied to the solenoid, completing the
circuit to the starter motor on the engine.
3-3.7.2 Electrical Fuel Shutoff. The fuel shutoff is installed on the fuel injection pump. Its purpose is to stop
the engine under normal operating conditions by stopping the fuel flow to the nozzles when the start switch is
moved to the OFF position.
3-3.7.3 Tachometer. The tachometer is electrically connected to a sender attached to the engine. It converts
mechanical motion to electrical impulses to cause the tachometer to indicate engine speed (rpm).
3-3.7.4 Lube Oil Pressure Switch. The lube oil pressure switch is a break-type switch set to actuate when the
lube oil pressure drops to eight psi. This completes the low lube oil alarm circuit to the control panel to activate
the engine warning light. The switch is located on the fuel pump side of the block.
3-3.7.5 Water Temperature Switch. The water temperature switch, which is located on the cylinder head, is
operated by a high cooling water temperature condition. When the cooling water temperature exceeds 225°F, the
switch closes a set of contacts that causes the engine warning light at the control panel to activate.
3-8
S9233-C9-MMA-010
CHAPTER 4
SCHEDULED MAINTENANCE
4-1. INTRODUCTION.
Required preventive maintenance procedures to be performed on a scheduled basis are provided in the
Planned Maintenance System (PMS) documentation OPNAVINST 4790.4 describes this system, which also cov-
ers departmental and work center record keeping, as well as the Maintenance Index Page (MIP) and Maintenance
Requirements Cards (MRC’s). MRC’s cover scheduled inspection and lubrication procedures for the diesel
engine. The extensive and comprehensive scheduled maintenance provided by PMS MRC’s eliminates the need
for any coverage within this chapter. Specific corrective maintenance (adjustment, alignment, and repair) is cov-
ered in chapter 6 of this manual.
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 require
personnel assistance and/or tools or other equipment not available onboard the craft.
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. Table
5-1 represents a list of potential problems, their probable causes, and suggested corrective actions.
5-1
S9233-C9-MMA-010
5-2
S9233-C9-MMA-010
5-3
S9233-C9-MMA-010
5-4
S9233-C9-MMA-010
5-5
S9233-C9-MMA-010
5-6
S9233-C9-MMA-010
5-7
S9233-C9-MMA-010
5-8
S9233-C9-MMA-010
5-9
S9233-C9-MMA-010
a. Measure the voltage between the positive battery cable and ground. Note the voltage.
b. Using a remote start switch, attempt to engage the starter while observing voltage.
c. If the voltage reads less than 20 Vdc, charge the battery.
d. If the voltage drops rapidly more than 4.8 Vdc, replace the battery.
e. If a low battery charge was found to be the problem, check the alternator.
f. Ensure proper battery cable connection. With the engine running, measure the voltage between the positive
battery to the ground. Replace the alternator if the voltage is less than 24 Vdc.
5-3.2 ENGINE CRANKS BUT WILL NOT START (SMOKE FROM EXHAUST).
5-3.3 ENGINE STARTS BUT WILL NOT KEEP RUNNING. Inspect for broken or bare wires. Those wires
not accessible can be checked for continuity between the wire and ground.
a. Check the temperature sensor for continuity. The sensor will have continuity only when coolant temperature
is above 225°F.
5-10
S9233-C9-MMA-010
b. Check the thermostat for correct operation. With the thermostat suspended in water, it should begin to open
when the heated water temperature reaches 181°F and be fully open at 203°F.
CHAPTER 6
CORRECTIVE MAINTENANCE
6-1. INTRODUCTION.
This chapter provides specific corrective maintenance procedures for shipboard, intermediate, and depot level
maintenance of the diesel engines. Adjustment and alignment procedures are presented in section 1 and repair
procedures (detailing removal, disassembly, repair/replacement, reassembly, and reinstallation) are presented in
section 2.
6-1
S9233-C9-MMA-010
6-2
S9233-C9-MMA-010
SECTION 1.
ADJUSTMENT AND ALIGNMENT
6-3. INTRODUCTION.
This section provides procedures necessary to perform adjustments and alignments to the diesel engine. Some
adjustment and alignment procedures require that the component be partially disassembled.
NOTE
If the flywheel is accessible, a handheld type tachometer can be used. If the rpm
can only be established from the front of the engine, an electrical type (strobe)
tachometer should be used.
d. Place the selector switch on the tachometer to the A position and adjust the tachometer to the engine idle rpm
(750).
NOTE
Valve clearance adjustment is made when the engine is cold, i.e., below 140°F.
a. Loosen the adjustment screw locknuts and back out all the way on the valve adjustment screws (figure 6-2).
6-3
S9233-C9-MMA-010
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.
NOTE
The clearance is correct when some friction is felt when the feeler gauge is
moved between the valve stem and the rocker lever.
e. Using the respective adjusting screw, adjust the number 1 intake valve clearance to 0.010 inch and the num-
6-4
S9233-C9-MMA-010
ber 1 exhaust valve clearance to 0.020 inch. By turning the adjusting screw clockwise or counterclockwise, as
necessary, lock the setting by holding the screw and tightening the locknut.
f. Adjust the number 2 and number 4 intake valves and the number 3 and number 5 exhaust valves with the
number 1 cylinder at TDC.
g. Ensure the timing pin is disengaged.
h. Mark the vibration damper pulley and rotate the crankshaft 360 degrees (the timing pin will not engage).
i. Set the number 2, 4, and 6 cylinder exhaust valves, the number 3. 5, and 6 cylinder intake valves; and the
number 4 cylinder intake and exhaust valve.
j. Torque all locknuts to 18 lb-ft.
SECTION 2.
REPAIR
6-6. INTRODUCTION.
This section provides general cleaning, inspection, and overhaul procedures to be used during repair. It also
provides specific procedures (including removal, disassembly, reassembly, and reinstallation) for the various
components used on the diesel engine.
WARNING
WARNING
CAUTION
Do not use harsh abrasives that might scratch, score, or otherwise mar sur-
face finishes.
6-5
S9233-C9-MMA-010
CAUTION
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
6-7.1 CLEANING. Observing all applicable warnings and cautions, clean components in accordance with the
following 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 to
remove hardened deposits of dirt or other contaminants.
b. Remove grease, oil, and dirt from exterior surfaces with an approved water soluble detergent (MIL-D-16791)
and water.
c. Rinse bearings in an approved lubricating oil MIL-L-2104B). Allow bearings to air dry as much as possible.
d. After cleaning, dry parts other than bearings thoroughly. Use filtered, dry, low-pressure air or a clean, lint-free
cloth.
e. Do not attempt to clean paper filter elements.
f. When cleaning, keep related parts together so that reassembly of parts is as close to the same position is pos-
sible.
6-6
S9233-C9-MMA-010
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 following
steps.
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 threads
for cracks.
d. Inspect bearings for flat spots and corrosion; verify smooth operation.
e. Inspect retainers for nicks, scratches, and burrs.
f. Check shafts for flat spots and uneven wear.
g. Check all springs for cracks and bends; verify uniform expansion/retraction capability.
h. Inspect passages for corrosion and blockages.
i. Inspect gears and pinions for broken or burred teeth and for cracks.
j. Inspect V-belt tension and all flexible hoses, lines, and fittings by following PMS procedures.
k. Replace parts in excess of stated wear limits.
6-8. REPAIR/REPLACEMENT.
6-8.1 GENERAL.
a. Work on a clean bench and protect gear teeth and oil seal surfaces from nicks and scratches.
b. Repair by standard shop practices, using standard shop tools unless otherwise stated.
c. Repair or replace pans as indicated by inspection.
d. If the condition of any part is questionable following inspection and repair, replace the part.
e. If replacement parts are available, replace all gasket seals, and O-rings each time they are removed. If 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 to
apply.
g. Refer to chapter 7 for listings of replacement parts.
h. Disassemble components only to the extent necessary to effect desired repairs.
i. Read procedures in full before starting repairs. Pay particular attention to safety precautions.
j. Tables appearing throughout this chapter provide data that may be useful for intermediate and depot level
maintenance.
6-7
S9233-C9-MMA-010
6-8.2 PRELIMINARY PROCEDURES AND SAFETY INFORMATION. Prior to performing any work on the
diesel engine, proceed as follows:
WARNING
Rotating machinery can cause injury or death. Ensure the engine is shut
down before working on equipment and that the starter is tagged OUT-OF-
SERVICE.
NOTE
WARNING
To prevent injury or death, ensure extreme care and proper lifting devices
are used during handling. The equipment is heavy.
CAUTION
6-8
S9233-C9-MMA-010
o. Using a spreader bar with a suitable sling and adequate chain, lift the engine from its base. Mount the engine
on an overhaul stand suitable to support the full weight of the engine.
WARNING
6-9.1 REMOVAL. Remove the starter motor according to the following steps. Unless otherwise noted, callouts
refer to figure 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 to figure 7-2.
a. Using a scribe or similar sharp-pointed tool, remove two core plugs (25) from drive end shield (7), exposing
two field terminal screws.
b. Remove the two field terminal screws.
c. Loosen Phillips head screw (54) and remove commutator cover (55), and lining (56).
NOTE
Removal of the brush lead screws also frees the field coil connections.
d. Remove brush lead screws and lock washers (71 and 23); raise brush springs and trigger (38) and remove
brushes (72).
NOTE
Use caution not to lose the steel ball which is under pressure from the spring.
e. Using a wrench, carefully unscrew and remove end cap (57).
f. Remove steel ball (59) and spring (60).
6-9
S9233-C9-MMA-010
WARNING
NOTE
When removing the commutator end shield, retain the shims for reassembly; end
float adjustment is simplified by fitting the original shims.
i. Carefully remove commutator end shield (73) and shim washer (67) from the end of the armature shaft.
j. Using a mallet, tap drive end shield (7) away from the housing; remove the end shield complete with arma-
ture (85). Remove and discard sealing ring (84).
CAUTION
WARNING
NOTE
Inspect the pinion for burrs or similar damage before withdrawing it from the
drive end shield.
p. Remove any burrs from the pinion and withdraw pinion assembly (83) from the drive end shield.
6-10
S9233-C9-MMA-010
q. Detach the flexible lead from moving contact (37); remove the link to the binding post on the moving con-
tact.
r. Using a suitable punch, remove securing rivets (47) to free resistor (45) from the drive end shield; remove
resistor bushing (44) and spacers (43).
s. Remove main terminal nuts (16), lock washers (15), screw (18) and lock washer (17). Remove washers (13
and 14), sealing ring (12) and insulator bushing (11). Rotate main terminal (8), 180 degrees axially and
remove from the drive end shield (7) along with support (9) and insulator (10).
t. Remove nuts (24), lock washers (23), washer (22), and insulating bushings (20 and 21) from solenoid 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 must
ride on the commutator to provide Proper performance. Check by hand to ensure the brush springs provide
firm contact between the brushes and commutator. If the springs are distorted or discolored, they should be
replaced.
NOTE
Do not turn the commutator or undercut the insulation on the motor. Use 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 are
sometimes produced by brush dust or copper between the bars.
2. Open circuits may be located by inspecting for loose connections at the points where the conductors am
joined to the commutator. Loose or poor connections cause arcing and burning of the commutator. If the
bars are not badly burned, leads originally soldered to the riser bars can be re-soldered. Check for 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 probe
is placed on the commutator and the other test probe on the armature core or shaft, the armature is
grounded and must be replaced.
c. Field coils. Using a test lamp, check the field coils for grounds and open circuits according to the follow-
ing steps.
1. Grounds. Disconnect the field coil ground connections. Connect one test probe to the field frame and
the other to the connector. If the lamp lights, the field coils are grounded and must be repaired or replaced.
2. Open circuits. Connect test lamp probes to the ends of the field coils. If the lamp does not light. the
field coils are open. If the field coils need to be removed for repair or replacement, a pole shoe spreader
and pole shoe screwdriver should be used. Care should be exercised in replacing the field coils to prevent
6-11
S9233-C9-MMA-010
grounding or shorting as they are tightened in place. Where the pole shoe has a long lip on one side, it
should be reassembled in the direction of armature rotation.
d. Solenoid coils and contacts. The coils can be checked for shorts or open circuits by measuring current con-
sumption at nominal voltage. A link should be made between the green lead and the terminal lug, refer to
table 6-2 and figure 6-4.
6-12
S9233-C9-MMA-010
ter reading with the specifications. A high reading indicates a shorted or grounded hold-in winding and a
low reading indicates excessive resistance. To check the pull-in winding, connect from the solenoid switch
terminal to the solenoid motor terminal.
2. Examine the contacts and, if necessary, clean them with white spirit or very fine carborundum paper. The
first stage gap should be 0.083 inch (2.1 mm) with a bottom limit of 0.076 inch (1.93 mm) and a maxi-
mum of 0.098 inch (2.5 mm). Press down the plunger and ensure the second stage contacts make, but only
after the trigger is tripped. If the contacts are badly burned, the gap excessive, or the coils appear to have
overheated, the solenoid should be replaced as a complete unit.
e. Dismantling the solenoid. To replace defective components, dismantle the solenoid according to the follow-
ing steps. Unless otherwise noted, callouts refer to figure 7-2.
1. Remove rivets (29) securing trigger guide (39) and the rivets securing contact stop (28); remove the con-
tact stop and trigger guide. Examine the trigger guide for wear on the pivot points; replace the trigger
guide, as required.
2. Remove plunger (36), spring (33), moving contact (37), and spring (35) as a complete assembly.
3. Unsolder the solenoid leads connected to the fixed contact lug and remove the fixed contact assembly
(figure 6-4).
f. Reassembling the solenoid. Following component replacement, reassemble the solenoid according to the
following steps.
1. Locate the fixed contact assembly on the solenoid; ensure the contact plate rivet holes align with those in
the solenoid coil plate.
2. Replace plunger (36), moving contact (37), and springs (33 and 35). The rectangular-shaped extension on
one side of the moving contact must face the two rivet holes for the trigger guide (39).
3. Push the solenoid plunger fully home. With the plunger held in this position, replace contact stop (28) and
trigger guide and rivet both into position.
4. Solder the solenoid leads, as required, to obtain circuit continuity.
5. Verify correct first stage contact gap of 0.076 inch to 0.096 inch; a slight gap adjustment can be obtained
by bending the brass contact stop.
g. Commutator end bearing. Ensure commutator end bearing bushing (68) is tight in its housing. Check the
side play between the armature shaft and bearing. If the side play is excessive, replace the end bearing bush-
ing as follows.
1. Press the old bearing bushing out of the commutator end shield.
NOTE
CAUTION
The retaining pad must be removed to prevent oil starvation of the bearing
after assembly. On new drive end shields, the retaining pad is fitted in the
oil way.
6-13
S9233-C9-MMA-010
1. Check the internal diameter of the drive end shield (7). If bearing bushing (6) is worn, the drive end shield
must be replaced with a new unit.
2. Ensure lubrication pad (4) is free to move under the influence of spring (2).
i. Pinion. If the pinion teeth are badly worn or damaged, replace the pinion with a new unit. Ensure the new
pinion has the same number of teeth and is a free-sliding fit on the armature shaft. If necessary, lightly lap
the pinion bore and shaft with a fine lapping paste. Remove all traces of lapping paste using a bottle brush
to ensure absolute cleanliness of the pinion helix. If the pinion is fitted with an oil seal in the bore, all burrs
or sharp, edges must be removed or the seal will tear. Install a new oil seal with the U-channel facing toward
the pinion teeth end (figure 6-5).
j. Springs. Ensure the starter motor springs are not damaged, discolored, or deformed and retain their ten-
sion. Refer to table 6-3.
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 light
cut should be taken using a diamond or tungsten carbide tip to obtain a high quality surface finish.
WARNING
6-14
S9233-C9-MMA-010
be machined is 1.56 inch (392 mm). Radius at the juncture of the risers and commutator must not exceed
0.040 inch (1.0 mm). The risers should not be skimmed and the commutator must not be undercut, as 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 helices
with an approved solvent and apply a small quantity of lubricating grease.
m. Field windings. Remove and replace field windings (80) according to the following steps. Unless otherwise
noted, callouts refer to figure 7-2.
1. Using a pole shoe screwdriver, unscrew pole shoe screws (78). Remove the pole shoes and windings; note
their original positions within the starter housing (figure 6-6). Mark number 1 position with tape or scribe
mark on housing.
NOTE
As an aid to correct assembly, the pole shoes are numbered and must be replaced
in the same positions as original. Otherwise, they might foul the armature during
operation.
2. Fit the replacement windings into the housing and replace the pole shoes in their original positions (figure
6-6).
3. Carefully align the pole shoes in the housing; insert and torque the pole shoe screws (78) 25 to 30 lb-ft
using a pole shoe screwdriver. When completed, ensure no space exists between the mating surfaces of
the pole shoes and the housing.
n. Brush gear. Using a 10-volt megger-type tester, check the insulation between all brush holders and the
starter motor frame. The insulation resistance must be not less than one megohm. Ensure all brush holders
am secure.
o. Brushes. During overhaul, always renew the brushes to ensure maximum life between overhaul periods.
Brushes must be fitted in complete sets and replacement brushes must be well bedded. To accomplish this,
proceed as follows:
6-15
S9233-C9-MMA-010
CAUTION
6-9.4 REASSEMBLY. Reassemble the starter motor according to the following steps. Unless otherwise noted,
callouts refer to figure 7-2. Refer to table 6-1 for special tools required for reassembly.
a. Remove any burrs or sharp edges on segments (34); place spring (35) on a clean, flat surface and position the
four segments inside the spring so they lie end-to-end in a circle; install the spring in the outer groove of the
segments.
b. Place the solenoid switch on the workbench, coil end facing upward. Gently push the spring and segment
assembly into the solenoid plunger bore so it fits into the recess provided.
c. Install split protection collar (tool 6244-6) in drive end shield (7) to protect oil seal (3) and insert pinion
assembly (83). Remove the split protection collar.
d. Place terminal insulator (10) under main terminal (8) of the assembled solenoid switch (figure 6-4); the end
with the hole must be upright.
e. Insert the solenoid assembly in the drive end shield and secure with self-tapping screws (30) and lock 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), lock
washer (23), and nut (24).
h. Repeat step f and step g to connect the green (or yellow, as applicable) return lead to the R terminal.
i. Press down the plunger (36) and insert main terminal (8) in position from inside the housing, through the
anodized metal strip and insulator, and into the hole in the drive end shield. Install insulating bushing (11)
sealing ring (12), washers (13), plain washers (14), lock washers (15), and nut (16) finger tight.
j. Insert lock washer (17) and Phillips head screw (18). Torque nut (16) to 5 lb-ft.
6-16
S9233-C9-MMA-010
k. Reinstall collar (48) to the pinion assembly (83) pinion sleeve; ensure the 45-degree chamfer inside the 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 retaining
ring (52). Ensure the external retaining ring locates properly in the ring groove; check with gauge 6244-3 to
ensure it is squarely seated.
m. Insert resistor (45) into its recess in the drive end shield; secure with insulating bushing (44) and spacer (43)
and rivet (47).
n. Connect the resistor flexible lead to the lug on the solenoid assembly (27) moving contacts (37). Secure with
washer (41) and hex head cap screw (46).
o. Reinstall the link bar between the lug and a corner of the moving contaCt. Attach one end with a washer and
screw; attach the opposite end to a post together with the resistor flexible lead using a washer and nut.
p. Insert the lock ring balls and overspeed balls (82) into the pinion assembly (83) pinion sleeve holes from
inside the bore. Use a small screwdriver blade with a spot of grease to feed the balls and apply a small amount
of grease to hold them in position.
q. Reinstall the pinion assembly and drive end shield assembly to the armature as follows:
1. Pull the pinion assembly pinion out of the drive end shield until collar (48) is pressed back against its
spring by the end of plunger (36). Hold the pinion in this position.
2. Press the lock ring balls fully into their holes to allow free entry of the armature shaft.
3. Slide the pinion assembly (83), and end shield assembly (7), onto the armature (85) shaft. Use care not to
dislodge the lock ring balls.
4. Engage the pinion with the shaft helix and release the pinion. Screw the pinion onto the shaft and ensure
the pinion assembly locking mechanism engages.
5. Support the weight of the drive end shield and rotate the pinion in both directions to ensure freedom of
movement and that the locking mechanism functions correctly. The locking mechanism can be released by
pulling the lock collar back against its spring.
CAUTION
6-17
S9233-C9-MMA-010
NOTE
On oil sealed starters only, use Loctite grade D on the threads when installing the
pinion stop nut.
r. Mount the armature in an armature clamping device or a vise with protected jaws. Reassemble spring (86)
and thrust washer (87) on the pinion shaft Screw a new stop nut (88) on the shaft in the opposite direction
of starter motor rotation. Torque the stop nut securely 40 to 50 lb-ft.
s. Reassemble armature (85) and the drive end shield assembly (7) to housing using a new sealing ring (84) and
ensuring the dowel (81) in the housing end locates in the commutator end shield slot.
t. Ensure shim washer(s) (67) have all been removed from the armature shaft and reassemble commutator end
shield (73). Reinstall two thru-bolts (69), lock washers (70), and torque securely 7 to 7-1/2 lb-ft.
WARNING
u. Replace retaining pad (58) and internal retaining ring (66); do not install the shim washer(s).
v. Adjust the armature end play according to the following steps. Refer to table 6-1 to determine the correct
gauge (5693-222, 5693-222A, or 5693-222B) to be used according to the required mounting flange dimen-
sion.
1. Bolt the appropriate gauge on the starter motor mounting flange with the arm marked CHECK toward the
pinion (figure 6-7); push the armature toward the drive end of the motor until the pinion face just touches
the gauge. With the armature held in this position and using standard feeler gauges, measure gap X
between the thrust washer and the commutator end shield. Shim washers having a total thickness equal to
the measurement should then be fitted between the thrust washer and the retaining ring. Ensure the shim
washers are well greased before use.
6-18
S9233-C9-MMA-010
NOTE
Example: If gap X is now 0.120 inch, shim washers having a total thickness of
0.020 to 0.040 inch should be fitted (i.e., four shims, each 0.008 inch thick).
These shims must be well greased before use.
2. Push the armature toward the commutator end of the motor (figure 6-8) and again measure gap X. The
gap should now be within the limits of 0.079 inch, + 0.020 inch, - 0.00 inch. If the gap is beyond this
limit, remove the commutator end shield (73) and reinstall the shim washers (67) on the armature shaft to
the value of the excess.
WARNING
NOTE
If a screwed end cap is installed in place of a bayonet type, the starter must be
held vertically (commutator end up) and the thrust pad attached to the cap with
grease. The cap must be torqued 7 to 10 lb-ft and the two thin corners of the
hexagon locked to slots in the bearing collar with a punch.
4. Apply grease to steel ball (59) and spring (60); refer to table 6-3. Insert spring, then the steel ball in the
armature shaft bore. Replace end cap (57) turning it in the direction of starter motor rotation to lock it in
place.
5. Ensure that any variation in the relationship of the pinion position to the check gauge is within the limits
of 0.076 inch, + 0.003 inch, - 0.002 inch. Correct, as required, by varying the shim washer amounts.
w. Fill the reservoir in the drive end shield with oil (table 6-4) and insert spring (2). Replace core plug (1) using
tool number 5693-300.
6-19
S9233-C9-MMA-010
x. Connect the field windings and the free end of the resistor to the solenoid switch lugs with screws (30) and
washers (23).
y. Install brush kit (72) and trigger and springs (38). Connect the brush leads and the field winding leads to the
brush gear. Ensure the brush leads allow free movement of the brushes in the holders.
6-9.5 TESTING.
6-9.5.1 Solenoid Engagement Mechanism. Test the solenoid engagement mechanism’s operation according to
the following steps.
WARNING
a. With all electrical sources disconnected, pull the pinion forward by hand approximately 5/8 inch and release.
The pinion should return to its original position.
NOTE
The batteries should be fully charged and in good condition before performing
any starter motor performance tests.
b. Connect the battery solenoid terminal S and solenoid terminal R. With the solenoid energized, the pinion
should move forward approximately 1.25 inch.
c. With the solenoid still energized, pull the pinion forward by rotating it opposite to normal rotation. The 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 sharp
movement.
e. Check the recoil spring action by applying a compression spring balance to the driving end of the armature
shaft. The force required before backward movement of the shaft occurs should be 30 to 38 lbs.
6-20
S9233-C9-MMA-010
a. Prior to performing any starter performance tests, ensure the brushes are thoroughly bedded on the commuta-
tor. Refer to paragraph 6-9.3, step o.
CAUTION
6-21
S9233-C9-MMA-010
a. Check the continuity between B+ and ST terminals and the insulation to frame of all terminals (figure 6-10).
b. Check relay contact gaps for 0.045 to 0.050 inch. When closed, the core gap should be 0.015 to 0.020 inch.
c. Connect a 1000-ohm, 5-watt variable-resistance and milliammeter in series with a 24-Vdc battery and the
relay winding, B+ to 5W + terminal, B- to junction of capacitor positive and the black relay winding start
lead. Increase the variable resistance and set the relay by adjusting the armature spring tension so the contacts
open between 32 and 34 milliamperes.
d. Connect a voltage source not exceeding 20 volts to terminals SW+ and E; observe that the relay momentarily
closes. Failure to close indicates a faulty capacitor, loose or broken connections, or an excessive core gap set-
ting.
e. Connect a 24-volt lamp and battery in series with the relay contacts, SW+ and SOL terminals. Press armature
to coil to close contacts and observe if lamp lights. Failure to light indicates dirty contacts or loose or broken
connections.
6-9.6 REINSTALLATION. Reinstall the starting motor in reverse order of removal, refer to paragraph 6-9.1.
Ensure the commutator cover (55), Phillips head screw (54) is at the bottom when the starter motor is mounted
on the engine. This is important, as fuel and water may enter the motor if the commutator cover is not correctly
positioned. Torque hex head cap screws (26) to 32 lb-ft.
6-10. GAUGES.
Remove/reinstall the gauges according to the following steps. Unless otherwise noted, refer to figure 7-6.
6-22
S9233-C9-MMA-010
6-11.1 REMOVAL. Remove the air cleaner/silencer according to the following steps. Unless otherwise noted,
callouts refer to figure 7-7.
6-11.2 REINSTALLATION. Reinstall the air cleaner/ silencer according to the following steps. Unless other-
wise noted, callouts refer to figure 7-7.
6-12. ALTERNATOR.
6-12.1 REMOVAL. Remove the alternator according to the following steps. Unless otherwise noted, callouts
refer to figure 7-3.
6-23
S9233-C9-MMA-010
a. Loosen and remove cap screws (2, figure 7-1) and belt guard (1, figure 7-1) from the engine.
WARNING
To prevent serious hand injury while removing/installing the drive belt, keep
hands out of the path of the spring-loaded belt tensioner.
b. Using a 1/2-inch square drive ratchet handle, release V-belt (11) million and remove the V-belt.
c. Tag and disconnect all electrical wires to the alternator.
d. Loosen and remove the hex head cap screw (2) that is bolted to the water inlet connection (figure 7-16).
e. Loosen and remove hex head cap screw (3) while supporting the alternator by hand. Lower and remove 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 to paragraph 6-12.1. Torque alternator brace cap screws (2) to 32 lb-ft and alternator mounting cap screw
(3) to 32 lb-ft.
6-13.1 REMOVAL. Remove the drive belt and belt tensioner according to the following steps. Unless other-
wise noted, callouts refer to figure 7-3.
a. Loosen and remove hex flange head screw (2, figure 7-1) and belt guard (1, figure 7-1) from the engine.
WARNING
To prevent serious hand injury while removing/installing the drive belt, keep
hands out of the path of the spring-loaded belt tensioner.
b. Using a 1/2-inch square drive ratchet handle, release V-belt (11) tension and remove the V-belt.
c. Loosen and remove hex head cap screw (8) and belt tensioner (9).
d. Loosen and remove two flat head screws (7) and belt tensioner bracket (10).
e. Loosen and remove four hex head cap screws (1, figure 7-12) and vibration damper (2 and 3, figure 7-12)
from the crankshaft
f. Clean and inspect parts according to paragraph 6-7.1 and paragraph 6-7.2.
6-24
S9233-C9-MMA-010
6-13.2 REINSTALLATION. Reinstall the drive belt and belt tensioner according to the following steps. Unless
otherwise noted, callouts refer to figure 7-3.
NOTE
a. Reinstall belt tensioner (9) and hex head cap screw (8).
b. Reinstall V-belt (11).
c. Prior to reinstalling belt guard (1, figure 7-1), check V-belt tension. Measure the belt deflection using the
thumb and pressing m the belt at the longest span of the belt.
d. Torque belt tensioner hex head cap screw (8) to 32 lb-ft, the vibration damper cap screw (1, figure 7-12) to
92 lb-ft.
e. Reinstall the remaining pans and belt guard in the reverse order of removal. Refer to paragraph 6-13.1.
6-14.1 REMOVAL. Remove the fresh water pump according to the following steps. Unless otherwise noted,
callouts refer to figure 7-10.
a. Remove filler cap (19, figure 7-15) from the expansion tank and pipe plug (5, figure 7-15) from water trans-
fer tube (6, figure 7-15). Drain the coolant into a suitable drain pan. Reinstall the pipe plug upon completion
of drainage.
b. Refer to paragraph 6-13.1 and remove drive belt (11, figure 7-3).
c. Loosen and remove two hex head cap screws (3).
d. Remove fresh water pump (1) and rectangular ring seal (2). Discard the rectangular ring seal.
NOTE
6-14.2 REINSTALLATION. Reinstall the fresh water pump according to the following steps. Unless otherwise
noted, callouts refer to figure 7-10.
6-25
S9233-C9-MMA-010
f. If required, refill the coolant system with a 50-percent mixture of fresh water and ethylene glycol-based anti-
freeze.
6-15. THERMOSTAT.
Replace the thermostat according to the following steps. Unless otherwise noted, callouts refer to figure 7-11.
a. Remove filler cap (19, figure 7-15) from the expansion tank and pipe plug (5, figure 7-15) from fresh water
transfer tube (6, figure 7-15). Drain the coolant into a suitable drain pan. Reinstall the pipe plug and tighten
upon completion of drainage.
b. Loosen and remove hex flange head screw and belt guard (2 and 1, figure 7-1) from the engine.
c. Using a 1/2-inch square drive, lift belt tensioner (9, figure 7-3) and remove drive belt (11, figure 7-3) from the
alternator pulley.
d. Loosen lower hose clamp (16, figure 7-18) and disconnect thermostat housing upper plain hose (17, figure
7-18).
e. Loosen alternator brace (1, figure 7-3), hex head cap screw (2, figure 7-3), and alternator mounting hex head
cap screw (4, figure 7-3). Lower the alternator to gain access to the thermostat housing.
f. Remove cap screws (1 and 2), lifting bracket (6), thermostat housing (3), thermostat (4), and gasket (5). Dis-
card the gasket.
g. Clean and inspect parts according to paragraph 6-7.1 and paragraph 6-7.2.
h. Install a new thermostat into the housing. Ensure the jiggle pin is in its notch and the tang on the thermostat
is in the notch on the thermostat housing. See figure 6-11.
6-26
S9233-C9-MMA-010
k. Reinstall all other components in the reverse order of removal. Torque the front cover cap screws to 18 lb-ft.
l. Refill the coolant system with a 50-percent mixture of fresh water and ethylene glycol-based antifreeze.
6-16.1 REMOVAL. Remove the sea water pump according to the following steps. Unless otherwise noted,
callouts refer to figure 7-14.
NOTE
If repairs are being made with the engine in the craft, ensure the sea water 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 hose
connection and lower hose clamp (6) at sea water pump (4) discharge hose. Loosen suction hose to allow sea
water drainage.
b. Disconnect suction and discharge hose from the sea water pump.
c. Loosen and remove pump flange mounting hex head cap screws (3).
d. Remove the sea water pump and flange assembly with gasket (5). Discard the gasket.
e. Place sea water pump and flange assembly on a clean work bench.
6-16.2 DISASSEMBLY. Disassemble the sea water pump according to the following steps. Unless otherwise
noted, refer to figure 7-14.
NOTE
The sea water pump and flange assembly consists of the sea water pump, which
is attached to the flange by two hex head cap screws, with the pump’s drive gear
on the pump’s shaft.
a. Pull pump drive gear from pump shaft with a T-bar puller and two M8 x 1.25 hex head cap screws.
b. Using a 9/16-inch open-end wrench, loosen and remove two hex head cap screws and remove the sea water
pump from the mounting flange.
c. Remove and discard the pump to flange sealing ring.
d. Loosen and remove three impeller housing mounting cap screws.
NOTE
6-27
S9233-C9-MMA-010
WARNING
6-16.3 REASSEMBLY. Reassemble the sea water pump according to the following steps.
WARNING
6-28
S9233-C9-MMA-010
WARNING
CAUTION
WARNING
To prevent injury, exercise extreme care and wear insulated gloves when
handling heated components. Heated metal pans can cause serious burns.
n. Heat the drive gear in a 400°F oven for 30 minutes.
o. Lubricate the pump shaft.
p. Support the impeller end of the shaft and install the drive gear flush with the end of the shaft. Ensure the gear
is installed with the lip up.
q. Reinstall the key on the shaft
r. Install a new gasket and spacer plate on the body.
s. Install a new O-ring in the housing. Use a small amount of general purpose grease to hold the O-ring in place.
NOTE
6-16.4 REINSTALLATION. Reinstall the sea water pump according to the following steps. Unless otherwise
noted, callouts refer to figure 7-14.
6-29
S9233-C9-MMA-010
a. Reinstall the pump assembly (4) and gasket (5) on the engine using hex head cap screws (3). Torque the hex
head cap screws to 57 lb-ft.
b. Reconnect the water connections and tighten band clamps (6) securely.
6-17.1 REMOVAL. Remove the heat exchanger according to the following steps. Unless otherwise noted, call-
outs refer to figure 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 the
water transfer tube hand-tight.
b. Remove drain plug on the marine transmission oil cooler and drain sea water from system.
c. Loosen the sea water inlet and outlet hose clamps at the heat exchanger sea water hoses.
d. Loosen upper hose clamp (7) and front lower hose clamp (7), and remove water transfer tube (6) from the
heat exchanger and fresh water pump outlet to the heat exchanger. Place the water transfer tube on wood 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 the
engine.
h. Support the heat exchanger while loosening and removing cap screws (21), retaining clamps (22), heat
exchanger (1), vibration isolators (2), and heat exchanger brackets (3) from the engine block.
i. Bag and tag the forward and after heat exchanger mounting components separately.
j. Rest the heat exchanger on wooden surface.
6-17.2 DISASSEMBLY. Disassemble the heat exchanger according to the following steps. Unless otherwise
noted, callouts refer to figure 7-15.
a. Loosen hose clamps (7) and remove plain hoses (4) from water transfer tube (6).
b. Bag and tag hose clamps (7) and plain hoses (4) as to relative position of removal, upper or lower.
c. Loosen hose clamps (16) and remove plain hose (20 and 14). Bag and tag the hose clamps and hoses to the
relative position of removal.
d. Loosen and remove zinc plug (8).
NOTE
Both ends of the heat exchanger are fitted with a removable end cover.
e. Loosen and remove cap screw (12), fiber washer (11), end cover (10), and gasket (9).
f. Remove drain cock (17) from expansion tank (18).
6-30
S9233-C9-MMA-010
NOTE
h. Clean and inspect parts according to paragraph 6-7.1 and paragraph 6-7.2.
6-31
S9233-C9-MMA-010
6-18.1 REMOVAL. Remove the marine transmission oil cooler according to the following steps. Unless other-
wise noted, callouts refer to figure 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 the
elbows and hose ends.
c. Clean up wasted oil. Discard rags or paper towels in accordance with PMS instructions.
d. Loosen and remove sea water drain plug and drain sea water from the cooler.
1. Loosen the cooler’s sea water supply and discharge hose clamps (3).
2. Disconnect supply and discharge elbow hoses (4 and 10) from the cooler.
3. While holding up on U-bolts (5), loosen and remove hex nuts (8). Remove the U-bolts and noise isolator
(6).
4. Remove the cooler (2).
e. Loosen and remove two cap screws (7) and remove oil cooler bracket (9).
NOTE
f. Use a 3/16-inch diameter brass rod to clean out any build-up in the sea water inside the cooler tubes. See
figure 6-14.
6-32
S9233-C9-MMA-010
NOTE
When back flushing the cooler, apply water pressure from the cooler discharge
side.
g. Flush all debris from the cooler with clean pressurized water. See figure 6-15.
h. Clean and inspect pans according to paragraph 6-7.1 and paragraph 6-7.2.
6-18.2 REINSTALLATION. Reinstall the marine transmission oil cooler in the reverse order of removal; refer
to paragraph 6-18.1. Apply liquid Teflon sealant to the threads of male adapter elbows (1) before securing the
supply and discharge oil hoses to the cooler.
6-33
S9233-C9-MMA-010
6-21.1 REMOVAL. Remove the fuel lift pump according to the following steps. Unless otherwise noted, call-
outs refer to figure 7-24.
6-21.2 REINSTALLATION. Reinstall the fuel transfer pump in the reverse order of removal; refer to paragraph
6-21.1. Use new sealing washers (1) and cover plate gasket (6).
6-22.1 REMOVAL. Remove the fuel piping according to the following steps. Unless otherwise noted, callouts
refer to figure 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.
6-34
S9233-C9-MMA-010
CAUTION
To prevent the fuel injection pump delivery valve holder from turning, use
two wrenches.
c. Using two wrenches, loosen and remove high-pressure fuel lines (16, 17, 18, 20, 21. and 22) from the fuel
injection pump.
d. Loosen and remove cap screws (4), plain washer (3), tube brace (2), and vibration isolators from the high-
pressure fuel lines.
6-22.2 REINSTALLATION. Reinstall the fuel piping in the reverse order of removal; refer to paragraph 6-22.1
Torque to 18 lb-ft.
6-23.1 FUEL FILTER. Replace the fuel filter according to the following steps. Unless otherwise noted, call-
outs refer to figure 7-26.
a. Using a strap wrench, remove the fuel filter element complete with Brings (2). Discard the element and O-ring.
NOTE
Unless the engine is to be immediately placed in service, do not fill the 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 and
turn 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 following
steps. Unless otherwise noted, callouts refer to figure 7-42.
NOTE
Use a suitable container to catch any fuel/water drained from the fuel/separator
bowl.
a. Loosen the separator vent plug (2) mid open the separator bowl drain knob (7) to drain all fuel/water from the
separator bowl. Close both after draining.
b. Disconnect the water level sending probe wiring and remove the element (4) with the bowl (6) connected.
c. Remove the bowl; discard the element and O-ring (5).
d. Clean the bowl and O-ring gland; lubricate a new O-ring (5) with fresh, clean diesel fuel and insert it in the
bowl O-ring gland.
e. Spin the bowl (6) onto a new element (4). Do not overtighten.
6-35
S9233-C9-MMA-010
f. Lubricate the element gasket with fresh, clean engine oil; fill the bowl/element assembly with fresh, clean die-
sel fuel.
g. Spin the bowl/element assembly onto the head. Do not overtighten.
h. Reconnect the water level sending probe wiring.
6-24.1 REMOVAL. Remove the fuel drain manifold according to the following steps. Unless otherwise noted,
callouts refer to figure 7-25.
6-24.2 REINSTALLATION. Reinstall the fuel drain manifold in the reverse order of removal; refer to
paragraph 6-24.1. Use liquid Teflon sealant on the fuel manifold and fuel drain tube end fittings. Use new banjo
seal connectors (12) and torque the banjo connector screws (13) to 18 lb-ft.
6-25.1 REMOVAL. Remove the fuel injection nozzles according to the following steps. Unless otherwise
noted, callouts refer to figure 7-25.
CAUTION
To prevent serious damage to the injection nozzle, ensure the interior of the
socket does not come in contact with the fuel drain outlet sealing surface.
f. Using a deep-well 24-mm socket, loosen and remove the fuel injection nozzle. Tag each fuel injection nozzle
with the cylinder number from which it was removed.
g. Place the fuel injection nozzle(s) on a clean working surface.
6-36
S9233-C9-MMA-010
6-25.2 DISASSEMBLY. Disassemble the fuel injection nozzles according to the following steps. Unless other-
wise noted, callouts refer to figure 7-27.
CAUTION
CAUTION
To prevent damage to the injection nozzle and needle valve, place parts in a
suitable bath of clean fuel oil.
NOTE
Hold the needle valve by the stem; skin oils will corrode the finely lapped sur-
faces. Also, the needle valve and nozzle tip are matched to fit and should not be
intermixed.
c. Remove nozzle needle valve (8), nozzle (7), and intermediate disc (9). Place the needle valve and nozzle in
a bath of clean fuel oil.
d. Remove the nozzle holder from the vise, then remove pressure spindle (4), compression spring (3), and shims
(2).
e. Clean and inspect parts according to paragraph 6-25.3.
6-25.3 CLEANING AND INSPECTION. 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 nozzle
side of the nozzle body. Edge filters are not removable.
NOTE
Never use emery paper or any other metal scraper to clean the nozzle.
b. Clean the nozzle seat with the scraper and polish needle valve (8) seat with a piece of hardwood dipped in
test oil.
6-37
S9233-C9-MMA-010
c. Clean the interior of the nozzle ring groove with the scraper. Rinse in an approved solvent to remove all dirt
and carbon residue and dip in clean test oil. Refer to paragraph 6-7.1.
d. Clean the spray holes in the injection nozzles with an appropriate size cleaning needle. Remove burned on
deposits with an approved solvent and rinse in test oil.
e. Clean the needle valve tip with a brass brush. Inspect for rough surfaces Or erosion. The pressure shoulder
will normally have a rough machined appearance. Deteriorated needle valves must be replaced.
f. Dip the needle valve in clean test oil and insert the needle valve all the way into the nozzle body. Now pull
the needle valve one-third of the way out of the nozzle body. The needle valve must slide all the way back
into the nozzle body under its own weight. If the nozzle fails the slide test, re-clean and re-test. Any nozzle
body and needle valve that cannot pass this test must be replaced.
g. Clean the nozzle bore with a bore brush.
6-25.4 REASSEMBLY. Reassemble the fuel injection nozzles according to the following steps. Unless other-
wise noted, callouts refer to figure 7-27.
NOTE
Prior to reassembly, ensure all mating surfaces and pressure faces are absolutely
clean and lubricated with fuel oil.
NOTE
a. Reinstall shims (2). Use compression spring (3) to ensure the shims are installed flat.
CAUTION
NOTE
While handling the valve, hold the needle valve by the stem. The needle valve
and nozzle tip are matched to fit. They must not be intermixed.
d. Reinstall needle valve (8) and nozzle (7).
e. Reinstall nozzle nut (6). Torque the nut to 22 lb-ft.
6-25.5 FUEL INJECTION NOZZLE TEST. Test the fuel injection nozzles according to the following steps.
6-38
S9233-C9-MMA-010
WARNING
Fuel spray from an injection nozzle can penetrate the skin and cause serious
injury. Use the proper equipment and keep hands clear when testing the
nozzles.
NOTE
All injection nozzles must be tested for opening pressure, chatter, and spray pat-
tern.
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).
6-39
S9233-C9-MMA-010
NOTE
A used injection nozzle should not be evaluated for chatter at lower speeds. A
used nozzle can generally be placed in service if it passes the leakage test, 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 atomize
the fuel. You should hear the valve open and should observe a well atomized spray pattern.
6-25.6 REINSTALLATION. Reinstall the fuel injection nozzles according to the following steps. Unless oth-
erwise noted, callouts refer to figure 7-27.
a. Apply a coat of antiseize compound to the threads of the fuel injection nozzle nozzle hold-down nut and
between the top of the nut and fuel injection nozzle nozzle body.
b. Install new copper washer (5) on nozzle (7).
c. Reinstall the fuel nozzle. Ensure the protrusion on the side of the nozzle fits into a notch in the head to 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 fuel
injection nozzle nut (6) to 44 lb-ft.
6-25.7 BLEEDING THE FUEL SYSTEM. Bleed the fuel system according to the following procedure. Unless
otherwise noted, callouts refer to figure 7-25.
NOTE
Manual bleeding of the fuel system is required if the fuel filter is not filled prior
to installation and if fuel injection pump is replaced.
6-40
S9233-C9-MMA-010
Control venting is provided at the fuel injection pump through the fuel drain
manifold. Small amounts of air introduced while changing the fuel oil filter/fuel
6-41
S9233-C9-MMA-010
injection pump supply line will be automatically vented if the fuel oil filter is
changed in accordance with the instructions.
b. Vent the fuel injection pump at the bleed screw (figure 6-20) as follows.
NOTE
The fuel injection pump can be vented both manually and through the use of the
starting motor.
NOTE
4. Ensure the throttle is in neutral and move the start switch to the START position.
5. Vent the fuel injection pump through the fuel drain manifold (5, figure 7-25) while operating the starting
motor (figure 6-21).
6-42
S9233-C9-MMA-010
Figure 6-21. Venting Fuel Injection Pump through Fuel Drain Manifold
NOTE
WARNING
Fuel spray from an injection nozzle can penetrate the skin and cause serious
injury. Use the proper equipment and keep hands clear when testing the
nozzle.
4. Crank the engine to allow air to bleed from the high-pressure fuel tubes (figure 6-22). Torque the high-
pressure fuel tube fittings at the nozzle.
6-43
S9233-C9-MMA-010
WARNING
Do not bleed a hot engine. This action could cause fuel to spill onto a hot
exhaust manifold thereby creating a danger from fire.
5. Refer to the engine technical manual and place the throttle in idle and start the engine. With the engine
running, vent one high-pressure tube at a time until the engine runs smoothly (figure 6-23).
6-26.1 REMOVAL. Remove the fuel injection pump according to the following steps. Unless otherwise noted,
refer to figure 6-24.
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; remove
the fuel pump brace.
g. Remove access cover and seal (17 and 18, figure 7-13).
h. Remove the fuel pump drive gear mount nut and lock washer.
6-44
S9233-C9-MMA-010
CAUTION
i. Using a socket and pull bar on the alternator pulley retaining nut while pushing in on the top dead center
(TDC) pin, turn the engine over to locate TDC for the number 1 cylinder (figure 6-25). Disengage the pin
after locating TDC.
j. Loosen the fuel pump lock screw (figure 6-26); position the special washer as shown, then tighten the lock
screw against the pump shaft. Torque the lock screw to 5 lb-ft.
k. Using a 75-mm T-bar type gear puller (figure 6-27), remove the fuel pump drive gear from the fuel pump
shaft.
6-45
S9233-C9-MMA-010
6-46
S9233-C9-MMA-010
NOTE
CAUTION
6-26.2 DISASSEMBLY. Disassemble the fuel injection pump according to the following steps. Unless other-
wise noted, callouts refer to figure 7-28.
a. Place the pump on its side with inspection cover plate (19) upwards.
b. Remove lead seal (15), hex head screws (17), and washers (18).
c. Remove nameplate (16), cover plate (19), and gasket (24). Discard the gasket and drain the oil into a 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 to
complete repairs. The throttle is indexed to the lever. Note the location of index
marks prior to disassembly.
f. If necessary, remove lever break back assembly (79) by removing self-locking nut (78), spring (77), washer
(76), and spring guide (75).
g. Remove lead seals and locking wire from cap nuts (80). Unscrew and remove the cap nuts, washers (81),
vent screw (70), and washer (71).
NOTE
The throttle shaft must be pressed through the cover and remain with the pump
and connected to the governor spring.
h. Lift off the governor control cover while at the same time lightly pressing down on throttle shaft (89). Dis-
card gasket (86).
i. Unhook and remove spring (91).
j. Remove idling spring (96) and spring guide (97).
6-47
S9233-C9-MMA-010
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).
6-48
S9233-C9-MMA-010
v. Remove screws (64); detach clamping plate (63) and end plate (62). Remove screws (12) and bracket (13)
from the hydraulic head.
w. Remove sleeve and piston (7), spring (5), filter (4), piston (6), and spring (9), and guide spring (10).
x. Remove transfer pump sealing ring (58) and transfer pump blades (61). Note the position of the slot in the
transfer pump liner (59), i.e., 3 or 9 o’clock when viewed from the transfer rotor end, then remove transfer
pump liner.
y. Hold the drive hub with a wrench and loosen the transfer pump rotor with tool number 7044-889 (figure
6-29). The direction in which the transfer pump rotor is loosened is indicated by an arrow marked on the
face of the rotor. Unmarked rotors are loosened in the direction of pump rotation. Remove tools, then 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 rotor
assembly (57) with a slight twisting motion in each direction. Remove and discard sealing ring (22).
aa. Place the head and rotor assembly on a clean work bench. Hold the drive plate with tool number 7144-744
and loosen the drive plate screws with tool number 7144-511A (figure 6-30).
bb. Remove the transfer pump rotor (60). Position the hydraulic head on a bench with the drive plate uppermost.
Remove the drive plate screws, drive plate, top adjusting plate (56), and shoes and roller assemblies (23).
Immerse the shoes and roller assemblies in clean test oil.
cc. Fit corks into the transverse rotor slots to retain the plungers (figure 6-31).
6-49
S9233-C9-MMA-010
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.
6-50
S9233-C9-MMA-010
WARNING
6-26.3 REASSEMBLY. Reassemble the fuel injection pump according to the following steps. Unless otherwise
noted, callouts refer to figure 7-28.
a. Immerse the two new replacement oil seals (45) in clean test oil. The oil seals must be inserted in the same
position noted prior to disassembly. Use tool number 7244-154. Install inner oil seal (45). Next, reassemble
housing retaining ring (46) with its open end adjacent to tell-tale holes where provided, then install outer
oil seal (45) using tool number 7244-154.
b. Secure fixture part number 7044-888F in a vise. Secure the pump to the fixture with the pump governor
control machined face upwards.
6-51
S9233-C9-MMA-010
c. Screw the drive shaft nut onto the drive shaft and stand the drive shaft, tapered end down, on a level sur-
face with the governor weight retainer face upwards. Place governor weights (49) into the governor weight
retainer with lips resting against the shaft.
d. Assemble thrust washer (47) and thrust sleeve (50) over drive shaft (48). Press down the thrust sleeve and
install shaft spring ring (51). Unscrew and remove the shaft nut.
e. Install protection cap number 7144-900 over the tapered end of drive shaft. Dip the protection cap in clean
test oil and insert the drive shaft with a rotating action through the oil seals. When the drive shaft is securely
home, remove the protection cap.
f. Install retaining ring (26) against the shoulder in the pump housing bore, positioning the square ear of the
retaining ring centrally in the housing inspection cover opening.
g. Install cam ring (25) against the retaining ring with the arrow facing the open end of the pump and in the
same direction as the arrow on the pump nameplate (16).
h. Invert the fixture in vise and screw hex head screw (52) into the cam ring. Torque to the correct value using
tool number 7144-14. Remove the tool and lightly tap the cam advance screw to ensure the cam ring is not
binding in the pump body.
NOTE
If the distributor head rotor screw has been removed or is loose, a new screw and
washer must be installed.
i. Unscrew and remove transfer pump rotor (60). Detach the distributor rotor from hydraulic head (57). Screw
the two drive plate screws fully home into the distributor rotor. Position the rotor so the heads of the screws
are gripped lightly by the jaws of a vise. Thoroughly de-grease the threads of the rotor and screw and lightly
coat the threads of the screw with Araldite. Insert the screw and, using tool number 7144-220 (figure 6-33),
torque to correct value. Allow Araldite to harden for six hours at room temperature before putting the pump
into service.
j. Position the hydraulic head on a bench with the machined surfaces upward. Position bottom adjusting plate
6-52
S9233-C9-MMA-010
(56) on the hydraulic head with its chamfered edges upward. Insert the distributor rotor and line up the
guide slots on the bottom adjusting plate with the tapered end cutouts on the rotor head.
k. Remove the corks retaining the twin pumping plungers (figure 6-31) in the rotor transverse slots. Insert
roller and shoe assemblies (23) with the ears in the roller shoe guides. The projecting ears on the shoes must
be placed in the eccentric slots of the bottom adjusting plate so the contour of the ears match the contour
of the slots.
l. Reinstall the top adjusting plate (figure 6-34) with its chamfered edges downward and engage the legs of
the plate in the guide slots of the bottom adjusting plate. Locate the two plates so the fuel adjusting slot in
the top plate coincides with the scribed line on the distributor rotor head. Reassemble the drive plate
machined recess downwards and align the slot between letters A and H with the top adjusting plate slot.
Reassemble the drive plate screws and finger-tighten.
m. Lift head and rotor assembly (57) and screw transfer pump rotor (60) finger-tight into the distributor rotor
body.
NOTE
Relief valve number 7144-155 must be fitted in the fuel line to ensure that the
test pressure of 440 psi (30 atm) is not exceeded. When other test pressures are
stated on test plans, this relief valve can be omitted but care must be taken not
to exceed the specified pressure. Excess pressure can cause damage to shoe
assemblies and adjusting plates.
6-53
S9233-C9-MMA-010
n. Install stirrup pipe tool number 7144-262A (figure 6-35) to two of the high-pressure outlet ports on the head
and connect it to a nozzle testing unit. Operate the nozzle testing unit to raise the pressure to 440 psi (30
atm).
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 must
be set to the correct test specification figure by movement of the adjusting plates.
NOTE
Drive plate screws are tightened using spanner tool 7144-511A and an adapter
fitted in a torque wrench. In use, the torque wrench handle and spanner must
form a straight line with the handle extending away from the spanner. The dis-
tance between the center of the adapter and the center of the ring spanner is 5
inches (127 mm). If the tools used are not kept in a straight line, the applied
torque will be incorrect.
p. Hold the drive plate with tool number 7144-744 and torque the drive plate screws evenly with spanner tool
number 7144-511A to the correct value. Slacken these screws and re-tighten to the same value. It is impor-
tant that this procedure of tightening, slackening, and re-tightening is followed. Tighten screws evenly to
avoid rotor distortion, which can cause sticking plungers.
q. Relieve pressure. Disconnect the nozzle testing outfit and remove the stirrup pipe from the high-pressure
outlets on the head.
r. Install a new housing gasket (107) to the pump housing. Ensure the blank end of the piston is toward the
6-54
S9233-C9-MMA-010
oil feed drilling end of the piston housing. Reassemble the housing and piston assembly (116) to the pump
housing, ensure the cam advance screw engages with the piston and lightly secure it in place with washer
(102) and cap nut (103).
s. Assemble seal (108) to piston plug (101) and install into the housing. Reinstall outer piston spring (109),
seal (108), insert shim washers (110), and piston spring cap (113) into the piston housing.
t. Invert the pump assembly and fixture in vise so the governor housing faces upwards.
u. Install new seal (22) into hydraulic head and rotor assembly (57). Lubricate the portion of the head that fits
into the pump with clean test oil and install the hydraulic head into the pump housing. Insert the head into
position, with a rotating motion, so the splines on the inner end of the drive shaft engage with the splines
in the drive plate. Rotating the head on entry prevents damage to the distributor head seal.
v. Align the metering valve bore with the contour in the machined face of the housing. When the head is in
position, secure with washer (29), screw vent (31), vent screw (30), and washer (29) finger-tightened.
Ensure the screw vent and vent screw are in the same location as noted during disassembly.
w. Invert the fixture in a vise and assemble sealing ring (106) and washer (102) to head locating fitting (105).
Screw in the head location fitting to secure the auto-advance housing to the pump housing. Progressively
and evenly torque cap nut (103) head location fitting, screw vent, and vent screw to the correct values.
Unscrew and remove piston plug (101). Ensure the piston is free, then reassemble and torque the plug to
the correct value. (Refer to table 6-7 for all torque values.)
NOTE
The transfer pump rotor must be tightened in the opposite direction of pump
rotation.
x. Hold the drive hub with a spanner and torque the transfer pump rotor with tool number 7044-889 to the
correct value (figure 6-29).
y. Insert transfer pump liner (59) into the pump housing with the slot in the same position (3 o’clock viewed
from rotor end) it occupied prior to disassembly.
z. Hold the transfer pump liner in position so the slot is located accurately and insert transfer pump blades
(61).
aa. Place spring (9) into end plate (62). Insert the piston (6), then spring (5) into the large diameter end of 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 dowel
on the inner face of the end plate engages in the slot in the transfer pump lines.
dd. Install bracket (13) and screws (12) onto the hydraulic head; torque all screws and the inlet connection to
the correct values.
ee. Reassemble governor arm (94) to the control bracket and reinstall the spring (95). Refer to figure 6-28 and
reassemble the spring linkage components onto the linkage hook as follows: spring retainer (large end first),
long linkage spring, and linkage spring washer. Pass the linkage hook through the correct hole in the 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
6-55
S9233-C9-MMA-010
end of the governor arm on top of the step of the thrust sleeve and at the same time insert the metering
valve into the metering valve bore in the hydraulic head.
gg. Position keep plate (90) on the control bracket so the slotted end faces away from the linkage hook 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 screw
tab 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 and
studs to the correct torque value; refer to table 6-7. Lock all tabs.
hh. Set the link length with a vernier gauge (figure 6-36) so the correct internal dimension [2.10 inch (53.5 mm)
.020 inch (0.5 mm)] is obtained between the larger diameters of the governor control cover stud and the
metering valve lever pin. Adjustment is made by slackening the linkage locking nut and tightening or loos-
ening the linkage nut on the end of the hook linkage. When setting, apply light pressure to the governor
control arm to hold the metering valve in the fully open position. Ensure the vernier gauge is held parallel
to the axis of the pump. After setting, tighten the linkage locking nut.
ii. Position gasket (86) on the governor housing face with the gasket tongues placed in the slots of the 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 control
cover onto the two studs (87). While lowering the governor control cover into position onto the pump
housing, engage the shutoff shaft peg in the crook of the shutoff bar (93).
nn. Reinstall washers (81) and cap nuts (80) and tighten.
6-56
S9233-C9-MMA-010
oo. Reinstall spring guide (75), washer (76), spring (77), and break back lever (79). Secure with self-locking
nut (78).
pp. Reinstall lever (84), lock washer (83), and cap nut (82). Torque all screws and nuts to the correct values;
refer to table 6-7.
qq. Reinstall nameplate (16) if removed, cover plate (19), and gasket (24) to the pump housing and secure with
hex head screws (17) and lock washers (18). Torque hex head screws to the correct torque values.
6-26.4 PRE-TEST.
6-26.4.1 Pressure Test. Pressure test the fuel injection pump according to the following steps.
6-57
S9233-C9-MMA-010
NOTE
All pumps must undergo a pressure test before and after a machine test.
a. Drain all fuel from the pump and connect an air line to the pump inlet connection. Ensure the air supply is
clean and free from water.
b. Seal off the low-pressure outlet connection on the pump and completely immerse pump in a bath of clean test
oil.
c. Raise the air pressure in the pump to 20 lb-in2 (1.41 kg cm2 ). Leave the pump immersed in oil for 10 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 air
pressure to 2 lb-in2 (0.14 kg cm2 ) for 30 seconds. If there is still no leak, increase the pressure to 20 lb-in2
(1.41 kg cm2 ); if the pump is still leak-free after 30 seconds, it can be passed as satisfactory.
e. Repair any and all leaks before testing and setting the pump.
6-26.4.2 Seal Testing. Test the fuel injection pump’s seals according to the following steps.
NOTE
Certain pumps have a single-piece drive shaft with two inward-facing lipped oil
seals. The gap in the retaining ring between the seals lines up with a tell-tale hole
in the pump body. The inner seal, nearest to the governor sleeve, is checked by
the normal pressure test, leakage being indicated at the tell-tale hole.
NOTE
A special tool is used for testing the outer seal. This tool consists of a flanged
cylinder with three fixing studs, an air pressure connection, and a sealing gasket.
a. Attach the tool number 7144-760 to the pump mounting flange and supply filtered air to the connection.
b. Immerse the pump and tool in a bath of clean test oil and apply air pressure at 4 lb-in2 (0.28 kg cm2 ) for 20
seconds. Bubbles at the tell-tale hole normally indicate an oil seal failure, but first ensure that these are not
caused by a faulty gasket.
6-26.4.3 General Testing Procedures. When testing the fuel injection pump, ensure the following precautions
are 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 a
pump with 46-mm spigot.
e. Unless otherwise stated, standard radial high-pressure connections must be fitted prior to testing.
6-58
S9233-C9-MMA-010
f. Prime the pump thoroughly before testing; also at all times indicated in the test plan.
6-26.4.4 Priming. Prior to performing any tests on the fuel injection pump, ensure the pump is primed 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, open
the bleeder valves at the nozzles.
e. Run the pump at 100 rpm. When test oil free of bubbles flows from all high-pressure pipes, re-tighten the
connections or close the bleeder valves.
f. Examine the pump after priming for oil leaks at all jointing faces, connections, and oil seals. The pump must
be free from leaks both when running and when stationary.
6-26.4.5 Pump Output. Fuel delivery is checked at the full throttle setting at one or more speeds of rotation by
measuring the volume passing through each nozzle during 200 pump cycles. The pump test data outlines the
maximum fuel delivery, overall tolerance, and the maximum permissible delivery variation spread between the
nozzles.
6-26.4.6 Shutoff Control. The shutoff control is checked by running the pump at 325 rpm with the shutoff 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 a
specified speed with the throttle and shutoff controls fully open; refer to the injection pump nameplate. If output
is not within the specified limits, adjust according to the following steps.
a. Loosen the screws securing the inspection cover and drain the pump.
b. Remove the inspection cover.
c. Loosen the two drive plate screws.
d. Engage tool number 7144-875 with the slot in the periphery of the adjusting plate.
e. Adjust the plate by lightly tapping the knurled end of the tool. The direction in which the drive plate is turned
to increase or to decrease fueling depends on the type of adjusting plates fitted.
f. Torque the drive plate screws evenly to the correct value using adapter tool number 7144-482, spanner tool
number 7144-511A, and a torque wrench. When using the recommended spanner tool, the distance between
the spanner and the adapter centers is 5 inches (127 mm). The torque spanner and the ring spanner must form
a straight line when tightening the screws and care must be taken to ensure the spanner does not contact the
side of the inspection aperture.
g. Replace and secure the inspection cover, refill the pump, vent as necessary, and re-check the maximum fuel
delivery. Repeat until the volumes are within the specified limits.
6-59
S9233-C9-MMA-010
6-26.4.8 Governor Test. Test the fuel injection pump governor according to the following steps.
NOTE
The final governor setting must be carried out with the pump fitted to the engine
and in accordance with the engine manufacturer’s instructions.
a. Run the pump at more than half the maximum permissible speed of the engine to which it will be fitted and
adjust the maximum speed stop until the specified fuel delivery is obtained. This specified volume is less than
that at the maximum fuel setting.
b. Reduce the speed of rotation, whereupon the fuel delivery should increase to a specified volume approximately
equal to the maximum fuel delivery.
6-26.4.9 Transfer Pump Setting. Check the fuel injection pump’s transfer setting according to the following
steps.
NOTE
Transfer pump vacuum is checked while the pump is running at a low speed,
with the two-way cock in the fuel feed line turned to the position that cuts off
the fuel supply and connects the pump inlet to the vacuum gauge. A given
depression must be obtained in a specified time.
NOTE
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 the
end plate. To adjust the transfer pressure, the operation of the regulating valve can be modified according to the
following steps.
a. On certain pumps with aluminum end plates, the transfer pressure can be adjusted within the limits of an indi-
vidual specification in one or both of two ways: by changing the end plate sleeve plug and by adjustment of
the screw passing through the plug.
b. Several plugs with different step thicknesses are available; the stepped portion in contact with the regulating
spring determining the spring compression. The screwed transfer pressure adjuster limits the movement of the
regulating piston and so controls the maximum uncovered area of the sleeve port. The first method above
modifies transfer pressure characteristics over the lower and middle speed ranges and the second method con-
trols the pressure rise over the upper speed range.
6-60
S9233-C9-MMA-010
NOTE
NOTE
Tools are available for setting the screwed adjuster in the end plate while the
pump is running. If a change of the end plate sleeve plug is necessary to com-
ply with the test plan, the appropriate numbers and the item designation are given
in the parts list.
c. There is a third type of transfer pressure adjuster that varies the pre-loading of the regulating spring and maxi-
mum lift of the piston. It has a spring peg fitted between the adjusting screw and regulating spring. This has
the same effect as the first method, but allows more variation and gives easier adjustment.
a. Install the test pressure gauge to the governor housing vent screw hole. On self-venting pumps, this must allow
the pressure to be read without restricting the permanent bleeding operation. This can be carried out by using
tools from service kit number HF-531.
NOTE
6-26.4.12 Advance Device Test. The appropriate test plan for the individual pump specifies the type of advance
device fitted and details the tests for the particular unit. All advance devices are tested using special tool 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 the
throttle and press inward; release the advance gauge pin a few times with the
pump running at 100 rpm.
a. Remove the small screw from the piston spring cap on the advance device.
b. Pass the threaded bushing of the feeler pin assembly through the hole in the tool bracket.
c. Insert the end of the plunger into the hole in the spring cap and screw the bushing into the spring cap hole.
This will clamp the bracket between the spring cap and the shoulder on the threaded bushing (figure 6-38).
6-61
S9233-C9-MMA-010
NOTE
The tests outlined in the test data must be applied to ensure that the degree of
advance obtained is within the stated limits at the speeds specified.
e. To adjust the degree of advance, increase or decrease the thickness of the shims between the piston spring and
the spring cap.
NOTE
On completion of all tests, the drive shaft screw must be slackened and
re-torqued three times to the correct value.
f. When the tests are satisfactory, remove the special tool and prime the pump.
6-26.4.13 Timing. Time the fuel injection pump according to the following steps.
a. After completion of tests, remove the pump from the test machine and drain by loosening the inspection cover
screws. Remove the inspection cover.
b. For internal or external timing, connect the stirrup pipe tool number 7144-262A to the fuel outlet X and to the
6-62
S9233-C9-MMA-010
outlet directly opposite. Install the relief valve tool number 7144-155 to the stirrup pipe and connect the 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 to
the 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, connect
the stirrup pipe directly to the nozzle testing unit, omitting the relief valve.
c. Turn the pump drive shaft in the direction indicated on the nameplate until resistance to further movement is
felt. This is the timing position.
d. Access to the timing ring may be obtained through the inspection cover. Move the timing ring until the straight
edge of the timing retaining ring aligns with the mark on the drive plate. Retaining ring with two straight ears
are only for spacing; the retaining ring ends are positioned remote from the inspection opening. After carry-
ing out this operation, reinstall the inspection cover and tighten screws securely.
6-26.5.1 Test Conditions. The following figures, for service use only, have been compiled on, and must only
be used on, a test machine conforming to the following ISO 400S standards.
6-63
S9233-C9-MMA-010
g. A .019-inch (0.5-mm) shim is fitted to the piston spring cap on assembly. Do not remove the shim. No 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’s
instructions.
6-64
S9233-C9-MMA-010
6-26.6 REINSTALLATION. Reinstall the fuel injection pump according to the following steps. Unless other-
wise noted, callouts refer to figure 7-28.
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.
6-65
S9233-C9-MMA-010
6-27.1 REMOVAL. Remove the intake manifold cover according to the following steps. Unless otherwise
noted, callouts refer to figure 7-18.
6-27.2 REINSTALLATION. Reinstall the intake manifold cover according to the following steps. Unless oth-
erwise noted, callouts refer to figure 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 gasket
can allow dust and dirt to be ingested into naturally aspirated engines.
a. Replace gasket (22) and position manifold cover (24) in its proper location.
NOTE
The hex head cap screws nearest the valve covers must be coated with liquid
Teflon.
6-66
S9233-C9-MMA-010
b. Apply liquid Teflon on hex head cap screws and reinstall. Torque cap screws to 18 lb-ft.
c. Reinstall the air cleaner/silencer on the model 6B5.9-M engine; refer to paragraph 6-11.2. Then reinstall hose
clamps (1) on the intake piping and air tube (3). Also reinstall hose section (2) and tighten the hose clamps.
d. Reinstall and bleed the high-pressure fuel supply tubes. Refer to paragraph 6-22.2.
e. On the model 6BT5.9-M, test the turbocharger supply air discharge to the intake manifold and flexible hose
connections using a liquid soap solution.
f. Test the intake manifold cover and pipe fittings for air leaks (figure 6-39).
6-28.1 REMOVAL. Remove the turbocharger according to the following steps. Unless otherwise noted, refer
to 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 to paragraph 6-14.1.
d. Loosen upper hose clamp (7) and disconnect hose (8) from the turbocharger. Remove the hose clamp.
NOTE
6-67
S9233-C9-MMA-010
i. Loosen and remove four cap screws (6), the turbocharger, and gasket (9). Discard the gasket.
6-28.2 DISASSEMBLY. Disassemble the turbocharger according to the following steps. Unless otherwise
noted, callouts refer to figure 7-20.
a. Scribe housings (3, 25, and 33) for reassembly in the same position as at disassembly.
CAUTION
c. Loosen V-band nut (4) and remove compressor housing V-band clamp (5). Remove and discard seal (6).
e. Remove impeller lock nut (7). Turn the nut to the right to loosen. The nut and shaft have left-hand threads.
6-68
S9233-C9-MMA-010
NOTE
The wheel and shaft assembly is balanced as a unit. Both must be replaced if
either is damaged.
h. Remove diffuser (9) and rectangular ring seal (10). Discard the O-ring.
i. Remove oil slinger (12) and split ring seal (11). Discard the seal. Check the diffuser for cracks or excessive
wear.
6-69
S9233-C9-MMA-010
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 shaft
are damaged or exhibit excessive wear, the entire assembly must be replaced.
o. Remove turbine shaft and wheel (28) and heat shield (26). Check the turbine blades and shaft for excessive
wear.
p. Remove and discard seal split ring (27).
WARNING
6-28.3 CLEANING AND INSPECTION. Clean and inspect the turbocharger according to the following steps.
a. Using a stiff bristled, nylon brush and solvent, thoroughly clean all parts. Do not use a wire brush to clean the
compressor wheel.
b. Remove carbon build-up from the housing with a scraper and a medium-grit emery cloth.
c. Polish the bearing surfaces with a crocus cloth.
WARNING
6-70
S9233-C9-MMA-010
6-28.4 REASSEMBLY. Reassemble the turbocharger according to the following steps. Unless otherwise noted,
callouts refer to figure 7-20.
a. Install seal split ring (27) and lubricate the groove with engine oil.
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 is
toward the bearing.
f. Lubricate and install the other turbocharger bearing (18) and outer retainer ring (17). Ensure the beveled face
is toward the bearing.
g. Reassemble turbine shaft and wheel (28) and heat shield (26) to bearing housing (25). Rotate the housing as
downward pressure is applied to assist in properly seating seal ring (27). See figure 6-41.
6-71
S9233-C9-MMA-010
All balance marks must be aligned during reassembly to ensure the wheel and
shaft assembly remain balanced.
h. Reinstall the thrust collar. Align the balance marks. Mark the top surfaces to ensure alignment can be veri-
fied after installing the thrust bearing. See figure 6-42.
6-72
S9233-C9-MMA-010
q. Reinstall locknut (7) onto shaft. Do not allow the impeller to turn when installing the nut. The impeller nut
and shaft have left-hand threads. Torque to 120 lb-inch.
t. Apply antiseize compound to the cap screw threads (19 and 24).
u. Reinstall clamping plates (21), lock plates (20), and cap screws (19). Torque cap screws to 100 lb-inch.
v. Reinstall lock plates (23) and cap screws (24). Torque cap screws to 50 lb-inch and bend the lock plate tabs
over the cap screws.
w. Using a dial indicator, measure shaft end play (minimum 0.001 inch, maximum 0.003 inch). See figure 6-43.
x. Using a dial indicator, measure radial clearance of the shaft (minimum 0.012 inch, maximum 0.018 inch). See
figure 6-44.
y. Reinstall compressor housing (3) with rectangular seal ring (6) and V-band clamp (5). Apply antiseize com-
pound to the V-band bolt threads. Torque V-band clamp nut (4) to 120 lb-inch. Tap against the V-band clamp
in four places around its circumference. Torque again to specified value.
6-73
S9233-C9-MMA-010
NOTE
6-74
S9233-C9-MMA-010
m. Reinstall the oil supply line and torque the fitting cap screws securely to 26 lb-ft (figure 6-40).
n. Apply antiseize compound to four cap screws (4, figure 7-19). Position exhaust elbow (figure 7-19) in place
against the turbocharger. Reinstall mounting cap screws (4, figure 7-19) and tighten.
o. Apply liquid Teflon to pipe plug (2, figure 7-19). Reinstall and tighten. Reconnect exhaust piping to exhaust
elbow.
p. Reinstall lower elbow hose clamp and elbow hose (3 and 4, figure 7-19) on the exhaust outlet connection and
tighten.
q. Reinstall upper hose clamp (3, figure 7-19) and reconnect upper elbow hose end to the heat exchanger (1,
figure 7-15) sea water discharge to the exhaust elbow connection.
r. Shut the transmission’s oil cooler (figure 7-17) sea water drain plug.
s. If required, open the sea water inlet valve.
t. If required, refill the engine with fresh water.
6-29.1 DISASSEMBLY. Disassemble the oil pressure regulator valve according to the following steps. Unless
otherwise noted, callouts refer to figure 7-23.
a. Remove plug (8), washer (9), spring (10), and plunger (11).
b. Clean and inspect the plunger and bore for nicks and scratches. Ensure the valve moves freely in the bore.
NOTE
The spring height limit for an open valve is 1.574 inches and 1.77 inches for
assembled valve height.
c. Check the spring height (figure 6-45).
6-75
S9233-C9-MMA-010
6-30.1 REMOVAL. Remove the oil cooler according to the following steps. Unless otherwise noted, callouts
refer to figure 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 to paragraph 6-12.1 and remove the alternator.
d. Drain coolant from the engine; refer to paragraph 6-14.1, procedure step (a).
e. Support water transfer tube (6, figure 7-15) and loosen water transfer tube forward hose clamp (7, figure 7-15).
Loosen water transfer connection (18, figure 7-18) and hose (17, figure 7-18) from the inlet water connection.
f. Disconnect water transfer tube hose (4, figure 7-15) from inlet water connection (1, figure 7-16).
g. Loosen and remove three cap screws (4, figure 7-16) and remove the water inlet connection from the 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 against
the step in the bore.
6-30.2 REINSTALLATION. Reinstall the oil cooler according to the following steps. Unless otherwise noted,
callouts refer to figure 7-23.
a. Install oil cooler gaskets (5 and 7), core (6), and oil filter head (2) using cap screws (12). Torque the cap
screws securely.
b. Lubricate the oil filter oil seal with clean oil and install a new oil filter cartridge (1) by turning the canister
clockwise onto its mounting stud 1/4 turn past gasket contact.
c. Reinstall the turbocharger oil supply fitting and line on the model 6BT5.9-M engine.
d. Install a new ring seal (2, figure 7-16) and reinstall the water inlet connection. Reconnect the water inlet con-
nection.
e. Reinstall the alternator and reconnect the wiring in reverse order of removal. Refer to paragraph 6-12.1.
f. Refill the coolant system and operate the engine to check for leaks.
g. Operate the engine to check for front oil seal leakage.
6-76
S9233-C9-MMA-010
6-31.1.1 Removal. Remove the front crankshaft oil seal (gear cover in place) according to the following steps.
Unless otherwise noted, callouts refer to figure 7-13.
a. Loosen and remove hex head cap screws and belt guard (2 and 1, figure 7-1) from engine.
b. Using a 1/2-inch square drive ratchet handle, release V-belt (11, figure 7-3) tension and remove the V-belt.
c. Loosen and remove four hex head cap screws (1, figure 7-12) and vibration damper (2 and 3, figure 7-12)
from the crankshaft.
d. Drill two, 1/8-inch holes into oil seal (15) casing 180 degrees apart.
e. Using a slide hammer and a number 10 metal screw inserted in the holes, remove oil seal (15).
f. Clean and dry the sealing surface of the oil seal.
6-31.1.2 Reinstallation. Reinstall the front crankshaft oil seal (gear cover in place) according to the following
steps. Unless otherwise noted, callouts refer to figure 7-13.
NOTE
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 101
lb-ft.
d. Reinstall the drive belt and front cover. Torque cap screws to 18 lb-ft.
6-31.2.1 Removal. Remove the rear crankshaft oil seal (flywheel housing installed) according to the following
steps. Unless otherwise noted, callouts refer to figure 7-30.
NOTE
Ensure the transmission has been removed from the engine and that the engine
is adequately supported.
b. Loosen and remove eight hex head cap screws (1).
c. Remove flywheel (4, figure 7-29).
6-77
S9233-C9-MMA-010
d. Drill two, 1/8-inch holes in the oil seal casing 180 degrees apart.
e. Using a slide hammer and a number 10 metal screw, remove oil seal (6).
f. Clean and dry the sealing surface.
6-31.2.2 Reinstallation. Reinstall the rear crankshaft oil seal (flywheel housing installed) according to the fol-
lowing steps. Unless otherwise noted, callouts refer to figure 7-30.
NOTE
a. Use the seal starter ring and install the seal over the crankshaft. Use a mild soap solution on the O.D. of the
seal to ease installation.
NOTE
6-32.1 REMOVAL. Remove the cam follower cover according to the following steps. Unless otherwise noted,
callouts refer to figure 7-31.
6-32.2 REINSTALLATION. Reinstall the cam follower cover according to the following steps. Unless other-
wise noted, callouts refer to figure 7-31.
NOTE
a. Pull off the protective cover on the gasket, if so equipped, to expose the adhesive surface.
6-78
S9233-C9-MMA-010
b. Attach cam follower cover gasket (1) to cover (3). Apply gasket sealant to the cylinder block side of the gas-
ket.
c. If a rubber cam follower cover gasket is used, it must be installed with the word FRONT toward the front of
the cover and the word FORWARD on the bottom and pointing toward the front of the cover.
d. Reinstall cam follower cover gasket and breather baffle (2) with mounting hex head cap screws (7) and grom-
met seals (8). When installing the cam follower cover, position the cap screw seals between the fuel drain lines
and cam follower cover. See figure 6-46.
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.
a. Remove special hex head cap screws (1), O-ring seals (2), valve covers (3), and gasket (4). Discard O-ring
seals and gaskets.
6-79
S9233-C9-MMA-010
b. Reinstall in the reverse order of removal. Torque the cap screws to 18 lb-ft.
6-35.1 REMOVAL. Remove the rocker lever assembly according to the following steps. Unless otherwise
noted, callouts refer to figure 7-33.
a. Loosen nuts (5) on the rocker lever and setscrews (9). Back off on the screws until they stop.
b. Remove hex head cap screws (2) from rocker lever support (1).
c. Remove hex head cap screws (3) from the rocker lever supports and remove the support and rocker 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 to figure 7-33.
WARNING
NOTE
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.
6-80
S9233-C9-MMA-010
b. Inspect the rocker levers for cracks and excessive wear in the bore and valve stem contact surface.
c. Measure the rocker lever bore (minimum 0.7480 inch; maximum 0.7500 inch).
d. Inspect the pedestal and shaft for cracks and excessive wear.
e. Measure the shaft diameter (minimum 0.7456 inch; maximum 0.7470 inch).
6-35.4 REASSEMBLY. Reassemble the rocker lever assemblies according to the following steps. Unless oth-
erwise noted, callouts refer to figure 7-33.
a. Reinstall setscrew (9) and nut (5) in rocker levers (4 and 11).
b. Lubricate the rocker lever shaft with clean engine oil.
NOTE
Ensure the intake and exhaust rocker levers are in the correct position as when
removed.
c. Position the levers on the rocker shaft.
d. Reinstall plain washers (8).
WARNING
6-35.5 REINSTALLATION. Reinstall the rocker lever assembly according to the following steps. Unless oth-
erwise noted, callouts refer to figure 7-33.
CAUTION
a. Insert push rods (10) into the engine block push rod bores; ensure the push rods are correctly and securely
seated in valve tappets (6, figure 7-36).
b. Position rocker lever support (1) complete with the valve rocker levers (4 and 11) installed on the engine head
mount pad; position both rocker lever adjustment screws (9) in applicable push rod (10) socket, and ensure
the valve rocker lever contact pad aligns with the stems of valves (7 and 8, figure 7-34).
c. Insert hex head cap screws (2 and 3) through the rocker lever support assembly and tighten securely.
d. Turn the intake valve adjustment screws, as required, to obtain 0.010-inch clearance between the valve rocker
lever contact pads and valve stems; turn the exhaust valve adjustment screws as required to obtain 0.020-inch
6-81
S9233-C9-MMA-010
clearance between the rocker lever pads and the valve stems. Measure the clearance with standard feeler
gauges. Lock adjustment screws by tightening the locking nuts while holding the adjustment screw with a
screwdriver. Refer to paragraph 6-5 for the complete valve adjustment procedure.
6-36.1 REMOVAL. Remove the cylinder head according to the following steps. Unless otherwise noted, call-
outs refer to figure 7-34.
WARNING
To prevent injury or death, ensure extreme care and proper lifting devices
are used during handling. The equipment is heavy.
e. Remove cylinder head (9) and gasket (4) from the cylinder block (figure 7-37).
6-36.2 DISASSEMBLY. Disassemble the cylinder head according to the following steps. Unless otherwise
noted, callouts refer to figure 7-34.
WARNING
To prevent serious eye injury, wear safety eye protection when removing
springs under pressure.
b. Using a valve spring compressor, compress valve springs (11) and remove collets (13).
c. Slowly release the valve spring and remove retainer (12) and spring (11).
d. Remove valves (7 or 8), whichever applies. Keep the valves in a labeled rack.
e. Repeat step b and step c for the remaining collets, retainers, springs, and valves.
f. Remove valve stem seals (14).
6-36.3 CLEANING AND INSPECTION. Clean and inspect the cylinder head according to the following steps.
a. Clean carbon from the injection nozzle seat with a nylon or brass brush.
6-82
S9233-C9-MMA-010
WARNING
6-36.4 VALVE SEAT GRINDING. Grind the valve seats according to the following steps.
NOTE
a. Install the valves (one at a time) without springs, in the designated location.
b. Measure the depth of each valve (minimum 0.039 inch; maximum 0.060 inch).
c. Grind valve seats to remove scores, scratches, and burns. Seat angles are 30 degrees for intake and 45 degrees
for exhaust.
6-83
S9233-C9-MMA-010
d. Install the valves in their respective bores and re-measure valve depth. Record the depth of each valve. 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. Replace
valves if the valve depth is not within specifications.
e. Apply a light coat of lapping compound to each valve. Lap each valve to its respective valve seat.
f. Clean the valve and seat after lapping. Measure the valve seat width (minimum 0.060 inch; maximum 0.080
inch).
g. If required, grind the valve seat with a 60-degree stone then a 15-degree stone to center the seat of the valve
face. Maintain the valve seat width limits (minimum 0.060 inch; maximum 0.080 inch).
6-36.5 REASSEMBLY. Reassemble the cylinder head according to the following steps. Unless otherwise
noted, callouts refer to figure 7-34.
NOTE
WARNING
To prevent serious eye injury, wear safety eye protection when removing
springs under pressure.
c. Using a spring compressor, reinstall and compress valve spring (11) and retainer (12) and reinstall collets (13).
Release the spring tension after reassembly; tap the valve stems to ensure the collets are seated.
6-36.6 REINSTALLATION. Reinstall the cylinder head according to the following steps. Unless otherwise
noted, callouts refer to figure 7-34.
a. If removed, reinstall the two cylinder head dowels. Drive the dowels to the bottom of the dowel bore.
b. Ensure the cylinder head is clean and free of surface imperfections on the gasket surface.
c. Ensure head gasket (4) is correctly aligned with the holes in the block and position the head over the 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).
6-84
S9233-C9-MMA-010
i. Reinstall rocker lever supports (1, figure 7-33). Ensure the supports are aligned with the locating dowels in
the head.
j. Using clean engine oil, lubricate the hex head cap screw threads and under the cap screw heads.
k. Reinstall hex head cap screws (2, figure 7-33) finger-tight.
l. Using clean engine oil, lubricate the hex head cap screw threads and under the cap screw heads.
m. Reinstall hex head cap screws (3, figure 7-33) finger-tight.
n. Using clean engine oil, lubricate the remaining hex head cap screws threads and under the heads.
o. Reinstall hex head cap screws (15 and 16) finger-tight.
p. Torque the cylinder head hex head cap screws (figure 6-47) as follows: 29 lb-ft; 62 lb-ft; 92 lb-ft.
q. Torque pedestal hex head cap screws (2 and 3, figure 7-33) at 18 lb-ft.
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.
6-85
S9233-C9-MMA-010
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.
6-39.1 REMOVAL. Remove the valve tappet (head installed) according to the following steps.
a. Insert wooden dowels of sufficient diameter and length into the push rod tube holes and into the top of each
tappet securely. When properly installed, the dowels can be used to pull the tappets up and should not be able
to be pulled out without considerable force.
NOTE
b. Pull tappets up and wrap a rubber band around the top of the dowel rods (figure 6-48). This will prevent the
tappets from dropping down when the camshaft is removed.
d. Insert a trough made out of plastic half pipe (PVC) to the full length of the cam bore (figure 6-49).
e. Remove the rubber band from two companion tappets. Secure the dowel for the tappet not being removed to
the nearest adjoining dowel.
6-86
S9233-C9-MMA-010
f. Pull the wooden dowel from the tappet bore; allow the tappet to fall into the trough.
g. Ensure the tappet is laying over (figure 6-49) in the trough before the trough is removed. Carefully pull the
trough and tappet from the cam bore and remove the tappet.
6-39.2 CLEANING AND INSPECTION. Clean and inspect the valve tappets according to the following steps.
a. Inspect the socket, stem, and face for pitting, cracks, or excessive wear. If excessive wear is noted on the face
contact surface, replace the tappet.
b. Measure the valve tappet stem diameter (minimum 0.627 inch; maximum 0.629 inch).
6-39.3 REINSTALLATION. Reinstall the valve tappets (head installed) according to the following steps.
a. Insert the plastic trough the full length of the cam bore.
b. Feed the installation tool down the tappet bore and into the plastic trough (figure 6-50).
c. Feed the installation tool through the cam bores by carefully pulling the plastic trough and installation tool
out of the cam bore.
6-87
S9233-C9-MMA-010
To aid in removing the installation tool after the tappet is installed, work the tool
in and out of the tappet several times prior to installation.
f. Slide the trough back into the cam bore.
g. Pull the tool and tappet through the cam bore and up into the tappet bore (figure 6-51). If difficulty is expe-
rienced in getting the tappet to make the bend from the trough up into the tappet bore, due to the webbing of
the block, pull the trough out just enough to allow the tappet to drop down and align itself, then pull the 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.
6-88
S9233-C9-MMA-010
6-40. CAMSHAFT.
6-40.1 REMOVAL. Remove the camshaft according to the following steps. Unless otherwise noted, callouts
refer to figure 7-36.
NOTE
Keep the adjoining gear from moving when checking the camshaft backlash or
the readings will be the total of both gears.
c. Prior to removing camshaft (5), measure the camshaft backlash as follows:
1. Position a dial indicator on a tooth of camshaft gear (1).
2. When checking the backlash, hold the adjoining gear (fuel pump drive) from moving.
3. Record the camshaft gear backlash. Mark the camshaft gear and crankshaft gear for further analysis if the
backlash exceeds limits; gear backlash limit A is 0.003 inch to 0.013 inch. See figure 6-52.
6-40.2 CLEANING AND INSPECTION. Clean and inspect the camshaft according to the following steps.
a. Clean the camshaft and gear with an approved solvent and a clean, lint-free rag.
6-89
S9233-C9-MMA-010
b. Inspect the fuel transfer pump lobe, valve lobes, and bearing journals for cracking, pitting, or scoring.
c. Inspect the gear teeth for pitting and cracks at the root of the teeth.
d. Measure the bearing journals and valve lobes. Lobe diameters at peak: intake (minimum 1.861 inch; 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 otherwise
noted, callouts refer to figure 7-36.
a. Using a hydraulic press, remove gear (1) and key (4) from camshaft (5).
b. Remove any burrs and smooth rough surfaces caused by removing the gear from the camshaft.
c. Reinstall key (4) in the camshaft keyway.
d. Lubricate the camshaft gear surface with Lubriplate 105.
e. Heat the gear in a 250°F oven at for 45 minutes.
WARNING
To prevent injury, exercise extreme care and wear insulated gloves when
handling heated solutions or metal.
f. Reinstall gear (1) onto the camshaft. Ensure the timing marks are facing away from the camshaft and the gear
is seated against the camshaft shoulder.
6-40.4 CAMSHAFT BUSHING. Replace the camshaft bushing according to the following steps. Unless other-
wise noted, callouts refer to figure 7-37.
NOTE
The limit of wear on the number 1 bushing is the same as for the other bores
without bushings.
NOTE
If the bores without the bushing are worn beyond the limit, the cylinder block
must be replaced.
a. Replace the camshaft bushing if it exceeds the wear limit. The limit is 2.1324 inches.
b. Remove camshaft bushing (14) with a bushing remover and hammer.
NOTE
Mark the cylinder block so the oil hole in the block and bushing can be aligned
when the bushing is installed.
6-90
S9233-C9-MMA-010
c. Install new camshaft bushing (14) so it is even with the front face of the cylinder block. Ensure the oil holes
align.
d. Measure the installed camshaft bushing. The limit is minimum 2.1295, maximum 2.1314 inches.
6-40.5 REINSTALLATION. Reinstall the camshaft according to the following steps. Unless otherwise noted,
callouts refer to figure 7-36.
NOTE
The end play is controlled by the thickness of the thrust plate and the groove in
the camshaft.
g. Using a dial indicator, measure the camshaft end play. The end play limits are 0.007 to 0.011 inch.
h. Ensure the gear backlash is correct for any replaced gears. Measure the gear backlash with a dial indicator.
The limits are 0.003 to 0.013 inch.
6-41.1 REMOVAL. Remove the lube oil pump according to the following steps. Unless otherwise noted, call-
outs refer to figure 7-22.
a. Refer to paragraph 6-13.1 and remove the belt guard, drive belt, and vibration damper.
b. Loosen and remove sixteen hex head cap screws (12, figure 7-13). Remove oil seal (15, figure 7-13). Discard
the gear cover gasket and oil seal.
c. Position a dial indicator on a tooth of the oil pump and measure the backlash of the crankshaft and pump
gears. The backlash limits are 0.003 to 0.013 inch. If the limits are exceeded, mark the lube oil pump gear and
idler gear for additional analysis.
NOTE
When checking the backlash, keep the adjoining gear from moving
d. Position the indicator on a tooth of the oil pump idler gear. Record the idler gear backlash. The backlash limit
is 0.003 to 0.013 inch. Mark the idler gear and crankshaft gear for additional analysis if the limits are
exceeded.
e. Remove hex head cap screws (2) and oil pump (1).
6-91
S9233-C9-MMA-010
f. Visually inspect the oil pump gears for chips, cracks, or excessive wear.
6-41.2 DISASSEMBLY. Disassemble the lube oil pump according to the following steps. Unless otherwise
noted, refer to figure 6-53.
WARNING
6-41.3 REASSEMBLY. Reassemble the lube oil pump according to the following steps. Unless otherwise
noted, refer to figure 6-54.
a. Reinstall the gerotor planetary in the oil pump. Ensure the gerotor planetary is installed in its original posi-
tion.
b. Measure the gerotor tip clearance (maximum 0.007 inch). See figure 6-54.
c. Measure the clearance of the gerotor drive to gerotor planetary to port plate (maximum 0.005 inch). See figure
6-55.
d. Measure the clearance of the gerotor planetary to the body bore (maximum 0.015 inch). See figure 6-56.
6-92
S9233-C9-MMA-010
e. Measure the pump gear backlash. The limit for a used pump is 0.003 - 0.015 inch.
6-93
S9233-C9-MMA-010
6-41.4 REINSTALLATION. Reinstall the lube oil pump according to the following steps. Unless otherwise
noted, callouts refer to figure 7-22.
NOTE
Ensure when replacing the pump the correct size pump is used. The six-cylinder
pump gerotor size is 0.715 inch.
b. Install pump (1). Ensure the idler gear pin fits into the locating bore in the cylinder block.
c. Reinstall hex head cap screws (2). Torque hex head cap screws to 18 lb-ft.
d. Install new gear cover gasket and gear cover (19 and 16, figure 7-13) with hex head cap screws (12, figure
7-13).
e. Reinstall new front oil seal (15, figure 7-13). Refer to paragraph 6-32.2.
f. Reinstall the vibration damper, drive belt, and belt guard; refer to paragraph 6-13.2. Torque the belt guard
mounting cap screws to 18 lb-ft. Torque vibration damper cap screws to 101 lb-ft.
6-42.1 REMOVAL. Remove the gear housing according to the following steps. Unless otherwise noted, call-
outs refer to figure 7-13.
a. Refer to paragraph 6-13.1 and remove the belt guard, drive belt, and vibration damper.
6-94
S9233-C9-MMA-010
NOTE
Do not remove the timing pin assembly unless the gear housing is being
replaced.
b. Remove hex head cap screws (12 and 14), belt retainer (13), cover (16), and gasket (19). Discard the gasket
and oil seal (15).
c. Remove hex head cap screws (11 and 12), gear housing (20), and gasket (1). Discard the gasket.
6-42.2 REINSTALLATION. Reinstall the gear housing according to the following steps. Unless otherwise
noted, callouts refer to figure 7-13.
c. Reinstall gear housing (20) and hex head cap screws (11 and 12). Torque the cap screws to 18 lb-ft.
d. Install gasket (19), cover (16), and hex head cap screws (12 and 14) and belt retainer (13). Torque the cap
screws to 18 lb-ft.
f. Reinstall the vibration damper, drive belt, and belt guard. Refer to paragraph 6-13.2.
6-43.1 FLYWHEEL. Remove/reinstall the flywheel according to the following steps. Unless otherwise noted,
callouts refer to figure 7-29.
b. Remove hex head cap screws (1), plain washers (2), and flywheel (4).
e. Reinstall hex head cap screws (1) and plain washers (2). Torque the cap screws, in sequence, to 101 lb-ft
(figure 6-57).
6-95
S9233-C9-MMA-010
WARNING
Wear eye protection when removing the ring gear from the flywheel. Do not
use a steel drift pin.
b. Using a brass drift pin, drive ring gear (3) off the flywheel.
c. Heat the new ring gear in a 260 °F oven for 20 minutes.
WARNING
To prevent injury, exercise extreme care and wear insulated gloves when
handling heated solutions or metal.
NOTE
The ring gear is properly positioned for installation when the bevel on the teeth
is toward the crankshaft side of the flywheel.
d. Position the ring gear and install on the flywheel.
e. Reinstall the flywheel.
6-43.3 FLYWHEEL HOUSING. Remove/reinstall the flywheel housing according to the following steps.
Unless otherwise noted, callouts refer to figure 7-30.
6-96
S9233-C9-MMA-010
6-44.1 REMOVAL. Remove the pistons and connecting rods according to the following steps. Unless other-
wise noted, callouts refer to figure 7-38.
a. Place the engine in a horizontal position with the pistons facing up.
b. Using a ridge reamer, remove the ridge from the top of all cylinders. Remove only enough metal to eliminate
the ridge. Do not gouge the cylinder bore.
c. Metal stamp each correcting rod (1) and rod cap according to the cylinder.
d. Metal stamp each piston (6) according to the cylinder.
NOTE
The rod cap, cap screws, and rod bearing should be kept together with the rod it
was from which it was removed.
e. Reposition the cylinder block until it is vertical to the deck and remove hex head cap screws (3), the rod cap,
and rod bearings (2).
6-97
S9233-C9-MMA-010
CAUTION
To prevent damage to the connecting rod and bearing, avoid the use of metal
objects during removal.
f. Push the rod and piston assembly out of the top of the cylinder bore. Do not drop the assembly.
6-44.2 DISASSEMBLY. Disassemble the pistons and connecting rods according to the following steps. Unless
otherwise noted, callouts refer to figure 7-38.
WARNING
6-44.3 CLEANING AND INSPECTION. Clean and inspect the pistons and connecting rods according to the
following steps.
CAUTION
b. After soaking in parts cleaner, wash the pistons and rods in a strong solution of laundry detergent and hot
water.
CAUTION
c. Clean the remaining deposits from the ring grooves with the square end of a broken ring. Do not use a ring
groove cleaner. Do not scratch the ring sealing surface in the piston groove.
6-98
S9233-C9-MMA-010
WARNING
d. Wash the pistons again in detergent or solvent; rinse and dry with compressed air.
e. Inspect the piston for damage and excessive wear in the areas of the piston top, ring grooves, skirt, and pin
bore.
f. Measure the piston skirt diameter (minimum 4.0088 inches; maximum 4.0117 inches).
g. Using a new piston ring and feeler gauge, measure the clearance in the ring groove top ring: (turbocharged,
use Keystone gauge; N.A.; minimum 0.003 inch; maximum 0.0059 inch); all intermediate rings (minimum
0.003 inch; maximum 0.0059 inch); and all oil control rings (minimum 0.0016 inch; maximum 0.0051 inch).
h. Measure the piston pin bore (minimum 1.5750 inch; maximum 1.5758 inch).
i. Inspect the piston pin for nicks, gouges, and excessive wear. Measure the pin diameter (minimum 1.5744 inch,
maximum 1.5749 inch).
j. Inspect the connecting rod for damage and wear. The I-beam section cannot have dents.
k. Measure the connecting rod pin bore diameter (minimum 1.5769 inch; maximum 1.5784 inch).
6-44.4 MEASURE ROD BEARING CLEARANCE. 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. Record
the smallest diameter.
b. Measure the mean diameter of the rod journal on the crankshaft (minimum 2.7150 inches, maximum 2.7170
inches; maximum out-of-round 0.002 inch; maximum taper 0.0005 inch; bearing clearance 0.0035 inch).
NOTE
The bearing clearance is the rod bearing inside diameter minus the crankshaft
journal diameter.
c. The bearing clearance can also be determined using plastigauge (figure 6-59).
6-99
S9233-C9-MMA-010
a. Align the piston and connecting rod pin bores. Ensure the FRONT marking on the piston and the number on
the connecting rod are properly positioned.
WARNING
6-44.6 CHECKING PISTON RING GAP. Check the piston ring gap according to the following steps.
a. Position each ring, one at a time, in the cylinder where it is being used. Use a piston to square the ring in the
cylinder bore about 3-1/2 inches from the top of the bore.
b. Using a feeler gauge, measure the gap of the ring (turbocharged, top minimum 0.0160; maximum 0.0275;
N.A. top, and all other rings: minimum 0.0100 inch; maximum 0.0215 inch).
6-44.7 PISTON RING INSTALLATION. Install the piston rings according to the following steps.
6-100
S9233-C9-MMA-010
NOTE
a. Position the oil ring expander in the lower oil control ring groove.
b. Install oil control ring (7) over the oil ring expander with the end gap 180 degrees from the ends of the oil
ring expander.
c. Install intermediate middle ring (8).
d. Install top ring (9).
6-44.8 REINSTALLATION. Reinstall the pistons and connecting rods according to the following steps. Unless
otherwise noted, callouts refer to figure 7-38.
a. Rotate the engine on the overhaul stand until the crankshaft is vertical.
b. Install bearing shells (2) into rods (1) and cap. Ensure the tang on the shells is in the slot of the cap and rod.
c. Lubricate the rod bearings with a light film of Lubriplate 105.
d. Lubricate the rings and piston skirts with clean engine oil.
e. Position the ring gaps about 120 degrees from each other.
CAUTION
NOTE
Ensure the four-digit number stamped on the rod and cap at the parting line
match and are installed on the oil cooler side of the engine.
i. Reinstall the piston/rod assembly in the cylinder bore and seat the rod bearing shell on the crankshaft.
j. Reinstall rod cap and hex head cap screws (3) to the connecting rod (1).
k. Alternately torque the hex head cap screws as follows: 26 lb-ft; 51 lb-ft; 73 lb-ft.
l. Measure the side clearance between the connecting rod and crankshaft. The limits are 0.004 inch to 0.012
inch.
m. Check the crankshaft for freedom of rotation as the pistons are installed. If the crankshaft does not rotate
freely, check the installation of the rod bearings and bearing size.
6-101
S9233-C9-MMA-010
6-45. CRANKSHAFT.
6-45.1 REMOVAL. Remove crankshaft according to the following steps. Unless otherwise noted, callouts refer
to 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 the
caps and upper bearing saddles with the correct numbers. Number 1 is the main
cap closest to the vibration damper.
b. Remove main bearing caps (11, figure 7-37). Do not pry on the main bearing caps to free, but use two of the
main cap bolts to wiggle the main cap loose.
WARNING
To prevent injury or death, ensure extreme care and proper lifting devices
are used during handling. The equipment is heavy.
c. Lift crankshaft (2) and gear (1) from the cylinder block.
d. Remove lower main bearings (6) from the caps and upper main bearings (4 and 5) from the bearing saddles
in the block.
e. Using a 3/16-inch pin punch, remove piston cooling nozzles (13, figure 7-37).
f. Reinstall the main caps in their original position so they will not be misplaced.
6-45.2 CLEANING AND INSPECTION. Clean and inspect the crankshaft according to the following steps.
WARNING
a. Clean the crankshaft oil passages with a nylon bore brush. Rinse with a clean solvent and dry with compressed
air.
b. Inspect the crankshaft seal wear surfaces for scratches or grooving.
c. Inspect the rod and main journals for deep scoring and overheating.
NOTE
The main bearing clearance is the main bore diameter with the bearing installed,
minus the crank main journal diameter.
6-102
S9233-C9-MMA-010
d. Measure the main journal diameters and determine the main bearing clearance (minimum 3.2662 inches,
maximum 3.2682 inches; out-of-roundness maximum 0.002 inch; taper maximum 0.0005 inch; bearing clear-
ance maximum 0.00475 inch).
6-45.3 CRANKSHAFT GEAR REPLACEMENT. Replace the crankshaft gear according to the following
steps. Unless otherwise noted, callouts refer to figure 7-39.
a. Using a heavy-duty bearing puller, remove the crankshaft gear. Use a flat nose center stud. Do not use a
pointed center stud; it may damage the threads in the end of the crankshaft.
b. Remove all burrs and ensure the gear surface on the end of the crankshaft is smooth.
c. If removed, reinstall roll pin (3) until it bottoms.
d. Heat the new crankshaft gear (1) for 45 minutes at 250°F. If heated longer, the gear will be permanently dis-
torted.
WARNING
To prevent injury, exercise extreme care and wear insulated gloves when
handling heated solutions or metal.
e. Install the hot gear, timing mark facing out, up to the shoulder on crankshaft (2).
6-45.4 REINSTALLATION. Reinstall the crankshaft according to the following steps. Unless otherwise noted,
callouts refer to figure 7-39.
j. Using clean engine oil, lubricate the main bearing cap screw threads and the underside of the heads.
k. Install hex head cap screws (10, figure 7-37) and torque (figure 6-60) as follows: 44 lb-ft; 88 lb-ft; 129 lb-ft.
6-103
S9233-C9-MMA-010
6-46.1 REMOVAL. Remove the cylinder block components according to the following steps. Unless otherwise
noted, callouts refer to figure 7-37.
6-46.2 CLEANING AND INSPECTION. Clean and inspect the cylinder block (figure 7-37) according to the
following 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. A
correctly de-glazed surface will have a cross-hatched appearance with the lines at 15- to 25-degree angles with
the top of the cylinder block; 30- to 50-degree angles on the cross-hatch. Use a fine grit flexi-hone drill, a
50-50 mixture of diesel fuel, and 30W engine oil to deglaze the bores.
6-104
S9233-C9-MMA-010
WARNING
6-46.3 REINSTALLATION. Reinstall the cylinder block components according to the following steps. Unless
otherwise noted, callouts refer to figure 7-37.
a. Apply a bead of Loctite 277 around the outside diameter of the oil passage expansion plugs (2).
b. Drive the expansion plugs in until they are even with the countersink in the block.
c. Apply a bead of Loctite 277 to the coolant passage expansion plugs (1, 4, and 6).
d. Drive the plugs in until the outer edge is flush with the countersink in the block.
e. Apply a bead of liquid Teflon sealant to pipe plugs (8 and 16). Reinstall the plugs. Refer to table 6-9 for cor-
rect torques.
f. Apply a bead of Loctite 277 around the outside diameter of the camshaft expansion plug (3). Position the plug
with the convex side out. Drive the plug flush with the cylinder block.
g. Reinstall front mounting supports (1 and 3, figure 7-4).
6-105
S9233-C9-MMA-010
e. If further repairs to the diesel engine are not required, replace plug and sealing washer and refill the oil sump
with correct oil. Refer to table 2-3.
f. Reconnect oil heater electrical cord.
6-48. START-UP.
Following engine reinstallation, proceed as follows:
WARNING
To prevent injury or death, ensure extreme care and proper lifting devices
are used during handling. The equipment is heavy.
a. Using a spreader bar and engine lifting device, set the engine on a suitable test stand.
b. Connect the engine to all necessary piping and electrical systems.
c. After the engine is secured in position, follow pre-operational checks listed in chapter 2, paragraph 2-3.1.
Check for proper connection of all systems. Ensure engine operating fluids are at proper levels; refer to table
1-1 or table 1-2, as applicable.
d. Start the engine and run at idle speed for a sufficient time to check for leaks, proper connection of controls,
and for the engine to warm-up to operating temperatures. Ensure the engine is ready for further testing. Com-
plete testing as per PMS instructions.
6-106
S9233-C9-MMA-010
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 Angle
Intake 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 Spring
Free 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 Pump
Tip 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 Motor
Brush 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.
6-107
S9233-C9-MMA-010
6-108
S9233-C9-MMA-010
6-109
S9233-C9-MMA-010
6-110
S9233-C9-MMA-010
CHAPTER 7
7-1. INTRODUCTION.
This chapter contains illustrations and parts lists for the major components used in the diesel engines. Each
illustration has a corresponding table that identifies component parts. Illustration reference numbers cross over to
component parts in the appropriate table which lists the following:
7-1
S9233-C9-MMA-010
7-2
S9233-C9-MMA-010
7-3
S9233-C9-MMA-010
7-4
S9233-C9-MMA-010
7-5
S9233-C9-MMA-010
7-6
S9233-C9-MMA-010
*
Includes relay (R) terminal parts
7-7
S9233-C9-MMA-010
7-8
S9233-C9-MMA-010
7-9
S9233-C9-MMA-010
7-10
S9233-C9-MMA-010
7-11
S9233-C9-MMA-010
7-12
S9233-C9-MMA-010
7-13
S9233-C9-MMA-010
7-14
S9233-C9-MMA-010
7-15
S9233-C9-MMA-010
7-16
S9233-C9-MMA-010
7-17
S9233-C9-MMA-010
7-18
S9233-C9-MMA-010
7-19
S9233-C9-MMA-010
7-20
S9233-C9-MMA-010
7-21
S9233-C9-MMA-010
7-22
S9233-C9-MMA-010
7-23
S9233-C9-MMA-010
7-24
S9233-C9-MMA-010
7-25
S9233-C9-MMA-010
7-26
S9233-C9-MMA-010
7-27
S9233-C9-MMA-010
7-28
S9233-C9-MMA-010
7-29
S9233-C9-MMA-010
7-30
S9233-C9-MMA-010
7-31
S9233-C9-MMA-010
7-32
S9233-C9-MMA-010
7-33
S9233-C9-MMA-010
7-34
S9233-C9-MMA-010
7-35
S9233-C9-MMA-010
7-36
S9233-C9-MMA-010
7-37
S9233-C9-MMA-010
7-38
S9233-C9-MMA-010
7-43
S9233-C9-MMA-010
7-44
S9233-C9-MMA-010
7-45
S9233-C9-MMA-010
7-46
S9233-C9-MMA-010
7-47
S9233-C9-MMA-010
7-48
S9233-C9-MMA-010
7-49
S9233-C9-MMA-010
7-50
S9233-C9-MMA-010
7-51
S9233-C9-MMA-010
7-52
S9233-C9-MMA-010
7-53
S9233-C9-MMA-010
7-54
S9233-C9-MMA-010
7-55
S9233-C9-MMA-010
7-56
S9233-C9-MMA-010
7-57
S9233-C9-MMA-010
7-58
S9233-C9-MMA-010
7-59
S9233-C9-MMA-010
7-60
S9233-C9-MMA-010
7-61
S9233-C9-MMA-010
7-62
S9233-C9-MMA-010
7-63
S9233-C9-MMA-010
7-64
S9233-C9-MMA-010
CHAPTER 8
INSTALLATION
8-1. INTRODUCTION.
This chapter provides installation procedures for the diesel engine.
8-2. INSTALLATION.
Install the diesel engine according to the following steps and the manufacturer’s specifications.
WARNING
To prevent injury or death, ensure extreme care and proper lifting devices
are used during handling. The equipment is heavy.
CAUTION
Prior to installing the engine, ensure that all engine mounts and system
interfaces are rust-free, clean, complete, and in good working order.
CAUTION
When installing the diesel engine, care must be taken to ensure proper
alignment of rotating components.
a. Set engine in place using a spreader bar and engine lifting device.
b. Install the engine using slings capable of supporting the weight of the engine.
c. Install all bedplate holddown bolts to structural foundation supports. The installation angle, flywheel down, is
three degrees minimum.
d. Uncap and connect the fuel oil return and supply lines, sea water lines, coolant lines, hydraulic piping 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.
8-1
S9233-C9-MMA-010
8-2
S9233-C9-MMA-010
8-3
S9233-C9-MMA-010
8-4