T9233-AF-MMC-020 e@ VOLUME II OPERATION INSTRUCTIONS, MAINTENANCE INSTRUCTIONS AND ILLUSTRATED PARTS BREAKDOWN (INTERMEDIATE MAINTENANCE LEVEL) ENGINE-DIESEL 10PC4.2V, XXXXXX CORRECTIVE MAINTENANCE Alsthom-Atantique ‘Noon24-83-¢-2012 DISTRIBUTION LIMITED TO U.S. GOVERNMENT AGENCIES ONLY: REQUEST FOR THIS DOCUMENT e MUST BE REFERRED TO COMMANDER, MILITARY ‘SEALIFT COMMAND, WASHINGTON, 0.C. 20390 FOR OFFICIAL USE ONLY 20/FEB/1987T9233-AF-MMC-020 INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. NOTE: The cortion of the text affected by the changes is indi cated by a vertical line in the outer margins of the page Changes to dlusiralions are indicates by miniature pointing hands. Changes to wiring clagrams are indicates by shaded Dates of issue for original and changed pages are: 20 February 1987 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 552 CONSISTING OF THE FOLLOWING: Page “change Page *Change No. No. No. No. ° ° o *Zeroin this column incicates an original page, |RECORD OF CHANGES CHANGE NUMBER DATE ENTERED TITLE OR BRIEF DESCRIPTION ENTERED BYAPPROVAL AND PROCUREMENT RECORD PACE APPROVAL DATA FOR: 19233~AF-MMC-020 ‘TITLE OF MANUAL: ENGINE - DIESEL - VOLUME 11 - MODEL: 1OPC4.2V SUPERVISOR OF SHIPBUILDING, CONVERSION AND REPAIR, USN, NEW ORLEANS, TAO-N-2012/9086, SER. 200-5791, 13 NOV 1986 APPROVAL AUTHORIT’ QUANTITY CONTRACT SHIP oF BUILDING NUMBER APPLICABILITY MANUALS, YARD No0024~83-C-2012 T-A0 187 2 Avondale Industries, Inc. Shipyards Division New Orleans, Louisiana 1N00024-83-C-2012 T-a0 188 2 Avondale Industries, Inc. Shipyards Division New Orleans, Louisiana 1N00024-83-C-2012 T-A0 189 2 Avondale Industries, Inc. Shipyards Division New Orleans, Louisiana REMARKS? DATE: JS" APART A, IGE? CERTIFICATION: It is hereby certified that 19233-AF-¥4C-020 to be provided under Contract Number NO0024-83-C-2012, has been approved by the approval data shown above. JERRY @. GOSLINE TECHNICAL PUBLICATIONS AVONDALE INDUSTRIES, INC. SHIPYARDS DIVISIONTECHNICAL MANUAL VALIDATION CERTIFICATE NAVSEA 416053 14-82 TECHNICAL MANUAL TITLE ENGINE ~ DIESEL ~ VOLUME II - MODEL: 10PC4.27 NAVSEA TECHNICAL MANUAL NUMBER, 19233-AF-MMC-020 CONTRACTITWCR NO N00024-83-C-2012 I-VALIDATION DATE 15 APRIL 1987 Except as stated in Il, the technical manual identified above has been satisfactorily validated in accordance with all requirements of the applicable TMCR and the approved Validation Pian. The technical manual is hereby cerlified to be accurate and complete, and the information, instructions, text, and illustrations conform in all respects to the applicable general and detailed specifications. H-EXCEPTIONS: EXCEPTIONS AUTHORIZED BY SIGNATURE OF PUBLICATIONS QUALITY ASSURANCE OFFICER DATE Beng A Cbrboe 1S APRIL PPPe VOLUME I LIST OF ILLUSTRATIONS. TABLE OF CONTENTS Page LIST OF TABLES . CHAPTER 6. Section | Section 1 Section IIL Section WV. Section v. Section VI Section VII — CORRECTIVE MAINTENANCE INTRODUCTION. 61. Purpose 6-2. Scope 6-3. Arrangement of Main SPECIFICATION DATA nance Data 6-4. General 6-5. Data ADJUSTMENTS 6-6. General. TURBOCHARGERS 67. General 6-8, Removal of Turbocharger 6-9. Disassembly of Turbochargers 6-10, Cleaning, inspection and Repair of Turbochargers, 6-11, Reassembly of Turbochargers ‘ 6-12. Installation of Turbochargers COOLING SYSTEM 613, Intercooler Water Piping 6-14. Turbocharger Upper and Lower Water Cooling Piging. 615, Intercooler Leak Detection Piping, Inlet Connection between Intercooler and Turbocharger and Intercooler 6-16. Injector Cooling Water Piping LUBRICATION SYSTEM 6-17. Bearing Lubricating Oi! Piping 6-18. Injection Pump Lubricating Oil Piping 8-18, Rocker and Valve Gear Lubricating Oil Piping « 6-20. Oil Mist Detector . : FUEL SYSTEM AND CONTROL LINKAGES. 6-21. Fuel Oil Piping 6-22. Steam Piping 6-23. Check of Overspeed Stop Circuit 6-24, Mechanical and Electrical Overspeed Governor Trip Checks 6-25. Adjustment of the Satety Stop coco 6-26. Adjustment of the Governor Stop 827. Adjustment of injection Pump Rack 6-28. Governor : 6-29. Fuel Pump Control Link Rod 6-30. Governor Drive Gear 6-31. Injection Discharge Tubing 6-32. Injector . 6-33. Injection Pumps 6-34. Injection Advance — Checking or Adjustment PNEUMATIC LINES AND DEVICES 6-35. Starting Air Piping 6-36. Main Air Starting ValveSection IX Section X. Section XI Section XII Section Xill Section XIV. Section XV. 6-37 6-38, 6-39 TABLE OF CONTENTS (Continued) Air Distributor Air Distributor Gontrot Gear Pneumatic Control Piping ELECTRICAL COMPONENTS 6-40) 641 Exhaust Gas and Discharge Air Temperature Sensor Assemblies Bearing Temperature Detector Probes and Conduit Assembly EXHAUST AND INLET AIR PIPING. 6-42 6-43, 6-44 6-45, Exhaust Piping Inlet Air Piping Scavenging Air Bypass (Anti-Surging and Waste Gate Bypass) Waste Gate Bypass Valve and Bypass Piping TIMING AND BARRING GEARS 6-46 6-47 6-48, 6-49 6-50, 6-51. 6-52, 6-53, 6-54 6-55. Timing and Barring Gears Visual Inspection of Gear Teeth Timing Gear inspection Doors Measuring Timing and Barring Gear Backlash General Information Regarding Backlash Measuring toler Gears i ‘i Camshaft Gears Checking Injection Timing Inspecting the Springs of the Camshaft Drive Gear Barring Gear CYLINDER HEAD ASSEMBLY 6-56 6-57 6-58, 659, 6-60, 6-61 6-62, Cylinder Head... Valve Cover Assembly and Rockers Tappet Clearing Adjustment... Exhaust Valves Intake Valves Starting Valve Safety Valve CONNECTING ROD AND PISTON ASSEMBLY 6-63 6-64 6-65, 6-66, 6-67. 6-68, Removal of Connecting Rod and Piston Assembly Preliminary Inspection of Piston and Connecting Rod Assembly Disassembly of Connecting Rod and Piston Assembly Cleaning, Inspection and Repair of Connecting Rod and Piston Assembly .. Reassembly of Connecting Rod and Piston Assembly Installation of Piston and Connecting Rod Assembly CYLINDER LINER AND WATER JACKET ASSEMBLY 6-69, 6-70. 671. 6-72, 6-73, 6-74, 6-75, 6-76. Cylinder Liner and Water Jacket Assembly Removal of Cylinder Liner and Water Jacket Assembly from the Engine . Removal of the Cylinder Liner from the Water Jacket ‘i Disassembly of Cylinder Liner and Water Jacket Assembly Cleaning, Inspection and Repair of Cylinder Liner and Water Jacket Assembly Inspecting the Sealant for the Cylinder Head Tie-Rods in the Frame Reassembly of Cylinder Liner and Water Jacket Assembly Installation of Cylinder Liner and Water Jacket Assembly CAMSHAFT AND CAM ROLLERS 6-77 Camshaft Assembly Page 6-208 6.212 6-218 6-225 6-225 6-231 6-235 6-235 6-245 6-268 6-273 6277 6-277 6-277 6-277 6-281 6-281 6-285 6-285 6-287 6-287 6-287 6-206 6-296 6-313 6-327 6-307 6-355, 6-389 6-372 6378 6-378 6-385 6-389 + 6-394 6-309 6-401 6-406 6-406 6-406 6-406 6-410 6-410 2 6-417 6-417 6-420 6-422 6-422Section XVI Section XVII SectionXviti Section XIX Section XX. Section XXt. Section XI TABLE OF CONTENTS (Continued) 6-78. Camshatt Casing Cover 6-79. Visual Inspection of Cam and Cam Roller . 6-80. Camshaft Thrust Bearing Assembly 6-81. Replacement of a Damaged One-Piece Cam by a Two-Piece Cam 6-82. Intake and Exhaust Valve Push Rods 6-83. Cam Roller Assembly 6-84. Camshaft Bearing 6-85. Replacement of Cam Roller Assembly Lube-Oil Sleeve O-Ring CRANKSHAFT, BEARINGS AND FRAME 6-86. Removal of Crankshaft Inspection Door 6-87. Main Bearing. 6-88. Oil Seal 6-89. Thrust Bearing 6-90. Reading of Crankshait Deflection 6-91. Measurement of Clearance between Crankshaft Journal and Lower Bearing Shells and the Calculation of Corrected Deflection Readings 6-92. Crankshaft Counterweights 6-93. Torsional Vibration Damper 6-94, Engine Fastening Hardware CONTROLS . 6-95. Ship Control Console (SCC) and Engine Roam Control Console (ERC) 6-96. Cleaning, Inspection and Repair of the SCC and ERC. 6-97. Local Control Panel (LCP) 6-98. Cleaning, Inspection and Repair of the Local Contra! Panel (LCP) COUPLING SYSTEM 6-99. Removal of Drive Line Couplings and Clutch 6-100. Disassembly of the Drive Line Couplings and Clutch 6-101. Cleaning, Inspection and Repair of the Drive Line Couplings and Clutch 6-102. Reassembly of the Drive Line Couplings and Clutch 6-103. Instaliation of the Pipe Line Couplings and Clutch SOME PREPARATORY MAINTENANCE AND. OPERATING PROCEDURES 6-104. Barring the Engine 6-105. Draining the Intercooler Water Circuit - 6-106. Draining the Jacket Water Circuit cesteneeeee MECHANICAL AND ELECTRICAL OVERSPEED TRIP ASSEMBLIES A 6-107. Mechanical Overspeed Trip Assembly. 6-108. Electrical Overspeed Trip Mechanism INSPECTION INFORMATION 6-109. Visual Inspection of Bearing Shells 6-110. Visual Inspection of Gear Wheels 6-111. Replacement of Ball/Roller Bearings 6-112. Visual Examination of Cams and Rollers WEAR AND CLEARANCE TABLE 6-113, General. 6-114, Description of Table 6-474 6-480 6-487 6-489 6-490 6-490 6-490LIST OF ILLUSTRATIONS VOLUME It Number 64 62 63. 64, 65. 66. 67 68 69. 6-10. 6-11 6-12, 6-13, 6-14 615 6-16 6-17, e18, 6-19, 6-20. 6-21 6-22 6-23, 6-24 6-26. 6-26 6-27. 6-28. 6-29, 6-30, 6-31 6-32, 6-33, 6-34 6-36. 6-36, 6-37, 6-38, 6-39, Title ‘Temperature Sensors Location Cooling Water Pipes for Turbochargers — Rear View (Sheet 1 of 3) Cooling Water Pipes for Turbochargers — Top View (Sheet 2 of 3) Cooling Water Pipes for Turbochargers — Side View (Sheet 3 of 3) By-Pass Pipes and Cover Assembly Exhaust Gas Transition Piece Attachment of Cleaning Piping for the Compressor Side of the Turbocharger Cleaning Piping for the Turbine Side of the Turbocharger (5 Sheets) Inlet Pipe between Turbocharger and Air Cooler (2 Sheets) Exhaust Pipe between Engine and Turbocharger (2 Sheets) Turbocharger Lifting the Turbocharger from Engine Air Filter and Silencer Assembly Air Filter Segments Disassembly and Reassembly of Air Filter Segments Bearing Chamber Cover on Air Compressor Side Bearing Chamber Cover on Turbine Side Bearing Chamber on Air Compressor Side Bearing Chamber on Turbine Side ‘Turbocharger Gas Inlet Casing Equalizing Passage on Air Compressor Side Intercooler Water Piping — Front View Intercooler Water Piping Three-Way Valve Upper Turbocharger Water Cooling Piping — Rear View (Sheet 1 of 3) Upper Turbocharger Water Cooling Piping — Top View (Sheet 2 of 3) Upper Turbocharger Water Cooling Piping — Side View (Sheet 3 of 3) Lower Turbocharger Water Cooling Piping — Rear View (Sheet 1 of 2) Lower Turbocharger Water Cooling Piping — Side View (Sheet 2 of 2) Intercooler Water Piping — Side and Front Views Cylinder Water Cooling Piping — Rear, Side and Top Views (Sheet 1 of 2) Cylinder Water Cooling Piping — Fastening Hardware (Sheet 2 of 2) Intercooler Water Leakage — Detector (Sheet 1 of 2) Intercooler Water Leakage Detection Drain Trap (Sheet 2 0f 2) Inlet Connection Between Turbocharger and Intercooler Inlet Connection Between Turbocharger and Intercooler — Fastening Hardware Inlet Connection Between Intercooler and Engine — Main View (Sheet 1 of 2) Inlet Connection Between Intercooler and Engine — Sectional Views (Sheet 2 of 2) Intercooler Assembly Intercooler Handling Tool Intercooler Cleaning of the Intercooler (Water Side) Intercooler Washing Too! Intercooler Cleaning Process for External Surfaces of Fins and Tubes Injector Cooling Water Piping — Barring Gear End Injector Cooling Water Piping — Support and Fastening Hardware, Barring Gear End . Injector Cooling Water Piping — Components to Cylinder Head (Sheet 1 of 2) Injector Cooling Water Piping — Components Along Ai not Sleeve and at Cylinder Head (Sheet 2 of 2) :e Number 6-40 eat 6-42, 6-43, 6-44, 6-45, 6-46. 6-47, 6-48, 6-49, 6-50. LIST OF ILLUSTRATIONS (Continued) Injector Cooling Water Piping — Support and Fastening Hardware to Cylinder Head Injector Cooling Water Piping — Connection from Inlet to Cylinder Head Bearing Lubricating Oil Piping for Distribution Manifold on Engine Bank (Sheet 1 of 4) Bearing Lubricating Oil Piping — Support and Fastening Hardware, Side View (Sheet 2 of 4) Bearing Lubricating Oil Sleeves, Ports and Individual Pipes — Timing Gear Side (Sheet 3 of 4) Bearing Lubricating Oil Support and Fastening Hardware for Sleeves, Ports and Individual Pipes — Timing Gear Side (Sheet 4 of 4) Bearing Lubricating Oil Piping for Thrust Bearing Inlets and Mechanical _ Overspeed Device (Sheet 1 of 2) Bearing Lubricating Oil Piping — Support and Fastening Hardware for Thrust Bearing Inlets and Mechanical Overspeed Device (Sheet 2 of 2) Bearing Lubricating Oil Piping for Barring Gear (Sheet 1 of 2) ‘Support and Fastening Hardware for Barring Gear Lubricating Oil Piping (Sheet 2 of 2) Bearing Lubricating Oil Piping for Camshaft Inlets (Sheet 1 of 2) Oil Bearing Lubricating Piping — Support and Fastening Hardware for Camshaft Inlet Pipes (Sheet 2 of 2) Injection Pump Seal Oil Piping — Barring Gear End of Engine (Sheet 1 of 5) Injection Pump Seal Oil Filter — Support and Fastening Hardware (Sheet 2 of 5) Injection Pump Seal Oil Piping — Engine Bank 8 (Sheet 3 of 5) Injection Pump Seal Oil Piping — Engine Bank B (Sheet 4 of 5) Injection Pump Seal Oil Piping — Top View Barring Gear End (Sheet 5 of 5) Rocker Lubricating Inlet Piping — Barring Gear End Rocker Lubricating Inlet Piping — Support and Fastening Hardware at Barring Gear End Valve Gear Lubricating Oil Pipes — Support and Fastening Hardware for Feed Return Pipes Valve Geer Lubricating Oil Pipes — Support and Fastening Hardware to Cylinder Head Valve Gear Lubricating Oil Pipe — Support and Fastening Hardware Rocker Lubricating Piping — Cylinder Head Outlet Rocker Lubricating Piping — Oil Discharge Rocker Lubricating Piping — Cylinder Head Outlet - Fuel-Oil Piping — Side View Detail at Barring Gear End of Engine Fuel-Oil Piping — Top View at Barring Gear End coven Fuel-Oil Piping — Gate Valve Detail Fuel-Oil Piping — Support and Fastening (2 Sheets) Fuel-Oil Filter and Piping Support and Fastening Hardware Fuel-Oil Filter Bracket . Fuel-Oil Piping to Both Engine Banks (3 Sheets) Fuel Piping, Pump and Leak Detectors — Engine Top View Fuel-Oil Piping Support and Fastening Hardware — Both Engine Banks e Sheets) Fuel Pipe Assembly (2 Sheets) . Fuel-Oil Piping Fastening Hardware and Insulation (2 Sheets) Steam Piping — Barring and Timing Gear Ends (3 Sheets) Steam Pipes — Support and Fastening Hardware Connecting Steam Pipes on Barring Gear End of Engine (2 Sheets) ...........22+200++ cee Heavy Fuel-Oil Steam Tracing Pipe (2 Sheets) Page 6-79 6-80 6-83 6-102 6-103 6-104 6-106 6-107 6-108 e111 6-112 6-113 64114 6116 e417 6118 6-121 6-123 6-126 6-128 6-131 6-134 6-136Number 6-69, 6-70. 671 6-72 6-73, 6-74 6-75 6-76. 6-77 6-78. 6-73 6-80. 6-81 6-82. 6-83 6-84, 6-85. 6-26 6-87 6-88, 6-29, 6-90, 691 6-92 6-93, 6-94. 6-95 6-96. 6-97. 6-98 6-99, 6-100. 6-101 6-102 6-103. 6-106. 6-105. 6-106. 6-107. 6-108. 6-109. 6-110. et 6-112, 6-113 6-114 6-115. LIST OF ILLUSTRATIONS (Continued) Title Steam Piping Hardware (2 Sheets) Seal Oil Inlet on Inlet Manifold Steam Piping — Timing Gear Side ‘Steam Cocks on Camshaft Casing Cover Fue! Rack Linkage Governor Hand Control Whee! and Connecting Rod (2 Sheets) Fuel Rack Linkage — Pin Storage Slot A and Slot 8 (2 Sheets} Fuel Rack Linkage — Safely Stopping Screw, Overspeed Cynder and Arm (3 Sheets) — Overspeed Governor Governor Outlet Lever Overspeed Governor (5 Shests) . Fuel Rack Linkage — Injection Pump Rack Adjustment Attachment of Connecting Rod to Outlet Lever, Fuel Pump Control Link Rod tees Governor Drive Gear . Tachometer Connection to Governor Drive Gear. Governor Drive Gear Assembly . Wrench for Discharge Pipe Connection Injection Tubing . Fuel Injector Injector Removal Too! Injection Calibration Test Stand 5 Tool for Unchocking of Fuel Injector Tip Spanner for Injector Pressure Adjusting Screw Tool for Fuel Injector Nozzle Tip Tightening Tool for Reconditioning Needle Lapping Too! Needle Lapping Tool Tool for Reconditioning Needle Seat Mandre! Needle Seat Lapping Too! Too! for Injection Pipe Washer Replacement. Too! for Mounting of Washer on Fue! Injector Cleaning and Lapping Too! for Surfacing Seating Surface in Cylinder Head Connecting Rod Linkage Bolts Injection Pump ~ Shim Location/Injection Advance and Replacing a Seized Barrel and Plunger Location fee . Injection Pump ~ Pump Head Casing Removal Pump Fixing Nut Loosening Too! Lifting Too! for Pump Handling Pump Maintenance Stand Checking and Setting of injection Advance Calculation of Injection Advance Starting Air Pipe Assembly — Piping and Components Leading to Air Distributor Starting Air Pipe Assembly — Main Feed Pipes fo - Slow Barr Detection Starting Air Pipe Assembly — Support and Fastening Equipment Starting Air Pipe Assembly — Outlet Piping Control Starting Air Pipe Assemby — Inlet to Distributor (Sheet 1 of 3) Control Starting Air Pipe Assemby — Intermediate Pipes (Sheet 2 of 3) Control Starting Air Pipe Assemby ~— Air Filter Pipes (Sheet 3 of 3) Control Starting Air Pipe Assemby — Air Inlet Control Starting Air Pipe Assemby — Piping Support and Fastening Hardware Along Engine Top Side .Number 6-116. 6-117 6-118 6-119. 6-120. 6-121 6-122 6-128 6-124. 6-125 6-126. 6-127. 6-128 6-129 6-130. 6-131 6-132 6-133. 6-134. 6-135. 6-136 6-137. 6-138. 6-139. 6-140. e141 6-142 6-143. 6-144, 6-145. 6-146, 6-147. 6-148. 6-149, 6-150. 6-151 6-152 6-153 6-154 6-155. 6-156. LIST OF ILLUSTRATIONS (Continued) Title Control Starting Air Pipe Assemby — Piping Support and Fastening Hardware at Cylinder Head Main Air Starting Valve Lapping Too! for Main Air Starting Valve Seat Air Distributor Angular Clearance of Air Distributor Disc Radial Clearance of Air Distributor Disc Air Distributor Timing Check Removal of Air Distributor Contro! Gear Thrust Flanges, Liner, Screw and Cross-Piece Air Distributor Control Gear Timing Adjustment Tool Friction Face Reconditioning Pneumatic Control Piping — Engine Top View Pneumatic Control Piping — Intercooler Leakage Detection, Governor Booster, Butterily Valves and Terminal Box (Sheet 1 of 5) Pneumatic Control Piping — Safety Stop Circuit, Turbocharger Cleaning and Barring Gear (Sheet 2 of 5) Bypass Valves and Bypass Valve Piping, Support and Fastening Hardwa’e {Sheet 3 of 5) Piping and Componentry at Pneumatic Station (Sheet 4 of 5) Pneumatic Control Piping at Pneumatic Jack (Sheet 5 of 5) Slow Barring Valve Pyropipe for Exhaust and Scavenging Air Temperature Measurement Pyropipe Parts 5 Junction Box for Exhaust Gas Temperature Modules Wiring Diagram for Junction Box . Exhaust Gas Temperature Detector Thrust Bearing Temperature Detector Main Bearing Temperature Detection Insulation Casing — End View Insulation Casing — Top View Expansion Bellows Handling Too! Exhaust Manifold — Main View (Sheet 1 of 3) Exhaust Manifold — Top View (Sheet 2 of 3) Exhaust Manifold — Connection at Cylinder Head (Sheet 3 of 3) Exhaust Manifold — Barring Gear End . Exhaust Connection Between Engine and Turbocharger Cylinder Head Alignment cess Permissible Offset at Expansion Joint Fitting Installation of Expansion Bellows Expansion Valve Seating Limits . Admissible Assembly Misalignment Positioning of Clamp/Gaps Turbocharger Cleaning Pipes Assembly (2 Sheets) Inlet Pipe — Intercooler to Air Manifold (2 Sheets) Manometers wee Intercooler Water Leakage Detector Pneumatic Control Piping (5 Sheets) : Iniet Air Manifold Assembly — Buttertly Valve . Butterfly Valve — Fastening Hardware Butterfly Valve — Air Cylinder Butterfly Valve — Air Cylinder Fastening Hardware Page 6-205 6-207 6-208 6-210 6211 6211 6-213 6-214 6-218 6-216 6-219 6-220 6-221 6-222 6-223 6-223 6-224 6-226 6-227 6-228 6-229 6-230 6-232 6-233, 6-236 6-237 6-238 6-238 6-240 6-241 2 6-243, 6-244 6-246 6-246 6-246 6-247 6-247 6-247 6-248 6-250 + 6-252 6-253 6-255 6-289 6-260 6-261 6-262Number 6-157. 6-158 6-159, 6-160, 6-161 6-162. 6-163, 6-164, 6-165. 6-166. 6-167. 6-168. 6-169 6-170. e171 6-172 6-173 6-174 6-175. 6-176 6-17 6-178. 6-179, 6-180. 6-181 6-182 6-183, 6-184. 6-185. 6-186. 6-187. 6-188. 6-189. 6-190. 6-191 6-192 6-193 6-194. 6-195. 6-196. 6-197. 6-198 6-199. 6-200. 6-201 6-202. vii LIST OF ILLUSTRATIONS (Continued) Title Inlet Air Manifold Assembly Inlet Air Manifold Assembly — Fastening Hardware (Sheet 1 of 4) Inlet Air Manifold Assembly — Inlet Sleeve Fastening Hardware (Sheet 2 of 4) Injet Air Manifold Assembly — Support Fastening Hardware (Sheet 3 of 4) Inlet Air Manifold Assembly — Engine Mounting (Sheet 4 of 4) Turbocharger Air Bypass Assembly (2 Sheets) Anti-Surging Valve Assembly . Bypass Piping Waste Gate Assembly Overspeed Sensor for Engine Bank B . Timing Gear inspection Doors (2 Sheets) Backlash Measurement Locations Backlash Measurement with a Lead Sheet ‘or Spur Gears Backlash Measurement with a Lead Wire Cutting Lead Sheet for Measuring with Micrometer Measuring the Minimum Thickness of the Two Prints of One Tooth Clearance Between Teeth Lead Sheet Cut Locations for Correct Backlash Measurements of Herringbone Gears Injection Timing Check Using Injection Pump Plunger Stroke Injection Timing Check Using Gauge Too! at Injection Pump Housing Timing Gears Barring Gear Assembly (3 Sheets) Heat Shield Assembly (End View — Opposite Timing Gear) Heat Shield Assembly for Exhaust Manifolc — Top View) Exhaust Manifold — End View (Sheet 1 of 3) Exhaust Manifold (Sheet 2 of 3) Exhaust Manifold — Top View (Sheet 3 of 3) Gaskets and Seals for the Cylinder Head Assembly Hydraulic Tightening Tool Lifting Too! for Cylinder Head Maintenance Stand for Cylinder Head Storing Stand for Cylinder Head Indicator Gock Assembly Pressure Test Tool for Cylinder Head Reconditioning Gasket Seats on Cylinder Head and Liner Valve Cover Assembly (2 Sheets) Rocker Assembly — Exhaust Rocker Lifting Tool for Rocker Assembly Maintenance Stand for Rocker Assembly Rocker Assembly — Intake Rocker Water Piping Connections Lifting Too! for Valve Cover Hydraulic Bushing Too! Aligning the Exhaust Valve Rocker Bushing in the Rocker . Aligning Match Marks ceveteeesee Exhaust Valve Ringspan Rotator Tools for Removing and Installing Exhaust Valves. Exhaust Valve Maintenance Stand Tool for Valve Spring Compression . Tool for Removing and Installing Valve Bushing 6-332LIST OF ILLUSTRATIONS (Continued) Title Start of Corrosion in Valve Head Deep Corrosion in Valve Head Burning (Holes) in Valve Head ‘Stem End (Marks Indicate Possible Wear of Rocker Bushing) Corrosion Limits for the Exhaust Valve Head Check Points for Exhaust Valve Cage Corrosion Flow Rate Test . Simplified Arrangement for Descating by Forced Circulation Grinding Too! for Valve Seats Grinding Too! for Valve Face Valve Face with Burn Marks Deeply Hammered Valve Face Dimensions for Remachining the Face of the Exhaust Valves Remachining the Face of the Valve Head Gauge for Adjusting Angle of Cutting Too! Dimensions for Remachining the Valve Cage Seat . Hunger Type VD3 Machining Tool for Remachining the Seat Grinding Tool for Reconditioning the External Seating Surface on the Exhaust Valve Cage Tool for Cleaning the Exhaust Valve Bore. Geinaing the Seat for the Exhaust Valve Cage Intake Valve Uneven Seating of the Intake Valves on a Cold Cylinder Hoad Damage from Blow-By Intake Valve Showing Damage to Its Coating Corrosion Limits for Intake Valve Head . Dimensions and Limits for Remachining the Intake Valve Seat Extraction Too! for Seat Insert Dimensions for Counterboring the Cylinder Head to Install a New Seat Valve Extractor for Starting Valve and Safety Valve Air Starting Vaive Seat Cleaning Tool for Seats of Starting Valve and Satety Valve Safety Valve Calibration Tool for Safety Valve Removing or Installing the Long Tie-Rod Using the Hydraulic Tie-Rod Tool Lifting Fixture for Hydraulic Tie-Rod Too! Hydraulic Tie-Rod Tool Removing or installing the Short Tie-Rod Using the Hydraulic Tie-Rod Too! Instaling or Removing the Bearing Cap for the Connecting Rod Connecting od . Bearing Shell Retainers Support for Piston and Connecting Rod Piston Lifting Fixture Guide Chute and Protection Tube Assembly Connecting Rod Maintenance Stand Piston Checking the Piston Grooves for Fouling. Gap Measuring Too! wee Wrist Pin Toot Liffing Fixture for Wrist Pin . Piston Ring Pliers Piston Maintenance and inspection Tool .Number 6-254, 6-255 6-256 6-257. 6-258. 6-259. 6-260. 6-261 6-262. 6-263. 6-264 6-265. 6-266 6-267. 6-268. 6-268 6-270. 6-275 6-272 6-273 6-274 6-275 6-276 6-27 6-278 6-279, 6-280, 6-281 6-282 6-283, 6-284 6-285 6-286. 6-287. 6-288, 6-289, 6-290. 6-291 6-292 6-293. 6-294 6-295, 6-296 6-297. 6-298. 6-298. 6-300. 6-301 6-302 6-303. 6-304 6-305. LIST OF ILLUSTRATIONS (Continued) Title Piston Head Removal Too! Measuring and installing Bushing for Small End of Connecting Rod Drilling Bushing in Small End of Connecting Rod to Ease Removal Alignment Marks for Reassembly of Piston and Connecting Rod Reassembly of Inner Sleeve in Wrist Pin Staggering of Piston Ring Gaps Piston Ring Compressor Checking Tightness of Blind Nuts Cylinder Liner and Water Jacket Assembly Cylinder Extractor Cylinder Maintenance § Liner Extractor Liner Lifting Too! Removing Wear Ridge ‘Chris Marine” Honing Too! Measuring the Liner for "Out of Round” Sealant for Protection of Cylinder Head Tie-Rods : Lifting Fixture for Cylinder Liner and Water Jacket Assembly Camshaft Casing Cover cee Cams Inspecting Cam Ramp to Nose Wear Rocker Assembly — Lower Valve Train (2 Sheets) Camshaft Thrust Bearing ...... Camshaft Longitudinal Positioning valve Casing . Removal of Intake Valve Push Rods Removal of Exhaust Valve Push Rods . Camshaft Bearings (3 Sheets) Stud Puller Disconnecting Cam Roller Assembly Lube-Oil Sleeve Gasket Hoist Anchor and Hoist for Removal of Crankshaft Inspection Door Crankshaft Inspection Door (2 Sheets) Main Bearing Hydraulic Jack for Tie Rods and Bolt Main Bearing Inspection Too! Hydraulic Jacks for Main Bearing Inspection Tool Engine Seating . Hydraulic Jack for Engine Frame Mounting Bolts Catch Pin for Main Bearing Shell Removal Oil Seal with Siphon (2 Sheets) Fitting of Shim . Immobilizing the Crankshaft ‘Thrust Bearing Removable Thrust Bearing Flange Tool for Inspecting Thrust Bearing Lower Half Thrust Bearing Shell Driving Tappet ‘Tappet for Removable Thrust Flanges Inspection Crankshatt Deflection Reading Sheet Crankshaft Deflection Recording Sheet Crankshaft : Bearing Shell/Crankshaft Journal Clearance Recording Sheet ... Hydraulic Lifting Too! for Measuring Crankshaft/Journal Clearance and Page 6-398 6-400 6-400 6-402 6-402 6-404 6-404 6-404 6-407 6-408 6-409 641 6-412 6-415 6-416 6-418 6-419 6-421 6-423 6-425 6-426 6-427 6-429 6-433 6-433 6-434 6-435 6-438 6-401 6-443, 6-446 6-447 6-450 6-451 6-452 6-453, 6-455 6-456 6-458 6-461 6-463 6-465 6-466 6-467 + 8-468 + 8-470 6-470 6-472 6-473 6-475 6-477 6-478LIST OF ILLUSTRATIONS (Continued) Number rile Page 6-306. Graph for Calculating Bearing Sheli/Crankshaft Journal Clearance 6-470 6.307. Tools for Counterwoight Jack Sorew Tightening {In Tightening Position) 6-481 6.308. Counterweignt Assembly (Sheet 1 of 2) : 6-48 Counterweight Jack Screw (Sheet 20! 2} 6-489 6-809, Hydraulic Wrenn for Tightening Counterweignt Jack Screw — 6-485 6.810. Tools for Counterweight Handling 6-485 6-311. Dye Penetrant Detection for Counterweights 6-486 6.312. Torsional Vibration Damper i 6-488 6.313. Gelsiingor Coupling — Main View, Counterciockuise Rotation (Sheet 148) vs........1. 6496 Geislinger Coupling ~ Main View, Clockwise Rotation (Sheet 2 of ) ‘ 6as7 Geislinger Coupling — Section View (Sheet 3018) wsv.evsses-: 6-499 6314. Coupling and Dual Drive Line Clutch (Sheet 1 of 3). 6-499 Dual Drive Line Clutch — internal Components (Sheet 2 of 3). 6-500 Dual Drive Line Clutch (Sheet 3 of 3) : 6-501 6-915, Flexible Link Coupling — Main View (Sheet 1 of 2} 6-508 Flexible Link Coupling — Section View (Sheet 2 of 2) 6-504 6-316. Clutch System 6-505 6317, Disassembly of he Tensioning Ring Subassembly 6-507 6318 Pressing of the Tensioning Ring Subassembly 6-508 6318. Pneumatic Piping of the Dual Drive Line Clutch 6511 6.820. One Inch Right Hand Rotorseal 6-513 6-221. Spline Wear 6-513 6-322, Spring Leat Wear 6-513 6-32. Cireiarity Adjustment 6-518 6-324, Coupling Alignment — Spring Bars, Spacers, Spacer Shims and Pins 6-518 6-828, Mechanical Overspeed Trip Mechanism — Electrical Switch 6-525 6-326. Mechanical Overspeed Trip Mechanism (2 Sheets) i 6-526 6-327, Electrical Overspeed Trip Mechanism Interconnection Block Diagram... I e501 6.308 Flectrinal Overspoed Trip Sensor vessronuusecenrnss 66592 6328, Pre-Amplifier» 6.500 6380, Acceptable Scratches 6-597 6-331. Unacceptable Scratches 6-597 LIST OF TABLES VOLUME I! Table Title Page G1. Specifications 62 6-2, Wear Measurement Sheet of Exhaust Valve Spindles and Guldes — Leakproof Guide .... 6-399 6-3. Wear Measurement Sheet of Exhaust Valve Spindles and Guides. ...--sroe-.es+eees sees 6-340 64. Weer Measurement Sheet of Intake Valve Spindies and Guides : 6-962 65. Wear Measurement Shee! for First Two Piston Grooves Sco 66 Wear Measurement Sheet for First Two Piston Rings and Scrapers Rings ......., 6-303 87, Cylinder Liner Wear Measurement Shoe — eee id 68 RTD Calibration Chart, ac : ee &8 Function Generator Calibration 6-498 ‘6-508 610. Wearand ClearanceCHAPTER 6 CORRECTIVE MAINTENANCE SECTION I INTRODUCTION 6-1. PURPOSE. The purpose of this chapter is to provide information needed to inspect, repair and adjust assemblies and systems that comprise the complete engine. 6-2. SCOPE. The maintenance instructions in this chapter can be performed at the organizational maintenance level. The instructions are not to be followed in their entirety, but only as necessary to ensure proper and reliable engine operation. Any required corrective maintenance that cannot be per- formed at the organizational level is referred to a higher maintenance echelon, or special shop where the work can be performed, 6-3, ARRANGEMENT OF MAINTENANCE DATA. Following the section on adjustments, below, the majority of maintenance data in this chapter is arranged by engine assemblies, subassemblies and components, For each mechanical item the foltow- Ing sequence of repair information is given as required: special tools and materials, and instruc- tions for removal, disassembly, cleaning, inspec: tion, testing, repair or reconditioning, reassembly. installation and adjustment. Sections concerned with wear and clearance limits and special inspec- tion notes follow at the end of the chapter. Torque tables, notes on seals, O-rings, and other general data are in Appendix A. An assembly number is specified wherever the spe- cial tools and materials are listed in this chapter. These assembly numbers correspond with those given in Chapter 7 and the Appendices so that find- ing parts information is made easy 61SECTION II SPECIFICATION DATA 6-4, GENERAL. a. The following paragraphs and table describe and give the specifications of the major engine com- ponents and accessories, b. The data Is supplied to allow the user to become familiar with items and components of the engines. 6-5. DATA. The following table, Table 6-1, lists the major components, their specifications and pertinent data, The engine is of metric design. US measurements are rounded off and may not be exact Table 6-1. Specifications Engine Model Type . Cylinders Installation Horsepower Injection’ Type . Injection lead angle Firing order Cylinders: Type Bore Stroke . Compression ratio Displacement Crankshaft: Crankpin diameter Main journal diameter External bearing diameter Timing, Intake valves: Opening Closing ...... Tappet clearance (cold) Valve lift Exhaust valves! Opening . Closing ei Tappet clearance (cold) Injection: Type Nozzle type Number of holes Nozzle hole diameter Nozzle calibration pressure Injection advance : 62 PCa.2v Diese! 10 : v-type 16,290 US (16,500 Metric) Direct, one pump per cylinder 33° 30) A1-82-A2-B4-A4-B5-A5-B3-A3-B1 4 Cycle 22.4in. (570 mm) 24.4. (620 mm) 7 11.83:1 9655 cu. in. (158.209 dm} 18.3 in, (465 mm) 18.3in. (465 mm) 20.5 in. (520 mm) 40° BTDC. ses. 84° 40° ATDC 045 in. (1.15 mm) 1.76 in, (44.85 mm} 85° BTOC 100° ATDC (045 in, (1,15 mm) Mechanical-direct . Multihole 10 039 in. (1. mm) 4350 psi (300 bar) 13° 30"Table 6-1, Specifications (Continued) Speed: Rated speed : 400 rpm Overspeed trip (mechanical) 5 460 rpm Overspeed trip (electronic) 440 rpm 200 rpm Minimum idle speed Piston velocity (at 400 rpm) 27 his (8.27 mis} Rated power: Per cylinder 1629 US hp (1650 metric hp) Torque: Per cylinder (at 1629 hp) 21,378 ft. Ib. (29,000 N-m} Cylinder pressures (at 400 rpm) Mean effective pressure . : 233 psi (23 bar) Maximum combustion pressure 4957 psi (135 bar) Compression at no load 435 psi (20 bar) One cylinder without fuel engine running at 90% (nine cylinders firing) Fuel: Feed pump minimum capacity (per cylinder) Minimum pressure at engine inict Cooling Water: ‘Turbocharger circuit Water quality Flow rate (per cylinder) Pressure drop through engine Temperature at engine outlet . 10 cu. in. (1.7 mms} + 65 10 79 psi (4.5 t0 5.5 bar) Treated fresh water 142.5 GPM (639.4 I/min} 23 to 26 psi (1.6 to 1.8 bar) 167 to 185°F (75 to 85°C) Minimum alarm 120°F (50°C) Heavy fuel engines minimum alarm 188°F (70°C) Maximum alarm. 194°F (90°C) 204°F (95°C) ‘Stop or automatic idling Injection nozzle cooling circuit: Flow rate (per cylinder) Iniet temperature Intercooler circuit Flow rate (per cylinder) Water temperature at air cooler inlet Normal On-low temperature alarm = GPM (3.78 /min) 120 to 140°F (50 to 60°C) 166 GPM (628.3 /min) = 80 to 98°F (27 to 32°C) 77°F (25°C) Lubricating Oil Engine circuit: ‘Temperature at engine inlet 122 to 182°F (50 to 55°C) Normal rating On low temperature alarm 7 = : 104°F (40°C) On high temperature alarm 7 7 : 140°F (60°C) Pressure in main oil pipe: Normal at 400 rpm First warning limit Second warning limit (engine stop) Valve gear separate circuit Flow rate (per cylinder) Normal pressure at 400 rpm Permissible minimum pressure 79 psi (5.5 bar) 60 psi (4.2 bar) 51 psi (3.5 bar) 1.1 GPM (4.16 min) 14.5 psi (1 bar) 8.7 psi (0.6 bar) 63Table 6-1. Specifications (Continued) Air and Exhaust Gases (at rated power, each engine): Aspirated air flow Max. depression at turbocharger inlet Charge air pressure Exhaust gas temperature at turbo outlet Maximum permissible back pressure at turbine outlet Engine Components and Weights: Cylinders: Type -..--+- Weight (complete) Cylinder sleeve Water jacket liner assembly Tie bolt .. Pistons Type -- Weight (complete) Piston head Piston skirt Piston pin Connecting rod. Weight (complete) Body Cap .. Long tie bolt Short tie bolt Cylinder head (one evinden Type «-..-- : Weight (complete) - Inlet valve (complete) Inlet valve housing Inlet valve Exhaust valve (complete) Cooled exhaust valve body Exhaust valve Starting valve (complete) Safety valve (complete) Valve housing: Valve gear (complete) Rocker arm bracket Inlet valve rocker arm (complete) Exhaust valve rocker arm Valve housing (complete) Housing lever part Housing cover Fuel injection components: Injector (complete) Fuel injection pump Timing gears Crown gear Idler gear complete Idler gear pin Camshatt gear (complete) 64 42160 CEM 10” H20 (250 mm WC) 47.8 psi (330 kPa) 690-700" F (365-382°C) 10" H20 (250 mm WC) Cast iron sleeve 6270 lbs. (2850 kg) 5500 Ibs. (2500 kg) 2200 Ibs. (1000 kg) 88 Ibs. (40 kg} 2 piece. 6 ring 1188 Ibs. (540 kg) 253 lbs. (115 kg) 550 libs. (250 kg) 396 Ibs. (180 kg) 1650 Ibs, (750 kg) 1034 Ibs. (470 kg) 396 Ibs. (180 kg) - AB lbs. (22 ka) 44 Ibs. (20 ka) Valve-in-head 3740 Ibs, (1700 kg) 114 Ibs. (52 kg) 38 tbs, (17.5 ka) 35 Ibs. (16 kg) 264 Ibs. (120 kg) 110 Ibs. (50 kg} 29 tbs. (13 kg) 50 tbs. (23 kg) 55 Ibs. (25 kg) 598 lbs. (245 kg) 290 Ibs. (132 kg) 112 Ibs. (51 kg) 138 Ibs. (63 kg) 759 Ibs. (345 kg) 607 ibs. (276 kg) 145 Ibs. (66 ka) 46 Ibs. (21 ka) 627 Ibs. (285 kg) 1122 Ibs, (510 kg} 1210 ts. (550 ka) 374 Ibs. (170 kg) 1958 Ibs. (890 kg)Table 6-1. Camshaft end bearing Timing gear closure door ‘Turning gear housing Geared motor Gear shatt Gear whee! Starting: Main ir strting valve (complete) Air distributor Exhaust manifold: Expansion bellows Lagged section Inlet manifold: Butterfly valve assembly Air cooler connecting pipe: Upper connecting box Turbo to cooler connecting pipe Torsion damper Frame: Type -. Weight - Main bearing: Type Weight (complete) Cap’ Vertical tie rod Tie rod nut Thrust bearing: Weight (complete) Lower part Cap Top casing il guard (complete) Balance weights: Crankshaft free balance weight Standard balance weight (complete) Turbocharger: Make Model Weight . Governor: Make Model ... Weight (approximate) Air Cooler: Make Modet Type . Weight ‘Specitications (Continued) 275 tbs. (125 kg} 495 Ibs. (225 kg) 44 Ibs. (20 kg) 609 Ibs. (277 ka) 96 Ibs. (44 ka) 1540 Ibs. (700 ka} 209 tbs. (95 ka) 473 Ibs. (215 ka) 88 Ibs. (40 kg) 308 Ibs. (140 kg) 242 Ibs. (110 kg) 3080 Ibs. (1400 kg) 80 Ibs, (400 kg) 4840 Ibs. (2200 kg) . Welded = 105,600 Ibs. (48,000 kg) . Tri-metal "1386 Ibs. (630 kg) 968 Ibs. (440 ka) 114 Ibs, (52 kg) - 26 Ibs. (12 kg) 2200 tbs. (1050 kg} 11320 Ibs. (600 ka} 550 Ibs. (250 kg) 264 Ibs, (120 kg) 165 Ibs. (75 kg) 32,120 Ibs. (14,600 ka) 1515 Ibs. (689 ka) Brown Boveri : VTRAS4-11 +7180 Ibs. (3250 kg) Woodward PGA-200 950 Ibs. (158 kg) Young Radiator 5 285503, Water, fire and tube ~ 2145 Ibs. (975 kg) 65SECTION III ADJUSTMENTS 6-6, GENERAL. Adjustments are periodically re «quired to insure proper and reliable engine perfor- mance. Adjustments of temperature, flow, pressure, ‘etc. during start-up, running and shut-down of the ‘engine are covered in Chapter 2. Adjustments need- ed to restore alignments, clearances, or calibration of assemblies after repairs are covered as needed in the maintenance instructions for each assembly. ‘These instructions followSECTION IV TURBOCHARGERS NOTE Corrective maintenance on the rotating as- semblies within the turbocharger cannot be performed at the organizational maintenance level. If repairs to such assemblies are neces- sary, refer the work to the turbocharger manu- facturer. 6-7. GENERAL. a. Repair of turbochargers is limited to repair/re- placement of the air filter, oi! pump, bearings, seals, gaskets or replacement of the entire turbocharger or follow recommendations of the BBC manual. Re- pairs to the internal rotating assemblies shall not be performed at this maintenance level. Refer such work toa higher maintenance echelon. b. Weights for assemblies/components covered in this section are ‘Assembly Component Weight 128 Expansion bellows 88 ibs. (40 ko) 328 Theust section 308 Ins. (140 kg) 425 Gulterlly valve assembly 242 Ios. (110 kg) 349. Turbocharger 80 Ibe, (2250 kg) 176 Intercooler 17700 Ibs. (3800 ko) 176 Elbow pipes. turbo: charger to intercooler £880 Ibs, (400 ko) 176 Upper connecting box, intercooler to inlet, rmaniald pipe 3080 Ibs. (1400 kg) 6-8, REMOVAL OF TURBOCHARGERS. 1a, Special tools, spare parts, and materials re- quired: none. b, Remove exhaust temperature sensors (1 and 2 Figure 6-1) and temperature sensor (3) on the jacket water cooling pipes connecting to the turbocharger. . Drain the jacket water circuit (par. 6-282) to lower the water level below the level of the turbo- chargers. 4d. Remove the jacket water cooling pipes con- necting to the turbocharger as follows: (1) Disconnect water outlets (8, 9 and 10, Fig- ure 6-2) from turbocharger. Remove parts (40, 34, 27, 46, 35 and 28). (2) Remove hardware securing flanges of water inlets (3, 4, 6 and 7) to bottom of turbocharger. Dis- connect water inlets (3, 4, 6 and 7) from bottom of turbocharger. €. Disconnect the by-pass pipes (6 or 7, Figure 6-3) as follows (1) Remove hose clamps (35. View D) andcover (34) (2) Remove worm drive clamp (11) and collar (10) securing coupling flange of by-pass pipe (6 or 7) to expansion bellows (8) (3) Remove gaskets (9) from the coupling flanges for the top and bottom of the by-pass pipe 1, Remove the exhaust gas transition piece (Fig- ure 6-4) between the turbocharger and exhaust stack as follows: (1) Position traveling crane over the exhaust transition piece to insure that transition piece is drawn away from center line of engine during lifting, Attach lifting straps from the traveling crane around exhaust transition piece, (2) Attach a hoist to a part of the ship or engine frame that is on the engine center line side of the exhaust transition piece. Attach lifting strap from this tackle block to pipe (1) and draw the strap tight. ‘The purpose of the hoist is to prevent the exhaust, transition piece fram swinging too quickly off of engine during removal (3) Remove the hardware securing the lower flange of the exhaust transition piece to the turbo- charger. (4) Remove the hardware securing the upper flange of the exhaust transition piece to the expan- sion bellows. (5) Tap on flanges of transition piece with a brass mallet to help them separate from exhaust stack and turbocharger. (6) Lift the exhaust transition piece off of turbo- charger, controlling the motion with both the tackle block and traveling crane. Remove lifting strap when transition piece hangs directly below traveling crane. Lower exhaust transition piece to engine room floor. Remove and discard any gaskets for the flanges of, the transition piece. g. Disconnect cleaning piping going to the com- pressor side of turbocharger (Figure 6-5). h. Disconnect cleaning pipe for turbine side (2 Figure 6-6, sheet 3 of §) from union (11). Bend clean- ing tube slightly away from turbocharger. 67Figure 6-1. Temperature Sensors Location49 a a & sents 2 DEAERATOR WATER INLET WATER INLET WATER INLET WATER INLET WATER INLET WATER INLET WATER OUTLET WATER OUTLET WATER OUTLET 26, 27 22. 3h a 34 25. a7 40, 4 COUPLING DIAPHRAGM ORIFICE PLATE GASKET GASKET GASKET GASKET PLUG screw SCREW screw ‘SCREW screw NUT Nut use CONNECTOR FLEX TUBE CONNECTION BLIND FLANGE. Figure 6-2. Cooling Water Pipes for Turbochargers — Rear View (Sheet 1 of 3)610 392411 4a 50 Figure 6-2. Cooling Water Pipes tor Turbocharger — Top View (Sheet 2 of 3) WATER OUTLET ‘SUPPORT ‘SUPPORT COLLAR Gasker asker PLUG 1 WASHER, WASHER | SCREW SCREW Nut FLANGE ADAPTER PluG.32-36 A at ar-as 31. GASKET. 32, SEAL RING 33. GASKET. 49, NUT 54, CIRCULAR FLANGE 55. GASKET ‘56. CONNECTOR 58. CLAMP 59, SCREW 60. THREAD SEALANT 61, ORIFICE PLATE 62. NUT 63. SCREW 81. COUPLING Figure 6-2. Cooling Water Pipes for Turbocharger — Side View (Sheet 3 of 3)ie 30 27-31 24849 40 42 16-19-2527 <=) © a 2, GaskeT. 16. WASHER TE 3. GASKET 16. STUD 31, SCREW 4. COVER 19. NUT 32, COVER 5. PIPE TEE 20. SCREW 33, SCREW 6. PIPE 21. SCREW ‘34, COVER PIPE 25, SCREW 35, HOSE CLAMP 8. EXPANSION BELLOWS 26. PIPE CHOCK 3 ASKET 27. THREAD SEALANT 41. ELBOW 10, COLLAR 28. PIPE CLAMP. 42. CONNECTOR 11. CLAMP Figure 6-3. By-Pass Pipes and Cover Assembly|. TRANSITION PIECE. 2. EXPANSION JOINT . ROUND FLANGE RECTANGULAR GASKET sTuD Nut LockwiRe ROUND GASKET CAPSCREW nut |. Exhaust Gas Transition Piece6-14 0 " w 13 on 15. DISCONNECT CLEANING PIPING HERE TuBe CONNECTOR THREAD SEALANT RIGHT SUPPORT LEFT SUPPORT RESERVOIR HOSE CLAMP NuT SCREW screw GaskeT NIPPLE GLOBE VALVE ‘CONNECTOR 46. FUNNEL w PIPE CLAMP. 16 SCREW. 19. SCREW a. COLLAR Figure 6-5. Attachment of Cleaning Piping for the ‘Compressor Side of the Turbocharger20 19, TERMINAL BOX a 4. SLEEVE 14 CONNECTOR 5. PLUG 35. CONNECTOR ©. CHAIN LINK 16. CONNECTOR 7. CHAIN 47. SCREW 8. AKLE PIN LINK 20. cLamP 9. GASKET 42, THREAD SEALANT 10. GASKET 52. ELBOW 12 ADAPTER 53, UNION an Figure 6-6, Cleaning Piping for the Turbine Side of the Turbocharger (Sheet 1 of 5)616 8 12. 14 24, 2 26. zr 2 20, 30. GASKET ADAPTER Connector DRAIN PIPE — UPPER SECTION DRAIN PIPE — LOWER SECTION SCREW WASHER NuT GASKET screw 32 28 27 42 42 27 42.39 ‘suPpoRT ‘SCREW PIPE CLAMP COLLAR CAPSCREW LUG supPoRT SCREW WASHER Nur THREAD SEALANT INSULATION. 38 27 Figure 6-6. Cleaning Piping for the Turbine Side of Turbocharger (Sheet 2 of 5) 28.4218 17-42 4, WATER INLET 2. PIPE 11, TEE UNION 17. SCREW. 18. CLAMP. 19. suppoRT 22. CONNECTOR 42. THREAD SEALANT. Figure 6-6. Cleaning Piping for the Turbine Side of the Turbocharger (Sheet 3 of 5) 64740 23 42-33-27} 48 43 Figure 6- 6-18 FUNNEL WASHER SCREW FLANGE ‘THREAD SEALANT . VALVE GASKET scREW saw Lever AXLE WASHER NUT. SCREW SPRING Cleaning Piping for the Turbine Side of the Turbocharger (Sheet 4 of 5)DRAINING VALVE ‘ASSEMBLY 107 108-109 4 102 103 a pe 41, DRAIN VALVE ASSEMBLY 101. BODY 402. VALVE 103. SPRING 108. VALVE GUIDE 105. WASHER 406, NUT 107. ORIFICE 108. ADAPTER 108. SEALING COMPOUND Figure 6-6. Cleaning Piping for the Turbine Side of the Turbocharger (Sheet 5 of 5)i. Disconnect pipe (2) from draining valve assem- bly (41, Figure 6-6, sheet 5 of 5) at adapter (108) j. Remove hardware securing draining valve as- sembly flange (40) to bottom of turbocharger. k. Remove strap assemblies (17 and 18, Figure 6-7, sheet 2 of 2) from heat shield (16). Remove heat, shields (16). Remove screws (9, Figure 6-7, sheet t of 2) securing diffuser (4, Figure 6-7, sheet 2 of 2) to, expansion bellows (5). |. Remove strap assemblies (15 and 17, View C, Figure 6-8, sheet 1 of 2) securing covers (8 and 9). Remove covers (8 and 9). m. Remove screws (19, Figure 6-8, sheet 2 of 2) securing insulated section (2) to turbocharger. 1. Remove nuts (4, Figure 6-8) securing turbo- charger cradle and turbocharger to their mounting bracket WARNING Use lifting straps with sufficient strength to lift the turbocharger. Turbocharger weighs 7150 3250 kg). Lifting straps may fail during 1g if they are not strong enough, causing severe damage to turbocharger and injury or death to personnel. p. Attach lifting straps to the turbocharger as shown in Figure 6-10. Check to see that all lines, pipes and wires are disconnected from the turbo- charger. q. Lift turbocharger slowly off its mounting studs. Move turbocharger away from engine and lower it to wooden shims on the engine room floor. 6-9, DISASSEMBLY OF TURBOCHARGERS. Com- plete disassembly is not performed at this mainte- nance level. The disassembly procedures below are only performed as needed to clean and inspect the bearing chambers. It is not necessary to remove the turbocharger to perform the limited disassembly procedures listed below. a. Special tools, spare parts, and materials re~ auired: none. b. Removal and Disassombly of Air Filter and Silencer Assembly. (1) Remove screws (2, Figure 6-11) and washers (1) from air tilter and silencer assembly (Figure 6-11) (2) Remove hood (3) from turbocharger. (3) Remove screws (4) and washers (5) from air filter and silencer assembly (Figure 6-11) 6-20 (4) Remove air filter and silencer assembly from turbocharger. (5) Remove screws (41) and washers (40). Re: move filter segments (22, Figure 6-11 or 6-12) from air filter and silencer assembly. (6) Remove protective screen (1, Figure 6-13) trom filter segment. Remove capper filter mesh (2) from filter segment, ©. Removal and Disassembly af Covers for Bear- jing Chambers, Item numbers 87 through 102, Figure 6-14, pertainto the bearing chamber cover on the air compressor side of the turbocharger. Item numbers 103 through 116, Figure 6-15, pertain to the bearing chamber cover on the gas turbine side of the turbocharger. (1) Remove plug (98 or 113). Remove plug (95 or 111). Drain oil from turbocharger. (2) Remove screws that secure cover (87 or 103) to bearing chamber. (3) Remove bearing chamber cover fram turbo: charger. 6-10. CLEANING, INSPECTION AND REPAIR OF TURBOCHARGERS. It is not necessary to remove the turbocharger to perform the cleaning, inspec- tion and repair operations listed below. These oper- ations are limited to manual cleaning of the bearing chambers, and of the sealing and equalizing air pas- sages. Other, more frequently performed cleaning operations are covered in Chapter 2. Operation, Section VII, Maintenance Actions. a. Special tools, spare parts, and materials re- quired: (1) Special tools and spare parts: none. (2) Materials: aly Name 10% Cleaning agent (P-0-680) b. Manually Cleaning the Bearing Chambers. WARNING Provide adequate ventilation when using clean- ing agent P-D-680. Avoid prolonged breathing of vapors and minimize skin contact. CAUTION Do not disassemble any of the rotating parts during cleaning or they may become damaged or unbalanced. If any of these parts are dam- aged, refer the repair work to a higher mainte- nance echelon or the manufacturer.7. GaskeT 8. GASKET 9. SCREW 10. SCREW 41, STUD 12 sTuD 13. NUT +4. NUT 15. WASHER 23, THREAD SEALANT | 6. caster Figure 6-7. Inlet Pipe between Turbocharger and Air Cooler (Sheet 1 of 2) 2aFigure 6-8. Exhaust Pipe between Engine and Turbocharger (Sheet 1 of 2) 5. “V"BAND CLAMP 7. COVER 8 Cover 8, COVER 410. INSULATION 11, INSULATION 15. ASSEMBLY 16. ASSEMBLY 23. INSULATION1. INSULATED ELBOW 2. INSULATED SECTION 3. EXPANSION BELLOWS. 4 GASKET. 6. GASKET 19. SCREW Figure 6-8. Exhaust Pipe between Engine and Turbocharger (Sheet 2 of 2) 6-244. TURBOCHARGER — LH MOUNT 2, TURBOCHARGER — RH MOUNT 4.NuT 5. THREAD SEALANT Figure 6-9. Turbocharger@z C 1. WASHER 2. SOCKET SCREW 3. BONNET (HOOD) ASSEMBLY 4 HEX HEAD SCREW 5. LOCK WASHER 6 z 8 SILENCER / CONNECTING FLANGE SILENCER SEGMENT ASSEMBLY 9, POP-BLIND RIVET. 40, TUBULAR RIVET 11. SPACER 12. IRON SCREEN SEGMENT 43. FELT SEGMENT 14. FELT SEGMENT 15. SILENCER SEGMENT 16. FRONT FUNNEL ASSEMBLY 7. POP-BLIND RIVET 18. TUBULAR RIVET 18. IRON SCREEN SEGMENT 20. FELT SEGMENT 21. FRONT FUNNEL 22, FILTER SEGMENT ASSEMBLY 23, PROTECTION SCREEN 24 COPPER MESH 25, FILTER FRAME 26. HEX HEAD SCREW 27. WASHER 28. COVER AND DOOR ASSEMBLY 29, HEX HEAD SCREW 50. COVER RING 31. COVER 22, DOOR 133. NAME PLATE 34. SELF TAPPING SCREW 38. LOCKING KNOB 36. PLATE 37. BENZING TIGHTENING WASHER 38. WASHER 39. PIN 40, WASHER 41. HEX HEAD SCREW 42, LIFTING PIN 43. WASHER 44, PRESSING BOLT 45. HEX NUT. 46, LOCK WASHER 47, HEX HEAD SCREW 48, WASHER, Figure 6-11. Air Filter and Silencer Assembly 6-2722, FILTER SEGMENT ASSEMBLY Figure 6-12. Air Filter SegmentsPEP EPP PPL EPID PLL DELLE EEL EE 1, PROTECTION SCREEN = 2. COPPER MESH —_ Figure 6-13. Disassembly and Reassembly of Air Filter SegmentsIV, BEARING SPACE COVER 487, BEARING SPACE COVER — CE 88, SCREW PLUG 89, GASKET 90, MARKED CAUCE GLASS. 91. SIGHT GLASS. 92, SCREEN 99. GASKET 94, THREADED BUSHING 98. SCREW PLUG 96. GASKET 97. PLATE FOR CONTROL MEASURE K 98, ROUNO-HEADED HELICOIDAL RIVET 99, SCREW PLUG 400. GASKET 401, OIL LeveL PLATE 102. ROUND-HEADED HELICOIDAL RIVET Figure 6-14. Bearing Chamber Cover on Air Compressor Side 6-30v. 103, 40s, 106, 107, +08. 109, 110. 1 m2. 113 114, 415, BEARING SPACE COVER — TE BEARING SPACE COVER — TE | SCREW PLUG GASKET MARKED GAUGE GLASS SIGHT GLASS. ‘SCREEN GASKET ‘THREADED BUSHING SCREW PLUG Gasket SCREW PLUG Gasket OIL LEVEL PLATE OUND-HEADED HELICOIDAL RIVET Figure 6-15. Bearing Chamber Cover on Turbine Side 6-31(1) Clean all surfaces and parts in the bearing chambers (Figure 6-16 and 6-17) using cleaning agent P-0-680. (2) Alter cleaning check thatthe injection hales in the centrifuge (72, Figure 6-16 or 41, Figure 6-17) are not clogged. If they are clogged, blow them out, with compressed air ©. Manually Cleaning the Equalizing Passages. (1) Remove screws (124, Figure 6-18) and washers (125) from bonnet (123) on turbine side of, turbocharger. Remove bonnet (123). (2) Remove flange with screen (122) (3) Remove screws (203, Figure 6-19) and lock- washers (204) from bling flange (201) covering the cleaning port for equalizing passage on compressor side of turbocharger. Remove blind flange. WARNING. Provide adequate ventilation when using clean- ing solvent, P-D-680. Avoid prolonged breath- ing of vapors and minimize skin contact. (4) Clean equalizing passages through the cleaning ports in both the turbine and compressor sides of turbocharger with cleaning agent P-D-680. (5) Clean flange with screen (122, Figure 6-18) It screen is damaged, replace it 4. Manually Cleaning the Sealing Air Passages. (1) Remove screw (120, Figure 6-18) and lock- washer (121) from blind flange (118) over cleaning port in turbine side of turbocharger. Remove blind flange from cleaning port. Remove and discard gasket (119) WARNING Provide adequate ventilation when using clean- ing solvent, P-D-680. Avoid prolonged breath- ing of vapors and minimize skin contact. (2) Clean the sealing air passage through the cleaning port with cleaning agent P-D-680. 6-11, REASSEMBLY OF TURBOCHARGERS. a. Special tools, spare parts and materials re- quired: (1) Special tools and spare parts: aly Name Figure & Gasket 9, 6-14 6r 109, 6-15, {See Contractors Installation Drawings) (2) Materials: 6-22 oly Name AR Turbine oi b. Reassembly and Installation of Covers for Bear- ing Chamber. Item numbers 87 through 102, Figure 6-14, pertain to the bearing chamber cover on the air compressor side of the turbocharger. Item numbers, 103 through 116, Figure 6-15, pertain to the bearing chamber cover on the gas turbine side of the turbocharger. (1) Install screen (92 or 108) in hole for oil leve! window assembly in bearing chamber cover. Install one new gasket (93 or 109) and marked gauge glass, (80 or 106) in hole for oil level window assembly in bearing chamber cover. Install another new gasket (83 0r 108) over gauge glass. Secure oll level window assembly in cover with threaded bushing (94 or 110). (2) Install one new gasket (93 or 109) in hole for bearing inspection window in bearing chamber cover. Install sight glass (91 or 107) over gasket in, hole for bearing inspection window. Install another new gasket (93 or 109) over sight glass. Secure bear- ing inspection window assembly in cover with threaded bushing (94 or 110) (3) Install screw plug (95 or 111). Fill bearing chamber with the turbine oil specified in step a. (2) above, tothe fill evel marking on the oil level window assembly. Install screw plug (99 or 113). ©. Reassembly and Installation of Air Filter and Silencer Assembly. (1) Install copper filter mesh (2, Figure 6-13) in filter segments, (2) Install protective screen (1) in filter seg- ments as shown in the figure. (3) Install filter segments (22, Figure 6-11 or 6-12) inair filter and silencer assembly (Figure 6-11), Secure filter segments with washers (40) and screws (41), (4) Install air filter and silencer assembly on air compressor side of turbocharger. Secure air filter and silencer assembly to turbocharger with washers (5) and screws (4) (5) Install hood (3) on turbocharger. Secure hood (3) to turbocharger with washers (1) and screws (2) 6-12. INSTALLATION OF TURBOCHARGERS. a. Special tools, spare parts and materials re- quired(1) Special tools and spare parts: oy — Name Assembly Figure 2 Gasket for exhaust 145 668 fas tange 5 Gasket for inlet war 667 pipe flange (Sheet #01 2) 2 Gasket for inlet, 2.67 pipe ange (sheet 1012) 2 Gasket for inet 8.67 pipe ange (Sheet 108 2) 1 Gasket for upper 352 Bea flange 1 Gasket foriower 352 4.64 fiange 2 Gasket fr couping ree 2.63 Hianges of waste gate by-pass pines 5 Gasket tor ilet ur 6.07 pipe lange (Sneet 1012) 2 Gasket for cooting 131 31,62 water inlet pipe flange 2 Gasket for coating 131 33.62 water inlet pipe flange 2 Gasket for cooling 131 ‘water outlet pipe flange 2 Gasket tor cooling 131 water outlet pipe Nange + Diaphragm for cooling 131 27.62 water return pipe flange (2) Materials: none. WARNING Use lifting straps with sufficient strength to lift the turbocharger. Turbocharger weighs 7150, Ibs (3250 kg). Lifting straps may fail during lifting if they are not strong enough, causing severe damage to turbocharger and injury or death to personnel. . Attach lifting straps to turbocharger as shown in Figure 6-10. Lift turbocharger over engine and lower it slowly onto its mounting studs on top of air plenum ©. Secure turbocharger to mounting studs using nuts (4, Figure 6-9) d. Install new gasket (6, Figure 6-8, sheet 2 of 2) between flange of insulated section (2) and turbo- charger. Secure flange of insulated section (2) to turbocharger, €. Install cavers (Band 9, View C, Figure 6-8, sheet 1 0f 2). Secure covers with strap assemblies (15 and 17). {. Install new gaskets (6, 7, and 8 Figure6-7. sheet 1 0f 2) in flange of expansion betlows (5. Figure sheet 2 of 2). Secure flanges together with screw (8, Figure 6-7, sheet 1 of 2). Q. Install heat shields (16, Figure 6-7, sheet 2 of 2) ‘over expansion bellows (5). Secure heat shields with strap assemblies (17 and 18) h. Install hardware securing draining valve as- sembly flange (40, Figure 6-6, sheet 4 of 4) to bottom of turbocharger, i. Connect tube (2, Figure 6-6, sheet 1 of 4) to draining vaive (Figure 6-6, sheet 2 of 4) j. Connect tube (2, Figure 6-6, sheet 1 of 4) to tee union (11). k. Connect cleaning piping to the compressor side of the turbocharger (Figure 6-5) |. If there were any gaskets on the upper or flower flanges of the exhaust transition piece, replace these with new ones. Install the hardware securing upper and lower flanges of the exhaust transition piece to the exhaust stack, above, and the turbocharger exhaust outlet, below. 'm, Install new gaskets (9, Figure 6-3) in the cou pling flanges for the top and bottom of the waste gate by-pass pipe (6 or 7). 1. Install collar (10) over upper expansion bellows flanges (8, View D). Secure collar on flanges with worm drive clamp (11) 0. Install covers (34, Figure 6-3, View D) and secure them with hose clamps (35) p. Install new gaskets (31 and 33, Figure 6-2 sheet 1 of 3) in the flanges of the water inlets (3, 4.6 and 7) connecting to bottom of turbocharger. Secure flanges with gaskets to turbochargers. Q. Install new gaskets (34, View A, and 35, View B) and orifice plates on flanges of cooling water outlets (8, 9and 10, Figure 6-2). Secure flanges with gaskets, and orifice plates to turbochargers. r. Install exhaust temperature sensors (1 and 2 Figure 6-1) and temperature sensor (c) on the jacket water cooling pipes connecting to the turbochar:5a, 60. 6. 2 3. 6 6, 66. 67 BEARING — TE ROLLER BEARING INNER BEARING BUSHING OUTER BEARING BUSHING SPACER DAMPING SPRINGS RADIAL BEARING FLANGE. LOCKING FLANGE SOCKET SCREW LOCKWASHER 68, HALF OF SECURITY RING. 78, PUMP HOLDER 68, HEX HEAD SCREW 78. HOLDING SPRING 70, LOCKWASHER HEX HEAD SCREW 71. LOCK PLATE PAL-LOCKING NUT 72. CENTRIFUGE WASHER 73. RING NUT GEAR OIL PUMP — TE (COMPLETE) 74, HEX HEAD SCREW GUIDE BOLT. 75. LOCK PLATE 5. HEX HEAD SCREW 76. GASKET. 86. LOCKWASHER 7, PUMP HOLDER Figure 6-16. Bearing Chamber on Turbine Side2 3. HEX HEAD SCREW BEARING — cE BALL BEARING INNER BEARING BUSHING OUTER BEARING BUSHING DAMPING SPRINGS RADIAL DAMPING SPRINGS AXIAL. BEARING FLANGE LOCKING FLANGE SPACER SOCKET SCREW LockwasHEn 7 Ol BAFFLE PLATE 48, HOLDING SPRING HEX HEAD SCREW 49, HEX HEAD SCREW LocKWwasHER 50, PAL-LOCKING NUT LOCK PLATE 51. WASHER CENTAIFUGE 52. GEAR OIL PUMP — CE (COMPLETE) RING NUT 53. GUIDE BOLT. 54, HEX HEAD SCREW 55. LOCKWASHER LOCK PLATE. GASKET 56, BEARING BUSHING PUMP HOLDER 57. SOCKET SCREW PUMP HOLDER 58. LOCKWASHER Figure 6-17. Bearing Chamber on Compressor Side 6-35137 SEALING AIR PASSAGE = an EQUALIZING PASSAGE 133: 134 182.131 119°118 120 121 124 125 723, VI. GAS INLET CASING ASSEMDLY 190. SEALING BUSHING 117. GAS INLET CASING 431. HEX HEAD SCREW 118. BLIND FLANGE 482, LOCK PLATE 119. GASKET 133, WASHER 120, HEX HEAD SCREW 434, LOCK PLATE 121, LOcKWaSHER 195. HEX HEAD SCREW 122, FLANGE/SCREEN 136. LOCKWASHER 123, AIR DUCT BONNET 197. SECURING PIN 124, HEX HEAD SCREW 138. KEY 125. SPRING WASHER 199. SOCKET SCREW 126. HEX HEAD SCREW 140. SCREW PLUG. 127, HEX HEAD SCREW 141. GASKET 5. WASHER, 142. SCREW PLUS. 328, LOCKWASHER 142, GASKET 148, CORE HOLE COVERS Figure 6-18. Turbocharger Gas Inlet Casing 6-361% 199, 200. 201 202. 203. 200. 206. 206. 207. 208. 210. 212. 218 215. 217. 218. 219. 220. 221, 22. 222. 224 225. 209. an 213. 216. AIR INLET CASING ASSEMBLY AIR INLET CASING SEALING BUSHING BLIND FLANGE GASKET HEX HEAD SCREW LOCKWASHER NozzLe GASKET HEX HEAD scREW LOCKWASHER WASHER, FLANGE GASKET HEX HEAD SCREW LOCKWASHER BLIND FLANGE GASKET HEX HEAD SCREW LOCKWASHER Gasket BLIND FLANGE LOCKWASHER HEX HEAD SCREW Gasket BLIND FLANGE LOCKWASHER HEX HEAD SCREW Figure 6-19. Equalizing Passage on Air Compressor Side 6-37SECTION V COOLING SYSTEM 6-13. INTERCOOLER WATER PIPING. Weights for assemblies/components covered in this section are: ‘Assembly Component Weight 040 Water coding pipe 11515. (2kg) 128 Elbow pipes, turbo- enarger to air cooler £880 Ibs, (400 kg} 430 Coating water piping 1496 tos. (680 kg} 176 intercooler 7700 tbs. (8500 ko) 6-13.1, REMOVAL OF INTERCOOLER WATER, PIPING. a, Special tools, spare parts and materials re- quired: none. b. Drain low temperature water level (par. 6-105) below the level of pipe (7. Figure 6-20) NOTE In the process of removing pipe sections it may be necessary to tap on adjoining flanges with a brass mallet (or equal) to separate them. c. Support pipe (8) with straps from traveling crane or suitable hoist attached to engine or ship's frame, d. Remove nut (18, Figure 6-21) from one end of each threaded rad (16 and 17) at flange connection to three-way valve (100). Remove threaded rod with remaining nuts attached. e. Remove nut (18) from one end of each threaded rod (21) at flange connection to top of pipe (9) Remove studs with remaining nuts attached f. Remove pipe (8, Figure 6-20) from engine. Remove and discard gasket (15, Figure 6-21) for flange connection to three-way valve and gasket (20) for flange connection to top of pipe (9). g. Support pipe (3, Figure 6-20) with straps from traveling crane or suitable hoist connected to en- gine’s or ship's frame h. Remove nuts (18, Figure 6-21) from threaded rods (16 and 17) on just one side of flange connec- tion to three-way valve. Remove threaded rods (16 and 17) from flange connection with remaining nuts attached. i, Remove nuts (18, Figure 6-20, View A) only from the ends of threaded rods (21 and 34) coming through the flange connected to pipe (3). Do not remove the nuts {rom the other ends of threaded rod (34) so that support (93) continues to hold inlet pipe 6-38 (4). Remove threaded rod (21) with nuts (18) at tached one end from the side of the flange con- nected to inlet pipe (4). Do not remove threaded rod (34) yet. i. Pull pipe (3) away from flange connections at the top and bottom. Litt pipe (3) away from engine. Remove gaskets (20) from lower flange of pipe (3) k. Removea nut (18, Figure 6-21) from one end of ‘each threaded rod (16) in flange connection at outlet, flange of three-way valve (100). Remove threaded rod with remaining nuts attached |. Disconnect pneumatic line leading to top of three-way valve (100). Bend pneumatic line slightly, away from three-way valve to allow room for the removal of the valve. Be careful not to kink line while bending it m. Disconnect electrical cable leading to switch behind valve (or remove switch from valve) CAUTION Do notattach itting straps to the upper portion, of valve containing hand wheel and diaphragm as this portion of the valve Is not strong enough to support the weight of the valve during lifting. 1. Attach straps from traveling crane or suitable hoist connected to engine or ship's frame to flanged, body of three-way valve. Remove the valve from the engine. Remove and discard gasket (15, Figure 6-21), from flange connection at outlet of three-way valve. ©. Attach lifting straps from traveling crane or suitable hoist to pipe (12, Figure 6-20). Remove a nut (18) from one side of each threaded rod (16) in flange connection between pipes (12 and 13). Re- move threaded rods (16) with remaining nuts (18) attached p. Remove a nut (18) from one side of each threaded rod (21) in flange connection between pipes (12) and (9, Figure 6-21), Remove threaded rods (21) with remaining nuts (18) attached. a. Support pipe (13, Figure 6-20) with suitable straps, Remove pipe (12) from engine. Remove and discard gaskets (20 and 25) for pipe flanges. r. Attach lifting straps from traveling crane or suitable hoist to pipe (9, Figure 6-21) s. Remove hardware (23, 31 and 32) from support (10)29. 1 27-28 33: 3. 32 32-34 29 18-19-20-22' 4 . 30 [18-20-21 a 2 ~13 |” ® wp 2 79 4. SUPPORT 21. THREADED ROD 2. PIPE 22, THREADED ROD 4. PIPE 24. ORIFICE 6. FLANGE 25. GASKET 7. PIPE 26. THREADED ROD 2. PIPE 27. SCREW 12. PIPE 28. THREAD SEALANT 12. PIPE 29, PLUG 46. THREADED ROD 30. shim 48. NUT 32, WASHER 49. ORIFICE 33. SUPPORT 20. GASKET 34, THREADED ROD Figure 6-20. Intercooler Water Piping — Front View 6-39100 16-18-24-25 15.16.1718 1% 29 23 100 7 16 28 28 18 31 32 5. FLANGE 21. THREADED ROD 9. PIPE 23, SCREW 40. SUPPORT 24. ORIFICE 11. PIPE SECTION 25, GASKET 1. FLANGE: 27. SCREW 15. GASKET 26, THREAD SEALANT 46. THREADED ROD 29, PLUG 17. THREADED ROD 31. NUT 18. NUT 32, WASHER 20. GASKET 4100, THREE-WAY VALVE Figure 6-21. intercooler Water Piping 6-40t. Remove a nut (18) trom one end of each threaded rod (16) in flange connection to pipe sec tion (11). Remove threaded rods (16) with remaining nuts (18) attached U. Lift pipe (9) with pipe (12, Figure 6-20) from engine, Remove and discard gasket (25) from flange connection to pipe section (11, Figure 6-21) leading from intercooler. vv. Support pipe (7, Figure 6-20) with titing straps from traveling crane or a suitable hoist w. Remove hardware securing flange of pipe (7) to inlet of intercooler for engine bank B x. Remove a nut (18) from each threaded rod (26) at flange connection from pipe (7) to bottom of inlet pipe (4). Remove threaded rods (26) with remaining attached nuts (18) from the flange connection y. Remove pipe (7) from engine. Remove and dis- card gasket for tlange connection to inlet of inter- cooler for engine bank 8. Remove and discard gasket (25) for flange connection to bottom of init pipe (4) 2. Support iniet pipe (4) with lifting straps from traveling erane or suitable hoist aa. Remove hardware securing flange from inlet pipe (4) to inlet of intercooler for engine bank A. bb. Remove a nut (18) from one side of each threaded rod (21) in flange of inlet pipe (4) connect- ing to low temperature cooling water inlet pipe sup- plying engine. Remove threaded rods (21) with remaining nuts (18) attached. cc, Remove threaded rods (34) with nuts (18) trom support (33). Remove slip-on flange (5, Figure 6-21). Remove inlet pipe (4, Figure 6-20) trom engine, Remove and discard gasket (20, Figure 6-21) for flange connection to low temperature cooling water pipe supplying engine. dd. Attach lifting straps from traveling crane or suitable hoist to pipe (13, Figure 6-20). Remove sup- port straps that were added in step q, above. ee. Remove hardware securing flange from pipe (1) to outlet of intercooler for engine bank A, ff. Remove pipe (13) from engine. Remove and discard gasket for flange at outlet of intercooler for engine bank A 6-13.2, DISASSEMBLY OF INTERCOOLER WATER PIPING. Disassembly of low temperature water pip- ing consists only of disassembly of the three-way bypass control valve. All other piping was disas- sembled during the process of removal a. Special tools, spare parts and materials re- quired: none. b. Remove nuts (15, Figure 6-22) and bolts (16) from upper diaphragm case (13). Remove upper case with hand operating device attached. Remove diaphragm (14). ©. Remove shoulder screw (27) from rod end assembly (28). Remove bolts from yoke (23) and lft actuator off of valve body. 4. Remove diaphragm disc (17) with stem (22) attached, adjusting spring (20), spring washers (24) and spring adjuster (25) from adjusting sleeve (26) @. Remove bolts (19) securing lower diaphragm disc (18) to yoke (23). Remove lower diaphragm disc from yoke. WARNING Remove all compression from adjusting spring (20) by screwing down spring adjuster nut (25). {. Remove nut (1, Figure 6-22), lockwasher (2), and handwheel (3) g. Remove packing gland (5), packing rings washer (7) and O-ring (8) from bonnet (9) 6), fh. Screw handscrew (4) down into bonnet (9) Until stem bottoms on bonnet threads. i. Remove handscrew disc (10) from lower end of bonnet (9). Remove handscrew (4) through upper end of bonnet (9) CAUTION ‘Support rotor while removing locknut or rotor may drop out of valve and become damaged. j. Remove cotter pin (41, Figure 6-22) from lower end of rotor shaft (35). k. Hold lever (28) with a wrench to prevent it from turning. Remove locknut (40) and washer (39) from rotor shaft (35) using a socket wrench with ex: tension. |. Loosen lever lock screw and remove lever (29) Remove woodruft key (38) from shatt. NOTE Before removing rotor shaft (35) check for shaft bearing wear by moving shaft from side to side. Shaft should be held securely by its bear- ings (46). Any excess movement indicates that bearings are worn and should be replaced m. Lift rotor shaft (35) upward out of actuator side of valve body. Remove O-ring (55) and U-cup (54) with O-ring energizer (56) from shaft. eat27 28: 29. 30. apa as—t s6— sat 35—F ay 0 371 39 a 6-42 38 33 48 46 32 55 34 146 49 38 J +36 Nut LockwasHEr HANOWHEEL HANOSCREW PACKING GLAND PACKING RING. WASHER, O-RING BONNET HANOSCREW DISC GaskeT Lock NuT DIAPHRAGM CASE DIAPHRAGM Nut . BOLT DIAPHRAGM DISC DIAPHRAGM DISC SCREW ADJUSTING SPRING 1 JAM NUT. UPPER STEM YoKe WASHER ‘SPRING ADJUSTER ADJUSTING SLEEVE SCREW ROO END ASSEMBLY Figure 6-22. Three-Way Valve Lever SCREW 1 WASHER SEAL DISC | PACKING WASHER \. PACKING SPRING. |, ROTOR SHAFT VALVE BODY ROTOR WOODRUFF KEY WASHER NuT COTTER PIN ORIVE SCREW DATA PLATE O-RING PACKING ADAPTER BEARING. BEARING HOUSING Nur WASHER THRUST WASHER INDICATOR PLATE POSITION INDICATOR SCREW 1 U-cUP O-RING O-RING1, Remove washer (33) over packing adapter (45). Unscrew packing adapter (45) with upper bearing (46) trom body (36) 0. Remove sea! disc (32) with O-ring (55), washer (33), under seal disc, packing spring (34) and lower bearing housing (47) with lower bearing (46) from rotor body. 6-13.3. CLEANING, INSPECTION AND REPAIR OF INTERCOOLER WATER PIPING. ‘a. Special tools, spare parts and materials re- quired: (1) Special tools and spare parts: None (2) Materials: oy Name AR Cleaning Agent (P-D-680) WARNING Provide adequate ventilation when using clean- ing solvent, P-D-680. Avoid prolonged breath- ing of vapors and minimize skin contact. . Cleaning, Inspection and Repair of the Three- Way Bypass Contro! Valve. (1) Clean all parts in cleaning agent P-D-660, (2) Remove any encrustations from metal parts with 320 Grade Aluminum Oxide sandpaper or cloth, Bore body must be clean and smooth. (3) Replace any worn or damaged parts. Re- place all O-rings and seals with new parts, (4) After cleaning, check bearings to make sure they fit securely in their recesses. Bearings must be properly positioned so that they donot interfere with or damage rotor shaft when it is inserted through bearings during reassembly. . Cleaning, Inspection and Repair of Intercooler Water Pipe Sections, (1) Check all pipe segments for cracks and stress. (2) Flushall pipe segments with the appropriate wash solution and air dry. 6-13.4, REASSEMBLY OF THE INTERCOOLER COOLING WATER PIPING. Reassembly of inter- cooler water piping consists only of reassembly of the three-way bypass control valve, Reassembly of the remaining piping takes place during reassembly. a. Special tools, spare parts and materials re- quired: (1) Special tools and spare parts: ay Name Assembly Figure 1 O-ring 132 44, 1 Gasket 132 16 1 Onning 132 56. 1 Deus ced 54 5 Ong 12 55, (2) Materials: none. b. Install the lower bearing housing (47, Figure 6-22) with bearing (46) in body bore followed by packing spring (34) and washer (33) ©. Install a rew O-ring (44) in upper groove rotor shaft (35), 4. Place washer over rotor shaft (35) and push water up over O-ring (44) until it rests against shoulder of sheft. @. Place threaded packing adaptor (45) over shaft (35) and push adaptor up over O-ring (44) until i touches washer, 1. Cover lower woodruff keyway with a piece of adhesive tape. CAUTION Donotuse any lubricant while installing U-cup. 4. Install O-ring (66) in U-cup (64). Slide cup over shat with lip seal end downward until seal enters lower shat groove. h, Remove adhesive tape from woodrutf keyway. After installation, apply a small amount of silicone grease to outside diameter of cup after it is in its, groove, CAUTION Carefully follow steps i andj, below when posi- tioning seat disc (32) and packing adaptor (45) over U-cup seal. Failure to follow these steps correctly could result in damage to the lip seal of the U-cup (54). i, Install a new O-ring (55) in seal disc groove. Slide packing adaptor (45) toward U-cup (54) until U-cup lip just enters adaptor bore, Slide seal disc (32) up over shaft j. Push seal disc (32) and adaptor (45) upwardasa unit until pacts rest against washer at top shoulder of shaft (35) k. Carefully Icwer rotor shatt (36) with assembled parts into bore of body (36). Screw packing adaptor (45) into body threads and tighten or bolt packing flange to body. 6-43|. Install woodruft key (38) in upper keyway of shaft. Install lever (29) over end of shatt in same position as when it was removed, Tighten lockscrew. m. Place washer (49) followed by thrust washer (50) over lower end of rotor shaft (35), Align wood- ruff key (38) in shaft and install rotor in same posi- tion as when it was removed 1. Hold rotor in place and install washer (39) and locknut (40). Hold lever (29) with wrench and tighten locknut (40), Insert cotter pin (41) through hole in rotor shaft to secure locknut (40), Spreadends of pin to lock it in place. ©. Install handserew (4, Figure 6-22) through upper end of bonnet (9) p. Install handscrew disc (10) in bonnet over bot tom of handscrew (4). 4. Install O-ring (8), washer (7), packing rings (6) and packing gland (5) in bonnet (9) 1. Install handwheel (3), lockwasher (2), and ut (1) on handscrew (4). s, Install new gasket (11) on bottom of bonnet (9). Install assembled hand operating device on upper diaphragm case (13). Install locknut (12) to secure hand operating device to upper diaphragm disc. +. Install lower diaphragm disc (18) on yoke (23) Install bolts (19) for securing lower diaphragm disc to yoke. . Install adjusting sleeve (26) in yoke (23). Install spring adjuster (25), spring washers (24), adjusting spring (20), and diaphragm disc (17) with stem (22) attached in adjusting sieeve (26). Install diaphragm (14) over diaphragm disc (17) v, Install upper diaphragm case (13) over dia- phragm (14) an lower diaphragm disc (18). Secure upper diaphragm case to lower diaphragm disc with nuts (15) and bolts (16). Tighten nuts and bolts evenly crosswise to avoid pinching any one side of the diaphragm. w. Attach the rod end assembly (28) to lever (29) with screw (27) and tighten screw. x. Adjusting Valve Travel. If length of rod end assembly was disturbed during maintenance it may be readjusted as follows: (1) Loosen rod locknut (48, Figure 6-22) (2) Make sure rod end assembly (28) and lever (29) are properly aligned. Remove screw (27). (3) Screw rod end assembly (28) eitherin or out of actuator stem threads until length of rod end is 6-44 sufficient for rotor to cover port, Replace screw (27) and tighten it (4) Compress the adjusting spring (20) sutti- ciently to move diaphragm (14) up against actuator stop. Align travel indicator plate (51) and tighten screws y. Adjusting Preload of Adjusting Springs. (1) Make sure that there is no residual pressure in the valve. (2) Apply 6 psig (0.4137 bar) air pressure froma local compressed air source into the upper dia phragm case (13). {f the spring preload is correct, the rotor (37) should just start to move under the application of the compressed air. If necessary turn the spring adjuster (25) to adjust the preload 6-135, INSTALLATION OF INTERCOOLER WATER, PIPING. a. Special tools, spare parts and materials re- quired: (1) Special toals and spare parts: ay Name ‘Assembly Figure 3 Gasketfor pipe tianges 132 20, 6-20, 6-21 5 Gasket forpipetianges 132 25,6-20. 621 5 Gasket forpipetianges 132 20,620, 6-21 AR Shim s2 30. 6-20 (2) Materials: none. b. Attach lifting straps to pipe section (11, Figure 6-21). Lift pipe section (11) into position on engine c. Install gasket between flanges of pipe section (11) and outlet of intercooler for engine bank d. Install and tighten hardware for securing flange connection to outlet of intercooler. e. Attach lifting straps from traveling crane or suitable hoist to pipe (13, Figure 6-20) {. Lift pipe (13) into position on engine. Install new gasket between flange of pipe section and outlet flange of intercooler for engine bank A. Install and tighten hardware for securing flange of pipe to intercooler. g. Attach support straps from pipe (13) to high temperature jacket water pipes leading out of inter- coolers directly above. These support straps are necessary to prevent damage to the outlet of inter- cooler on engine bank A due to the weight of pipe (13) when the lifting straps from the crane or hoist are removed. Remove lifting straps from pipe (13)h. Attach lifting straps from traveling crane or suitable hoist to intet pipe (4). Lift inlet pipe (4) into position on engine. Be sure to position the flange of inlet pipe (4, View A) to the left of support (33) i. Install new gasket for flange connection of inlet pipe (4) to inlet of intercooler for engine bank A. ‘Attach and tighten hardware for securing flange of pipe (4) to intercooler j. Install threaded rods (34, View A) (with nuts attached on one side of each stud) through holes in support (33, View A) and through holes in adjoining flange of inlet pipe (4). Do not attach remaining nuts on other side of these studs at this time. , Install new gasket (20, Figure 6-21) between flange of iniet pipe (4, Figure 6-20) and adjoining flange of low temperature cooling water inlet pipe supplying engine. Install threaded rods (21, Figure 6-21) and nuts (18) in flange connection. Tighten nuts (18). |. Attach lifting straps from traveling crane or suitable hoist to pipe (7. Figure 6-20). Lift pipe (7) into position on engine. im, Install new gasket between inlet of intercooler for engine bank 8 and adjoining flange of pipe (7) Install and tighten hardware for securing flange of pipe to intercooler. fA. Install new gasket (25) between lower flange of inlet pipe (4) and pipe (7). Install threaded rods (26) and nuts (18). Tighten nuts (18). ©. Attach lifting straps to pipe (9, Figure 6-21). Lift pipe (9) into position on engine, p. Install hardware (23, $1, and 82) to attach pipe (9) loosely to support plate (10) 4g. Install orifice (24), new gaskets (28), threaded rods (16) and nuts (18) in flange connection between pipe (2) and pipe section (11) r. Tighten nuts (31) to secure pipe (9) to support plate. s, Attach lifting straps from traveling crane or suitable hoist to pipe (12, Figure 6-20). Lift pipe (12) into position on the engine. 1. Install new gasket (20), between flange of pipe (12) and pipe (9, Figure 6-21). Install threaded rods (21, Figure 6-20) and nuts (18) in flange connection. Tighten nuts (18). Remove lifting straps from pipe (9). CAUTION Donot attach lifting straps to the upper portion of valve containing hand wheel and diaphragm 1s this portion of the valve is not strong enough tosupport the weight of the valve during lifting. uu, Attach lifting straps from traveling crane or suitable hoist connected to engine's or ship's frame to flanged body of three-way valve (100, Figure 6- 21), Lift valve and install it in position on engine. v. Connect electrical cable switch behind three- way valve (or install switch on valve) w. Connect pneumatic line to top of three-way valve. x. Install new gasket (15, Figure 6-21), threaded rods (16) and nuts (18) for securing outlet flange of three-way valve to flange of outlet pipe for low temperature cooling water. Remove lifting straps from three-way valve y. Attach lifting straps trom traveling crane or suitable hoist to pipe (3, Figure 6-20). Lift pipe (3) into position on engine 2. Install new gasket (15, Figure 6-21) between flange of pipe (3, Figure 6-20) and flange of three- way valve (100). Install threaded rods (16 and 17, Figure 6-21) and nuts (18) in flange connection. Tighten nuts (18) aa, Install orifice (19, Figure 6-20) and new gas- kets (20) between lower flange of pipe (3) and flange of inlet pipe (4). Install studs (21) in flange connec- tion. Install and tighten nuts (18) on threaded rods (21 and 34). Remove lifting straps from pipe (3). bb. Attach lifting straps from traveling crane or suitable hoist to pipe (8). Lift pipe (8) into position on engine ce. install new gasket (20, Figure 6-21) between flanges of pipe (9) and pipe section (8, Figure 6-20} Install threaded rods (21, Figure 6-21) and nuts (18) in flange connection. Tighten nuts (18) dd, Install new gasket (15) between flange of pipe (8, Figure 6-20) and inlet flange “A” of three-way valve (100, Figure 6-21), ee. Install shims (30, Figure 6-20) to obtain an appropriate thickness to take up the remaining sep- aration between flange of pipe (8) and inlet flange of three-way valve. ff, Install threaded rods (16 and 17, Figure 6-21) in flange connection of pipe (8, Figure 6-20) and three- way valve. Install and tighten nuts (18) on threaded rods (16 and 17, Figure 6-21) 6-456-14. TURBOCHARGER UPPER AND LOWER WATER COOLING PIPING. WARNING Use appropriate lifting apparatus when remov- ing the high temperature water piping. Failure to exercise appropriate caution may result in damaged engine components and personal injury. 6-14.1. REMOVAL OF INLET AND OUTLET PIP. ING TO AND FROM TURBOCHARGERS. a, Special tools, spare parts and materials re- quired: none. b. Remove screws (40, Figure 6-23, sheet 1 of 3) securing water outlets (8, 9 and 10) to both turbo- chargers. ¢. Remove screws (46) from water outlet (10) extension piece on both turbochargers. Remove nuts, screws and washers (50, 44 and 39, Figure 6-23, sheet 2 of 3) securing water outlets (8 and 10, Figure 6-23, sheet 1 of 3) to collar (24, Figure 6-23, sheet 2 of 3) 4d. Install lifting strap to water outlet (10, Figure 6-23, sheet 1 of 3). Remove hardware securing cou- pling (26) to water outlet (10) at deaerator tank (1). Use traveling crane and remove water outlets (10 and 9) from engine, Remove diaphragm (27), orifice plate (28) and gaskets (34 and 35) , Install lifting strap to water outlet (8). Remove hardware securing coupling (26) to water outlet (8) at deaerator tank (1). Use traveling craneand remove water outlets (8 and 9) from engine. Remove dia- phragm (27), orifice plate (28) and gaskets (34 and 36) 6-14.2. REMOVAL OF TUBES FROM DEAERATOR ‘TANK AND INTERCOOLERS. a, Special tools, spare parts and materials re- quired: none. b. Disconnect tubes (53, Figure 6-23, sheet 1 of 3) atadapter (57, Figure 6-23, sheet 2 of 3) on deaerator tank (1, Figure 6-23, sheet 1 of 3) ©. Remove screws (59, Figure 6-23, sheet 3 of 3) securing clamps (58) over tubes (53, Figure 6-23, sheet 1 of 3). Remove clamps (58, Figure 6-23, sheet 3 of 3). d. Remove remaining screws and clamps (59 and 58) over tubes (53, Figure 6-23, sheet 1 of 3) 6-46 fe. Remove screws and nuts (63 and 62, Figure 6-23, View L, sheet 3 of 3) securing tube segments (53, Figure 6-23, sheet 1 of 3). Disconnect tube seg- ments and remove circular flanges, orifice plates and gaskets (54, 61 and 55, Figures 6-23, sheet 3 of 3). Remove free tube segments (53, Figure 6-23, sheet 1 of 3) from engine f. Unscrew and disengage connectors (56) at both intercoolers. Remove remaining tube segments (53) from engine. 6-14.3. REMOVAL OF WATER INLETS AND OUT- LETS FOR ENGINE BANK B. a. Special tools, spare parts and materials re~ auired: none. b. Install lifting strap around water inlets (2,3.and 4, Figure 6-23, sheet 1 of 3) to be removed from the engine asa single unit without swaying c. Remove nuts and screws (44 and 31, Figure 6-24, sheet 1 of 2) securing water inlet (2, Figure 6-23, sheet 1 of 3) to tube (9, Figure 6-24, sheet 1 of 2). Remove hardware fastening water inlets (3. and 4 Figure 6-23, sheet 1 of 3) to turbocharger. Use travel ing crane and remove water inlets (3, 4 and 2) from engine. Remove gasket (24, Figure 6-26, sheet 1 of 2) from water inlet (2, Figure 6-23, sheet 1 of 3). Remove any gaskets from water inlets (3 and 4). Remove gasket and plug (33 and 37) d. Install lifting strap totube (9, Figure 6-24, sheet 1 of 2), Remove nuts, washers and screws (45, 29 and 40) securing collar (19) aver tube (9). Remove col- lars (19), fe. Remove nuts and screws (44 and 31) securing water outlet (8, Figure 6-23, sheet 1 of 3) to water outlet (9). Use traveling crane and remove water outlet (9) from engine. Remove gasket (24, Figure 6-24, sheet 1 of 2) f. Remove screws (34, Figure 6-24, sheet 2 of 2) from collars (21). Remove collars (21). Remove nuts and screws (44 and 31) securing tube (10) to tube (11). Remove tube (10) through turbocharger mount- ing bracket. Remove gasket (25) and O-ring (27). 9g. Remove screws (42) securing tube (8) to box (4). Remove outlet (8) with gasket (22) h. Remove screws (37) securing box (4) toengine frame. Remove box (4) and O-ring (26) i. Remove nuts and screws (45 and 38, Figure 6-24, sheet 1 of 2) securing tube (11, Figure 6-24 sheet 2of 2) to valve (18). Remove tube (11) and any gaskets.40 34 1 2 3 4 5. 6. 7 8 8 0. DEAERATOR WATER INLET WATER INLET WATER INLET WATER INLET WATER INLET WATER INLET. WATER OUTLET WATER OUTLET WATER OUTLET ‘couPLING. DIAPHRAGM ORIFICE PLATE GASKET GASKET Gasker asker PLUG SCREW SCREW SCREW 5 SCREW SCREW NUT. NUT Tube CONNECTOR FLEX TUBE CONNECTION BLIND FLANGE Figure 6-23. Upper Turbocharger Water Cooling Piping — Rear View (Sheet 1 of 3) 6-4711, WATER OUTLET 38. suppoRT 18, SUPPORT 24. COLLAR 29, GASKET 33. GASKET a7. PLUG 38. WASHER 39. WASHER 41, SCREW 44, SCREW 50. NUT 52. FLANGE 57. ADAPTER 665, PLUG Figure 6-23. Upper Turbocharger Water Cooling Piping — Top View (Sheet 2 of 3) 6-48231, GASKET 22, SEAL RING. 38. GASKET 36. PLUG. a7. PLUG 4. screw 49, NUT 54, CIRCULAR FLANGE 55. GASKET 56. CONNECTOR 58. CLAMP. 59. SCREW 60. THREAD SEALANT 61. ORIFICE PLATE 62. NUT 63. SCREW 83, COUPLING Figure 6-23. Upper Turbocharger Water Cooling Piping — Side View (Sheet 3 of 3) 6-496-50 NUT 46. “8 50, st. 53, 4 58. ee 81 46-56 50 49 43-46 39 16 29 45 29 nut ‘OUTLET BEND ASSEMBLY couPLING THREADED OUTLET plus GaskeT screw Figure 6-24, Lower Turbocharger Water Cooling Piping — Rear View (Sheet 1 of 2)3. JUNCTION TUBE ASSEMBLY 27. O-RING JUNCTION Box 29, WASHER ourter 30, SCREW Tuse 31. SCREW ‘use 32, SCREW casing 34. SCREW VALVE 35. SCREW SUPPORT 37. SCREW 3. SUPPORT 42, SCREW COLLAR aa. NUT GaskeT 45, NUT GASKET 47. WASHER, GASKET 48. GASKET Gasket 55. ORIFICE O-RING Figure 6-24. Lower Turbocharger Water Cooling Piping — Side View (Sheet 2 of 2) 65112. 2 16 16. 20. a. 22, a 2. 20, 2 4. 64 65, 67 6s 6 70. 7. 2. 73 ™ 75 78. 7. 78 6-52 OUTLET TOWARD INTERCOOLER COOLANT INLET INTERCOOLEA WATER OUTLET Tue ELBOW SUPPORT SUPPORT COLLAR { cross BAR PIPE COUPLING GaskeT ‘SCREW ‘Screw SCREW Nut Plus WASHER GASKET HLT. WATER INLET. HIT. WATER OUTLET FLANGE asker ADAPTER, NIPPLE GATE VALVE ‘ScREW ‘SCREW Figure 6-25. Intercooler Water Piping — Side and Front Views(210 1 1904s) smaiq doy pue pig 1eay — Buidig Buoo9 s01e sepUIIKD “92-9 B1NBI (ea, iach ne auos mai mat did wav ONII009 3 sb zm Hb 6-53,6. stor 12. SCREW 13, SCREW 44 SCREW 15, SCREW 16. SCREW 18. GaskeT 20. GASKET 22. WASHER 23. PLUG 24, LOCKNUT 25. THREAD SEALANT. Figure 6-26. Cylinder Water Cooling Piping — Fastening Hardware (Sheet 2 of 2)6-14.4, REMOVAL OF WATER INLETS AND OUT- LETS FOR ENGINE BANK A. a, Special tools, spare parts and materials re- quired: none. b. Install lifting strap around water inlets (5. Gand 7, Figure 6-23, sheet 1 of 3) to be removed from the ‘engine as a single unit without swaying. Remove nuts and screws (44 and 31, Figure 6-24, sheet 1 of 2) securing water inlet (5, Figure 6-23, sheet 1 of 3) to tube (6, Figure 6-24, sheet 1 of 2) c. Remove hardware fastening water inlets (6 and 7, Figure 6-23, sheet 1 of 3) to turbocharger. Use traveling crane and remove water inlets (6, 7 and 5) from engine. Remove any gaskets from water inlets (6 and 7). Remove gasket and plug (33 and 37) 4. Install lifting strap to tube (6, Figure 6-24, sheet 1 0f 2), Remove nuts, washers and screws (45, 29nd 40) securing collar (19) over tube (6). Remove collar (19) e. Remove screws and nuts (31 and 44) securing tube (6) to outlet (5), Use traveling crane and remove tube (6) from engine. Remove gasket (24). {. Remove screws (42, Figure 6-24, sheet 2 of 2) securing outlet (5, Figure 6-24, sheet 1 of 2) to box (4, Figure 6-24, sheet 2 of 2). Remove outlet (5, Fig- Lure 6-24, chest 1 of 2) from engine. Remove gasket (22, Figure 6-24, sheet 2 of 2) 9. Remove screws (37) securing box (4) to engine frame, Remove box (4) and O-ring (26). 6-14.5, REMOVAL OF WATER INLETS AND OUT- LETS OF CYLINDER HEADS. a, Special tools, spare parts and materials re- quired: none. b. Remove tubes (53, Figure 6-23, sheet 1 of 3). (par. 6-14.2), Remove low temperature cooling pipe (8, Figure 6-20), (par. 6-18.1, b through f) ©. Install lifting strap to inlet connection elbow (1, Figure 6-28) between engine Bank B and its inter- cooler. Remove elbow (par. 6-15.2) d. Install lifting strap to elbow (16, Figure 6-25) Remove plug and gasket (67 and 69) fe. Remove nuts and screws (65 and 64) securing elbow (16) to tube (15) on deaerator tank (1, Figure 6-23, sheet 1 of 3). Use traveling crane and remove elbow (16, Figure 6-25). Remove gasket (30) and any gasket at connection of elbow to deaerator tank. {. Install lifting strap to tube (15). Remove hard- ware securing pipe coupling (25) between tube (15) and outlet (14). Slide pipe coupling (25) off tube (15). g. Remove screws (45) from collar (22). Remove collar from tube (15) and outlet (12). Use traveling crane and remove tube (15) from engine. h. Intall lifting strap to outlet (12). Remove screws and nuts securing outlet (12) on deaerator tank Figure 6-23, sheet 1 of 3) i. Loosen and remove hardware securing pi coupling (25, Figure 6-25) to outlet (12) and inlet (13). Slide pipe coupling (25) off outlet (12). Use traveling crane and remove outlet (12) from engine. |. Remove hardware fastening support (20) 10 engine, Remove support (20). Install lifting strap to, inlet (13). Remove nuts and screws (65 and 64) se- curing inlet (13) to inlet (70) leading to radiators. Unscrew and disconnect adapter (74) with gate valve (76), then remove gasket (69). Remove plug and gasket (67 and 69) from inlet (13). Use traveling crane and remove inlet (13) from engine. Remove any gasket between inlets (13 and 70) k. Install lifting strap to outlet (14). Remove nuts and screws (65.and 64) securing outlets (14 and 77). Unscrew and disconnect adapter (74) with gate valve (76), then remove gasket (69). Remove any other plugs and joints. Use traveling crane and remove outlet (14) from engine, |. Install lifting strap to inlet (70). Remove hard- ware securing inlet (70) to both intercoolers. Use traveling crane and remove inlet (70) from engine. Remove any gaskets. m. Install lifting strap to outlet (71). Remove hardware securing outlet (71) to both intercoolers. Use traveling crane and remove outlet (71) from engine. Remove any gaskets, 1, Install lifting strap to engine Bank B outlet bend assembly (49, Figure 6-24, sheet 1 of 2). Remove hardware securing coupling (50) to outlet bend assembly (49), Slide coupling (50) off outlet bend assembly (49). Remove nuts and screws (46 anc 43) securing outlet bend assembly (49) to section (8, Figure 6-26, sheet 1 of 2). Use traveling crane and remove outlet bend assembly (49, Figure 6-24, sheet 1 of 2) from engine. Remove gasket (48, Figure 6-24, sheet 2 of 2). ©. Perform step (m., above) at engine Bank A outlet bend assembly (49, Figure 6-24, sheet 1 of 2) p. Remove hardware securing all eight pipe cou plings (18, Figure 6-26, sheet 1 of 2) to their respec- tive sections (8 and 7). Adjust the position of each pipe coupling (18) s0 that each section (Band 7) may 6-55be removed from the engine when disconnected from its cylinder head connection tube (View 0) a, Remove screws (14, Figure 6-26, sheet 2 of 2) securing section (8, Figure 6-26, sheet 1 of 2) to its. cylinder head connection tube. Remove section (8) from the engine +. Proceed down engine Bank B, then up engine Bank A, removing each section (7 and 8), step (16, above). 5. Install lifting strap to pipe (11). Disconnect hardware securing pipe (71) to ship's inlet source pipe. Remove inlet source pipe. Remove locknuts and screws (24 and 12) securing pipe (11) to elbows (and 10). Use traveling crane and remove pipe (11) from engine. Remove gaskets (20) t. Install ifting strap to elbow (9). Remove nuts and screws (24 and 12) securing elbow (9) to section {2). Use traveling crane and remove elbow (9) from engine. Remove gaskets (20). us Install lifting strap to elbow (10). Remove plugs (28, Figure 6-26, sheet 2 of 2). Remove nuts and screws (24 and 12) securing elbow (10) to section (3). Use traveling crane and remove elbow (10) to section (3). Use traveling crane and remove elbow (10) from engine. Remove gasket (20) WARNING. Consult supervisory personnel on the appro- priate support, harness and/or removal appa- ratus for sections (1,2 and 3, Figure 6-26, sheet 1 of 2). v. Properly support and harness section (2, Fig- ure 6-26, sheet 1 of 2). Remove screws (13, Figure 6-26, sheet 2 of 2) from stops (6). Disengage section (2) from its support on engine frame, then remove section (2) from engine. w. Perform step (v., above) for all remaining sec- tions (1 and 3, Figure 6-26, sheet 1 of 2) around engine frame. 6-14.6. CLEANING, INSPECTION AND REPAIR OF THE TURBOCHARGER UPPER AND LOWER WA- TER COOLING PIPING. a. Special tools, spare parts and materials re- quired: (1) Special tools and spare parts: ay Name Assembly 6 Gasket 1 Seal ring 14 Gasket Gasket 6-56 2 Gasket 131 2 Gasket 13 4 Gasket 131 1 Gasket 131 5 O-ting 135 1 o-nng 131 1 Gasket 131 2 Gasket 131 2 Gasker 131 8 Gasket x20 5 Gasket 130 4 Gasket 130 4 Gasket 130 Gasket 130 (2) Materials: none. b. Check that all gaskets, seals and O-rings have been removed. If not, remove remaining ones with the appropriate scraping or prying tool. Be careful not to damage flange seating surface. c. Inspectall piping sections and components for cracks, stress and irregular bending. Inspect all seat ing surfaces. 4, Wash all piping sections and components with the appropriate wash solution and allow to dry. e. Replace all gaskets, seals and O-rings (Figures 6-28 through 6-26) 6-14.7. INSTALLATION OF TURBOCHARGER UP- PER AND LOWER WATER COOLING PIPING a. Special tools, spare parts and materials re- quired: none. b. Check that all gaskets, seals and O-rings nave been replaced (see par. 6-14.6; a.) NOTE Installation of the turbocharger upper and lower piping and components requires no spe- cial alignments, torques or tools. Lock ail nuts, and screws with the appropriate materials as, required. lilustrations used for removal identity all such hardware, lubrication and locking material(s) WARNING Use appropriate harnessing, support and lift- ing apparatus when installing piping. Failure to exercise appropriate caution may result in damage to components and serious personal injury. ©. Install turbocharger upper and lower water cooling piping in the reverse order of removal (par. 6-14.1 through 6-14.5).6-15, INTERCOOLER LEAK DETECTION PIPING, INLET CONNECTION BETWEEN INTERCOOLER AND TURBOCHARGER, AND INTERCOOLER. 6-15.1, REMOVAL OF INTERCOOLER LEAK DE- TECTION PIPING. a. Special tools, spare parts and materials re- quired: none. b. Disconnect connector (2, Figure 6-27, sheet 1 of 2) with tube (1). c. Remove hardware securing U-bolt (7) around air pipe leak detector (6) d. Remove nuts and screws (36 and 36, Figure 6-27, sheet 2 of 2) securing feed trap (27, Figure 6-27, sheet 1 of 2) to support pipe (13, Figure 6-27, sheet 2 of 2). e. Unscrew and disconnect tube flared fitting (25) connecting tube (41, Figure 6-27, sheet 1 of 2) to automatic drain trap (9, Figure 6-27, sheet 2 of 2) f. Disconnect and remove tube (41, Figure 6-27, sheet 1 of 2) from air intake manifold g. Remove both screws securing tube (24) from underneath air intake manifold. Remove tubes and feed trap (41, 24, 1 and27) together with air pipe leak detector (6) from engine. Remove gasket (29, Figure 6-27, sheet 2 of 2) and nut (33) h. Remove nuts and screws (36 and 37) securing automatic drain trap (9) to cover (16). Remove trap (9) with gaskets (98 and 29) i. Unscrew and remove adapter (20) with elbow (21) from detection box (10). Remove gasket (22) j, Remove screws (40) and gaskets (38) securing diaphragm valve (100) to detection box (10). Remove diaphragm valve (100) from detection box (10) Remove gaskets (29) and diaphragm (17) k. Remove hardware securing detection box (10) to engine frame, Remove detection box (10) from engine, |. Remove connector (2, Figure 6-33) with tube (1) (on timing gear side engine Bank B. m, Remove hardware securing U-bolt (7) around air pipe leak detector (6) 1, Remove nuts and screws (36 and 35, Figure 6-27, sheet 2 of 2) securing feed trap (26, Figure 6-27, sheet 1 of 2) to support pipe (13, Figure 6-27, sheet 2 of 2) ©. Unscrewand disconnect tube flared fitting (25) and tube (41, Figure 6-27, sheet 1 of 2) to automatic. drain trap (9, Figure 6-27, sheet 2 of 2) p. Disconnect and remove tube (41, Figure 6-27, ‘sheet 1 of 2) trom air intake manifold 4g. Remove both screws securing tube (24) trom underneath air intake manifold. Remove tubes and feed trap (41,23, 1 and 26) together with air pipe leak detector from engine. Remove gasket (29, Figure 6-27, sheet 2 of 2) and nuts (33) t. Repeat steps (h through k, above) at opposite engine Bank 6-15.2. REMOVAL OF THE INLET CONNECTION BETWEEN THE TURBOCHARGER AND INTER- COOLER. a. Special tools, spare parts and materials re- quired: none. b. Removal of Inlet Connection Between Turbo- charger and Intercooler for Engine Bank A (1) Remove nuts (22, Figure 6-28) securing strap assembliss (17 and 18) around heat shields (18). Remove strap assemblies (18 and 17). Remove heat shields (16). Install lifting strap to elbow (2) WARNING Elbows (1 and 2, Figure 6-28) weigh 880 Ibs (400 kg). Use appropriate caution when remov- ing them from the turbocharger and air ple- ‘um, Install lifting strap at their approximate center of gravity and use the traveling crane to support their weight before removing hard- ware securing each to their respective engine components. (2) Remove screws (9, Figure 6-29) securing bellows (5, Figure 6-28) to diffuser (4). See WARN- ING, above. (3) Remove nuts (13, Figure 6-29) from screws (10) securing elbow (2, Figure 6-29) to pipe spacer (3). Use traveling crane and remove elbow (2) with bellow (5) from engine (4) Remove gaskets (6 and 7, Figure 6-29) from elbow (2, Figure 6-28) and bellow (5) respectively. Install lifting strap (5) to diffuser (4) (8) Remove nuts (14, Figure 6-28) trom studs (11) securing diffuser (4, Figure 6-28) to turbo- charger. Use traveling crane and remove diffuser (4) from turbocharger. Remove studs (11, Figure 8-29) and gasket (8) (6) Installfting strap to pipe spacer (3, Figure 6-28). Remove nuts (13, Figure 6-28) from studs (12), securing pipe spacer (3, Figure 6-28) to air plenum Use traveling crane and remove pipe spacer (3) and gasket (6, Figure 6-28) from engine 6-57© 45 %6-47-28 4. TUBE 2, CONNECTOR 4. PIPE SUPPORT IPE SUPPORT 5. AIR PIPE LEAK DETECTOR 7. U-BOLT 12. Tee 23. TUBE 24, TUBE 26. FEED TRAP 27, FEED TRAP Figure 6-27. Intercooler Water Leakage Detector (Sheet 1 of 2) WE-48 28, THREAD SEALANT 31. GASKET 32, PLUG 34, SCREW 41, TUBE, 42. TEE 44, ADAPTER 45, HALF CLAMP 46. SCREW 47, NUT8, AUTOMATIC DRAIN TRAP. 40, DETECTION BOX 18, SUPPORT PIPE 14. SUPPORT PIPE 15, SCREW 46. COVER 17, DIAPHRAGM 10, Level swiTcH 19, FLANGE 20, ADAPTOR 21, ELBOW. 22, GASKET ‘TUBE FLARED FITTING THREAD SEALANT . GASKET asker Nut ‘screw NUT SCREW GASKET SCREW SCREW DIAPHRAGM VALVE Figure 6-27. Intercooler Water Leakage Detection Drain Trap (Sheet 2 of 2) 6-59WASHER @ 23. THREAD SEALANT Figure 6-29. Inlet Connection Between Turbocharger and Intercooler — Fastening Hardwarec. Removal of Inlet Connection Between Turbo- charger and Intercooler for Engine Bank B. (1) Remove nuts (22. Figure 6-28) securing strap assemblies (18 and 17) around heat shields (16). Remove strap asemblies (18 and 17). Remove heat shields (16). Install lifting strap to elbow (1). (2) Perform step (b.2, above). Install traveling crane to elbow (1) (2) Remove nuts (13, Figure 6-29) from studs (12) securing elbow (1, Figure 6-28) with bellow (5) toair plenum. Use traveling crane and remove elbow (1) with bellow (5) from engine. Remove gaskets (6 and 7, Figure 6-29) from elbow (1, Figure 6-28) and bellow (5) respectively (4) Install lifting strap to diffuser (4). (5) Perform step 6.5, above) 6-15.3, REMOVAL OF THE INTERCOOLER. a. Special tools, spare parts and materials re- quired: (1) Special tools and spare parts: ay Name Figure 1 Intercooier handling toot 632 (2) Materials: none. b. Drain the high and low temperature cooling water piping (par. 6-105 and 6-106). c. Remove the low and high temperature cooling water piping from the front of the intercooler (par. 613.1 and 6-14.2). . Remove the transition piece (1 or 2, Figure 6 30, sheet 1 of 2). Refer to par. 6-42.3. for this, procedure. e. Disconnect the drain tine from the bottom trough of box (3 or 4), by removing screws (21, Figure 6-30, View H, sheet 2 of 2). Separate flange (6) from the trough. Remove and discard gasket (13). 1. Support the box with a sling attached to the hoist of the traveling crane. 9. Disconnect and clear any other lines, piping or sensor wires that may impede the removal of the box. h. Remove screws (18, View B) that secure the lower drainage trough to support plate (2, Figure 6-31, View A) i, Remove the remaining screws (16, Figure 6-30, View B, sheet 2 of 2) that secure the box to the support plate. 6-62 j. Remove the box from the support plate k. Position handling tool (1, Figure 6-32) diago: nally over the intercooler as shown. Install the four screws (2) that fasten the handling tool to the inter cooler. Install shackles (3) on the tool WARNING The intercooler weighs 7700 Ibs (3500 kg). Use a crane, hoist, slings and spreader beam of ‘SUFFICIENT CAPACITY in the following steps, ‘Serious damage and injury to personnel could result if any part of the lifting assembly fails. Keep all unauthorized personnel away while 9. |. Attach a wide spreader beam to the hook of the traveling crane, NOTE The spreader beam must be just wide enough so that its chains will clear the turbocharger and hang straight down to the shackles on the handting toot m. Position the traveling crane and the spreader beam above the intercooler. Attach the slings to the handling tool. Raise the spreader beam until all of the slack is out of the slings, but do not tighten the slings any further. WARNING There must be no spring tension in the slings when the intercooler is unfastened from its mounting in a later step. Any spring tension could cause the intercooler to jump tree too quickly as the last fastening screws are being removed. This could damage the intercooler and injure personnel. 1. Position hoist under the top plate of the air plenum, dircctly over the ends of support plate (2 Figure 6-31, View A), and attach their lifting hooks to the plate. Remove slack from the lifting lines of the hoist. 0. See WARNING above. Remove hardware (11 and 12, View B) that fastens the support plate (2, View A) to the intercooler, and screws (10) that fasten the support plate to the top plate of the air plenum. p. Remove support plate (2, View A) q. Remove and discard gasket (6, View 8)6-63ee FOR MAIN VIEW, SEE FIGURE 6.37. surpopr piste 21 ye 6. FLANGE 7. COVER PLATE 8. COVER PLATE 10. GASKET 11. GASKET 12, GASKET 48. GASKET 16, SCREW 47. SCREW 18. SCREW 18, SCREW 21. SCREW 22, SCREW 24, WASHER 25. WASHER 27. PLUG 28. PLUG 29, GASKET 30, THREAD SEALANT Figure 6-30. Inlet Connection Between Intercooler and Engine — Sectional Views (Sheet 2 of 2) 6-644 mainview 3 4. AIR COOLER 2. SUPPORT PLATE 3. SUPPORT PLATE 4. SUPPORT PLATE 5. GASKET 6. GASKET 7. SCREW 8. NUT 8. SCREW 10. SCREW 11. SCREW 42, WASHER 19, THREAD SEALANT. Figure 6-31. Intercooler AssemblyWARNING The intercooler must be fully supported by the handling tool and traveling crane before re- moving the hardware in the next step. The slings must be free of slack but with no appre- ciable tension that could cause the intercooler to jump tree too quickly. r. Remove screws (9, View A) that secure support plate (3 or 4, Main View) to the side of the air plenum. s. Lift the intercooler slightly off of its leveling screws (7. View 8) and away trom the engine. t. Remove and discard gasket (5, View A) u. After setting the intercooler down, remove the hardware (11 and 12, View B) that secures support plate (3 or 4, Main View) to the intercooler. Remove the support plate. v. Remove and discard gasket (6, View 8) 6-15.4. DISASSEMBLY OF THE INTERCOOLER. a. Special tools, spare parts and materials re- quired: none, b. Remove screws (6, Figure 6-33) and washers (8) from the front of the intercooler. c. Remove screws (7) and washers (8) from the back of intercooler. 4d. Remove retainer (5) from frame (2) fe. Remove O-ring (4) from frame. Discard O-ring. f. Slide frame (2) away from tube bundle (11) g. Remove and discard gasket (3) h, Disassemble tube bundle (11) as follows: (1) Remove screws (6, 15, 16 and 17) and washers (8) from front of tube bundle, (2) Remove front tank (9) from front of tube bundle, (3) Remove and discard gasket (12) (4) Remove screws (6, 15, 16 and 17) and washers (8) from back of tube bundle. (5) Remove tank piece (10) from back of tube bundle, {6) Remove and discard gasket (13) (7) Remove plug (18) from back tank (10). (8) Flemove zink anodes from front tank (9) 6-15.5. CLEANING, INSPECTION AND REPAIR OF THE INTERCOOLER LEAK DETECTION PIPING. a. Special tools, spare parts and materials re- quired: (1) Special tools and spare parts: ary Name Assembly Figure © Gaskor 230 0 Gasket 230 2 Gasket 230 2 Gasket 230 16 Gasket 230 (2) Materials: none. b. Check that all gaskets have been removed, If not, remove remaining ones with the appropriate scraping or prying tool. Be careful not to damage flange seating surface. c. Inspect all piping sections for stress, cracks and irregular bending. Inspect all seating surfaces. 4d. Wash all piping sections and components with the appropriate wash solution and allow to dry. ©, Replace all gaskets. 6-15.6. CLEANING, INSPECTION AND REPAIR OF THE INLET CONNECTION BETWEEN THE TUR- BOCHARGER AND INTERCOOLER. 1. Special tools, spare parts and materials re- quired: (1) Special tools and spare parts: Oly Name Assembly Figure 5 Gasket 147 66-29 2 Gasket 7 7.6-29 2 Gasket ur 8.6.29 (2) Materials: none, b. Remove screws (9, Figure 6-29) securing bel- lows (5, Figure 6-28) to elbows (1 and 2). Separate both and remove gaskets (6, Figure 6-29) c. Check diffusers and bellows (4 and §, Figure 6-28) for damage or excessive wear. Replace if necessary, 4d. Check elbows (1 and 2) and pipe spacer (3) for cracks. Replace if necessary. e. Clean diffusers, bellows, elbows and pipe spacer (4, 5, 1, 2 and 3) with the appropriate wash solution and allow to dry. 1. Remove and replace all gaskets. 6-15.7. CLEANING, INSPECTION AND REPAIR OF THE INTERCOOLER. The intercooler has been designed to cool the compressed air, and thereby maintain constant efficient engine operating condi- tions. The fins and tubes are made of nonferrous materials which can become subject to corrosion, 6-671. INTERCOOLER ASSEMBLY 2 FRAME ‘2. GASKET © O-RING 5 RETAINER, © SCREW 7. SCREW WASHER #4 TANK 30. TANK 1 TUBE BUNDLE 6-68 12. Gasket 32, GASKET 14, ZINC ANODE 15. SCREW. 16. SCREW 17. SCREW 18. PLUG. Figure 6-33. Intercoolererosion, and contamination. Follow these cleaning and inspection steps carefully to ensure proper intercooler operation. a. Special tools, spare parts and materials re- quired: (1) Special tools and spare parts: ay Name Figure 1 Intercooler washing teol 635 (2) Materials: oy Name aR Degreasing agent 53Ga. Flushing solution b. Water Side Cleaning (Internal Surfaces). As part of scheduled maintenance, the intercooler should be drained and reverse flushed every 3 to 6 months. Itis not necessary to remove the intercooler from the engine to carry out this process. However, it isnecessary to first remove the low and high cooling water piping (par. 6-13.1 and 6-14.1 through 6-14.5) from the front of the intercooler. Reverse flushing is necessary as a corrective maintenance procedure if the pressure drop between the inlet and outlet of the intercooler exceeds the normal pressure drop (re- corded in tests prior to sea trials) by more than 20, percent. However, if the pressure drop exceeds the norm by more than 30 percent, the tubes are exces- sively clogged; internal cleaning of the tubes, using the method described below, will be ineffective. Per- form the following steps when flushing the inter- cooler: WARNING Carefully heed all warnings and cautions pro- vided by the manufacturer of the particular flushing solution you u: (1) Assemble the flushing pipe arrangement as ‘shown in Figure 6-34 (2) Fill the tank with 53 gallons (200 liters) of flushing solution. (3) Insure that the flushing solution is circu- lated for a period of at least 3 hours by means of a motor driven pump. (4) Drain the acid from the air cooler and tank Circulate clean, fresh water through the air cooler. WARNING Low pressure steam has a temperature of at least 212°F (100°C). Itcan cause severe burns. Do not allow any part of your body to come in contact with the steam. ©. Air Side Cleaning (External Surtaces). Clean the fin and external tube surfaces with low pressure steam. applying the steam in turn to each face of the core. these surfaces are oily, clean them by spray- ing them with a solvent or degreasing agent such as P-D-680. Use the intercooler washing tool (Figure 6-35) to spray the degreasing agent onto the tubes. To use the washing tool, follow these steps: WARNING Provide adequate ventilation when using clean- ing solvent P-D-680. Avoid prolonged breath- ing of vapors and minimize skin contact. (1) Fill the container with 6.6 gallons (25 liters) of degreasing agent (2) Back off the set screw for the air pressure reducing valve as far as possible. WARNING Wear protective clothing and goggles when using the cleaning tool. The fluid output pres- sure is extremely high. The pressurized stream can penetrate your eyes and skin, causing blindness and blood poisoning. (8) Check that the gun valve is closed (4) Connect the air supply line to the tool, and open the air feed valve. (6) Tighten the set screw for the air pressure reducing valve until the air pressure reaches 85.27, psi (4.5 bars). This air pressure corresponds to 5,800, psi (400 bars) fluid outlet pressure, (€) Unscrew the intercooler washing plugs (Fig- ure 6-36) (7) Insertthe gun nozz!e into the upper washing hole and adjust spray direction, and stroke length (toavoid going out the other side of the intercooler). Use a'ternating strokes equal to the length of the intercooler. When the proper cleaning methos is acquited, proceed with cleaning through all of the washing holes (8) Allow the degreasing fluid to sitin the tubes for about an hour. (9) Fill the container of the tool with water (hot water if possible) and rinse the intercooler through the washing holes. (10) Thoroughly drain the intercooler and biow steam or compressed air through the washing holes and over external surfaces to remove all traces of the solvent, 6-69200 L 4 7 ler (Water Sid‘A = S31N. (1940 mM) 1B = 981N. (960 MM) ¢ = 551N. (620MM) W= 7018. (15¢KG) LO |. SPRAYING SET ASSEMBLY PUMP HP ASSEMBLY 1. HOSE PIPE 2, CONTROL VALVE 3. GUN 44, FLUID FILTER 5, HANDLING CARRIER 6. CONTAINER 7. OER 8. PRESSURE REDUCING VALVE 9. PNEUMATIC PUMP 10, EXHAUST SILENCER IR PRESSURE GAUGE 12, AIR FILTER Figure 6-35. Intercooler Washing Too! 6716-72 CLEANING FROM EITHER POSITIONS (1 OF 2) DEPENDING ON THE ARRANGEMENT AND AVAILABLE ROOM CONNECTION FLANGE /AIR INTAKE SIDE “ROD LENGTH Position 1 | Position 2 4250 - INTERCOOLER Figure 6-36. Intercooler Cl ining Process for External Surfaces of Fins and Tubes4. Inspect the intercooler surfaces for cracks, corrosion, pitting, and other damage. Replace parts as necessary to effect repairs. 6-15.8. REASSEMBLY OF THE INTERCOOLER. a. Special tools, spare parts and materials re- quired: (1) Special tools and spare parts oy Name Assembly Figure 1 Zine anode 76 14,6041 1 o-ring 176 4641 1 Gasket 176 36a 1 Gasket 176 126-81 1 Gasket 176 136-41 (2) Materials: none. b, Reassemble tank core as follows: (1) Install zinc anodes in inlet head (9, Figure 6-33) (2) Install plug (18) in return head (10) (3) Install a new gasket (13) on return head (10) (4) Install return head on tank core (11), Secure return head to core with hardware (6, 8, 15, 16 and 17). (5) Install a new gasket (12) on inlet head (9). (6) Install inlet head on tube bundle (11). Se- cure inlet head to core with hardware (6, 8, 15, 16 and 17) c. Install a new gasket (3) on front of frame (2). d. Slide frame over tube bundle (11) e. Secure frame and tube bundle together at the front with hardware (6 and 8). {, Install a new O-ring (4) on back of frame. g. Install retainer (5) on back of frame and secure it with hardware (7 and 8) 6-15.9. INSTALLATION OF THE INTERCOOLER, LEAK DETECTION PIPING. a. Special tools, spare parts and materials: none. b. Lock all nuts and screws with the appropriate materials as required. Illustrations used for removal identity all such hardware and locking material(s) WARNING Use appropriate harnessing, support and lift- ing apparatus when installing piping. Failure to exercise appropriate caution may result in damage to components and serious personal Injury. ¢. Install intercooler leak detection piping in re- verse order of removal (par. 6-15.1 and 6-15.2) 6-15.10. INSTALLATION OF THE INLET CONNEC- TION BETWEEN THE TURBOCHARGER AND IN- ‘TERCOOLER. a. Special tools, spare parts and materials: none, b. Lock all nuts and screws with the appropriate materials as required. llustrations used for removal identify all such hardware and locking material(s). WARNING Use appropriate harnessing, support and lift- ing apparatus when installing piping, Failure to exercise appropriate caution may result in damage to components and serious personal injury. ¢. Install inlet connection between turbocharger and intercooler in reverse order of removal (par. 6-152) 6-15.11. INSTALLATION OF THE INTERCOOLER. a. Special tools, spare parts and materials re- quired: (1) Special tools and spare parts required: ay Name ‘Assombly Figure 1 Intercooler = 632 handling too! 2 Gasket 148 9,6-30 1 Gasket 148 13.6.00 1 Gasket 176 5.631 2 Gasket 76 6.6.31 (2) Materials: none. b. Install a new gasket (6, Figure 6-31, View B) on the side of the intercooler that will be mated to the air plenum. ¢. Install support plate (3 or 4, Main View) over the gasket. Secure the support plate to the intercooler with hardware (11, 12 and 13, View 8) 4. Position handling too! (1, Figure 6-32) diago- ‘ally over the intercooler as shown. Install the four bolts (2) that fasten the lifting too! to the intercooler. Install lifting eyes (3) on the tool, WARNING The intercooler weighs 7700 Ibs (3500 kg). Use a crane, hoist, slings and spreader beam of ‘SUFFICIENT CAPACITY in the following steps. Serious damage and injury to personnel could result if any part of the lifting assembly fails. Keep all unauthorized personnel away while lifting. 6-73€. Attach a wide spreader beam tothe hook of the traveling crane. NOTE The spreader beam must be just wide enough 80 that its slings will clear the turbocharger and hang straight down to the lifting eyes on the handling tool. {. Install a new gasket (5, Figure 6-31, View A) on the side of the air plenum. g. Lift the intercooler and attached support plate (Sor4, Main View) into position against the air ple- num on the engine h, Install ang tighten hardware (9 and 13, View A) to secure the support plate to the side of the air plenum. i. Install anew gasket (6, View 8) on the outer side of the intercooler. j. Using the hoist as in step n, of par. 6-15.3, above, lift support plate (2, View A) into position. Secure it to the top plate of the air plenum with hardware (10 and 13), and to the intercooler with hardware (11, 12 and 13, View B). k. Install two new gaskets (9, Figure 6-30) on the support plate. |, Attach a sling from the traveling crane to air dryer (3 oF 4). Lift the box into position against the support plate. m. Secure the air dryer to the support plate with screws (16 and 18, Figure 6-30, View B, sheet 2 of 2) 1. Install a new gasket (13, View H) on the end of the drainage trough for the box. Reconnect the drain line to the trough by connecting the fitting box (6) to the trough with screws (21). Also reconnect or reposition any other lines, piping or sensor wires that may have been disconnected or moved when the drainage box was removed. ©. Install the transition piece (1 oF 2, Figure 6-30, sheet 1 of 2) and its associated piping and sensor lines. Refer to par. 6-43.4 for this procedure. p. Reconnect the low and high temperature water piping to the front of the intercooler (par.6-13.5 and 6-147) 6-16. INJECTOR COOLING WATER PIPING. 6-161. REMOVAL OF INLET AND OUTLET PIP- ING ON BARRING GEAR END OF ENGINE. a. Special tools, spare parts and materials re- quired: none. 6-74 b. Remove nuts (10, Figure 6-37) from studs (9) fastening inlet pipe (3) to inlet pipe (4) ©. Remove nuts (10) from studs (9) fastening outlet pipe (1) to outlet pipe (2) d. Remove nuts, washers and screws (19, 18 and 17, Figure 6-38) securing pipe clamp collars (16) around pipes (3 and 1, Figure 6-37). Remove ali four pipe clamp collars. fe. Remove nuts and screws (19 and 22) fastening pipes (3.and 1) to pipes (1 and 2, Figure 6-39, sheet | of 2) 1. Remove nuts, screws and washers (19, 20 and 18, Figure 6-38) securing pipe clamp collars (16) around pipes (3 and 1, Figure 6-37) at rear of cylinder Bank A. g. Remove both pipes (3 and 1) and both pipe clamp collars. Remove gasket (7) and joints (21) h. Remove nuts and screws (13 and 12, Figure 6-38) securing tube clamps (11) around pipes (4 and, 2, Figure 6-37). Remove both tube clamps. i. Remove nuts, washers and screws (19, 18 and 17, Figure 6-38) securing pipe clamp collars (16) around pipes (4 and 2, Figure 6-37). Remove all four pipe clamp collars. j. Remove nuts and screws (19 and 22) fastening pipes (4 and 2) to pipes (1 and 2, Figure 6-39, sheet 1 of 2) k. Remove nuts, screws and washers (19, 20 and 18, Figure 6-38) securing pipe clamp collars (16) around pipes (4 and 2, Figure 6-37) at rear of cylinder Bank B. Remove both pipes (4 and 2) and both pipe clamp collars, Remove joint (21) and gaskets (7). 6-16.2. REMOVAL OF VALVE GEAR LUBRICAT- ING OIL PIPING AND COMPONENTS TO INDI- VIDUAL CYLINDER HEADS. a. Special tools, spare parts and materials re- quired: none. NOTE The two injector cooling water inlet and outlet pipes are located outside of the three pipes secured against the air intake manifold by sup: port (13, Figure 6-40). The inlet is the right pipe and the outlet is the left. 6. Remove hollow screw (24, Figure 6-41) se- curing inlet and outlet pipes to cylinder head from inlet and outlet pipes (1 and 2, Figure 6-39, sheet 1 of 2), Disconnect inlet and outlet pipes and remove all four rings (20, Figure 6-41)AN ‘Ob ons’ aid adi “1