Text

Shoreham Diesel Generator Recovery Program
	ML20083G315
Person / Time
Site:	Shoreham File:Long Island Lighting Company icon.png
Issue date:	11/22/1983
From:	Muller A; LONG ISLAND LIGHTING CO.
To:	;
Shared Package
ML20083G308	List: ML20083G315; SNRC-1003, Forwards Shoreham Diesel Generator Recovery Program, & Summary.Owners of Similar Diesel Generator Units in Nuclear Svc Have Formed Owners Group;
References
	NUDOCS 8401110245
	Download: ML20083G315 (535)
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T TABLE OF CONTENTS Page I. ABSTRACT.............................................. 3 II. EISTORICAL REVIEW..................................... 3 A. The Shoreham Diesel Generat9rs.................... 3 B. Identical or Similar Machines..................... 4 C. Shoreham Test Program and Status.................. 5 III. OPERATIONAL REVIEW PR0 GRAM............................ 9 A. P r o g r am El eme nt s . . . . . . . . . . . . . . . . . . . . . . . . . . . .'. . . . . . 9 B. Analysis of Data................................. 10

1. Classification............................... 10

2. Causes....................................... 18

3. Vibration.................................... 21 Trending..................................... 23 4.

IV. REVIEW OF RESULTS OF OPERATIONAL REVIEW PR0 GRAM....................................... 25 V. CONCLUSIONS.......................................... 28 VI. RECOMMENDATIONS...................................... 28 A. Short Tera......,................................ 29 B. Long Term........................................ 32 Appendix A - Significant Occurrences Appendix B - Vibration Survey Report Appendix C - Trend Analysis Charts .

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DIESEL GENERATOR OPERATIONAL REVIEW PROGRAM I. ABSTRACT The objective of the Operational Review Program is to assess the significance of work related instructions on the op-erational capability and reliability of the diesel generators.

The conclusion reached by the analysis performed during this operational review, coupled with the preoperational and quali-fication test program, is that the diesel generator sets will meet or exceed the reliability required of these units.

II. HISTORICAL REVIEW A. The Shoreham Diesel Generators The diesel generator sets were purchased on May 20, 1974 and were delivered to the site in June 1976. Installation began in 1976 and initial testing commenced on the first engine in October 1981. Initial testing of the second and third on-gines began in March and April 1982, respectively. Construc-tion practices for nuclear Class 1E (safety related QA Category I) equipment were employed during the installation.

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O 3. Identical or similar Machines The same basic engine as the Shoreham diesel genera-tors has been in production since the early 1950's with the first engine going into service in 1954. The first engine es-sentia11y identical to the Shoreham engine went into service in 1969. Delaval has manufactured and sold a total of ninety-seven (97) engines either essentially identical to, or very similar to, the Shoreham diesels. The majority of these enginas are already in service. Of the ninety-seven (97) en-gines, thirty-four (34) engines are essentially identical to the Shoreham diesels. Collectively, engines either identical to or very similar to Shoreham's diesel generators have accumu-lated a total of one thousand, one hundred fifty-two (1,152) operating years of experience. Engines essentially identical to Shoreham's engines have accumulated a total of one hundred fifteen (115) operating years of experience. The average num-ber of operating years on the ninety-seven Delaval engines mentioned above is twelve (12) years per engine and the average for engines essentially identical to Shoreham's is three point four (3.4) years. Many of these engines are in continuous operation. These figures demonstrate the reliability of die-sels designed and manufactured by Delaval. Significantly, Delaval diesel engines comprise 40% of the domestic medium O

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O speed diesel market, including a significant portion of the i emergency standby diesels at domestic nuclear plants.

C. Shoreham Test Program and Status The test program for the emergency diesel generators at shoreham began at the Delaval factory in Oakland, California. Factory tests' performed on the three emergency diesel generators included starting capability tests, high load i

runs, load sequencing and load rejection tests. In fact, Emer-gency Dipsel Generator 101 was the engine used by Delaval to j qualify the entire R4-8 series diesel engine for nuclear appli-l cations. The emergency diesel generators were delivered to the Shoreham site in 1976 and installed by construction personnel.

Turnover to the startup organization for testing occurred in August 1980 for D/G 102 and in October 1981 for D/G 101 and D/G 103. The turnover procedure from construction to startup in-cluded QA inspection of the diesel generators and a formal walkdown and acceptance by the test engineers.

The diesel generator test program is designed to comply with LILCO's commitraents in the Shoreham FSAR, including Regulatory Guide 1.108, Revision 1 (August 1977) concerning diesel generator testing. The test program was carried out in

. accordance with the requirem~ents of the Shoreham Startup Manu-al.

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O The test program for the Shoreham diesel generators uses a building block approach starting with the checkout and initial operation tests for individual components. These com-ponents are then combir.ed into subsystems and systems and test-ed again. The diesel generator test program consisted of ap-proximately 135 test packages in the checkout and initial operation phase. In addition, twelve flush procedures (4 for each diesel generator) were performed on auxiliary systems which supported the diesel generator. Flushes were performed on the lubricating oil system, fuel oil system, jacket water system and air starting system. Following completion of the flushes, fifteen functional test proceduras (5 for each diesel generator) were performed to demonstrate the ability of the diesel auxiliary systems to function properly and to support the complete operation of the diesel generators. These fune-tional tests included demonstrations that standby pumps started at the proper time and that the proper pressures and flows were achieved. Functional tests were performed on the lubricating oil system, fuel oil system, jacket water system, air starting system and pneumatic shutdown system.

U pon completion of the above tests, the diesel gen-erators were operated for *,he first time in October 1981 (D/G 102), March 1982 (D/G 103) and April 1982 (D/G 201). The preoperational test program, consisting of twelve b

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O preoperational testce (4 per diesel magine), started in September, 1982. A me:Sanical preoperational test checks the mecharical trips on the diesel engine and the air starting ca-l pabikityoftheairstartsystem. Two electricL1 groope:ational tests demonstrate the electrical trips for'the i generator: and include various' high load runs, load sequencing operation and load rejection testa. The final test is the die-sel generator qualification test which demonstrates the capa-bility of the diesel generators to complete successfully a total c'f 60 consecutive starts. In accordance with Regulatory Guide 1.10S; litevision 1, each diesel engine must successfully complete 23. consecutive starts. Successful compittion of the 69 starts and the other asheets of the test program ' establishes 9 that the diesels, have achieved the reliability goal of 99*4 1

, T' reliability (ets a inominal 50*4 confidence level) endorsed by the t <

regulatory 9:ide.

,On June 24, 1983,:the emergency diesel generator preoperational test program, including all pechanical, electri-cal and qualification tests, was completed for all three diesel generators. The test results are currently undergoing final t.

review by Joint Test Group and other personnel responsible for the review and approval of preoperational test results. It is

'I . anticipated that the test results will be reviewed and approved j, so that final turnover of the emergency diesel generators can be made to plant staff by July 15, 1983.

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O In addition to the testing described above, the Shoreham startup organization, in conjunction with the plant staff, has performed trici runs of all diesel generator sur-veillance procedures which must be performed by plant staff during the operation of the plant in accordance with Shoreham's Technical Specific'tions. a This has confirmed that the diesel generators can meet the test requirements imposed to assure continuing reliability during operations.

Finally, although the diesel generators have com-pleted their formal preoperational test program, one remaining demonstration of diesel generator espability must be completed prior to fuel load. The integrated electrical test is an inte-grated emergency core cooling system and emergency diesel gen-erator operational demonstration. During this test, the entire plant is subjected to various LOCA conditions along with simul-teneous loss of offsite power to demonstrate the proper starting of the diesel generators and acceptance of various emergency core cooling system and safe shutdown system loads.

This demonstration, scheduled for early August 1983, will be accomplished in accordance with a JTG approved preoperational test procedure. LILCO is confident the integrated electrical test will be successfully completed because the test procedure has been used in several trial runs which demonstrated that the diesel generators and the emergency cooling systems will respond as required.

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In summary, the test program for the diesel genera-tors has been a comprehensive, thorough and complete test pro-gram. It has resulted in the diesel geraerators accumulating 2,119 hours0.00138 days 0.0331 hours 1.967593e-4 weeks 4.52795e-5 months of operation as of June 24, 1983 as follows:

Emergency Diesel Generator 101 -- 617 hours0.00714 days 0.171 hours 0.00102 weeks 2.347685e-4 months Emergency Diesel Generator 102 -- 693 hours0.00802 days 0.193 hours 0.00115 weeks 2.636865e-4 months Emergency Diesel Generator 103 -- 809 hours0.00936 days 0.225 hours 0.00134 weeks 3.078245e-4 months During the last four months, which includes the most signifi-cant portion of the preoperational test program, the diesel generators have been subjected to 223 starts, all of which have been successfully accomplished. In addition, during the month of June, the engines performed 114 consecutive starts and expe-rienced no unscheduled outages or trips. In other words, the diesel generators were started 114 times, loaded, tested or op-erated as anticipated, and shut down in .a normal shutdown se-quence. This record is a strong and convincing demonstration that the rigorous LILCO test program has brought the diesel generators to a high state of reliability.

III. OPERATIONAL REVIEW PROGRAM A. Program Elements The program contains five (5) elements as follows:

1. Identification and review of each work related

. instruction (" work related instructions" means Repair Rework Requests, LILCO Deficiency Re-ports, EADCR's or other types of documentation used to control work on equipment at Shoreham)

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2. Classification of each instruction as to type

3. Review of each instruction as to cause

4. Evaluation of each instruction as to operational / safety significance

5. Development of conclusions and recommendations B. Analysis of Data

1. Classification LILCO reviewed all work related instructions relating to the diesel generators. It should be recognized that in many' instances, more than one work related instruction was necessary to resolve a single item. Therefore, the total number of different, distinct items pertaining to the diesel generators is substantially smaller than the total number of work related instructions.

Each work related instruction was classified by general type. A summary of the classification types is as fol-lows:

No. of No. of Classification Type instructions Distinct Items A. Routine construction and 552 N/A maintenance B. Industry reported 22 4 C. Product improvements 94 31 O

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O D. D/G occurrences detected 247 5B at Shoreham E. Ancillary equipment occurrences 23 12 detected at Shoreham .

These clasm.ification types are defined as follows:

A. Routine Construction and Maintenance This category consists of activities normal-ly encountered during construction or installation prior to turnover to the licensee, or normal or expected maintenance.

These activities are necessary to install or maintain the equipment for test and operation. Typically, these activities include setting the diesel generator sets on their foundations; installing parts shipped separately; installing and connecting interfacing ancillary systems and components not furnished by the D/G vendor; inspecting for conformance to documents; repairing and/or replacinq parts damaged during shipment or handling; cleaning and flushing components and piping; calibrating instruments; verifying alignment; changing lubri-cants and filter / strainers. In light of the nature of these activities,. these work related instructions, comprising almost 60% of the total, are not problems requiring further analysis.

The breakdown of the 552 work related in-structions within this sub-classification is as follows:

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O No. of Work Related Category Instructions Routine installation activity 58 Documentation and procedures 18 Voided - no work required 20 Torque bolts, replace gaskets 53 Alignment of pwnps, motors 7 Calibration 19 Lubrication, filter and 52 strainer changes cleaning and flushing 78 Inspections - no physical work 59 Temporary test connections 11 Reworks per QA inspections 17 Rrepair or replace defective / 160 damaged items TOTAL 552

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B. Industry Reported Items This classification type consists of activi-ties required to correct specific items reported to the Commis-sion by the ini$ustry as potential defects in accordance with 10 CFR Part 21. There were four such items, requiring 22 work in-structions to implement the necessary corrective actions.

These four items, described in more detail in Appendix A, are as follows:

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1. Addition of turbocharger bearing prelube system l

2. Engine piston modifications l 3. Engine jacket water pump modifications

4. Capscrew replacement on air-start starting valves l

C. ProJuct Improvements

! This category consists of actions which in-i crease the margin of reliability, improve operations, reduce l maintenance intervals or enhance maintainability but which are

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not necessary for operation of the engine generator sets within specified requirements. A total of 31 such items were identi-fied, requiring 94 work related instructions. Typical examples are as follows:

1. Added insulation over diesel exhaust line expan-sion joint to reduce heat released to the room, thus maintaining ambient room temperature at a lower level.

2. Added shield over governor shut down control switch on the engine control panel to prevent inadvertent actuation.

3. Replaced engine push rods with rods of Icnger length to improve the method of adjustment and thereby facilitate maintenance.

4. Moved lube oil filter strainer to a more acces-sible location to improve access and facilitate maintenance.

. 5. Installed flanges in the air start piping to f a-cilitate engine main.enance.

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D. Diesel Generator Occurrences Detected at Shoreham This category consists of occurrences detected during the operation of tne shoreham diesel generator sets which required corrective action.

A total of 58 such items requiring 247 work related instructions were identified. Each of these items was analyzed to determine any potential impact on safety. It should be noted that all work related instructions are reviewed for reportability at the time of issuance. During this program all of the work related instructions were reviewed again to cor. firm the original reportability determination. Of the 58 items, only four were considered to be of sufficient signifi-cance to warrant reports in accordance with 10 CFR 5 50.55(e).

These four items, which had been previously identified and reported, are: jacket water pump shaft (SNRC-777), engine cyl-inder heads (SNRC-878), engine rocker arm shaft bolt (SNRC-883), and fuel oil injection line failure (SNRC-892).

These items are discussed in more detail in Appendix A.

The remaining items were considered to be occurrences of the type normally found during shakedown of large diesel generator sets. These items were not of suffi-

-cient significance to require reporting under 10 CFR 5 50.55(e). LILeo did, howaver, analyse these occurrences and O

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O has made recommendations, where appropriate, to preclude or minimise occurrences of this type. The recommendations are discussed in section VI below. To illustrate items of this type, the following examples are given:

1. Novement of the engine's turbocharger caused capscrews on the turbocharger supports and connecting flanges to break. These failures would not have prevented diesel operation. The movement of the turbocharger was due to a reso-mance at 30 Bz. which was excited by the firing frequency of the engine. This was remedied by installing supports for each engine to eliminate the resonance. No further incidents have occurred in approximately 2000 hours0.0231 days 0.556 hours 0.00331 weeks 7.61e-4 months of engine operation since the supports were installed.

2. Compressed lifter springs were discovered during

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inspections of the diesels conducted after the operators nc-ticed valve lifter noise. Since the engine rocker arm area is not prelubed prior to startup, the lifters operate ' dry" for a few cycles until lube oil fills the lifter. This was resolved by reversing the lifter so that there is always oil trapped in the lifter during standby periods. This change has no effect on engine operation since the lifters are designed to function in either direction. Operation of the engine prior to the

. change would not have prevented continued engine operation dur-ing an amergency, but would have increased valve clearance with subsequent wear and decreased valve life over the long term.

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1 O 3. During startup testing of D/G 102, it was discovered that the air supply hoses to the pneumatic barring device were not installed per the manufacturer's drawings.

This condition is attributed to assembly error and was not present on the other two engines. This condition could not have gone undetected during testing and had no effect on reliability or availability of the engine.

4. Crankcase inspection disclosed excessive crank-shaft thrust and deflection measurements. These measurements are required as part of the installation procedure. The prob-lem was attributed to damage incurred during the rail shipment of the engine to the site. This is a commonly experienced problem on rail shipments. Main bearing caps were removed, damaged dowels replaced, correct crank thrust established and bearing caps reinstalled. The corrective action was completed before operation of the diesels which have since accumulated over 2000 hours0.0231 days 0.556 hours 0.00331 weeks 7.61e-4 months with no indication of thrust clearance occur-rences.

E. Ancillary Equipment Occurrences Detected at Shoreham This category consists of occurrences relat-ed to essential equipment external to the diesel generator sets which were identified during the operation of the diesel O

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O generators and which required corrective action. Ancillary equipment is defined as piping, equipment or structures required to support operation of the diesel generators but supplied by a source other than the diesel generator manufac-turer.

A total of 12 such items requiring 23 work related instructions were identified. Each of these items was analyzed to determine any potential impact to safety and none was found. These items were considered to be occurrences of the type normally found during equipment shakedown. Typical examples are as follows:

1. During system checkout, one air start compresser

() experienced vibration. While this condition would not affect operation of the diesels, it would result in more frequent re-placement of compressor bearings than is normally required.

The compressor belts were replaced and the motor realigned with the compressor. Thic action corrected the problem and no addi-tional action is required to maintain the diesel at the required reliability.

2. Testing disclosed that when the fuel oil trans-fer pumps were shut down for longer than one day, it required an inordinate amount of time to establish suction. This condi-

. tion did not affect operation of the diesels. A foot valve was installed in the suction line of each fuel oil transfer pump I

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-which corrected the problem. No additional action is required to maintain the diesel at the required reliability.

2. Causes Each of the 58 items classified as a " Diesel Generator Occurrence Detected at Shoreham" and the 32 items classified as " Ancillary Equipment Occurrences Detected at Shereham" was reviewed to identify the cause. It was not nee-essary to investigate the cause for the other categories of oc-currences. Categories A and C (" Routine Construction and Main-tenance," and "Prodact Inprovements," respectively) are not considered problems. For Category B, " Industry Reported

() Items," the cause was identified as part of the required 10 CFR Part 21 report. The review of the causes of occurrences was intended to identify any underlying reasons for the number of items observed during the operation and testing of the Shoreham diesels. LILCO has been able to draw a number of conclusions from this review. First, although a few items were attribut-

'able to discrepancies in technical documents (such as technical h manuals or instructions), this cause represented only a small percentage of the total population. Similarly, very few items were caused by human error in the startup and testing process.

LILCO concluded that the actions taken to correct these specif-ic items were adequate.

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I O pecause a number of the items identified were related to vibration, there was a concern that a potential cause of the occurrences might be excessive vibration of the diesels. LILCO undertook a vibration study which is discussed in more detail below. The study concluded that the Shoreham diesels do not vibrate excessively.

A number of the items reviewed in this study were attributable to the state of the art for various aspects of diesel generator design and manufacture. For example, Delaval used accepted state of the art casting techniques in the early 1970's when the heads for the Shoreham diesels were manufactured. As described in Appendix A, LILCO experienced leaks in three of these heads because of imperfections left by the casting process. Subsequently, Delaval improved its cast-ing techniques and quality assurance checks such that cylinder heads of recent manufacture will not contain the imperfections which resulted in leakage in three of the original Shoreham cylinder heads. While corrective action had been taken to rem-edy each occurrence attributable to state of the art changes, LILCO concluded that additional steps would enhance the roliability of the Shoreham diesels. Thus, LILCO requested that Delaval review product improvements potentially applicable to the Shoreham diesels and inform LILCO of any that had not already been incorporated at Shoreham. This review was

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completed and LILCO has decided to incorporate an improved head stud design which is described in section VI below. In addi-tion, LILCO has engaged Delaval to keep LILCO informed of fu-ture product improvements. This program is also described in section VI below.

Finally, the majority of the items identified w

,ere of the type expected during the test program for large diesel generators. Examples include loore bolts, oil and water leaks, broken tubing and isolated instances of defective compo-nents. These occurrences were not unusual and no common dence.inator was identif2ed. As a result of its review, LILCO concluded that the corrective action taken for each of these items was adequate.

Because the Diesel Generator Operational Review Program resulted in a comprehensive review of all aspects of diesel generator operation, LILCO did develop a number of rec-ommendations not directly related to any of the occurrences found by the test program. These recommendations will ensure that the high level of reliability achieved during the test

' program will be maintained. First, LILCO and NRC personnel noted a number of instances of damaged tubing, oil leaks and other minor problems in the course of cbserving the diesels.

. As a result, LILCO initiated an engine walkdown review to iden-tify and correct this type of problem. Questions were also I e

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raised concerning torquing of bolts. LILCO reviewed the issue and concluded that there was adequate assurance that bolts had been properly torqued following maintenance activities. These activities had been performed by trained, qualified persennel under the supervision of service representatives from Delaval.

To ensure that torquing will continue to be done properly in 4

the future, Delaval conducted a review of the diesel instruc-tion manual to ensure all necessary torque values were properly specified. The Operational Review Program also highlighted a number of ways in which the maintenance program for the diesels

.could be improved. These recommendations are discussed in sec-tion VI below.

3. Vibration Because a number of occurrences during testing related to resonance and vibration, a vibration study was ini-tiated. This study, conducted by vibration consultants employed by Stone & Webster Engineering Corporation, compared the vibratory characteristics of the three Shoreham diesel gen-erators with two other diesel generators of the same R-4 straight eight (8) cylinder model, but with a greater number of operating hours. One diesel generator, located in San Antonio, Texas, had 5,800 hours0.00926 days 0.222 hours 0.00132 weeks 3.044e-4 months of operating time and the other, located in Lincoln, Kansas, had approximately 50,000 hours0 days 0 hours 0 weeks 0 months of operating

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O time. The selection for comparison of the diesel generators in San Antonio, Texas and Lincoln, Kansas is appropriate because they are the same model as the Shoreham diesel generators and because they heve extensive operating histories demonstrating their proven reliability. The fact that the San Antonio, Texas and Lincoln, Kansas diesel generators are net installed in nu-clear plants does not affect the validity of the comparison of the vibrato,ry characteristics of the engines. Vibrations were measured for major components of the diesel generators, the foundation and surrounding floor areas. The representative lo-cations on each machine were chosen after a review of the vi-bration levels of the entire machine.

The vibration study concludes that the diesel

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generators are not vibrating excessively. This conclusion is confirmed by comparison of the vibration of the Shoreham diesel to the vendor's criteria and comparable machines at other sites. It is LILCO's conclusion that occurrences related to vibration were induced by normal vibratory response or by reso-nance. All such items were corrected and no additional occur-rences have been experienced for over 600 hours0.00694 days 0.167 hours 9.920635e-4 weeks 2.283e-4 months of operation.

Therefore, LILCO's program has been effective in detecting and correcting vibration related occurrences.

. This operational experience also leads to the conclusion that there will be no long-term vibration related

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effects. This conclusion is supported by fatigue analysis principles which bold that long-term vibration failures will occur prior to ten million (10,000,000) cycles if they are to occur at all. Given the engine vibration frequency of 30 Hz.

and the number of operating hours on the Shoreham diesels. it can easily be computed that the Shoreham diesels have essen-tially completed ten million (10,000,000) cycles. Moreover, the ten million cycle figure is a very conservative number.

LILCO's vibration consultant believes a more realistic figure is three to four million cycles, which has been far surpassed by Shoreham's diesels. Thus, it is appropriate to conclude that additional vibration related occurrences are unlikely to occur during long-term operation.

The vibration study is included as Ap?endix B.

4. Trending The Diesel Generator Operational Review Program included a trend analysis to gain further insight on the diesel generator occurrences at Shoreham. The review of the cause of the items in classifications D and E, which is discussed above, was an essential part of the analysis to determine whether there were any discernible trends or common causes. As already t

. moted, no common causes were identified by the review. In ad-dition, L1140 developed a trend an'alysis graph for the items

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O identified, eaclusive of those in classification A, ' Routine Construction and Maintenance." Appendix C illustrates the trcnds in diesel generator occurrences. The graph contains two curves, one which plots engine hours versus time and one which plots items per month versus time. The graph also indicates the initial operation date for each diesel.and the start of pre-operational testing.

The trend analysis graph reveals two peaks in the number of items per month curve. The first occurred at ap-proximately the time of initial operation for all three die-sels. This is an expected trend because (1) C&IO testing was underway identifying problems with individual components and (2) the initial operation of any complex machine identifies problems that must be corrected. The second pecr.c, w .. 4 after the pre-operational test program started. An increase in the identification of problems is an expected trend when com-plex machines are subject to a rigorous and demanding test pro-gram. Two important aspects of the second peak in the items / month curve are worth noting. First, the slope leading to the peak is rather sharp, suggesting a rapid shake-out of items needing correction rather than the identification of chronic problems which might affect reliability. Second, and most important, the trend curve shows a precipitous drop imme-diately after reaching its powk. This, again, suggests that O

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l O the pre-operational test program identified initial problem areas, as intended, and that once corrected, the machines oper-ated reliably. The precipitous drop in the number of items / month is particularly reassuring given the rapid increase in the number of engine hours during the same time period.

Delaval has confirmed that the trends found in Shoreham's preoperational test program for the diesels are typical of the startup of similar machines.

In summary, the trend analysis reveals that the diesel generator occurrences at Shoreham followed an expected t pattern with peaks occurring after initial operation and after commencement of the test program. 7' also convincingly demon-strates, after correction of the problems identified in the initial stages of the test program, the diesels have performed quite reliably during a period of intensive testing.

IV.

SUMMARY

OF RESULTS OF OPERATIONAL REVIEW PROGRAM A. The Shoreham diesel generators derive from a family of diesel generators which have demonktrated reliable operation for many years commencing from the early 1950's. Ov=r 1152 operating years of experience have been accumulated on ninety-seven (97) engines in this family of machines of which thirty-four (34) are essentially identical to the Shoreham ma-L chinea.

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S.- The Shoreham machines have been through the rigorous and extensive test program outlined in section II. As the trend analysis reflects, the number of occurrences has de-creased as the pre-operational test program has progressed.

The diesel generators have now operated for more than 350 hours0.00405 days 0.0972 hours 5.787037e-4 weeks 1.33175e-4 months without a significant occurrence. During most of these 350 hours0.00405 days 0.0972 hours 5.787037e-4 weeks 1.33175e-4 months , the diesels were operating at high power levels, including a number of extended runs at or above rated loads.

C. The problem areas identified were of the type nor-mally experienced during shakedown of a large diesel generator set. This conclusion is supported by the similarity to the types of occurrences identified by the Institute of Nuclear Power Operations (INPO) in their Significant Operating Report 83-1 of March 3, 1983 for diesel generstors in operating plants and in NUREG CR-0660, Enhancement of On-site Emergency Diesel Generator Reliability.

D. The Shoreham evaluation showed that only a small percentage of the diesel generator occurrences ~were significant and were reportad to the NRC either by the Industry or by LILCO as potential deficiencies. This group of reportable matters consists of a total of eight items, four of which fall within the Industry Reported Item category and four of which fall

. within the ' Diesel Generator Occorrences Detected at Shoreham" category. Appendix A contains a more metailed description of these eight items.

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O E. Apart from these 8 reportable items, the majority of the remaining diesel generator items or occurrences at Shoreham were of the type expected during the shake-down of a large die-sel generator. The success of the corrective actions taken for these items is demonstrated by the sharp decline of occurrences after remedy of the items detected during initial testing. The Operational Review Program also revealed that a number of die-sel generator items involved product improvements which were designed to increase the reliability of the Shoreham diesels or decrease the maintenance requirements.

F. The vibration analysis performed as part of the op-erational Review Program confirmed that vibration is not a con-corn since the vibratory response of the Shoreham machines is well within expected levels as confirmed by vendor and by com-parison to two essentially similar engines at other locations with a large number of engine hours. The effects on other en-gine sub-systems due to expected or normal vibration or reso-nance have been corrected and further occurrences are not an-ticipated.

G. The preoperational test program for the Shoreham ma-chines was instrumental in identifying those problem areas The which were the result of a variety of different factors.

sharp decrease in the nu.mber of problems after the initial wave of occurrences is strong evidence that the Shoreham diesels are t

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. . . . .._.s__.

O mow finely tuned machines that will operate reliably during the operation of Shoreham. LIISO's confidence in the reliability As of the diesels is supported by their recent performance.

already noted, the diesels have completed 223 successful con-secutive starts. During the month of June, the engines com-pleted qualification tests, started 114 consecutive times and successfully completed all required activities without a trip or forced shutdown.

V. CONOLUSIONS The conclusion of the Operational Review Program coupled with the results of the test program is that the Shoreham die-sel generators currently have the reliability and operational capability to provide standby power to the Shoreham Nuclear Power Station when and if required. The completion of the test program, and the implementation of the recommendations of this program (section VI) will ensure their continued reliability.

VI. RECOMMENDATIONS A number of activities were recommended as a result of the operational review program and are underway or planned.

These activities enhance the diesel generator system by increasing reliability and availability.

--_._n. - - - - - _ - _ _ _ _ _ _ _ _ - _ _ - _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

O A. Short Term A number of recommendations were made during the course of the Operational Review Program. These recommenda-tions have already been adopted by LILCO and are in the process of being implemented.

1. LILCO is conducting a complete engine walkdown review of each engine to identify and correct deficiencies such as damaged tubes, oil leaks and loose bolts. The review also checks the clamping of tubing, hangar adjustment and locking devices.

2. LILCO has committed to replace existing cylinder heads with an improved design. The cracking problem associated with the diesel generator heads is described in Appendix A. As noted there, the original cylinder heads would be adequate for reliable diesel operation. LILCO, however, decided to replace all cylinder heads with the improved Model P/N 1A-6646 cylinder heads. This model, qualified for nuclear engines in March 1982, incorporates minor modifications including the addition of an oil shield and wiper on the inlet valves to decrease lube oil consumption at part load, thereby increasing reliability by decreasing carbon formation in the cylinder. The primary ad-vances with this model are the improved casting techniques used in its manufacture and the extensive inspections (magnetic O

4

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particle, ultrasonic and dye penetrant), to which it is subjected. The end result is an extremely reliable cylinder head and improved engine reliability. These new cylinder heads will be installed as soon as possible on a schedule which will not interfere with fuel load. Since some existing heads may not be replaced until after fuel load, LILCO has also committed to a surveillance procedure to check for cylinder head leaks following each shutdown of the engine. This surveillance gives e

added assurance that the diesels will be available for rapid start if necessary.

3. LILCO has coseitted to replace existing fuel in-jection lines with an improved design. The problem associated with the fuel injection lines for the diesels is described in Appendix A. Although the existing fuel line design could be used in the future, all fuel injection lines will, instead, be replaced with shrouded type fuel lines to protect against the effect of high pressure fuel line breaks. The design has been qualified for nuclear applications by analysis and consists of a special steel tube with both ends swagged to seat in the pump and injector. A steel shield cnclosee the high pressure tube in its entirety and, therefore, will protect against im-pingement of fuel from a ruptured line on het parts of the sn-

. gir,e creating a potential fire hazard. The new tubes will also be subjected to additional quality inspections to reduce the ,

likelihood of tube leaks such as those found at shoreham.

O

4. LILCO asked Delaval to conduct a review of all '

product improvements applicable to the R-4 engine design in order to determine whether these improvements should be made at Shoreham. As a result of this review, LILCO has decided to in-stall improved cylinder head studs. These studs have a necked down design with. improved fatigue characteristics. Although Delaval had not experienced problems with the non-necked down design, the new design reduces the stress loading of the studs.

The new studs will be installed at Shoreham when the improved diesel generator heads are installed.

5. LILCO will ensure that information learned dur-ing the preoperational and qualification testing program and

() the manufacturer's latest maintenance recommendations are in-corporated into the preventative maintenance (PM) program to be ,

used during the operation of Shoreham. The PM program will continue to emphasize the inspection, cleaning and adjustment of control and protection system components, the correction of leaks and the prompt cleanup of secumulated oil, and tightening of components. In addition, Delaval has provided LILCO with enhanced maintenance schedules which include periodic schedules (daily, monthly, etc.) in addition to the traditional schedules tied to the number of engine hours. This enhanced maintenance program will include sampling and analysis of the lubricating oil to detect developing engine problems or deterioration of

( . _

O oil quality. Analysis of jacket water will also be performed to ensure that the corrosion inhibitor is maintained within specified limits. Present sampling frequencies, techniques, and criteria vill be reviewed with the engine manufacturer and oil supplier to verify their continued applicability.

6. LILCO will conduct a review of the diesel gener-ator service nanuals to ensure that they include the latest service bulletins and applicable subvendor information. As part of the effort, Delaval has conducted a review to ensure that all torque values are properly specified.

B. LONG TERM O The Diesel Operational Review Program also resulted in long term recommendstions to ensure the Shoreham diesels maintain the high state of reliability achieved during the preoperational test program. LILCO has adopted these recommen-dations.

1. Delaval was asked to provide a program for con-tinued reporting of the following information to LILCO on a monthly basis:

a. All products improvements made to the R-4 series engines not already considered by LILCO for incorporation at Shoreham;

. b. All product improvements made to the newer R-5 series engines which are applicable to the R-4 series engines at Shoreham; O

c.; Changes to the operating procedures, lubri-cant requirements, coolant treatment, main-tenance procedures, etc. for the R-4 series engines; and

d. Reports of all operating information and all problems from other R-4 engine installations which may affect reliability.

i Delaval has agreed to provide a service engineer in Oakland

{

devoted exclusively to providing this program for Shoreham.

Tha feedback program for Shoreham is unique because it is not provided for any other Delaval customers at this time.

2. As part of the design improvements to the fuel injection linas. (see short term recommendation no. 3), LILCO will install a tank to collect leakage from the new shrouded fusi injection line should a leak occur. This tank will be equipped with an alarm to alert plant operators. The design of-this modification has not yet been completed and thus no sched-ule for this installation has been established.

3. Continuation of LILCO's training and maintenance program, enhanced by short term recommendation'no. 5 and up-dated to reflect the information received as a result of long term recommendation no. 1, vill help ensure the future reliability of the Shoreham diesels.

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APPENDIX A SIGNIFICANT OCCURRENCES t\

\

1. TURBOCHAkGER PRELUBE As a result of a failure of a turbocharger thrust bearing at another nuclear site, Transamerica Delaval reported the deficiency to the NRC in accordance with'the requirements of 10 CFR Part 21. LILCO notified the NRC verbally and in writing on March 27, 1981 via SNRC-549.

The original system design permitted lubricating oil to flow to the turbocharger bearings only when the diesel was running and prevented oil flow to the bearings when the y t diesel was in the standby mode. Because of the relatively long

' time periods between diesel operations, lube oil could drain out of the thrust bearing, causing premature waar of the w

bearing during starts. LILCO. installed a modification which 6

provides for controlled lubrication to the thrust bearing dur-

\

ing the standby mode. +

A significant number of starts from the standby mode have been conducted subsequent to the modification with no abnormal turbocharger operation noted. Accordingly, the cor-rective action has been effective in remedying this occurrence.

3 .

C 2. ENGINE PISTON Transamerica Delaval informed LILCo of a piston i# - .

, crown separation on an engine at another nuclear site. This LO k.

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wact roported to the NRC in accordance with the requirements of 23 CTR Part 21. This occurrence at another nuclear station was

\, . i reported to the HRC by LILCC in SNRC-649. The problem was attributed to the failure of a spherical washer. The Shoreham engines were modified to preclude this type occurrence by in-stalling opposing stacks of Belville washers in place of the

<x spherical washer. Prior to the notification by TDI, no prob-

,; ! > less were experienced at Shoreham and none have occurred in

- over 2000 hours0.0231 days 0.556 hours 0.00331 weeks 7.61e-4 months of operation since the modification.

. 3. ENGINE JACKET WATER PUMP W

(In accordance with'10 CFR Part 21, Transamerica Delaval raported to the NRC that a potential for failure of the engine drkven jacket water pump ar.isted which would result in engine',no[-avai? ability. Delave: informed Stone & Webster of this potential defect prier to the start of testing of the shorSham engines. The SNoreham jacket water 1 pumps were re-turned to the vendor and the appropriate modifications were

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performed. LILCO has experienced no difficulties with the jacket water pump drive shafts in over 2000 hours0.0231 days 0.556 hours 0.00331 weeks 7.61e-4 months of operation.

4. AIR START STARTING VALVES )

Delaval reported a potential deficiency to the NRC

- in accordance with the requirements of 15 CFR Part 21 involving l the starting air valve hold-down capocrews.. Delaval reported 2

. ... ..a ...

O that the additive impact of dimensional tolerances might result in installed clearance less than desirable. The hold-down capscrews could possibly bottom out, resulting in air leaks at the starting valve due to inadequate compression of the gasket.

A modification recommended 1,y ;';. level provided for capscrews of 1/4" shorter in length to assure for sufficient clearance with adequate thread engagement such that the I- capscrew would not bottom out in the tapped hole. The modifi-cation was performed on all Shoreham engines as a precaution, even though the condition had not occurred at Shoreham. The now capscrews have been installed for approximately 1500 engine hours.

5. JACKET WATER PUMP SHAFT The jacket water pump shaft for D/G 103 failed due to a fatigue crack. LILCO notified the NRC that it was a po-tantially reportable deficiency. first verbally and subse-quently in writing via SNnC-777. Failure analysis indicated that the fatigue crack occurred at the keyway on the shaft.

This resulted in the impeller end of the shaft twisting efi in a conical fracture. The initiation of the fatigue crack has been attributed to movement of the impeller due to an improp-erly tightened impeller hub nut.

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Redesigned pump shafts have been installed on all three Shoreham diesals and modified impeller i'astening tech-aigues were used. No additional failures of thirs type have been noted in over 1500 hours0.0174 days 0.417 hours 0.00248 weeks 5.7075e-4 months of engina operation since the corrective action was taken.

6. ENGINE-CYLINDER HEADS A crack in a diesel cylinder head was discovered when leakage was observed in the jacket water standpipe level for D/C 101. An inspection revealed that water was leaking into one of the cylinders of this diesel. Subsequently, in-spections were performed on each cylinder of each diesel en-3 gine. Small amounts of water were discovered in two of the re-maini.ng 23 cylinders.

The three leaking cylinder heads were sent to Delaval for a failure analysis. The analysis revealed that in two of the leaking cylinder heads a crack existed in the ex-haust passage near tha flange and in the third leaking head, a crack existed in the fire deck. The analysis concluded that these cracks were attributable to casting defects during the manufacturing process. The cracks were found to be self-relieving and non-propagating. Concaquently, they are of a non-serious nature. The analysis concluded that the cracks would not have caused catastrophic failure or compromised the 4

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- . - _ _ _ _ _ _ _ __ _ _ _ - ~ . . - - - -

O ability of the engines to operate and to carry the required lead because the water leak was very slow. During operation, the small amount of water that could enter the combustion cham-bers would be blown out of the exhaust system along with other combustion by-products. The harmless nature of these failures is demonstrated by the fact that marine engineers will operate engines continuously with known similar failures for extended periods until it is convenient to repair the head.

The failure analysis dispositioned the leaking heads as suitable for repair. Thus, LILCO could have had the E.xisting heads repaired and returned to service. LILCO believes that this action would have ensured reliable operation of the diesels because in almost 1300 additional hours of cperation, no additional cracking of the cylinder heads has occurred.

According to Delaval, it is unlikely d at a cylin-der head would develop a crack similar to those found previous-ly at Shoreham after 500 hours0.00579 days 0.139 hours 8.267196e-4 weeks 1.9025e-4 months of successful operation. Each of shoreham's diesels has more than 600 hours0.00694 days 0.167 hours 9.920635e-4 weeks 2.283e-4 months of operation, much of which was at high load. Nevertheless, LILCO has taken, or will take, the following actions to enhance reliability.

First, the defective heads were replaced ws.th improved heads.

. These new heads were produced by manufacturing techniques which either prevented defects in the fabrication process or ensured

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and detection capabilities of the vendor. A replacement schedule is being developed. Because of the nature of the cracks and the surveillance procedure adopted by LILCO, the re-placement work will be completed on a schedule that will not impact or otherwise interfere with fuel load. In all probabil-ity, some replacements will occur after fuel load.

7. FUEL OIL INJECTION LINE FAILURE Two high pressure fuel lines ruptured on the Shoreham diesels and these were reported to the NRC orally and in writing (SNRO-892) as potentially reportable items. The failure analysis concluded that the failures were attributable to fatigue induced by cyclic loading stemming from the high pressure pulsations of the fuel oil injector pumps. In each case, longitudinal cracks, originating at a machine tool draw mark, developed on the internal wall surface and propagated l outward, causing the tubing to rupture under the cyclic loading caused by the injector pump high pressure pulsations. The re-sults of the failure analysis lead to the conclusion that these were not vibration related failures. This cenclusion is supported by the fact that the failures occurred near the l midspan of the tuoing and not near the ends as would be expect-i ed if the failure were caused by vibration. The ruptured fuel lines have been replaced. There have been no further I

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their detection. The process includes improvements such as additional geting, new risers, stress relief and heat treatment which have effectively eliminated the potential for defects similar to those found in the three leaking heads. Moreover, improved inspection techniques now in use, such as a higher pressure hydro-test and ultrasonic testing, ensure that imper-factions of this type, in the unlikely event they occur, will be detected.

Second, in addition to replacing the leaking cylin-der heads, LILCO has committed te a surveillence program, ree-ommended by the vendor, which will detect cylinder head leaks should they occur. As noted above, the leakage resulting from cracks of this type has no impact on the operation of the die-sel generators. When the diesels are placed in staniby, leak-age from the cracks may occur while the engine is still hot.

To detect this leaksge if it occurs, LILCO will conduct period-ic surveillance of the cylinder heads until the engine cools This procedure is described in SNRC-873. Thus, although down.

LILCO does not anticipate any further diesel generator head cracks given the number of operating hours since the last oc-currence, this procedure will ensure detection of leakage if it occurs.

Third, LILCO will replace all cylinder heads with the improved models to take advantage of the present prevention

--- 1 _z _ ..oo . o _ . coo o ao og .- o a -o

O occurrences of this nature in more than 1000 hours0.0116 days 0.278 hours 0.00165 weeks 3.805e-4 months of engine operation. It should be noted that although the fuel line failures might create a fire hazard they would not have any substantial effect on the diesels' ability to continue operating. Delave'. has conducted tests on similar engines and has demonstrated that they are capable of carrying full load ,

with only seven cylinders operating.

To give added assurance that failures of this type will not occur in the future, LIICO has decided to install improved fuel injection lines. Although the existing fuel line design could be used in the future, all fuel injsetion lines will, instead, be replaced with shrouded type fuel lines to protect against the effect of high pressure fuel line breaks.

)

The design has been qualified for nuclear applications by anal-ysis and consists of a special steel tube with both ends swagged to seat in the pump and injector. A steel shield en-closes the high pressure tube in its entirety and, therefore, will protect against impirgement of fuel from a ruptured line on hot parts of the engine, creating a potential fire hazard.

The new tubes will also be subjected to additional quality in-spections to reduce the likelihood of tube leaks such as those found at Shoreham. Eventually, LILCO will install a tank to

. collect any leakage from the new shrouded lines. (see long term recommendation no. 2.)

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I I

O S. ENGINE SOCKER ARM SHAFT BOLT During full load operation of the 103 engine, one ef the two 1" diameter retaining bolts (or capocrews) on the There intermediate rocker are shaft broke on the el cylinder.

wore approaimately 350 accumulated hours on this engine at the time of this in-ident. This incident was reported orally and in writing (SNRC-883) to the NRC.

The broken bolt, and three other identical bolts removed from the engine, were subjected to a detailed failure cnalysis by John F. Wallace, Professor of Metallurgy, Case Western Reserve University, and transmitted to Transamerica Delaval Corporation. The results of the analysis indicated

. hat (1) the undamaged bolts had all material properties, ctrength characteristics and dimensions required by their spec-ification, and (2) the broken bolt failure resulted from high otress cycle fatigue.

In order to preclude the possibility of future in-cidents of this type, all 96 of the capscrews of this type at Shoreham were replaced with a modified rocker arm shaf t bolt.

As explained in SNRC-883, the redesign of the bolt is to:

reduce fatigue sensitivity in the bolt by transferring the regions of highest stress away from the stress concentra-tions in the root of the threads and re-ducing the cyclic loading on the belt.

The reduction in cyclic loading is achieved by decreasing the diameter of the shank, thereby increasing the

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l O APPENDIX 3 BASELINE VIBRATION SURVEY

1. PURPOSE N

A baseline vibration survey was undertaken to provide en overall comparison of the vibration characteristics of the three standby diesel generators at the Shoreham Nuclear Power P.lant with two other generators having the same model engine but with a considerably greater number of operating hours. The two offsite generators were located in San Antonio, Texas and Lincoln, Kansas.

2. SYSTEM COMPARISONS The generators are each connected to a turbocharged, straight-eight, four cycle diesel engine. The following table summarizes the nameplate data on the diesel generators at the three sites. The engine generator at San Antonio is referenced by the three letters (SAN) while the engine generator at Lincoln is designated (LKN). The three generators at Shoreham are designated 101, 102 and 103.

System 101-103 SAN LKN

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Engine data:

Model DGSR 48 DGSR 48 DGSR 48 Serial No. 74010, 74011, 74012 78029-2974 70036-2287 Bore (in) 17 17 37 Stroke (in) 21 21 21 H.P. 4875 4875 3588 RPM 450 450 400 Generator data 2500 KWatts 3500 3500 Volts 4160 4160 12.470/7200 Amps 606 607 147.5/256 Hz 60 60 60 Power Factor 0.8 0.8 0.8 3 3 3 Phase Total Running Approx. 1000 Combined 5,800 50,000 Mrs.

Foundation Soil Rock Soil O

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_ ___~_:______'_' - _ - _ _ _ _ _ _ _ _. ._

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3. MEASUREMENTS l (

Vibration was measured on major diesel generators components, as well as the foundation and surrounding floor area as identified on Figures 1 and 2. 3ach location is identified by a number and a capital letter designating the direction of vibration as either vertical (V),

horisontal (N), or axial (A). In some instances, a lower case letter following the location number was used to designat: the repeat of a sequence.

The location of points chosen for measurement included the profile of the engine block at a suf ficient number of locations to define its vibration pattern. Maximum vibration locations are normally found at each end of the engine and these were used for comparison ir. the Tables of the report.

Measurements were also made on auxiliary components such as heat exchangers, the turbo charger, and oil filtert to detect excessive vibration.

Due to the many appurtenances associated with the diesel engines, a visual examination was used to verify O. that no unusual or unexpected vibrations existed.

i All measurements were taken using velocity transducers.

The outputs from these transducers were recorded on sognetic tape in analog form for future analysis if required.

The signals were simultaneously processed and analyzed with a dual channel Fast Fourier Transform (FFT) Analyzer (Nicolet Model 660B) in terms of rms velocity amplitude in in/see vs. frequency over the range of 0 to 50 Hz.

Plots of vibration data for ksy selected locations used for comparison of one engine with the other are provided in Figs. 3 through 38. The digitally processed data were stored on 5.25 inen diskettes for additonal analyses and plotting.

At the Shoreham site, one set of measurements was taken on each unit running at 75% output power and a fourth set was taken on unit 101 at 100* power. The output power of the generator at San Antonio varied from 37t to 691 of full power, and the unit at Lincoln, Kansas was running between 544 and 64% of full power at the time of the measurements.

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{ 4. XIBRATION CHARACTERISTICS 4.1 vibration Frequencies It is noted on all of the plots of vibration vs.

frequency that the engine vibrates at discrete frequency components. Each of these is an exact multiple.of the firing frequency associated with one cylinder: 1.e., at one-half times the engine RPM. The maximum vibration amplitudes are usually found to correspond to the firing frequency of all cylinders combined which in this case is four times the engine RPM. The second highest vibration usually corresponds to a frequency of two and one-half tines the engine RPM. The vibration plots label the components corresponding to one times the RPM and four times RPM.

For comparison purposes, the vibration levels corresponding to one times the RPM, two and one-half times the RPM and four times the RPM were tabulated at representative engine locations. These were the vertical motion at the top of the numbers 1 and 8 cylinders, the horizontal motions at each end of the engine at the top and near the floor level.

4.2 Vibration Amplitudes The data presented in Tables IA through 4A are in j terms of vibration velocity and the data presented in

' Tables 1B through 4B are in terms of amplitude (either RMS or Peak to Peak).

The conversion of rms velocity to mils peak to peak 3 (p-p) may be made using the following equation:

Mils (p-p) = 2828 X(rms velocity) /(2FF) where rms velocity is in/see and f is Hz.

5.1 General En.gine Vibration In general, the vibration amplitudes are well below 1 in/see rum over the frequency range of 0 to 50 Hz sor all engines measured. For reciprocating equipment, these vibration levels are considered norwal.

Comparisons of the five engines are provided in the tables 1A through 4A below. The tables are each tabulated in order of increasing vibration level. Table I compares

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( overall vibration while Tables 2, 3 and 4 con 4 pare vibration N. at frequencies of 7.5, 18.75 and 30 Hz, respectively. The locations chosen were the horizontal and vertical vibration of the engine at each and at the top and floor level of the engine.

The data provided in Tables 1A through 4A show that the engine vibratior.s are comparable for all cases, even though the conditions for SAN and LKN are more favorable in terms of lower power of operation, a rock foundation at SAN, and the lower RPM at LKN.

Tables 1B through 4B provide a comparison of the Shoreham, San Antonio & Lincoln machines converted to either mils peak to peak or Mils RMS and normalized to reflect differences in power level and RPM.

Normalization of vibration data to compensate for differences in power level and RPM is based upon the following fundamental relationships:

a. RJ2L, The magnitude of the dynamic unbalanced force provided by rotating equipment is given by the following expression:

()

F = mr (2Wf)2 (Ref. 1) where m = the rass unbalance (constant for a given machine) r = the distance from center of rotation to the center of the mass, m. ,

f = frequency of rotation From the above equation, it is observed that the dynamic forces are proportional to the square of the engine speed. Since vibration displacement is directly proportional to force, the square law relationship may be used to normalize the vibration data to 450 RPM. Thus I

450 "

RPM

TE6 This is the vibration amplitude that would be measured if the unba, lanced forces were equal in magnitude to those that would exist at 450 RPM.

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O Power Level

The vibration variation associated with power level is based upon the relationship between vibration amplitude and energy. The energy from a diesel engine is in the form of an impulse from the firing of each cylinder. Each impulse 4

imparts a strain energy into the system. For an elastic system the energy - displacement relation at maximum displacement is 2

E=h/fKX max (Ref. 2) where K = the system stiffness, Thus the scaling relationship for power is Xp2 = Xpg h Ref. 1 Rogers, G. L. , " Dynamics of Framed Structures",

John Wiley & Sons, Inc., 1949, pg. 22 Ref. 2 Jacobsen, L.S., and Agre, R.S., " Engineering Vibrations", McGraw-Hill, 1958, pg. 67

\ Tables 1B through 4B further demonstrate that vibration of the Shoreham machines is comparable to and consistent with the other two machines studied. The amplitudes of the vibratory motions are all within expe.-ted limits are are acceptable in industry experience. In short, the Shoreham machines are not experiencing excessive vibrations.

5.2 Generator Bearing Vibration During the course of the vibration measurements at Shoreham, vibration in the axial direction on the generator bearing was observed at about 37Hz with a periodic peaking at 3.75Hz. This was observed on all three engines and was diagnosed as a resonant excitstion of the generator bearing by the No. 8 cylinder. Modification instructions to the bearing support have been issued to increase the axial atiffness and therefore eliminate the resonant excitation of the bearing.

6. CONCLUSIONS On the basis of comparisons of vibration data taken, the Shoreham diesels have only the expected and normal vibration

and are not subjected to any excessive vibration and this normal, #3pected vibration does not prevent the diesels from reliably performing their functions.

1 TABLE 1A Diesel Generator Vibration Comparisons (overall-2R to 50H2)

Engine Meas. Loc. Power % in/sec 04 101 2a-H 100 0.0385 SAN 3c-H 46 0.059 101 3a-H 75 0.0591

'801 2c-N 200 0.0616 SAN 3a-H 46 0.068B SAN 24-V 37 0.0743 SAN 31-V -

37 0.0756 LKN 31-V 54 0.0896 LKN 24-V 55 c.0909 LKN 3e-H 61 C.103 LKN 3c-H 61 0.!07 102 3c-H 75 O.108 103 3s-H 75 c.121 103 3c-H 75 O.123 102 3a-H 75 O.130 LKN &c-H 55 O.140

. 102 31-V 75 0.143

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101 24-V 24-V 75 75 c.149 0.151

\~ 103 31-V 75 0.152 102 60-H 75 0.158 103 24-V 75 0.160 101 31-V 75 0.163 101 24-V 100 C.196 g 102 ec-H 75 0.197 101 31-V 100 C.199 LKN &a-H 64 0.232 101 ec-H 100 0.251 103 ec-H 75 O.260 101 ea-H 75 O.296 SAN &c-H 40 C.298 SAN ,64-H 46 0.346 103 6a-H 75 O.406 101 ea-H 100 0.425

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TM2 1B k Diesel Genarator Vibration Comparisons (Overall Vibretions in Mils RMS, 2Hz to 50 Hz)

Measurement Location Engine 3a-H 6a-H 3c-H 6c-H 24-V 31-V 101 0.34 1.88 0.50 1.85 1.59 1.44 102 0.58 1.05 0.62 1.49 1.57 1.39 103 0.68 2.52 0.71 2.01 1.66 1.48 SAN 0.85 2.55 0.41 2.19 1.17 1.C 3 LKN 0.97 2.41 1.00 1.58 1.40 1.39

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. . . . . . . . - a - . . .. .

TABLE 2B Diesel Generator Vibration comparisons ,

Mils Peak to Peak 97.5 Hz)

Measurement Location Engine 3a-H 6a-H 3c-H 6c-H 24-V 31-V 101 0.25 0.72 0.36 1.34 2.52 1.14 102 0.30 0.24 0.31 1.47 2.57 1.37 103 0.31 0.30 0.36 0.38 2.66 1.13 SAN 0.33 0.42 0.38 0.46 2.12 0.88 LKN C.18 0.67 0.23 0.67 1.84 1.02

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TABLE 2A

(. Diesel Generator vibration Cornparisons (7.5 Br)

Engine Meas. Lec. Posser E in/sec res a 2000 801 2a-H 300 .633

LKN 3a-H 61 2.17 801 2c-e4 300 2.t?

LKN 3c-H 61 2.78 102 ea-H 75 4.03 tot 3a-H 75 4.23 SAN 3a-H 46 4.27 SAN 3c-H 46 4.94 802 3a-H 75 5 803 es-H 75 5.00 103 3a-H 75 t' . 09 102 3c-H 75 -

5.23 BAN 6a-H 46 5.45 SAN ec-H 40 5.59 103 3c-H 75 5.93 103 ec-H 75 6.26 LKN &c-H 55 7.51 LKN &a-H 64 S.16 SAN 31-V 37 10.3 31-V 54 11.4 j [ LKN lo! 6e-H 75 12.0

(*

101 ' &c-H 100 15.3 103 31-V 75 33.9 101 31-V 75 19.0 Lei 24-V 55 20.7 301 33-V 100 21.7 302 31-V 75 22.9 102 ec-H 75 24.5 BAN 24-V 37 24.B 301 6a-H 100 27.0 101 24-V 75 42.0 i

102 ~24-V 75 42.9 l 24-V 75 44.4 i

103 301 24-V 100 49.9 1

1 I

l 4'

l l

.. ~ . _ _ _ _ _ ., _

)

TABLE 3A Diesel Generator Vibration Comparisons (18.75 Hz)

Engino Mess. Loc. Poeer % in/see res a 3000 SA!1 3c-H 46 .677 SAN 3a-H 46 .898 101 2a-H 100 33.6 IC1 2c-H 100 34.5 301 3a-H 75 3S.1 24-V 37 28,2 SAN 102 3a-H 75 28.5 SAN &c-H 40 29.7 303 3a-H 75 30.2 LKN &c-H 55 31.7 LKN 24-V E5 31.9 302 sc-H 75 33.S SAN 31-V 37 34.5 LKN 3a-H 61 34.7 LKN 3c-H _;1 35.0 103 3c-H 75 38.8 LKN 31-V 54 40.2 SAN &a-H 46 51.4 302 24-V 75 79.5 103 24-V 75 60.3 102 31-V 75 66.2 101 24-V 75 69.0 302 6a-H 75 70.4 101 31-V 75 72.5 )

6c-H 100 73.5 101 31-v 75 76.8 303 87.2 tot 31-V 100 101 24-V . lov 97.3 302 ec-H 75 101.

301 &a-H 75 SOS LKN 6a=+: 64 124 103 ea-H 75 136 103 &c-44 75 170 101 6a-44 100 176 P*

. . , .p. . . . . . - . . - . = = - * - = .

l

... . .2 - - - . . . . .

TABLE 35 Diesel Generator vibration comparisons (Mils Peak to Peak 9 18.75 Hz)

Measurement Location Engine 3a-H Ga-H 3c-H 6c-H 24-V 31-V 101 0.43 2.59 0.50 2.02 1.66 1,74 102 0.68 1.69 0.81 2.42 1.43 1.59 103 0.72 3.26 0.93 4.08 1.45 1.84 SAN 0.03 1.58 0.02 0.98 0.96 1.18 LEN 1.17 4.08 1.18 1.12 1.13 1.44 M

S w i eii ii i o. ..

l . . . - - .. - _.

l TABLE 4A

\

i C' - Diesel Generator Vibration Comparisons (30 Es) l Engine Meas. Lec. Posser E in/sec res a 8000 801 24-V 75 7.45 -

l 303 31-V 75 3S.6 101 24-V 800 21.7 SAN 24-V 37 24.

LKN 31*V 54 28.1 303 24-V 75 29.2 l SAN 31-V 37 29.4 301 2a-H 300 32.5 102 24-V 75 37.0 102 6c-H 75 35.2 101 3a-H 75 44.7 LKN 24-V 55 46.1 l

102 31-V 75 46.4 SAN 3c-H 46 53.7 l

101 2e-H 300 56.1 BAN 3a-H 46 43.3 l

LKN &c-H 55 69.7 tot 31-V 75 33.9 LKN 3c-H 61 89.5

. LKN 3a-H 61 39.6

) 302 3a-H 75 92.S 302 3c-H 75 97.0 303 6c-H 75 801, 101 31-V 100 104 102 . es-H 75 806 303 3a-H 75 3to i

103 3c-H 75 813 LKN es-H 64 130 301 6c-N- 100 353 301 6a-H 75 230.

SAN 6c-H 40 279.

301 6a-H 100 289.

303 ea-H 75 311.

SAN &a* 44 314.

O:

t

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l

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\

TABLE 4B Diesel Generator Vibration Comparisons (Mils Peak to Peak 9 30 Hz)

Measurement Location Engine 3a-H Ga-H 3c-H 6c-H 24-V 31-V 101 0.67 3.45 1.89 5.43 0.11 1.26 102 1.39 1.59 1.46 0.57 0.56 0.70 103 1.65 4.67 1.70 1.52 0.44 0.?B SAN 1.21 6.02 1.03 5.73 0.51 C.63 LKN 1.89 2.67 1.88 1.55 1.02 0,63 Cb

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Appendix B O..

(

August 24, 1983

+

l

M. S. Pollock EMERGENCY DIESEL GENERATOR 102 CRANKSHAFT FAILURE - M7. STER PLAN Shoreham Nuclear Pouer Station - Unit 1 W. O. No. 44430/48923 This document describes the steps Lilco will take in investigating the failure of the Diesel Generator 102 crankshaft and in determining the generic implications upon Emergency Diesel Generators 101 and 103.

l This document has been sent to the NRC-Sr. Resident Inspector, Mr.

~~ J. Higgins for his ir. formation.

'N / In addition, copics have been sent to the peopla listed below:

7 J. Rivello

y. J. Museler

/M. Milligan W. Steiger (Chairman of the ROC Committee)

R. A. Kubinak (Chairman of the NRB) i B. McCaffrey (Chairman of IEEG)

T. Ellis - Funto.7 & Williams C. Uells - F?A l . *iciugh- TDI I

J. S.aith - Liecnuing

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2 *.0 l' L , . J. C. , -

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s 9 Shoreham Nuclear Power Station Emergency Diesel Generator 102 Crankshaft Failure Analysis / Recovery Master Plan Approvals:

1 XJL - %.(Jz .

7 ' Areighty;m/

Project Engineer I

l N ,'

l l/ :>,am

'rR Opegational Quality Assurance Engineer l

Startup( anager l

>; Em i Chairman Joi/it' Test Group P

. /A nt Manager u

/

!. Vice President Nuclear u

11 l4 I

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{ Dated: August 23, 1983

,I i

9

4 SHOREHAM NUCLEAR POWER STATION EMERGENCY DIESEL GENERATOR 102 CRANKSHAFT FAILURE ANALYSIS / MASTER PLAN I. PURPOSE: ,

~The purpose of this master plan is to describe the organization and organizational responsibilities for implementing the investigation-into and recovery from the crankshaft failure on the Emergency Diesel Generator 102 t at the Shoreham Nuclear Power Station. This master plan includes a description of those activities associated with the failure analysis; the disassembly of the Emergency

. Diesel Generator to' allow for the investigation of the failed components; the review of the implications of this failure ca the reliability of the other two diesel generators 4101 and #103; and the identification of required retecting to ensure reliable diesel generator operation following repairs.

L It must be emphasized that the master plan is necessarily

preliminary in nature. Revisions to the approach will be l made,_if necessary, as information is obtained during the actions set out in this plan.

I

() This master plan has been put in place by the organization described herein, has been reviewed by representatives of LILCO Project Engineering, LILCO Startup, the Shoreham Joint Test Group, Operaticnal Quality Assurance and the i: Vice-President of Nuclear. In_ addition, this plan has

been developed with the assistance of TransAmerica DeLaval i Inc. of Oakland, California and Failure Analysis Associates'of Palo Alto, California.

II. ORGANIZATION:

As a result of the failure of the crankshaft on Emergency Diesel Generator 102, an organization has been put in place consisting of the necessary expertice to assess the cause or causes of the crankshaft failure; to recover from that failure and i perform suitable retesting following recovery and to determine the implications of this failure on diesel generators 101 and 103. The essential areas of expertise are shown in Attachment No. 1 Organizational l Interface Diagran and consist of the following:

ll l ,

a. Startup Personnel

b. Engineering Persennel

c. Scheduling Personnel i d. Vendor Representatives (TDI) 1

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}

x, ; - '

e. Plant Staff Maintenance Support Personnel

f. Failure Analysis Consultants

g. Operational Quality Assurance and TDI QA Personnel l In additioh to the organization shown on the I attachment, support from the LILCO Office of Nuclear l as well as the entire Long Island Lighting Company are available, such as the Purchasing, Engineering, Maintenance Services and Quality Assurance Departments.

A. LILCO Startup LILCO Startup under the direction of the Startup Manager has the primary line responsibility for

_j implementing and scheduling the entire effort on the I

three diesel engines since the Emergency Diesel Generators are still under Startup jurisdiction.

l Repair Rework Requests initiated by Test Engineers I will be the base document for the rework with Maintenance Work Requests (MWR's) being used to support administrative requirements of the maintenance contractor, Catalytic Inc. and other maintenance t

rs , support organizations. Implementing maintenance and I

test procedures will be generated by Project

! ! \ ') Engineering, Startup and TDI and will be provided to l,

the field via the above base documents.

f i B. MAINTENANCE Catalytic Tnc., a supplemental maintenance contractor

~

j

! to the LILCO Plant Staff maintenance section, will prepare thc' equipment for removal of diesel generator

,I 102 from the Dicsel Generator Room by disconnecting the piping, electrical and other appropriate connections to the engine and generator in accordance l

' with Diesel Generator 102 Disconnection Checklist and implementing work request documents.

Gerosa Inc., a rigging and hauling contractor, will jack and skid the diesel engine out of the room and transport the equipment to the Turbine Building turbine deck, Elevation 63'.

l TransAmerica DeLaval Inc. (TDI), the diesel engine manufacturer, will perform the disassembly and rebuilding of the engine. Additionally, the generator

will be inspected under the cognizance of its manufacturer (Portec) to determine if it sustained any damage.

2 I.'

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TDI representatives will observe all activities associated with this investigation and will provide technical direction. TDI will provide-required replacement parts.

C. LILCO Project Engineering LILCO Pro 3ect Engineering (LPO) assisted by the Stone

& Webster Site Engineering Office (SEO) will provide engineering support and is responsible for the failure analysis. To accomplish these tasks LPO will use its own resources supplemented by Stone & Webster Engineering Corporation, TDI, Failure Analysis Associates and other consultants as required. Failure Analysis Associates has been charged to take whatever steps are necessary to determine the cause or causes of the failure.

D. Quality Assurance Operational Quality Assurance will provide the required Quality Assurance coverage in accordance with the LILCO Quality Assurance Program. TDI QA representatives will be present during the period of engine disassembly and reassembly by the TDI work force. The LILCO Quality Assurance Department will provide support to the OQA organization for quality assurance matters.

. E. Shift Compliment Dur2ng this investigation and the subsequent recovery the on shift compliment will consist of the following:

Startup Test Engineer Engineering Representative TDI Representative Failure Analysis Accociates Representative OQA Representative Maintenance Support Supervisor The Test Engineer will be the Shift Director and is responsible for implementing the activities designated to be accomplished during that shift. A pre shift I meeting will be held to insure proper coverage is available and to review those activities with the shift compliment.

F. Stop Work Authority

, OQA has the authority to "STOP WORK" based on the QA manual.

Persuant to the memoranda from the Startup Manager, 7s Attachment #2 and #3 the on shift FAA representative

( )

?' and TDI representative have been authorized to stop 1 work through the Test Engineer.

3 l

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G. Review and Audit The overall work effort will be under the review and audit of the Joint Test Group as described in the Shoreham Startup Manual.

III. . DIESEL GENERATOR 102 CRANKSHAFT FAILURE ANALYSIS AND CRANKSHAFT DESIGN ADEQUACY ASSESSMENT A. Failure Analvsis Conduct an investigation of, and develop a detailed failure analysis for the Diesel Generator 102 I crankshaft to determine causes for failure. This effort consists of the following.

! 1) Attendance, inspection and documentation of Diesel Generator 102 during teardown and reassembly.

2) Appropriate analysis of the failed crankshaft.

3) Review maintenance and operational history.

B. Crankshaft Desian

- Conduct an inspection and assessment of the adecuacy of the existing (13" x 11") and replacement (13" x 12") TransAmerica DeLaval Crank Shafts for Diesel Generators 101, 102 and 103. This effort consists of

[/)

x_ the following:

1) Review of the TDI design calculations.

2) Performance of independent calculations, as required.

3) Performance of operational torsional vibration tests at various speeds and engine loads on the existing 13" x 11" crankshafts in diesel generators 101 and 103 and on the replacement 13" x 12" crankshaft for diesel-generator 102.

IV. DIESEL GENERATOR REWORK & INSPECTION A. Inspections & Tests - Diesel Generator 102 The inspections and tests on diesel generator 102 include but may not be limited to the following:

1.) The connecting rod for cylinder nc. 7 will be pulled to allow for inspection / examination for cylinder liner damage.

2.) Main bearings 48, 9, 10 s 11 adjacent to the failure will be pulled to inspect for damage to the bearing, bearing shell and bedplate. This will be performed as soon as possible to allow

' evaluation of damage.

3.) Analysis of engine oil, jacket water and bearing L (_)

Q 4.)

metal will be performed.

An overall engine inspection during detailed

( disassembly for crankshaft removal will be i performed.

I 4

i i

^

A .

5.) A generator inspection will be performed.

NOTE: Item 1 and 2 atove to be accomplished prior to removing the~ diesel generator from the room. .

B. -Inspection and Tests - Diesel Generater 101 and 103 The inspections and tests on diesel generator 101 and 103 include but may not be limited to the following:

1.) 100% visual inspection of crankshaft webs and dye penetrant tests where appropriate.

2.) -The connecting rods on cylinder 6, 7& 8 will be

- pulled to perform 100% LP and UT of the connecting rod journal.

3.) Torsional vibration testing of the crankshaft in the 101 & 103 will be performed following the above inspections per procedure provided by TDI.

C. Diesel Generator 102 Rework LILCO has overall responsibility for the Diesel Generator 102 rework effort. The Startup Test Engineer on shift will supervise the various aspects of the work described below.

/~ Catalytic personnel will remove pipe, tubing and

()h electrical connections, disconnect the turbocharger; and disconnect the generator in preparation for jacking and skidding the engine out of the room.

Gerosa personnel will rig and jack the engine, skid it out of the room and move it around via flat bed to the turbine building truck bay. The entire engine will be lifted via the turbine building crane and set inside an existing caged-in area on the turbine building deck. A clean rocm will be set up and access control

.will be established.

TDI personnel will perform the disassembly allowing the appropriate inspections to take place. The TDI Service Representative will be the responsible supervisor for the TDI workman. The~ generator will ,

' also be inspected for damage while on the turbine deck. LILCO.and FAA inspections will be performed I during this work.

Once removed, the. damaged shaft will be sent off site for failure analysis.

I TDI personnel will rebuild the engine under the supervision of a TDI Service Representative and following reassembly, the engine will be transported O back into the diesel generator room by Gerosa personnel. ,

5

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P Ca'talytic personnel will reconnect all apertar.ances.

At this point retesting will begin.

V. RETESTING DIESEL GENERATOR 102 Upon completion of the Emergency Diesel Generator 102 rework and reinstallation, the Preop test program for this engine will be reperformed as follows.

a. All components disturbed'hy the rework will be subjected to appropriate C&IO, including calibrations, electrical wire checks, and pneumatic tubing connection reverifications.

b. The Lube Oil, Jacket Water, Fuel Oil and Air Start system will be reflushed as required.

I c. Initial engine run-in per TDI direction.

d.

4 The Mechanical Preop test will be reperformed in its

. entirety.

! e. The two Electrical Preop tests will be reperformed.

f. Following completion of the above and review and concurrence by the JTG, the Qualification Preop test will be reperformed.

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ATTACHMENT #2 (llf-August 18, 1983 R. T. Purcell M. Milligan J. Notaro STOP WO3K AUTHORIZATION - DIESEL ENGINE 102 FAILUR2 Shorehan Nuclear Power Staticn Unit 1 W. O. No. 44430/48923 During the investigation of the Diesel Generator 102 failure the duly authorized Failure Analysis Associate Representative fS on shift has the authority to stop work as long as the stop

( 1 work order does not cause a personnel safety concern.

3.)

This stop work authorization is being given to ensure that the Failure Analysis Associates people are in a position to ensure that they get the maximum information from the failure investigation.

Upon issuing a stop work order the Failure Analysis Associate Representative shall notify the undersigned of this action immediately. *

^

l t

E. J. Youngling Startup Manager p

EJY:eom e

cc: M. S. Pollock

(~'x J. Rivello

(_) W.

W.

Museler Steiger

A. Muller G. Rogers - FAA J. Kammeyer-SEO

- ATTACHMENT 33

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! August 22, 1983 R. T. Purcell M. Milligan J J. Notaro

'1 STOP WORK AUTHORIZATION FOR TRANSAMERICA DELAVAL INC.

j DIESEL ENGINE 102 FAILURE cj Shoreham Nuclear Power Station - Unit 1 W. O. No.- 44430/48923 i

i During the investigation of the Diesel Generator 102 failure, the duly authorized Transamerica Delaval Inc. Representative on shift has the authority to stop work, as long as the stop work order j does not cause a personnel safety concern.

This stop work authorization is being given to ensure that Delaval

' ' (' personnel are in a position to ensure that they obtain the maximum information from the failure investigation.

q Upon issuing a stop work order, the Transamerica Delaval Representative J shall notify the undersigned of this action immediately.

I Chk -

M T (% H ,

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"E. J. YoYtngling V Startup Manager EJY:eom

, cc: M. S. Pollock i J. Rivello I W. Museler i W. E. Steiger i I A. Muller G. Rogers -

FAA l J. Kammeyer -

SEO j L. McHugh - TDI

)

1

r Appendix C-1 a

('C LONG ISLAND LIGHTING COMPANY SHOREHAM NUCLEAR POWER STATION - UNIT 1 DG 101 EMERGENCY DIESEL ENGINE TEAR DOWN GUIDELINES FOR REPLACEMENT OF CRANKSHAFT General Notes: 1. The steps below need not be performed in the exact order in which they are listed.

2. All parts removed are to be cleaned, tagged, and or bagged and marked.

3. All parts removed are to be visually inspected for damage at time of removal. All problems will be identified by use of the LDR program.

4. Prior to implementation of this procedure, certain steps may have already been performed. In these cases, inspection shall fm be performed to ensure that the intention of the procedure step has been met. A note should be added in the sign-off block of these steps to indicate these cases.

5. All fube ends shall be covered with plastic and taped.

Signoff on the enclosed signon sheet indicates that responsible parties have read the above general notes which are applicable to this entire procedure. All Test Engineers and OQA personnel signing in body of procedure shall sign below.

TE Date OQA Date l

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l UtJCONTRou.E0 '

r;,; W0rn,atiLii #'N L ,,7 ,a , s u #

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d' i .

CUIDELINES NAME NAME INITIALS TITLE / .

LEVEL

(Printed) (Signed) (Printed / Written) ORGANIZATION OF QUALIFICATION d

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'uncorc:n.m r: mo. s.

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2 iTG AFPPOYO SEP %

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GUIDELINES STEP 1 Cylinder head removal and teardown. Cylinder No. 1 A. Inspect area about cylinder for cleanliness. Clean as necessary.

TE Date OQA Date B. Remove cylinder head cover.

TE Date C. Remove starting air jumper.

TE Date D. Disconnect the exhaust and intake air manifolds and the jacketwater outlet flange.

TE Date E. Disednnect the fuel injection lines and nozzle drain fittings.

Take care to avoid damaging the tube ends. Cover the ends.

TE Date F. Disconnect the outer air start pilot lines and lube oil supply line. Cover tube ends.

TE Date G. Remove fuel injection nozzle holder assemblies, and nuts.

TE Date H. Remove the 2 inner air start pilot lines to starting air valve from subcover.

t

[ TE Date 'y}ynOt4TPOLLED

p ,, n .;cn ors s

C 2

iTG APFi@ D 3

_._ . _ _ . _ . - _ _ ~ _ . _ - . . _ . - ._ - . _ _ _ . _._

E V GUIDELINES STEP CYLINL2R NO. I 1 (cont.)

1. Remove cylinder head subcovers.

TE Date J. Attached lifting fixture P/N 00-590-01-BA to fuel injector studs. Attach an overhead hoist to the lifting ring of the fixture.

TE Date K. Remove the cylinder head bolts and washers. Record breakaway torque on attached sheet.

l TE Date OQA Date O FAA Date i L. Lift the head from the block. If the head sticks, it may be necessary to take a strain on the hoist and break the head loose by striking the sides with a babbit or lead hammer.

TE Date M. Visual inspection of cylinder heads for cracking, distortion, fretting.

-TE Date FaAA Date OQA Date l

tINCONTROI LED Fu information Only O

l .

4

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s lI t .C\

s GUIDELINE _S

. STEP l

1 Cylinder head removal and teardown. Cylinder No. 2 A. Inspect area about cylinder for cleanliness. Clean as

necessary, l

TE Date l B. Remove cylinder head cover.

TE Date C. Remove starting air jumper.

l TE Date l D. Disconnect the exhaust and intake air manifolds and the l- jacketwater outlet flange.

I TE Date E. Disednnect the fuel injection lines and nozzle drain fittings.

Take care to avoid damaging the tube ends. Cover the ends.

l l TE Date F. Disconnect the outer air start pilot lines and lube oil supply line.

Cover tube ends.

TE Date G. Remove fuel injectior. nozzle holder assemblies, and nuts.

TE Date H. Remove the 2 inner air start pilot lines to starting air valve from subcover.

JTG APPRCVi3 S E P 1 i D pf'W'ONTROLLED 5 UTm tion Only

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-STEP CYLINDER NO. 2 1 (cont.)

'I. Remove cylinder head subcovers.

TE Date

'J . Attached lifting fixture P/N 00-590-01-BA to fuel injector studs. Attach an overhead hoist to the lifting ring of the fixture.

TE Date K. Remove the cylinder head bolts and washers. Record breakaway torque on attached sheet.

TE Date 0QA Date

[\

FAA Date L. Lift the head from the block. If the head sticks, it may be necessary to take a strain on the hoist and break the head loose by striking the sides with a babbit or lead hammer.

TE -Date l

M. Visual inspection of cylinder heads for cracking, distortion, fretting.

TE Date FaAA Date OQA Date l

UNCONTPOLLED rer Information Only, 3TG :Fi:CYD 5 F ' : Ii"O 6

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n GUIDELINES

. STEP

l :

~! 1 Cylinder head removal and teardown. Cylinder No. 3 )

. l, .

j A. Inspect area about cylinder for cleanliness. Clean as necessary.

TE Date OQA Date B. Remove cylinder head cover.

TE Date C. Remove starting air jumper.

TE Date D.. Disecr.nect the exhaust and intake air manifolds and the jacketwater outlet flange.

l TE Date l

l E. Disednnect the fuel injection lines and nozzle drain fittings.

Take care to avoid damaging the tube ends. Cover the ends.

TE Date F. Disconnect the outer air start pilot lines and lube oil supply line. Cover tube ends.

.TE Date G. Remove fuel injection nozzle holder assemblics, and nuts.

TE Date l , H. Remove the 2 inner air start pilot lines to t. tarting air valve-from subcover.

. UNCONTROLLED i

TE Date FF ir*ormation Only

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GUIDELINES STEP CYLINDER NO. 3 1 (cont.)

1. Remove cylinder head subcovers.

TE Date J. Attached lifting fixture P/N 00-590-01-BA to fuel injector s t'ud s . Attach an overhead hoist to the lifting ring of the fixture.

TE Date K. Remove the cylinder head bolts and washers. Record breakaway torque on attached sheet.

TE Date OQA Date O FAA , Date L. Lift the head from the block. If the head sticks, it may be necessary to take a strain on the hoist and break the head loose by striking the sides with a babbit or lead hammer.

TE Date i

M. Visual inspection of cylinder heads for cracking, distortion, fretting.

TE Date FaAA Date OQA Date

/ UNCONTROLLED for informatica Only O -

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8

GUIDELINES STEP 1 Cylinder head removal and teardown. Cylinder No. 4 .

l l

A. Inspect area about cylinder for cleanliness. Clean as .

necessary. I TZ Date OQA Date

. B. Remove cylinder head cover.

TE Date C. Remove starting air jumper.

TE Date l D. Disconnect the exhaust and intake air manifolds and the I jacketwater outlet flange.

l l TE Date l

l E. Disconnect the fuel injection lines and nozzle drain fittings.

L Take care to avoid damaging the tube ende. Cover the ends.

l TE Date F. Disconnect the oncer air start pilot lines and lube oil supply line. Cover tube ends.

l l

l TE Date G. Remove fuel injection nozzle holder assemblics, and nuts.

l l TE Date H. Remove the 2 inner air start pilot lines to starting air valve from subcover.

/ UNCONTROt.! En TE Date l

h) for In y rin..t,m. '.e.

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-GUIDELINES STEP CYLINDER NO. 4 1 (cont.)

1. Remove cylinder head subcovers.

TE Date J. Attached lifting fixture P/N 00-590-01-BA to fuel injector "

studs. ~ Attach an overhead hoist to the lifting ring of the ;

fixture. '

I TE Date K. Remove the cylinder head bolts and washers. Record breakaway torque on attached sheet.

TE Date OQA Date O

b FAA Date L. Lift the head from the block. If the head sticks, it may be necessary to take a strain on the hoist and break the head loose by. striking the sides with a babbit or lead hammer.

TE Date M. Visual inspection of cylinder heads for cracking, distortion, fretting, i TE Date FaAA Date OQA Date

, UNCONTROLL9

. Fcr informMi1 O*

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4

,s 10

a l

GUIDELINES

, STEP 4

1 Cylinder head removal and teardown. Cylinder No. 5

I A. Inspect area about cylinder for cleanliness. Clean as necessary.

TE Date OQA Date B. Remove cylinder head cover.

TE Date C. Remove starting air jumper.

TE Date D. Disconnect the er.haust and intake air manifolds and the jacketwater outlet flange.

! TE Date l E. Dist6nnect the fuel injection lines and nozzle drain fittings.

Take care to avoid damaging the tube ends. Cover the ends.

i l

l TE Date l

F. Disconnect the outer air start pilot lines and lube oil supply line. Cover tube ends.

I TE Date G. Remove fuel injection nozzle holder assemblies, and nuts.

TE Date H. Remove the 2 inner air start pilot lines to starting air valve from subcover.

I TE Date 0

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~~GUIDELINES STEP CYLINDER No. 3 3~~

~~D. Re. cave the 4 bolts holding the connecting rod bearing cap to the rod. Maneuver the bearing cap out the inspection door.~~

~~Record breakaway torque on attached sheet.~~

~~TE Date OQA Date 4~~
FAA Date E. Carefully lift the piston and attached rod with an everhead hoist taking care not to allow the piston to bind in the liner.
Continue to lift until the piston and rod are clear of the liner. Place piston and connecting rod in a prefabricated stand or using a nylon strap, set piston down by rotating piston and rod parallel to the floor.
TE Date F. Remove piston pin retaining rings from grooves at end of the piston pin. Slide the piston pin out of the bore, then lift the rod out of the piston and set aside.
TE Date STEP CYLINDER NO. 4 1
l' 3 Piston and connecting rod removal and disassembly:
[ A. Completely remove carbon and other combustion deposits from the l upper end of the cylinder liner before removal of the piston is l- attempted. As a minimum method, use 80 grit sandpaper.
TE Date B. Attach a piston pulling fixture to the crown of the piston.
(Delaval Dwg. 03-490-013).
TE Date UNCONTROLLED sg & Information Ony JTG Afif;6@ SED 1i M3 22
- _ = . . . _ --
II
.J CUIDELINES STEP CYLINDER NO. 4 3
C. Attach a chainfall or overhead hoist to the piston pulling tool and take up the slack. Attach eyebolts to the tapped holes in the rod bearing caps. If no holes are present, install a suitable means of attachment such as a nylon strap, etc.
Attach a suitable lifting device to the eyebolts and take up the slack. An alternate method for bearing cap support removal may be employed using a wooden support located under the cap while unbolting the 4 bearing cap bolts.
TE Date D. Remove the 4 bolts holding the connecting rod bearing cap to the rod. Maneuver the bearing cap out the inspection door.
Record breakaway torque on attached sheet.
TE Date OQA Date O FAA Date E. Carefully lift the piston and attached rod with an overhead hoist taking care not to allow the piston to bind in the liner.
Continue to lift until the piston and rod are clear of the liner. Place piston and connecting rod in a prefabricated stand or using a nylon strap, set piston down by rotating piston and rod parallel to the floor.
TE Date F. Remove piston pin retaining rings from grooves at end of the piston pin. Slide the piston pin out of the bore, then lift the rod out of the piston and set aside.
TE Date
~~,. 7 6R0l!ED~~
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e GUIDELINES STEP CYLINDER NO. 5 3 Piston and connecting rod removal and disassembly:
A. Completely remove carbon and other combustion deposits from the upper end of the cylinder liner before removal of the piston is attempted. As a minimum method, use 80 grit sandpaper, i TE Date B. Attach a piston pulling fixture to the crown of the piston.
(Delaval Dwg. 03-490-013).
TE Date C. Attach a chainfall (at least 1 ton) or everhead hoist to the -
piston pulling tool and take up the slack. Attach eyebolts to l the tapped holes in the rod bearing caps. If no holes are present, install a suitable means of attachment such as a nylon strap, etc. Attach a. suitable lifting device to the eyebolts
,' and take up the slack. An alternate method for bearing cap support removal may be employed using a wooden support located j under the cap while unbolting the 4 bearing cap bolts.
TE Date D. Remove the 4 bolts holding the connecting rod bearing cap to the rod. Maneuver the bearing cap out the inspection door.
l Record breakaway torque on attached sheet.
TE Date OQA Date FAA Date l' E. Carefully lift the piston and attached rod with an overhead l hoist taking care not to al)ow the piston to bind in the liner.
Continue to lift until the piston and rod are clear of the l
liner. Place piston and connecting rod in a prefabricated
~~stand or using a nylon strap, set piston down by rotating j piston and rod parallel to the floor.~~
l ( TE Date UNCONTROLLED \
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~~'N d GUIDELINES~~
~~STEP CYLINDER NO. 5 3~~
F. Remove piston pin retaining rings from grooves at end of the piston pin. Slide the piston pin out of the bore, then lift the rod out of the piston and set aside.
TE Date STEP CYLINDER NO. 6 3 Piston and connecting rod removal and disassembly:
A. Completely remove carbon and other combustion deposits from the upper end of the cylinder liner before removal of the piston is attempted. As a minimum, use 80 grit sandpaper.
TE Date s B. Attach a piston pulling fixture to the crown of the piston.
(Delaval Dwg. 03-490-013).
(
TE Date i
C. Attach a chainfall (at least 1 ton) or overhead hoist to the piston pulling tool and take up the slack. Attach eyebolts to
~~the tapped holes in the rod bearing caps. If no holes are~~
! present, install a suitable means of attachment such as a nylon strap, etc. Attach a suitable lifting device to the eyebolts and take up the slack. An alternate method for bearing cap support removal may be employed using a wooden support located under the cap while unbolting the 4 bearing cap bolts.
TE Date D. Remove the 4 bolts holding the connecting rod bearing cap to l the rod. Maneuver the bearing cap out the inspection door.
l Record breakaway torque on attached sheet.
TE Date OQA Date l
G FAA Date ea-ur .71 TROLLED h ,
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O GUIDELINES STEP CYLINDER NO. 6 n 3 E. Carefully lift the piston and attached rod with an overhead hoist taking care not to allow the piston to bind in the liner.
Continue to lift until the piston and rod are clear of the liner. Place piston and connecting rod in a prefabricated stand or using a nylon strap, set piston down by rotating piston and rod parallel to the floor.
TE Date F. Remove piston pin retaining rings from groovec at end of the piston pin. Slide the piston pin out of the bore, then lift the rod out of the piston and set aside.
TE Date STEP CYLINDER NO. 7 1
3 Piston and connecting rod removal and disassembly:
I A. Completely remove carbon and other combustion deposits from the l uppet end of the cylinder liner before removal of the piston is attempted. As a minimum, use 80 grit sandpaper.
TE Date B. Attach a piston pulling fixture to the crown of the piston.
(Delaval Dwg. 03-490-013).
TE Date C. Attach a chainfall (at least I ton) or overhead hoist to the piston pulling tool and take up the slack. Attach eyebolts to
, the tapped holes in the rod bearing caps. If no holes are l present, install a suitable means of attachment such as a nylon l strap, etc. Attach a suitable lifting device to the eyebolts and take up the slack. An alternate method for bearing cap support removal may be employed using a wooden support located under the cap while unbolting the 4 bearing cap bolts.
TE Date iTG AFF.00 4 -- -
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CUIDELINES STEP CYLINDER NO. 7
~~l 3~~
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.i i D. Remove the 4 bolts holding the connecting rod bearing cap to
.l the rod. Maneuver the bearing cap out the inspection door.
Record breakaway torque on attached sheet.
TE Date OQA Date FAA Date E. Carefully lift the piston and attached rod with an overhead hoist taking care not to allow the piston to bind in the liner.
Continue to lift until the piston and rod are clear of the liner. Place piston and connecting rod in a prefabricated
~~i stand or using a nylon strap, set piston down by rotating~~
~~, piston and rod parallel to the floor.~~
TE Date F. Remove piston pin retaining rings from grooves at end of the piston pin. Slide the piston pin out of the bore, then lift the rod out of the piston and set aside.
TE Date l
l l
UNCONT N' For infMmW"k O ,
,s e n-27
l -
s- CUIDELINES STEP CYLINDER NO. 8 i
i 3 Piston and connecting rod removal and disassembly:
A. Completely remove carbon and other combustion deposits from the upper end of the cylinder liner before removal of the piston is attempted. As a minimum, use 80 grit sandpaper.
TE Date B. Attach a piston pulling fixture to the crown of the piston.
(Delaval Dwg. 03-490-013).
TE D&te C. Attach a chainfall (at least 1 ton) or overhead hoist to the piston pulling tool and take up the slack. Attach eyebolts to the tapped holes in the rod bearing caps. If no holes are present, install a suitable means of attachment such as a nylon strap, etc. Attach a suitable lif ting device to the eyebolts and take up the slack. An alternate method for bearing cap (s/)
,, support remova.1 may be employed using a wooden support located under the cap while unbolting the 4 bearing cap bolts.
TE Date D. Remove the 4 bolts holding the connecting rod bearing cap to the rod. Maneuver the bearing cap out the inspection door.
Record breakaway torque on attached sheet.
TE Date OQA Date i
FAA Date E. Carefully lift the piston and attached rod with an overhead hoist taking care not to allow the piston to bind in the liner.
Continue to lift until the piston and rod are clear of the liner. Place piston and connecting rod in a prefabricated stand or using a nylon strap, set piston down by rotating piston and rod parallel to the floor.
~s TE Date.
s, m 'i-cc ;s.
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. . . .. - . . ..- -. . . .-- . - - . . -. . . . - . . =-_ _ .
4 I
i GUIDELINES l STEP CYLINDER NO. 8 ,
3 F. Remove piston pin retaining rings from grooves at end of the piston pin. Slide the piston pin out of the bore, then lift the rod out of the piston and set aside.
l TE Date 1
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,1 4
i GUIDELINES 4
, STEP 4 Cylinder liner removal:
A. Inspect piston and cylinder liner for ev'.dence of scuffins, improper firing, unusual deposits, etc. Prior to piston removal.
Cylinder 1 FaM Date Cylinder 2 FaAA Date Cylinder 3 FaAA Date i Cylinder 4 FaAA Date cylinder 5 FaAA Date Cylinder 6
. FaAA Date Cylinder 7 FaAA Date
, Cylinder 8 i FaAA Date l
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GUIDELINES STEP 4
C. Install cylinder liner pulling fixture to the bottom of the liner. Attach a chain hoist to the lifting pad of the tool.
Pull line straight out of the block. It may be necessary to use blocking and a hydraulic jack to break liner free from cylinder block.
Cylinder 1 TE Date OQA Date Cylinder 2 -
TE Date OQA Date cylinder 3 .
TE Date OQA Date Cylinder 4 TE Date OQA Date Cylinder 5 TE Date OQA Date TE Date OQA Date Cylinder 7 TE Date OQA Date Cylinder 8 TE Date OQA Date D. Mark bearing cap and sleeve (insert) for orientation.
Cylinder 1 l FaAA Date Cylinder 2 FaAA Date Cylinder 3 FaAA Date Cylinder 4 i FaAA Date C)
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V GUIDELINES STEP 5 Disconnect lube oil pump, jacket water pump, fuel oil, pump, overspeed trip, and miscellaneous tubing.
TE Date OQA Date 6 Remove governor actuator from engine.
TE Date OQA Date 7 Remove outboard support for cam shaft and idler gear.
TE Date 8 Support as necessary the gear case cover with nylon straps. Attach straps to a suitable lifting mechanism and take up the slack.
TE Date 9 Remove all front gear case to engine capscrews. Remove front gear case from engine be'ing careful to clear dowel pins before vertically lifting the gear.
TE Date 10 Remove all cylinder block to base through bolts. Record breakaway torque on attached sheet. Inspect for any opening of gaps between block and base.
TE Dati OQA Date FAA Date 11 Remove cam drive idler gear.
TE Date FAA Date ..,p @Tgr0 hon 7_
1* S 31 jW IN
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GUIDELINES STEP
'I 12 Remove all engine base to sub base bolts. Record breakaway torque.
'I Inspect for any opening of gaps between block and base.
TE Date OQA Date FAA Date 13 Install the 4 heads that are used to support the lifting lugs for the engine or rig as directed by TDI representative to lift block from base.
TE Date 14 Install lifting lugs in accordance with DeLaval dwg. LE-2059.
TE Date OQA Date STEP l 15 Remove cylinder block from engine base.
! CAUTION: 'If binding occurs, stop lifting and investigate and correct as required.
TE Date OQA Date 16 Remove main bearing caps in the order directed by FaAA representative. Record breakaway torques. Photo documentation required.
l TE Date OQA Date FAA Date
~~7. . a-j 32~~
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f I GUIDELINES s STEP !
Il 17 Remove the crankshaft from main bearing saddles as directed by TDI .
representative.
l TE Date OQA Date
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Appendix C-2 I
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. GUIDELINES FOR INSPECTION PROCEDURES GENERAL NOTES:
~~1. The steps below need not be performed in the exact order in which they are listed.~~
2. Prior to implementation of these guidelines, certain steps may have already been performed. In these cases, an inspection of these parts shall be perfornce erd the data recorded on the appropriate sheet or if the data is already taken the data stculd be transfered to this document.
~~3. All personnel signing in the body of the precedure shall sign in on the attached sheet.~~
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, EXCEPTION SHEET Supplemental Sheet #
Description of Exception Initials Date Disposition Tnitials Datc
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SECTION A CAM SHAFT THRUST AND BEARING CLEARANCE CHECK GUIDELINE
~~1. Remove com galley inspection doors.~~
~~Date TE Date OQA Perform a visual inspection of car pc11ey area looking for visual~~
~~2. Record findings on work supervisor'n cracks or any abnormaliticc.~~
work summary sheet. Also perforn a thrust clearance check sud a bearing to camshaft clearance check. Date to be recorded on data sheet 350-2-1, parts group No. 350. Acceptance criteria per Appendix III.
Inspection of thrust clearance and bearing to crrebsft clearance complete.
Date TDI Date TE Date OQA
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('- Cuesomee CAMSHAFT BEARING SHELLS - Model R Engines 350 2 1 towomens Loseten E ngme hacoes $erei 4e Customer's De.apriaten Tote' E ngine Moves Mewes sace Lost eneestsen Date The enepeci.on fruiruction Manuaf, Sectian 6, Part E l for purposes of recording information on '*'***
this form. bearingt are numberedin ***s-*'*
sequence, starting with the thrust bearing ~'"**'n'****c'****
st the Georcase end andproceeding , -
l towards the flywheelend. '"
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i-..e =%s l THRUST CLE AR ANCE cierm 1
j l Move camshaf t all the way af t with a ba then measure thrust I Cs Clearance with a feeler gauge between camshaf t thrust collar )
l \ ,,/ and thrust bearing T.D i .DATE T E. J) ATE Oq/) J)4TE BE ARING CL2ARANC"E/ THICKNESS Measure bearing shell to camshaf t clearance with a feeler gauge, o' bearing shell thickness w?1h a micrometer. Indicate method used and record in appropriate spaces below.
BEARING TO-CAMSHAFT CLE ARANCE - Feeler Gauge 1 2 3 4 l 1 5 ,6 7 8 9 10 l Remarks:
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( APPENDIX 111 TABLE OF CLEARANCES MODEL R.4 ENGINE Caserence Wuhen toe. Reelece whe* 0eer l g enc *es eldhmeteci taenm Is. wce o ein,es createstr ie me genemoi . . CJ074All 3.1784270 --- ---
sos ter ativire nsaen .. ..
Creatike4 is Them: Reas: . . . . . 04229 030 0 650 4 762 0 440 1016 Res4ce et erest eae
, Ceaascim6 Red Bee'* to Creekshoh . 00064 010 0.162/8 254 --- ---
See tw.as sviii..so n
I Censheft Gaarags se Ceeshoti (mesesdate) 0A044 A0? 8.1m4.170 --- --- See tw.aa s**' tW.as Censhe4 Thrusr Asistment . 00044A07 0.102/0 170 --- ---
Asivit e:0 012 ' ei er Psion Pa se Red tsehme 0 0054A15 02209.301 0 020 0508 Psion Pm to Peen . . OA02/O 90e 0051/0102 0 005 0 127 teer Geer teshmas te $ heft . . . 0A024 A05 0A514127 0010 0 254 seer Geer These se Brecket tin.=med) . . 0 Sud4 A07 0.1024 170 --- ---
Rea.= si 0 012 or s..'
l Rector A+m tsheng ts snets S A049306 01024 152
. . 0A12 0 3C5
! taste Recher Arm Amy to $ebtene lead shace! SA10/CA25 SJte/C (35 0 045 1 143 Esheai neese- Arm Amt te sus Ceserland senersacel SA0iT 015 0.127/0381 0 030 0 762 taiste sad.t eheut Teppeta m Gusse 88044 A06 0 1024 152 0 015 0 331 l'
Fuel Teport e Gede IA034A05 BA769 til 0 012 0 305 Teoret kaller m Reter g eshag SAC 24 A04 0A514102 CA06 0 152 Reiser enhagio Pm 8vi'.na 8 001/0A02 0A25/0051 0 004 0 102 Pm Bah.og to Pea O A014 002 04254 051 0A05 0127 An Vrve P.stea m Cop . 0 0C1/0 003 03254 076 0 009 0229 PatSa to L mer'
,Q Crown Top Le*d (Teased) - Tee 0450 t All IJ7C/1 A21 --- --- Ross Cinersace
( Crema fee toad - Above test ears St.ri - Sear.eg 5.srince 0431105C 0 017/2 013 0762'1270 --- --- Rese' C se este 0432'O493 --- ---
see i.as resaceer twe
{1 Psiaa mmg iad Ger Teo Compres ea Rea the 11 00754 090 1A0572t6 0J00 5 08C Coraeroseen peg (he 21. . . 0 875'0 000 13057216 0 70G 5 080 Compressoa Ras the 3) * . 0 A504365 1J70/1651 0J00 S 0st Cseprem.on Reg tho 4) . . . 0 050/0 065 IJ70/1951 0100 5 080 Od Centrol Amg (Useed . 0 A259 D60 0A0511.524 0 230 Sf83 Od ControlReag fLemerl . . . 0435!0A60 03 5/1.524 0J00 5 040 Paton Rea s $ses Cleerere a Groese.
l Tes temprem.on neg feie.1) S A074 A11 0.1704J71 0 020 0 5Ct Cecipresen Amt the 2) . 02054A00 0.1274J25 0 C20 0 508 Compreseen Ame the 3) . . . CA051309 01274 229 0A20 0 504 l Comssamme Ragite.4) . . . . . 04124 210 8264443 0330 07&2 Od Cement Reis (Uesed . SA034A07 037&1.170 SA20 040s Od Conest Reg itomer) . 00039A07 0876'O.170 0 020 0 408 l totste Ve sa $ rem to Gv.de . . 00064A07 0127/O 08 9A12 0 3~5 satste Veive Gmee leert Demour to Gode . . 03074 All 0.l?LT173 0All 0 40E Duet f w' ens an ede Ga laseci.en Paron a mg Iad Gee . f2104All 0Se41.331 04400 1016= 0.se f=i sas*ei e*i.
1.50C ee 3410 s e tehest Vein Stem is Gees Upper
~~0 0064 ACS O1524203 --- ---~~
tie wwe roches tes t ahest Vein Stem to G see (tomed 0i350tA80 1473/2222 --- ---
See volve reck'as tee teheat vesse Rettes tr evement) Test 0 0124J17 0305'O432 0 045 1 143 te: Seci..a 6.Pe i ? f r erri1 et to6.,g mesi re* ea:
Demeeer Overl hrt e' R evae Laer tere 17A00llf A01 4314/431425 17.060/0 020 433 324 'u t00 Seerec Th ctasa tsheiti; maga)
M"'" ***" h" "'* * * * '"'
ble.a Beerrig Ene:m . . . . OA284 020 16.773/16 740 0 515 15821 Lowersvi h.a Beerug Thrrs' Regi 0 A164 813 16 646115 570 --- --- See "Croats**'s se Tho r * ~ ,-
Coeaste.ag Red Seer ag sausts 0 821/0 $20 15 773115 740 0 (15 1562I Um Ev' .
Caesah Berig Sr.ett (asiterwom) O M 0207 1203'SJ50 0 202 5 121 Lo.ne 5at's Comsfe'i teereg Threet Finage SJt15J00 5253; g203 --- --- See
~~Comshefi thive te a i 1%~~
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_ , . STARTUP FORM 7.6 PAGE 2 1 -
I REWORK SUPERVISOR WORK
~~SUMMARY~~
f BRIFT DESCRIPTIO*: OF WORK:
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l COMFOND3TS REPLACED (IT APPLICABLE) .
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ADDITIOt:AL COMMENTS:
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SECTION B i PISTON RING INSPECTION GUIDELINE NOTES: 1. Acceptance Criteria per Transamerice. Delaval Instruction Manual 74010/12 (Appendix III).
2. Gap (end or bolt) clearance of the pisten ringn is measured with the ring in the liner. Used rings must be measured when installed in the liner from which they were recoved, and if new rings are to be used, their end clearance must be ncasured when installed in the liner in which they will be used.
~~3. The rings shculd be square with the surface of the bore prior to taking clearance measurements ensuring that the ring is the same distance from the top or bottom of liner.~~
4 The ring must be positioned in one of two positions in the liner prior to taking measurements, the preferred position being six inches frem the bottom of the liner, the riterrate e position being three inches from the top of the 15ner, (Reference drawing: Transamerica Delaval Inspectier. and f}
\,,/ Maintenance Record (Sheet 315-1-1)).
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) Fo: b'# n (U7 PROCEDURE STEP 1 Perform a visual inspection of all piston rings t.rd record all findings. If abnormal conditions are suspected, replace the set of rings for that piston and record the events on the k'ork Supervisor's Sumrary sheet.
TE Date OQA Date TDI Date 2 Measure piston ring clearances for all 48 piston rings (eight pistons: 6 rings per piston) using a feeler gauge in accordance with Transamerica Delaval, Inspection and Mairterance Record (part group No. 341 - sheet 341-2-1). Record measure data ento (sheet 342-1) in the applicable chart provided. Complete the OQA Feld Signoff for all eight pistons provided on each piston's ring data rheet. The following step signoff cust only be signed upon i
I completion of all cight piston's ring clearance crer.urements.
TE Date OQA Date 'TD] Date (i
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's CYLINDER LINERS 315 1 1 c ., se. a. i . a aa. w s. = i = .. c .o aei a v.wiaae. w. . ,
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~~t. Estabirsh reference meesw e . ment sad record. If pstoa is out of liner or if line'~~
~~removed from block.we. PREF ERRED REF ERENCE PostTION l' p'stoais l~~
I installed en tener.um ALTERNATE REFERENCE POSITION Take two readings.
s 90 deges.: elArt lA and S).
~~1. y 2. Teke reading,a et Possten t and recoed-~~
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~~I~ 3 Take rud;ags et Position 2 and v. cord.~~
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Instruction Manual .Section 6.Part C Cylinder NoJBank l lw-- --
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eriown on sneet 3151
) 1. Measure piston ring side clearance in groove with feeler gaJge. Measure each ring in three locatioas.120 deg'ees aca" g Record results below.
~~2. Remove rings irom piston fo* cleaning and measurement of end gap clearance Refe to Instruction Manua' an:' Ins:+:~~
~~and Maintenance Record Sheet 3151 for the proper processre. Record gap and percent ring face conta:1.~~
~~3. If new rings are instatied.' note reasons in " Remarks" below~~
~~4. If new rings are insttiled, record end gap and side clearance in grooves.~~
Old (Removed) Rings New (Replacementi Rings l Side Clearance End % Face S'de Csearance End Ring A B C Gap Contact A B C Gao 1 Top Compression !
l 2 Top Compression ,
3 Intermediate Compression !
4 intermediate Compreuion l 6 OilContrel
6 Oil Controf i Remarks MCTE 6 LI' p), p, t p F
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l instruction Manual .Section 6.Part C l
Cylinder No./ Bank 2 I
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i 1. Measure piston ring side clea ance in groove with feeler gauge. Measure each ring in tnree locatior's,120 deg et s ana" Record results below.
~~2. Remove rings from piston f o cleaning and rneasurernent of end gas clearance Refer to Instruction Manua' an:: Ins;+: ."~~
and Maintenance Record Sheet 315-1 fof the proper procedure. Record gap and percent ring fate conta:-
3.11 new rings are installed." note reasons in " Remarks" below 4.11 new rings are installed, record end gap and side clearance in grooves Old (Removed) Rings New (Replacement) Rings l f Side Clearance S'de Clearance i End End
% Face Ring A B C Gao Contact A B \ C t Gar j
1 Top Compression j 2 Top Compression 3 Intermediate Compression l l !
4 Intermediate Compression l f 5 OilContret l l 6 Oil Control }
Remarks ME, i E Rio -
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~~1. Measure piston ring side clearance in g'oove witt. f eele gauge. Measste each ring in three locations.120 deg eet aca" L' Record results below.~~
~~2. Remove rir;s fro'n piston for cleaning and measurement of end gap clea'ance Refer to Instruction Mansa! an: Insse: .'~~
~~and Maintenance Record Sheet 3151 for the proper procedsre. Record gap and percent ring face conta:t~~
~~3. If new rings are ir.statted[ note reasons M " Remarks" below.~~
~~4. If new rings are ir.statied record end gap and side clearance in grooves.~~
Old (Removed) Rings New (Reotacement) Rengs Side Clearance End % Face S'de Clearance l End Ring A B C Gao Contact A B C l Gar 1 Top Comoression l l I
2 hp Compression i
3 Intermediate Compression 4 Intermediate Compression l 5 Oil Controf 6 Oil Control Remarks t'it'T~E &
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instruction Manual .Section 6, Part C Cylinder No./ Bank '/
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~~1. Measure piston ring side clearance in groove with feeler gauge. Measure ea:h ring in three locations.120 deg ees aca" V Recora results below Ins e:t.:-~~
~~2. Remove rings from piston for cleaning and measur ement of end gap clearance Refer to Instruction Manua' a*:~~
~~and Maintenance Record Sheet 3151 for the proper procedure. Record gap and percent ring face conta:t.~~
~~3. If new rings are installed, note reasons in " Remarks" below~~
4. If new rings are installed. record end gap and side clearance in grooves l Old (Removedl Rings New (Replacement Rings See Clearance End % Face S'de Clearance End l C G a:-
Ring A l B C Gap Contact A B 1 1 Top Compression 2 Top Compression l I
3 Intermediate Compressien 4 intermediate Compression !
5 Oil Contrel 6 Oil Conteel I J Remarks M y h k"t 1
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. imCONTFOU.TU f or Inicrmatien Or'y C') Transamenos inspection and Maintenance Record V -
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Instruction Manual .Section 6, Part C l
Cylinder No./ Bank 5
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(/ ,1. Measur e piston ring s!de Clea'ance in groove with feeler gauge. Measure ea h ring in three locations. 120 deg'ees a!,a"
_ Recoro resa'ts below.
~~2. Remove rings trem prston for cleaning and measurement of end gas clearance Refer to instruct >on Manva' an:: Ins.e: -~~
~~and Maintenance Record, Sheet 315-1 for the proper procecure. Rece,rd gap and percent ring face conta:t~~
~~3. If new rings are installed, note reasons in " Rems'ks" below.~~
A 11 new rings are installed, record end grp and side clearance in grooves Old (Removed) Rings New (Reolacementi Rings Side Clearance End. % lace S'de Clearance End Ring A B C Gap Contact A l B l C Gac 1 Top Compression l l l ,
2 Top Compression l l 3 Intermediate Compression l 4 Intermediate Compression l l !
5 Oil Contrel l
t 6 Oit Controt l Remarks i MM tsb
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~~1. Measur e piston 'Ing' r side clearance in g' cove with fceler gauge. Measure ea:h ring in three locations 120 deg.ets apa i~~
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Record results below.
~~2. Remove rings from piston ior cleaning and measurement of end gap clearance Refer to instruction Manua: an:' Ins:e- .:'~~
~~and Maintenance Record Sheet 3161 for the proper procedure Record gap and percent ring face conta:t.~~
~~3. If new rings are instaMed. note reasons in ** Remarks" below.~~
~~4. If new rings are instaHed. record end gap and side clearance in grooves.~~
Old (Removed) Rings New (Replacement) Rings Side Clearance End % Face S'de Clearance End C Ring A B C Gao Contact A B l C Gac 1 Top Compression 2 Top Compression 3 Intermediate Compression 4 Intermediate Compreuion l
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l l 1. Measure piston ring side clea ance in g'oove with feele* gauge Measure ea:h ring in three locatier 5.120 deg'est ara -
Record resatts below.
~~2. Remove rings from piston for cleaning and measurernent of end gas clea an:e Refer to instruction Manaa' an: irss;er ,-~~
~~and Maintenance Record Sheet 315-1 for the proper procedure. Record gap and percent ring fa:e conta:t~~
3. If new rings are instaHed, note reasons in Remarks ** below.
~~4. If new ringt are installed record erd gap and side clearance in grooves l~~
l Old (Removed) Rings New (Reof acement) Rings l
Side Clearance End % Face S'de Clearance End Ring A B C Gap Contact A B l C Gar l 1 Top Compression 2 Top Compression l l 3 Inte. mediate Compression 4 Intermediate Compression l
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~~2. Remove rings from piston fo' cleaning and measurement of end gas clearance Refe to Instruction Manaa' an:: Inspe ct .: -~~
~~and Maintenance Record Sheet 31E1 for the proper procecare. Record gap and perant ring fa:e conta:t 3 If new rings are installed, note reasons in " Remarks" below~~
4. If new rings are installed. record end gap and side clearance in grooves Old (Removed) Rings New (Replacementi Ringt Side Clearance End % Face S'de Clearance End l R ng A B C Gap Contact A I B C Gao l
l 1 Top Compression l 2 Top Comprenion l 3 Intermediate Compression i 4 Intermediate Compreuion l
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( APPENDIX lil TABLE OF CLEARANCES MODEL R 4 ENGINE
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Pm 8.shes to Pin 00014 002 0 0259 CS1 0 005 0 127 l Av veiw Fen e ces 80011032 0025/0076 0 3tt 02/9 Pe's ie L.ner
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{j Sa ni - tweg $vriere Pe p Reae(niGas C017tC19 04321441 --- --- g. a.e s. neir,m,y ,y, Tcp Comprun.sa Reg the il 00754 060 1406'22t6 0200 5 08e CompemeaSagfile !!. 00751 390 1405/2276 0 2C3 5 0t3 I Compennen Ame the 31 f . SASC.T. 00% i270'1651 CJ00 $ 080 Compras.en R.ag the 4) . . 00601 M 5 tJFC'1Eli 0J00 6 053 04 Centret Reg tuppel 03354A60 0389/1 524 0 7C0 5 6ti, C.i Contrei nng itomer) . . 03354A60 0Ast'1124 IJ00 1 05 l Psea E*s Se Cimsanse e Groom Tes temrumesa pag tta Il 03074All 01784J73 BCN f SCI Compeu.ca mme lho.2) . . GADS 9 Art 01274J29 0A20 0 5C4 Cearessa mes(We 31. . . SA05.tA00 01274229 0 220 0 605 Compeema nas the ol . . . . . 03121A10 0 3054 403 0A30 070 l Dd Consol Awg(ttsport 03039A07 0A264178 0SN O 504 i Od Coavelams fle wl 90039AC7 0A701170 S C22 0 60!
letate valve Swm to Gefe . 00054307 01274 175 0 012 034 laute Wale Gvieslaws Deaster to Gwee 0 0074 All 01741279 0All 0 436 Duel tw easae n'e Ce lasecten Paan R mg Ias Gas 0 0018 T 015 0 A461381 0 0430 1.Ctbe Desi f mi eat aen sale 1.500 se 38tosa Isheet Vrw $mm es Gwee (Uperl 000Lt308 0194203 --- ---
See ww esches tec E s' erst Vs n $>em as Gese , tower, D DSP 0 003 1473'2C:2 --- ---
See vs.* eetkes tw tehei,st ve*w Ar.st*s imawmeert Ter 0 312C 317 0.304/O432 0 045 1 la J 5ee Sectica & Pet I 8 a * ' .8 r
of enes messe ement D e -w'* Dier!De se a q,,e i mea tore 17.CJCilf A01 431 A/431825 1706C4 A23 433 374 9 605 0..es Tn.ttans 15hea s's.ap) D'd *" *** "'#*'" #" h -
ase.a Sereg 5aette . . . 01214 020 16 773/11 748 e til 15 t21 Le.w shea tes.a Serms t wec Rep 0 A169 013 18 846!15 570 --- --- ser "Cra*tihe,s ie t here' Per Ceaneet.5 and See'as laeth 8 021/0 (2 1517315141 0 615 15(71 uesc sn es' Camshe't tes q SseN tmemove:a) SJoe 0107 SJt3'52*& SJf2 5 131 Lo v 5*et' l ] Camine'i tw as 7h+ve* f.ap OJ119238 SJ53' 5 2e3 --- --- See 'C omea a %.ii a s,.s -*
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STARTUP. FORM 7.s pace 2 R$ WORK SUPERVISOR WORK SUPNARY f
I BRIFF DESCRIPTION OF WORK: l l
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I, StrIIO!; C ENGINE BASE INSPECTION GUIDELINF_S
~~1. Reniove main bearing shells from base if they have not already here removed for inspection, being sure to record and mark which beariPF.~~
rhells are taken from. If shells are alrady removed, record on attached sheets the markings on the shells and hearing it var rceoved from. Use nngi? marker or other suitable marking device to mark shells.
TE Date OQA Date TDI Date
~~2. Inspect base for cleanliness, area clear of all foreigt cU ects.~~
~~TE Date OQA Date TDI Date~~
~~3. Perform a viruel inspection on engine base assembly.~~
~~NOTE: If areas in the base area are found to be in qurrtier a p~~
g nondestructive test should be performed at this time.
l t Record all findings on work supervisors surnary sheet l attached.
TE Date OQA Date TDI Date 4 Level entire base assembly to TD1 and contractor perforcirr,clignment checks satisfaction. Level cchieved .
TE Date OQA Date TDI Date f 5. Perforn an alignn.ent check using a paragon level, wire, laser, etc. on
! nain bearing saddleF. Fccord findings on work supervisors work surnary sheet attached.
l IE Date OQA Date TDI Date
~~6. Replace hearing shells and install bearing caps on all main bearings.~~
Torque main bearing cap studs torque to 2150 FT-lbs in a criss creer pattern.
TE Date OQA Date TDI Date JIG Efifa.YE' b *,_ r' ...',
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~~7. Meanure the inside diameter of all main bearings per attached sheet.~~
~~t TE Date OQA Date TDI Date~~
~~8. hemove all r.ain bearing caps.~~
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Eciin* M S SECTION D PISTON PIN CLEARANCE CHECK
~~NOTE: Acceptance criteria per Transarerica Delaval Instruction Manual 74010/12 (Appendix Ill).~~
~~1. Perferm a visual inspection of all piston pins and piston pin bur,tingr.~~
If irregularities from designed conditions are suspected e nondestructive test (i.e. dye penetrant test) may be performed to the suspected areas. Record all tests and test results perferred on attached inspection forms.
TE Date OQA Date TDI Date
2. Measure the outside diameter of crch piston pin with a micrometer in accordance with Transamerica Delavel, Inspection and Maintenance Kecord (part group sheet 341-1-1). Record reasured data onto sheet 341-1-1 in the applicable chart provided. Complete the 00A Hold Signoff for all eight piston pins provided on each piston pin'n data sheet. ~1he following step signoff must only be siFned upcn cocpletion of all eiRh t
[_s piston pin measurer.cnte.
y TE " Date WA Date TDI Date
3. Measure the inside diameter of each pisten pin bushinF with a micrometer in eceordance with Transamerica Delaval Inspection and Maintenance Record (parts group No. 341-1 sheet 341-1-1). Pecord reasured data onto sheet 341-1-1 in the applicable chart provided.
Complete the OQA Hold Signoff for all eight pisten pin bushings provided on cech piston pin bushing's data sheet. The following step signoff must only be signed upon completion of all cinht pirten pin bushing r.easurements.
l TE Date OQA Date TDI Date
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~~Position A B TDi D0TEi Forward End Att End W 73 te. 044 3a~~
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Position A 8 D UM Forward End Att End .
TE Pa te. OGA } ate
~~3. u ... i. .. esa w. in pic.a en emision. A.A. s siin ch one et w. (.= r s o n.~~
~~Position 1 A 8 Forward End Ol ben Att End~~
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Instruction Manual 84 l
(. APPENDIX 111 TABLE OF CLEARANCES I
MODEL R 4 ENGINE Camerence When how Se,4ece whea 0 <*
tism latee W A*ce i larhei 61.8
~~v ie s ti s.e. _~~
I l Crphspe+t to gare genemp . . SA074311 0.129 9 270 --- ---
see toer.as inen sacaen .g..e, e
Creauett to Thrimi Amy 03224 A30 0.650/0 752 0Dec 1.018 Rep's e ei teeii ne l . .
l Connect.as Aed See me to CreaWeh SA064A10 0162/LJb4 --- --- see t,erme e te.cnness.6 e-l Coasteh tear nos to ComeNN imesn=eders) 03044 307 0 t$2/0176 --- --- Em bw.ag sher th.cusas 8-se.
I Cemensh Thrust A8t.stmeat 8A049307 0102/0'18 --- --- As,ai a 0 Olr s' e e-Petea p.a se Red evshN 0A031 815 0229/0est 0 520 O SC8 Puisa pe te r.stea IA02/0A04 0 051/0 102 SA05 0 127 leer Ges Svih.ap is Shah . 0302'OA05 03514 127 0 010 0J54 lame Ges Thrust to tracket (an==med) . 0A044 007 010210178 --- --- Res*.e ei 6 012 er e.c Rectw Arm 0vs%ag ie $aett . SA049 006 0 102/0 152 CAtt 0 235 eeone micky Are Asv ee $abCent (ew! charece) 0410!0025 SJb45635 0 046 1943 (shoist Recir Are As, te $at Covedead ctearancet $3051Atl 0127/03 1 0 030 0 762 taiste me t ahavst f aeperi m Cease SA04/CA06 3 102/0 152 0 015 0 181 Fami tas;we .a Co.de 8303%A05 007t?D127 0 012 0305 Tae:mi Rota, a heuee tw*nig IA023A04 Call,0102 0A06 0 152 R ehe 8 an*6 's ** 8.: heas OA014A02 05h1 OSI e004 0 102
P.a Sen.ss te r.a 80011301 0 025 1 311 0 0c5 0 127 An vvw Pistan e Cae 00014A03 0025S 076 0 007 0 22'.
Petoa to Lmer
[y Ces== Ten to e fispeeds -Tes Crowa Teo Lee - Aten feet e.as 02601 272 OS331C50 IJ70.1879 0 75241 270 Asse' Cissem e Res.a' Cuenea e 3 n e - 0.e<*g $v'me 0017/0All 0432'04s3 --- ---
See 'ee< <as.re-e e twe Pataa Rag (t 4 Gao
{ Too Coorse se Reg me 11 047h9 0$0 13057 28E O 203 5 CIO Compos.iea Reg lare 21. . . 00759 480 13062286 0200 5 08:
l Corne emma nne tte 31.* 054/D A65 1J70/1831 0 100 SC80 CompreseaRae me 48 00541 385 127;/1851 020L 5 093 l
l OdControlResfuese) SA259360 SAtt'4624 0 233 5 04:
l Od Coartel R.ag fleesen . 0231.1 360 0383!1124 0200 5 043 Pmen Reag See Causeence e Green f ee Ceepresseea R.ag tse 16 0 A07/0 A11 0170/3273 O t?" C log Com.yes, Reg me 21. OA0k1AOS 3.1275 229 0 473 0 tot Compemes Reg me. 3) . 0305/0A05 01274229 CA2; e let Comproven Reg me 4) . 0A124A19 030k%483 0430 07(2 CJ Centro! p eg (Jaes i SA034A07 0A741178 CS2G 05t!
Od Cor.Pe! Ang 4e.sq 00C3/0 A07 Sa7tt 178 0 020 O bct 6 mens Vs..e tiem ta Ger.e 0AOSS At? 8.127/0til 0312 0 3e5 entste vaiw Guise 6*m Demer ic Guds 8 007/0 A11 0170/D278 Call 0 408 D uel t al e* Pwi er's Ga lare:i.ea emer mee t. 4 Ge; CA018/CAI5 004610281 0049 lA18d De'feleg+iv' 139: de 3410to f ehsioi be'a $te
t:, C wee f opp-) 0 0380A07 0 112/:233 --- --- toe ve'w eectepet inhesi vra ssem ie Cu ce Len # 0 0u1300 1473/2 0J7 --- --- see vow re:ees :en is%svit Ve'* Rett.as emowmaaC Test 00125 017 6 335/0 AU 0 f,4! 114; see Soci e 6. Feet 8 'e' me' Lf et tatre manav emeat D e =w'e' __.
Owe 9 A e' eev f Lae Se's 17.000'173c1 4313!431376 17 063/2A20 433 324150A N"'"""""'" #""#"*
Seere's Th.daem smenes nago lae.a Basems $>eas . . O g219 A20 16 773'll 748 0 $15 15 C21 L own' She%
i Me.a teneg Thr.st Rep Saigg):3 15 045 15 570 --- --- see Cenaas wh ee l>. wet peg' l Conaen.cs Ilee t e**me 5e88 0 821!0 $20 15 773/15 7tt 0 $15 1' t?1 Upoe' Shen l Ceme. see s or= <,i.,me. .
0200 n0F 52:1 u n 0202 s i31 to-- s*eu n 4 J'.S' SJ83 --- see Ca*sheh 7"'vr 41,ataem
( j} Co-shah 8es**g Thrust Flease 9111 9 108 ---
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~s UMCONTROl'JD Fc Informatica C*
(
SECTION E GEARSET BACKI. ASH INSPFCTION
~~1. After the cylinder head has been removed, remove the gearset cover.~~
~~2. Inspect gears for broken teeth or other damage. If gear is damaged, inspect camshaft with a dial indicator to determine if shaft is bent.~~
Fix as necessary. Record data on work superviser's work summary sheet attached.
TDI Date TE Date OQA Date
~~3. Mark each gear in 4 positions, 90 degrees apart (3, 6, 9, 12 o'cleek -~~
~~see illustration on attached record form).~~
4. Select gear pair to be measured (see table on attached form). Mount a magnetic base dial indicator with its stem rerting on the side of the gear listed in the " Rote.ted" column. Rotate gear to renove all slack.
Zero indicator, then rotate gear in opposite direction to remove all slack. DO NOT MOVE STATIONAP.Y CEAP! Record backlash in (bc
[_s appropriate space en the attached form. Perfor= check et the 4
\ predesignated positions.
l TDI D,nte TE Date OQA Date
~~5. Compare backlash readings to the acceptance criteria contained in Appendix III and gear set drawing attached. Perform corrective actierr rr deemed necessary.~~
TDI Date TE Date OQA Date i
i
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Inspection andNainte~ndnce Record K yTransamenos p c -i Delaval
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355 2
1 GEARSET - Model R Engine
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n.. . o. . n e, in:*ruction Manuat,':ection 6. Part E & Section 8, Page 4A Mens Ab 3
1 Com.h... G e 6 2 tes.e G e 3 Cr ea. .h.'i G..'
4 W.m Pump oe.v . G ..'
6 Lute...t no Oli Pump G..e i
I 6 G.v.ra.e & T ech.m.i.' oe.v. G..'
6 .
3 7 G v.ra.' or....no orv.a G..'
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I Measurirn+nt Positions h %' ~' ', t-)[ l~ s b p (. fj;ii D C i; '- '..",
tintoad vo've train'by loosening eocker arms, and by hf ting fuel tappets and inserting pins through tappet housings to hold them of t tt.e fue: cams Mark each geaf in four positions.90 degrees apart (3.6.9.12 o' clock - see illustrat'on)
Select geo. pa'r to be meassted (see table below) Mount a rnagnetic base dial indicator with its stem resting on the si'ic of the geo hsted in the "Rotatect" column Rotate gear to remove all stack. Zero indicator. then rotate gea in oppos te
<fis ection io remov. all slac. . Do Not Move Stationary Geor/ Record backlash in appropriate space c 'i tabic Hotata g-c 1o next three position, recording backlash in each position Measure backlash in four positions in each gea-iwe hsted on table
.. .._ . i y. g . ; g 7.:7 .-n i-.u.: ;g g.y; ;;. : - 3. w- d :: :p ; -m I
Gear Peer Backtash - Thousandths of an inch Stationary 3 O'Cinck 6 O' Clock 9 O'Ciock l 12 O'Ciod l l Rotated l
1_ _ 2 2 3 l 2 5 i 2 6 2 8 4 9
,m
( ) 6 7 w n Tc DAT C . 04A DATE-
' 8. 350 2 e m s nt om E *4 5 .
e
= eween, s . oe u es e
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R 3 CAMsHArTGEAR 1
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GOVERNOR & T ACHOMETER
7. S . I DRIVE GEAR Q *O Noemas Rec htash .008 .080" (j c. AIR
DISTRIBUTOR DRIVE / l gA am / -
" 8
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[ ' . GOVERNOR DRIVEN GE A I['
Normal Backlasm .004 .006' C3
'} '
E FUFt. OIL PUMP AND l
- l-' h~ ~- OVE R$PE ED GOVERNC
\ ,
Noemal Backlasm .008 .0
%.,f,j Nm._ _. _ _-
Pat Neue SusMass 19 Cheerence E ncende .010" --
LPI' l LM i
N m., E -, e -. .
A.,... . . R ._ ne ._.
If Cesarence E nceede .010* ~
Normal Hechtash .008 .010"
( K CD J - _ +9( '-
eDLER GE AR M
t LieBE OIL PUMP GF AR Normal Rachaash .008- 010" L-fj \f
~ ~ ~" ~ ~' ~ ~
g,- .\ ., y WATE R PUMP GA
- Norma 8 Backlash
.004 .006" W A TE R PUMP GE AR .- L
'4 Norman Rachtash 004 -.006' - '*
^
~
~~) T C RANK 5H AF 1~~
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t .
/
-} ;, . s SPf f D UP GF A
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Normal Bachlain .000 .010" Position Of Crankshaf t May With ,
t No. I Cylinder To T.O.C.
NOTE: Check backlash in at least four positions of gear Model **R" With Twenty Degree Pressure Angle Goats 4 n u.s.A.
~
9AR SET ">wbm f. r o,m o-o v
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Instruction Manual -- - . - - . -
e4
( APPEN0lX lil TABLE OF CLEARANCES MODEL R 4 ENGINE C ea. a.e. Re,..e.ne,0 .
,,e . ~ ,,-..-, ,a .s:
. . ~e e., . m e, Creae e...e . r . . Smuit .n un -- --- m e., - - o ,. ....e.
Cre.. ., ,e T. R, . . . .nm.0 . n..nu .30 1m R e .. .e., .e C. nae.., R ed .ser, Cre s , . . A10 .luew --- --- i.e .e,m, ~ , .e w .,,e, Cem . .serm .e C.mehe,, - d.e,e> 04. .lueln --- --- see , ,,, -e me. , e...
C.m-, ,hr.s .d mmen, . . . . o.4 . . in,01 n --- --- A.. , e, 0 0,r . ..e.
,.,ea ,m ,e R e. ..~, .-
..,m .22, u .i un 0 52,
,.or. ,m e ,.es .... .0,14 1 .ml ein
,de.Go.. g...ne, . . . . . ,. 5 . 14in # 10 Om te e Ges. Theer to Brecket tehemed) . . SAS44 207 01021 178 --- --- Resh m ei 0 012 er c.e-Aette Arm Ishwg to Shaft . OADe!CDOE 91024 152 0312 0 305 spoke Retter Are Ame.se 54tever tend :Jue en el 93109A25 0254!0835 0 045 1143 teheat Re am Are As, eeldte.or teadcieereace) 08054815 0127 m 81 0 039 0 762 emene ead t ahees tepeats m Gesee 9A04.1A06 0102'0152 0 015 0.38 t Fwi fessei m Gue . 32039305 0476.1 127 0 412 C 20:
Teasei Relim ia mense tushme 68021304 00t1#0102 05 6 O tt?
Retsp lahmg te Pia $v.f:s93 90019.302 CA25T 051 0 004 01C2 Pie 8sh.cg to Pia 00014 002 0C25)C'1 0 005 0 12'
~~An vein P.ston a Cap . O801/CD03 0 C;5'D 076 0 009 C225~~
( Petea to Lee' b Csowa Too lead (Teoreds - Tee OAnc1372 1J70'13.'l --- --. Rede C. sus i, j ( Crema Top Lee.d - Abese fast sing Sart - teorieg 5.e4ece I A30 C C50 0017/00;s 0 7L2.1274 --- --- Rees Cises o 04*.210411 --- ---
Ese 6rr ierewa'i.e 'e Psion Reg f ad Gac
{ f es tempeam.sa mme (he. Il 0 0754 09c 1 305'2.284 C200 5 0fC Comprem ea Ar1the 21. . 00'59003 1 805/2 286 020" lG83 Compemma Ring the 31.- . 0950!OD66 1.270/1 451 0100 l 0.0 Compos.ea pag tho 4) . 8 0505 365 1270/1851 8203 S C2?
0.* Cor.oref Ree fueer) OC35SD60 0 4a9/1524 02:0 E C8:
0 i Ceastel Rme ttesel . 83359AS4 8383/1 524 0 700 let:
Pac, Reg 5.se Camersas n Grasse-.
Tee Compreneen Reg the 11 0 A071J11 0 in9271 0 020 05;2 l Cameramen Reg the 2) . 0A05% DOS 8 1274 M 0 420 0 101 l Compres.ca Rene the 3) . SA05.1 6 81274229 CAM OEe
! Con. pas en Reg the ol . . SA129All 8 305 4 443 0330 0 7t?
l Od teanst amg quesert gADHA07 087L1178 BA20 05P l Od Control Ras tlemel . 388 M A07 837E1178 8020 O 6al l lesene W wsumteGe* 4A051DA07 31273 178 0 412 0 3C6 leisee vadw G*ee tae Danets to Gode 83074 All 01784 279 8All 0 405 O mi f.e8 anyar, or f, Go tapoien Peen Ras iad Gee . 8 missAll eeset341 8 esop - 1 C1p Dues f ort eat aos ea's 1300 de. 3410da l tshemi ve<w Stem to G de (usecl 0 Sets Aes 8152102C3 --- ---
See =*n esches ter isheat w 'we lism se G.de (Lemer1 0 CSS.%000 1473.2332 --- --- See .e'n re:6.as tec I shevst Vale R ete eg (menmentl Test CA12? Call 9135T,432 0 045 1143 See Sect sa 6. Pvt 8 4 me'not
~~e. ., me e re m e,i j Degrar .~~
Oe.'Dut e'r e ;-j_
(ene' S ore 17A(E/17 1 4313/831325 17A E 4 220 4:33241 508 g Tbtkamm Whee hoe R - '- me er er tem m.a S.:mg SaeN - g3214 820 16.n3.15 744 0 815 14 821 leser Sne.i 18e Beweg Thr6s R egi eA164313 15.046'11 170 --- ---
see "Creakdali to f a'uc Pes /
Ceawet.ag R .8 tearms $heit 08219 E29 16.T73/16.744 0til 15 521 Uppee $*.e','
p) C.* e ....,5~,.imi edes Ceewa Best.as Tom, tienge C .w C2119204 im, im Om 5250'5283 ---
5,r to e. 5,e Sw 'Ca*shefs luvr e bt'*"'
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For intermatic:' C .,,
-(l .SHOREHAM
-NUCLEAR POWER iSTATION "$[5figif/]
STARTUP FORM 7.s Pace 2 REWORK SUPERVISOR WORK
~~SUMMARY~~
BRIFF DESCRIPTIOt1 CT WORK:
l l
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Cg'[Ot.0:3Ts REPLACED (IF APPLICABLE):
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MSTE. CA'IDRATED tools . UTILIZED:
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ADDITIO :AL COS2ENTS:
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Rework Supervisor Signature /Date t Y
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UNC f L m For information
(] _J SECTION F PISTON SKIRT INSPECTION
~~NOTE: Acceptance Criterin per Transamerica Delaval Instruction Manual 74010/12 (Appendix III).~~
i ). Perform a visual inspection of all eight piston skirts for wear l
and other abnormal conditions such as scruffings, scratcher, etc.
Record all findings on attached sheets. If irregularities from designed conditions are suspected a nondestructive test (i.e. dye penetrant test) nay be performed to the suspected areas. Record all tests and test results performed on attached forms.
! TE Date OQA Date TDI Date t
2. Measure the piston skirt outside diameters of each pistou in accordance with Transamerica Delavel. Inspection and Maintenance Record (part group No. 341 - sheer 341-1-1). Record all the measurements onto sheet 341-1-1 in the applicable chart provided.
Complete the OQA Hold Signoff for all eight piston skirts provided l
on each piston skirt's data short. The following step signoff
'3 must only be signed upon completion of all c!r}t pisten skirt measurements.
Date Date TDI Date TE OQA l
I l
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a a. .. s .. . c. s. a=ea o.i. v a. in ...
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PISTONS - Two Piece 341 1 1 G a.-- 38 L.et*a Cu.t.m.e
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Customer's Doogn. ten 5 es No gn,.n. es.gos D.t. ,he ena. action t se gn,.n. Now,s M.v.s Sms. L t on esten D.i. Me .e. s v m.ie.eness instruction Manual, Secti on 6.Part C s
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1 1 c.t 5eral No Catemer's Donapneten Eng.no esege DateThe rc-teon Mours 5. nee best snepecten tess e Eng.no eso rs Deta Asseesso sv metersames instruction Manus', Section 6, Part C Cylinder No./Banh C
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4 in. te'o* benom ..no t'oove ano e 'a ebeve.bonom o'sa.et tee. F.e AL Weeswee tow pos+t.ons ( A.A. 3 5. C-C D D) en seen toces oa (see F .e Cl AA B-B CC DD l
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instruction Manual. Section 6. Part C 1
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~~e'e'easen instruction Manuaf, Section 6. Part C l >~~
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TABLE OF CLEARANCES MODEL R.4 ENGINE Casernace when gees, gestece tv%ee Over lache ts.stemetri sac hes I/ .i., tivi n o,n ,
l tee +
. 0 A074311 01709270 --- --- Cae ew.ag emen tschaen t p :s l Croatst v: es he tes.mos CA224 030 06524 752 SMO 3 C16 Rep;me si 6sas* *ae l Creat uait ti. Thrmt p.ap ,
Ce==acimg Fed 8weg to Croaka8eh 00064 A10 0.162 9 254 --- ---
See tw.as saei en.ckaet tesu .
a 03044 807 0.102/5.178 --- --- See tise.a;iaene..chassi .g n Camma*t Jearess te Camshot:(etsmedessi Caminv> Tvus As,wimaat . 04044 007 01024 178 --- --- Ad.ustet08t? ore.r Psise r.* es R ad 8vah as 0305'0A16 0J204381 0520 0 5CI P, sis ; Pm to Patsa 00024304 0051!0102 0 C05 0 127 edic Gw fusNags te f asti 03024A05 03511C827 0010 0254 0A044 007 0.1024178 --- --- Renaa si c ot2 er eve.
idwe G:c Theuct ie trocket tshemmedi . .
0 004 4 005 0.102/0 152 0.012 0 305 Rute A< m e wheas te $astt tetste hrer Arm Amy te tutieser iend simersace) 0A10/0 025 0J64!0535 0 045 1.143 E nhavit R xtee Arm As, te sse Co.se lead ciwance) 04051216 0.127/0301 BA30 0 762 lese 6e ed i easvst Tappses a Gree 0 0041 A06 0.102/0.152 0 015 0 381 7 mi Torpet e Ge+ 0003%A05 0A764127 0 812 0.305 Taspe' Rehe*
Relie'IseNag 80024 24 0 3614 102 0 806 0 152 Rour 6 2:s.r4 se P = 8at=ag 80014 002 0A254 051 0 004 0 102 P.= 8d ; to P.= 00014 002 0025'O051 0 005 0127 a n v i tve P g s ec tsp . 0 001/0 003 0325/0076 0 009 0229 Psio .s t.-er Co.w Top Lord finoe ed)- Top OD509472 1270/l329 --- --- Rad 4 Cwaraate 8830/0D50 07E2/lJ70 --- --- ReJ.e' Dew e ste C.e.e.1cs Lead - Aten to e.as 54 . 0.c.ag Ser9 ace 04174 019 0 4324 443 --- . - - - See i.aer ewece*wai f u's t
Pero. Nc (e.d Cap Ty Cemc'em.o= Reg (No 1) 0075/0090 1305!!J85 0J00 S Lt3 Compees.on Reg the 21. 0 A75/0 000 1306/2286 0200 ESE Capisen,e* ams (to 3)
O2504 AEl 1J70/1651 0200 6 080 Ct, ;rme= Rag (me as 0.0509D65 1.170/1 851 0100 6 080 Ori tert'el Ret fuspel SA354 D60 0300/1524 0100 S C40 02354 360 0305/1524 0 100 5 053 04 Ccat 06 R.es tte sal i Pase- R eg f.4e Caseance in Green.
ur. Csap m.sa Reg the 1) O 807/0 A11 01784278 0125 0.500 Cre p es.ea Reg ime. 21. . 03059 005 0.1274.220 SAIC 0 500 Ce riorez.or, peg 14e 31. CA05/0D05 0.1274J20 0A20 0 500 Coms.es.en Reg (Na 41. . 0Al2/0J10 0.354 483 0830 0782 04 CentrJ Reas tupport SA034A07 03704.170 0520 028 0 Contrei n es k omeq 03034A07 0A704170 0 020 Satt treste va;c tiem e- Gv oe 93054 007 0.1274 170 0312 SJ06 SA07/0211 L170/0J70 Saft 0 405 Duel let ee aes ea',
satane vsa.e 3mee sawt Demeter se Geds 030185A15 0 044 9.301 SM00 lA15# Ones tvet evnet eat, rim insect.or enna Rmg E ad Gap 1300 d.e 3010 de 0 8041 A08 0.1524J03 --- --- See ts** sectng em t saewa vew teem ic t,cce tgeverl 00504A80 1.473!2022 --- --- See sein rectias test E srw b e .e site is G eds (Lesse<!
0 012/0 017 SJ06/0432 0 345 1 143 Ese see= 6.re s t fo r i>%d t e%ew-. sa e *nens tmc ment: Test of tokmg measuremoni Daamise Deer %t s8 Row =d Lee' f' ore 87 A00'17 A01 4313/421 A25 17360!OA20 423 324 4.508 Swms imcares Is%,its/R agit
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l IAll4A13 16 04t/15 570 --- --- see f.esatsteit to Thret Ra.se 88.a 8esinsThrat Rmes 0821/0620 15.773/18 748 $ $11 15021 Uppe' She" Coavectms ped O neteg 5heit Cave't Bees as twin (mtermedete) 0208 1 207 5.203/ S254 0 202 5 131 to-v 59'.
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SECTION C MAIN BEARING AND FLYWHEEL STUD INSPECTION Perform a visual inspection of all 6 flywheel bolts. Also perform a dye penetrent test on all bolts, recording findings on work supervisors sumary sheet.
TE Date OQA Date TDI Date
' Perfom n visual and a dye penetrant test on all scain bearing studs. Record find!ngs on work superviscr's sumary sheet.
TE Date OQA Date TDI Date 8
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SECTION H CONNECTING ROD INSPECTION
~~NOTE: Acceptance Criteria per Transamerica Delaval Instruction Manual 79010/12 (Appendix III). Attached 1~~
1. l'erform a visual inspection of all eight NEW connecting.rnds for any l ahnormal conditions such as scratches, cracks, burrs, etc. Note fsudings on form 340-3-1 attached.
~~TE Date OQA Date TDI Date~~
2. Measure the thickness of each connecting rod hearing shell using a micrometer in acccrdance with Transamerica Delaval, Inspection and Maintenance Record (parts group 340 - sheet 340-3-1). Record measure data onto attached sheet 340-3-1 in the applicabic chart provided.
Complete the OQA HOLD SIGNOFF for all eight NEW connecting rods provided on each connecting rod's data shect. The following utep signoff must only be signed upon completion of all ci Fbt connecting rod bearing shell measurements.
! 'v' l TE Date OQA Date TDI Date
~~3. Assemble the conrecting s rod box to the connecting rod WITHOUT BEARINGS INSTALLED. Torque nuts to full torque valve (675 ft-lbs as per Appendix IV) as shown on sheet 340-3-1 attached.~~
~~l TE Date OQA Date TDI Date~~
~~4. ' Measure the connecting red bearing bore inside diameter at both ends, i~~
one inch in f rom the outer edges using a ball ricrometer in accordance
! with sheet 340-3-1. Record ressure data onto attached sheet 340-3-1 in l the applicable chart provided. Complete the OQA hold signoff for all
! eight NEW connecting rods provided on each connecting red data sheet.
~~j. The following step signoff must only be signed upen completion of all 32 connecting rod bearing box nut torque and all eight connecting rod bearing bore measurements.~~
TE Date OQA Date TDI Date i
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_ Connecting Rod inspection *
-5. Disassemble connecting rod be.arfrg box from the connecting rod and tag and bag all parts.
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~~6. Remove and tag bearing shells.~~
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conditions at connecting rod bearing bore Do not instatt bea ings Torose nst le to full toroue value as shown in instruction Marival. Measure conne: ting to beateng bore inside diameter at both ends, one anch en from outef edges Mfo1J't
. in vertical (A A) and horaontal (B 8) planes. Measure one fourtt inch in o;-
posite s. des of split line.
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Bott Tortiues Record disassembfy (breakaway) and assembly torques for connecting rod bolts identif v bo"s 7 by nurnber (see illustration). Torque bolu in sequence shown, applying torage in 20% fitts unt i final torove is rasched Refer to instruction Manual for correct torove vs:ves f
/n' g Step 4 Connecting Rod Bott Nut Torove (f t test 4 ;
1 2 3 I
Disassembly Assembly
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12 to full torove value as shown in Instruction Manua: Measure connect.n; voc l beareng bore inside diameter at both ends, one inch in from oute edges Measu's
. in vertical (A Al and horizontal (B B) planes Measure one tourth inen in C; posite sides of split line l A Connecting Rod Bearing Bore i D Step 2 A-A B-B l l Gearcase End I l
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Bolt Torques D Record disassembly (braskaway) and assembly torques for connecting rod bolts identify botts by numbee (see illustration). Toroue botts in seovence shown, applying torque in 20'> hf ts until final toroue is reached. Refer to instruction Manual for correct torque vstues Connecting Rod Bolt Nut Toroue (f t Ibs) f
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Ta s' T t s' N / Record manufacturer's data as it appea's on bea eng s**
Side View uppe sneir 1 Lower Sne :
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each measurement position Use a ball micromete-
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8 I s cond:tions et connecting rod bearing bort Do no' install bearings To'ou* t' to full toroue vatse as shown in Instruction Man uai. Measur e conne:1 n; t o; le bearing bore ins.de diameter at both ends. one inch in from oster edges Yeass'.
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Record disassembty (breakaway) and ?ssembly torques for connecting tud bolts identif y bo5 by number (see illustration). Torave bo!ts in sequence shown, appfying toroue in 205t. hf ts u-'
l f anat tocoue is reached. Ref er to Instruction Manual f or correct toroue values (N Connecting Rod Bott Not Toroue (f t Ibs) {
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T as-T 15-N / Record manufacturer's data as it appears on bea .n; sm- l Side View upper Snen
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it .
to full torove value as shown in instruction Manua'. Measure conne:tini. 'D:
bearing bore inside diamete' at both ends. one incn in from outer edges Meass -
. in ve'tical (A A) and horizontal (B.8) planes Measure one.f ourth inch ir' u posite sides of split hne Conne: ting Rod Bearinc Bo'+ t C i Step 2 A-A b-B Gearcase End 8
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Bolt Torstues TDI .DATE Record disassembly (breakaway) and essembly torques for connecting rod botts identif v botts by number (see illustration). Torove botts in sequence shown, applying toroue in 20% htts or t.
final toroue is rsa:hed Refer to Instruction Manuel for correct toroue volves I
Connecting Rod Bolt Nut Toroue (f1 !bu f')
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1.- .o.o T .e CONNECTING RODS - Model R 3 and R-4 Engines 340 3 1 c iom., E o .- L ..on Eng.no hoosei 5erasi ho c.etomer's Des.pnet on Tote. E ngine Moors No.te 5.nta Last enesection Date The eneoest.on mete.ences Data mecoeese av instruction Manual. Section 6, Part C a Lo e, saetas snen 1 P.stonP a s.= hine 3 cor.necting Roo 7 connect.nomoa soit Not e aveene, ROD we 5 3 poweis e Connect.no moa som e Lect 6ae Dowes M.,, A s upoo, s=,.no snen 1o connect.as oe n moei OsI' . .9 3 roR9er ww/ MrE NP
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Connecting Rod Bearing Bore Reassembie conne: ting rod box to connecting rod to rneasure to out-o' ro...c
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conditions at connecting rod bearing bore Do not install bea'ings Toroue n.,t' to full torque value as shown in instruction Manual. Measure conne: tin; to:
It bearing bore inside diameter at both ends, one inch in from outer edges MCaut
~~in ve'ticat (A A) and horizontal (B B) planes. Measure one-f ourtn inct in o; posite sides of spli? fine.~~
Conne: ting Roc Bearing Bo't I.D
. Step 2 A-A B-B l
Gearcase End
' Flywheel End m
TF PA T~
f" A
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73 8 . B i
ocpA P47t A
Bott Tocques TDI DATE Record disassembly (breakawey) and essembly torques for connecting rod bolts identify bo'n by number (see illustration). Torque bolts in sequence shown, applying iorque in 20% hf ts unt J
@@ final toroue is reached. Refer to Instruction Manual for correct forque values.
ov Connecting Rod Bolt Not Torque (f t-lbs's gg Step 4 1 2 3 4 Disassembly Assembly
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~~7. CONNECTING ROD BEARING SHELLS~~
s. 340 1 1 Customoe t o..oment Losetoon E ng no hoose. 6erens no Custome's Designeten Totes Engine How's How's s nce Last aneescten Date This ensoest.on instruction Manua' Section 6. Part C COWNECTIN6 ROD Na (o Tt s' T t s-
\ N Q Record manufacturer's data as it appea s o- bea r.; s+.-
Side View upper Snei I Lowe' Sr.ef t w
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Measure each bearing shell in sin positicas (ma' e: "x e-(,, g' _ _ , _g drawings to the lef t),and retorc rneasurements in t.o.e t ,
. . each measurement position. Use a ba'l micrometer
. , i i MtTG rso.
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CONNECTING RODS - Model R 3 and R-4 Engines 340 3 1 Custom *' e aw.pmani Leest.on Eng.no Moses see.es No Customer's Desseneseen Teene Eng.no Mowre nowre s nce taen enesettson Date The eneoest.on Instruction Mar ual. Section 6. Part C C" #
i esione.n awen.no e Lower seeriaeshen /--
a conn ei.no nea 7 connec RDD N9 V>
s o weie a weene, tins R.o sei, noi 4 Connect no Roe g e Lect.no oowei M., A s veo < seer.no n sa 1oos conn cuas noe soai O NP
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g Connecting Rod Bearing Bore j , j - Reasse neie connecting rod bow to connecting rod to measste for out-o* ro.r l
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conditions at connecting rod bearing bore Do nr.,1 instatt bea'ings Toroue s'at:
1 it to full torque value as shown in Instruction Manua'. Measure conne: tin; to:
bearang bore inside diameter at both ends, one ench in from outer edges Meau.
, in vertical (A A) and horirontal (B B) planes Measure one tour th inch in c;,
pos'te sides of split line.
Conne: ting Rod Bearing Bo'e i D i Step 2 A-A B-B
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Gearcase End f*',
! ! Flywheel End l
TF .PA 7~f*
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Bolt Toroves YDI ME l Record disassembly (breakaway) and assembly torques for connecting rod bolts identify bot:s r
by numbe* (see illustration). Torque bolts in sequence shown, applying iorQue in 20%. htis u til final toraue is reached Ref er to instruction Manual for correct forque values Connecting Rod Bott Nut Toroue (f t tbs,
@ Step 4 4 2 3 V 1 Disassembly Assembly 14 e 4. W 34031 Form e 2s? sao 6ecMon H .
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7-t CONNECTING ROD BEARING SHELLS 340 1 1 cv.i . e o ,,-ani om,on Engine neoces Sernet No Cwetomer's Dee.pnotion Totes Eng no Mowrs Mowre Since i.ast enesect.on Date Thss snspect.on
'**~~
Instruction Manual. Section 6. Part C T
CONNECT.rNb ROD Na 7 n- ,Ts-N / Record manufacture <'s data as it appea s on bea eg st.
Side View upper sneri I Lower Shell
,. n .
(, w Measure each bearing thell en sin pos*1 ions (ma
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b g'_ drawings to the lef t).and re:ord measu r e-ents in bone b,
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1 Transamenos inspection and Maintenance Record I3
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a. c-no.aoa. o, o T.i e e.n o. ,o ao sw e.c CONNECTING RODS - Model R 3 and R 4 Engines 340 3 1 c-io... c. .-i c ei.oo
^j E ng.no Moce. See.ei ao Cusieme.'s Desaenei on T.es* Eng no esows Howes since Lost enepect.t.m Deie The eneoect.on
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instruction Mar'ual. Section 6. Part C i P ion r.. saw.as 2 Connect.no Roe s Lo== seeeeas saois 7 Ceanecting Rod Soit pews ROD M 7
= Doweis O tiveeher 9 Lt ow M.,.
. 4 Co,naec.
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h. 'a Connecting Rod Bearing Bore Reassemble Connecting roc box to Connecting rod to measure io' out otro.m l s g Cond tio9s at Connecting rod bearing bore Do not install bea'ings To'Qat r
~~13 to full torque value as s*1own in instruClion Manuai. Measure conne:teg 'c::~~
bearing bore inside diameter at both ends, one inch in from oute< espes Wa;; -
in verticai (A Al and horizontal (B-B) planes. Measure one tou th inct. in c s,osite sedes of split line.
A Connecting Rod Bearing Bye i D
' ' Step 2 A-A e-B f *j Gearcase End
! Flywhee! End j TF .PA rf A
- a 1' T-3
~~s s C, ; ;;~~
6- ! -B v C9A PA7f i A Bett Toripues Record desassemb'y (breakaway) and essembly torques for connecting rod bolts identify bo'ts by number (see illustration) Torque bolts in sequence shown, applying torove in 20% litts nu i.'
l imal torque is reached Refer to Instruction Manual for correct torque values l
Connecting Rod Bott Nut Toroue (f t lbu l O g Step 4 1 2 3 4 l t. )
Disassembly Assembly l
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s. CONNECTING ROD BEARING SHELLS 340 1 1 Custome, towayment Locaten E ng.ne Moo,i Sereas ho Customer s Dessensteen Totes E ng ne .4 owes Moore Sance Lost :. ten Deve The sneoection instruction Manual. Section 6. Part C CONNECT.rNb- ROD Na 6 Tr s- T rs-
\ N / Record manufacturer's data as .i appea's on bea '>; $4 Side View upper Shei:
I l Lowe' Shei!
m

I w l Measste each bearing shett in sin positions (r*a s ed "X " c-
{_ _ _; _g orawings to the lef t),and reco'c measure nents in bo es b, each measurement position Use a ba'l micromete-
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Form E 267 _Q _ , _ _ , ..M 9 9 '
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i. 340 3 1 CONNECTING RODS - Model R 3 and R.4 Engines Ee.., . .t Leasion Cwesomer i .e'est No Customer's Des.pnet.on l Engene adoser How's Since Lost Basoecteen Deve Tees oneoect.on f osse Eng.no noves Instruction Manual Section 6,Part C 1 P.sion een avowing 2 connociens moe a Lower saarine taoii 7 connectine meo soit Nws RCD NP h 3 Deweis a weenee
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@,] Reassembie connecting rod bos to connecting rod to measu's fo' oui.cf ro..n ,
(- ; conditio9s et connecting rod bearing bore Do not instaff bea ings To<ose r%*-
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to full torque value as shown en instruction Manual Measure connett n; ioo fd bearing bore inside diameter at both ends, one inch in from oute edges M(aL .
in vertical (A A) and horizontal (B.B) planes. Measure one f ou'tr. inch in c; pos:te sides of split line A Connecting Rod Bearing Bo'e LD
. i Step 2 A-A B-B i e Gaarcase End
! ! Flywheel End j L
TF .PA T~f" A
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l 09A PA7f j
. A Solt Torques Record disassembly (breakaway) and assembly torques for connecting rod botts identif y bfn s by number (see illustration). Torque bolts in sequence shown, applying forove in 209c lif ts u f d final toroue is reached. Ref er to instruction Manual f or correct torque values I
Connecting Rod Bott Nut Toroue (f t-lbs) g step 4 4 (O-) t 2 3 Disassembly Assembly lh O b uoi, e w- i => ... 3c_4 g
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(, APPENDIX lil TABLE OF CLEARANCES MODEL R 4 ENGINE chwent,who sia. R,s.uewaea0.,
l tee leLhes bi heete+3 parbes tp.thmetets tetti l Croatshe's se anom gearmy . . . . SA074All 0.1791279 --- --- See ter.ag seen in etaan e.g ,n I
Crentshe's se fairst R.ngs , . . SA224A30 SM9/C.752 0 G40 1 015 Repuce si seen one Ceanectas Red Germs to Createkeet . 63064A10 0 3 2/0254 --- --- see tes .agine s in.ctaeu v 5. ..
Censheti Germes to Ceeshe's (meermedate) . 68044 407 0.102/C 178 --- --- $se efer ng sheh th.cn aru '.gwer Cornhof Tares Adietmeae . . 0404/0 A07 0 102/0178 --- --- Ad vsi si O O12" ei ow Pseen Pa se Red geshes 0 000/0All 02291 381 0 020 0 5tl Petea rm ee Paron . . . . 08024 504 SC51/0lC2 0 034 0 127 lorv Geer tessap ie snett . CA029 0G5 0451/0127 0 01C 0 254 Iser Gee Theest to Greceet (emines) . . SA04/C 007 0.102/0178 --- --- Rein m etO Ot2oro w Rectee Arm Baghes to Shatt 00(#4.5008 0102"i152 0 #12 0 305 toute Gotter Arm Amy. se 5 4Coser tend cessene) GA10/0425 02b44 635 0 t, 5 1 143 E ataust Reces Arm As, to $dCesar(and sleerence) 04051 015 0 127/0.14l 0 030 C 752 seveste sad E eheers: Ter gen e Gmee . 0A04TA06 0.1024 152 0 015 0 381 Felfspoet m Gesse . . . 63034AOS 00764 127 0 012 0 305 Top;4t Raw m Roller Guih.g SA024A04 0 05110 tC2 0 DCE O 152 Reine tsshes se Pe tush.no 0801/0002 03251 051 C C'M 0 107 Pm 8. anes to Pin 00014 002 0 02hT 351 C PCC 0 177 An We* Faton a Cap . OA01/0203 0C254 C?S 0 Dai c 225 Puton te Lme.
Cieen Top toad (Tapeisdt - Top 0A501A72 1J701175 --- --- Res.e DweNe 5 Cteern Tea Lead - Above f ase rmg 05301 CSC 07E2 6.273 --- .-- Rau C rare t*
! Cans - Searmg surfece . 00174 #19 0432'Oe42 --- --- Cee uer espieceww*e fisee Petea Reg f ad Gee
{ Top Comprom.on Reg (No.1) . 0 075/O #90 IJ35'2.2 P6 02D 5 C80 Compresses pas the 2) . . . SA7 ETA 00 1305/2J16 0 232 S C8C Compremen Reg the 3) *. 04504 46% IJ 70/1.551 0 20. 5 020 Ceepremien Reg the 4) . . . . 0A5010265 1.270/1.851 CJr. 5 083 Od tentret a mg (Uppert . . SA354A60 0A05/1574 G 2:3 5.02D Od Cenerst pas itseerl . . SA35.1400 SAtt't.524 0 100 5 080 Paes Ang $sse Cimrene m Greew.
Tee Compressen mag the 1) . . 6A074 231 0.170/0279 0 02C 0 504 Comosessan neg ime. !! . . SA051400 0.127/0229 0 02C G 50t Compree.se Reg ths.3) . . 03941A00 01274J20 022" 0 5C8 Csepresse'i mag fue. 4) . . . . 0Al2/0410 030l'5403 053C 0 762 Od tesesl Rg(Upserl . . . 0234A07 0 A76/0.170 O t2(r $ 508 04 Centrol Rag (Leserl . . 0234m7 057E5178 002; 0 658 Is;ehe We've sten te Gmee . . SASL1207 0.12713170 Otti 0 305 lagets ve:ee Cmeo INet Demeter se Gees . . . 0N74311 0 870'CJ71 0116 0436 Ouel f.mt engines er'r Ce inieci.es f men Rme t nd Geo . O A0104 015 0Sc6'O381 0 043# l0156 Oues f.e' sag +er eMe 1500de 141064 Eshowet ve's Stem to Genes (Upperl . . 0 00E9A00 0 IL242C3 --- ---
Sei new eoekee test t ahowt ber
~~5:em te Case ttemert . 0A6013A50 1.473 '2.C32 -- ---~~
5.e nw eech es tet-t shevst vehe nectmg .movementl Tat . 0A124 017 0.305/0 432 0 045 1143 See sect ea tJr' B ice er 4 '
of een ag owns se Desuw Ovr/Ca e' Rov e Laer 00'e . . 17ASC/17A01 431 8'431.825 17CCC1C20 433 324 1 508 g,,,,,3,,,,,,,m,,,,,,
Echen W*** . ' tea -. ag.ste.%
ate senemg snes s .. . . . , . . SA214A20 15 773:15 743 0 $15 16 $21 to , Smen Iden tearmen thrust Rmes . . 03104Jt3 16646'15570 --- ---
See Ceenshe's te Theinst Res/
l* Ceanectag Red teer.eg sae4 . 8 021 4 820 15.773/15 748 0 $15 ll 671 Upse. Sned l Cemsheft Be'ag She#s (meensafets) 0J00 %207 5203' 5255 C 2C7 litt Lew $nen l Ceenhee i Sw.ag Tneve Fleage 0211g2;g $259' 5283 --- ---
5er *Cearish inese U..mm
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g;,COMICOLLO fc Inform 30v 0"3*
SECTION I MAIN BEARING SHELL INSPECTION CUIDELINES STEP 1 Using a ball micrometer, measure cach bearing shell in six positions as shevn in the attached inspection forms. Also record the measurements on the attached forms.
2 Visually inspect the bearing shell for dar*Fe er.d record all findings on attached sheets. If cracking is suspected, perform a dye penetrant check on all surfeccc including sides and ends of both shells. Note the results on the attached inspection forms.
3 Compare the reecrded readings with the acceptance criteria contained in Appendix III to determine acceptability for each main bearing shell.
4 Inspection complete for all 11 main betricts shells.
~~
TE Date OQA Date TDI -Date l
wJ '
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, MAIN BEARING SHELLS 310 2 1 c.. .. . - .o. . n eng.no poses 5.r et h o Customer's Desagneten T ot.: e as.ne M w's M'*'s 5.nce Last eno ecten Oste The aneness n a,. .n D.i. a .. a e ,
instruction Manual. Section 6. Part D Bearing Shell Position T- T rr a s-s j Record manufacturer's data as it appea s on bea nv s'e Side View Upper Snen
\
l Lower Shell
= 4 Measur e ea:n bearing snett in sim pos tions (ma 6 ec X" v w drawings to the lett), anc reco*d measa ements ir. cose; : .
j,- - -
-t . ea:h measurement oos-tion use a ba:: m.cromete-(s - ; Sketch bearing surface cond.tions-note any atr.o &r i n
~
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l Top Shell
=
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, l Perform non-destructive dye check on all surf aces. inciac r; i sides and ends of both shetis Note results belov.
- -*' 4.-
. Results i !
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- .* s. _
l ! Remarks
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Bottom Shet!
TE .DATL i OQA D AT C g ,ings reused? Yes N.
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a. . ., o.s. a= e, instruction Manua'. Section 6, Part D Bearing Shell Position E T. T s Reco'd manufacturer's data as it apoca s on bee ing s'e-y Side View upper Sne::
] Lower Sneti v"
Measur e each bearing shell in l'a pos'tions (ma*6 tc X" 0'
,5 w *
(N i j
,. Orswings to th. lef t), and reco'd rneasu'ements ir boats t ,
s {,- - - -g sa:h measurement pos.tio^ Us. a bail micrometer L/ . .
g m l Sketch bea ing su,tsce cond.tions-note ani abr.o ma' -
- - ~
PAfTE f$n
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' F%
'. i a .<-
ll -
8 Top Shell x
+- -
i m - -
l_- -- -; -1 il.
~~l Perform non destructive dye check on all surfaces. int 60 r; i~~
sides and ends of both shells. Note results be'on -
- .m 4 -
~~, i Results l .~~
i i
- l i
- -A m. -
<
~~I t Remarks Bottom Shell~~
" TE DATE _
.[
OQA D AT ' 8eerings teused? Yes No f
r=- e a, gg Sc.c b n 1 y
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k,' MAIN BEARING SHELLS 310 2 1
.., e e _, ..e, g ng.no use i See.e'*se C.ss.emer e Doog'.steen Tetes E ng ne e*ow's *eew's S.nse Last snepect.en Date t h.s ensoort.ee neve.ences Dete meco.een e, instruction Manuaf.Section 6. Part D Bearing Snell Position 3 T< T er er g s j Record manufacturers data as it appea s on bea r, s*e
\ Side View upper snea l
1 Lower Snen i
1~
i . .
i Measure ea:h bea ing sneti in s. pos tions e a t: "x'e- I O ,,
w *
, dramngs to the letts. and reco'd meass'ements i- Dos e: : .
y> 3- - -- g sa:n meas.rement pos tion use a ban m.crome:e-l \ .
Sketch bearing surfa

e conditions-note an, acno*ma'
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s-MlTE d l ?
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Top Shell l x \
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' i l " Perform nonestructive dye ched on eli surfaces. in: tad ';
. s.
sides and ends of both shells Note resatts beton 4 -
l l v s _ Results l
8 m .
' I
- .6 s< -
\
f
= Remarks .
Bottom Shell x J' 7, ,4rc OQA b AT E Bearings reused) Yes No ,
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. 4 .{ ig sio n ,
~~UNCOtFROt.iXU~~
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(, MAIN BEARING SHELLS 310 t ow m.a, L n 2 1 Cu.,.m.,
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Instruction Manual. Section 6. Part D Bearing Shell Position 4 T. T n- n- Record manviseturer's data as it appea's on bea ins e.
s j Sirle View Upper Snen
\
\ Lower Sheit
=.
a a Measure ea;h bea'ing shell en sia positions (ma 6(0 "F' ',;'
L w ,
drawings to the lef t), and reco'd measa'ements s' bose. t .
{,- - -
-g each measurement pos t.on Use a bais m.cromete k - ; Sketch bearing surface cond.tions-note any senc*ma' t e
?
- +
I-Mf, iY tb -
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i m .
4
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!' i Top Shell
~ '.
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' Perf orm nonetructive dye check on all surf aces. int i ud n; l ,
i e
sides and ends of both shetis Note results belo..
~ ~
Results e l 8 s i m !
i t
- 4 m< -
~~i 1 Remarks m~~
Bottom Shell TE DATE OQA D AT C Bearings reused? yes Nu OI DATE W F.'m E 267 em p 31C 21
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~~UNCONTROLLED~~
.x o for informat::n OntV n W Transamerios inspection and Maintenance Record iy > E Delaval
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k, MAIN BEARING SHELLS 310 2 1 Customoe towemoni Losaiec E ngeae Moe.' &*'*'feo Customer e Doognstion 1stee E ng.no Moves Me7s $ sue Last eneestseen Det. Tne enspectica m . . . .=
o.i. n a, instruction Manva! Section 6. Part D Bearing Shell Position 5 T>
t s-T a s-
/g s f% Record r :anufacturer's data as it appea s on bea ing s*e Side View Upper Shen
\
l Lower Sheli w Measure each bea'ing shell in sin Dos'tions (ma >td "F" '/
, drawings to the lef t), and fecord measJrements in bDne' t.,
(] {,- - --
-3 en:h meassrement oos<t on use a bali m cromete-s -
l Sketch bearing surfa:e conditions-note an, sono ma' :.e-r i.
Mi6t=.sk) i l t e I l l
=
1 I l
w Top Shell
=
- . .. e-j;s. l . .. , . . . . ' ?'
~~g. 4 e~~
l husd 1 f-l,- -; i I '
s Perform nondestructive dye check on afi surfaces,inc's;
- .m ap. _
sides and ends of both shells Note results below
. . Results i m .I i
i 9
1 m Remarks Bottom Shell
(_./ TE DATE OQA D AT C brings reused? Yes No Form e-j gg M bfC- Op Y\ 1 31o 2 1
&4 14
" UNCONTROLLEC
.. ,. For Ir.farv.st;cn Or4 inspection and Maintenance Record p) s g-s y Transamenos Delaval C.ca a.a. G..v. t et'. P.ri. G' . N. 8 %.i
~~ege k, MAIN BEARING SHELLS 310 2 1~~
~~c. t.. - i6.ui .~~
e w...i s.. .No c. . om=i a v.w e a . n ... a.... s . i . in . a o.i. v a. . .. a a.. o.s. a n e, instruct.on venua'. Sect on 6. Pi t D ,
Bearing Shell Position b T* s' T
~~s" i s Record manufacturer's data as it spoea s en bea inj s*e~~
> %j Side View Upper Snen l Lower She's
~~~ Measure each bea ing sher in si, pos.t:ons (mathe "X' */
p]
( {,- -
w
+
-g
, drawings to the lef t).and reco c measfements in tec.e: t.-
each measurement pos.t.on use a bau m>cremete-5 + ; Sketch bea ing surfa:e cond,tions-note an, abno ma e.
i.
MWG t t
I e l s- -
i! -
Top Shell
~
, J'.-
4 i
l
.
~~i i,-,:- -; -1 l ^ l Perform non destructive dye check on att surfaces. insud ;~~
i i
sides and ends of both she'Is. Note resutts trio..
~ ~-
T. - Results i m ,i i
1
-p -
~
I Remarks w
-~s Bottom Shell TE DATC OQA D AT E brings reused? Yes Nu 3E ^
DI F.em E 267 Seo Ok 6 31021
.J UNCCNTROLLEU For liformatier 0 W Transamenos inspection and Maintenance Record I3y Delaval I. .......v.i.. .......~. .~., ....
%, MAIN BEARING SHELLS 310 2 1
c. a.. a. 6 a e . .i s *. c .. .on.e,. .
v.m s o.. . . s.a . u.i sa a o.i.1a.sa ...a n.. o. . = =.. s, instruction Manual.Section 6. Part D Bearing Shell Position I Trr T t s-g s j Record manufacturer's data as it appea's on bea ng sv
~\ Side View upper sne:i l Lower Snei!
a .._
Meas re Aa:h bearing shell in sia positions (ma 6(d "Y' /
, w
~~drawings to the lef t), ano reco'd measurements in t.ostc t .~~
\ g- - -
-3 ea:h measuremer.t oos. tion Use a ball micromete.
Sketch bea'ing surface cond.tions-note any abn0'ma' t e.
. ^
. v ,
M N, E th -
i
. i a sa-
~~l. - 8 w_~~
Top Shell m
m
~
f" i
- : p, t; .- .
ei . . . . . m . ,
r-.r -: -r i
^ l Perform non<$estructive dye check on all so faces incis:! **;
i i
sides and ends of both shells Note results belov.
~
a w Results I i i
i 1
- -* s< -
- I I
Remarks n\ Bottom Shell
/
\
%s) 76 DATE OQA D AT E bring remd) ws %
~~-- e -~~
l jf}TE W Y0% N e.o g , p i3 mri
.. _ _ _ . . r
.., .? UNCONTROLLEO inspectioh'd?8N5iEenance Record (i(j y Trananmenos c
Delaval
~ . . . T ., .. ..e.,~. . ~e , . .e.
' t, MAIN BE ARING SHELLS 310 2 1 ce. . ..-i 6. n a no.no M.o.. 6erms No C.st.m soogneten T.t.s e ng.ae PS..'s h- e Sd's. Less enn.ecion oeie Tn. one, ci a mee .nc o.se m o e, instruction Manusf. Section 6. Part D Bearing Shell Position b T- T u s- er s f Record manufacturer's data as it sexa s on bea ent s'e
\, Siet view uppersnen l
I Lower Snet!
1 I
t l
. '. Measure ea:h bearing she!! en sin pos tions (ma'6 to ")' p q w (J>
i {,- -
-g
, dramngs to tne lef t), and reco'd mer fements ia bone * ,
ea:h measu ement pos. tion use a t,.. m.cromete Sketch bea*ing surfa:e conditions-note an, aeno ma :+
~~* b~
- MNTE NO.
, . 4 t
i e .
I
- -h n
' ~ '
ii I w.
Top Shell x
~
l
-,y
}.
Ji s l .
l e.
I. i .-
. -t
'
~~l Perform non destructive dye check on all surfaces. inclue n; sides and ends of both shells Note results beloc.~~
~~,' 4, .- Results~~
~~t l l c l m !~~
' 1
- -A s- -
I l
~~Rernarks w~~
Bottom Shell
%d TE DATE NA Saarings reuwd? Yes No e-- e .n'iQ ,j g ton 1
. en ma,
.9a
uwmow For h.terndM D'"
ENE Transamenos inspection and Maintenance Record n 5 Dalaval
(') e.,........ ..........~. . . . , ....
,' MAIN BEARING SHELLS 310 2 1 e . ,.. . . . - . . . .
l e as. .i . . ~ . c .. . .. a t s=i e a,.a. . .we s.a . u., sa . a oei. Yn sa n..a n.e cn o.u en e, instruction Manual. Section 6. Part D Bearing Shell Position Y T>
s s-T a s-Record manuisetu'er's data as it appea s on bea. s' e -
/g s f%
Side View Upper Snen
\
I I Lower Sne.i l
, up .-
Measste each bea'ing shell in s's Dos'tio9s (ma e t:: X*^*
~~' drawings 1o the lef t), a9d reco c measJ'e r ents in tone t.~~
n ,,
3- -
-l es:5 measu.eme91 Dos. tion Use a ba'l m romen-h +
Sketch bea ing sJrfect Cond tions-note a% aDrc ma' <
b-M h, rb i e .
. i
-L6 a- -
ll
~~Top Shell 3 ,~~
-.. 4 i
ll ..
I. -
i.- .
-t
'l e
^
Perform non<$estructive dye check on all surfaces. inclui ;
sides and ends of both shetis Note results befoe.
- -* 4. -
l . Results i l m !
' I
- -Ar m. _
" I I Remarks Bottom Shett
\
a) TE DATC OQA D AT E g,ings reused? Yes Nt.
"CDl 3M *:he,CM n 1 e .m e lp o{ g sic > i
?. 3 UNCONTROLt.E0 ruc ir.enr.wu cm l g gu Trangenes inspection and Maintenance Record LJ c . i o. . v. .. c.,n o,m =. s, . ..,.
k,. MAIN BEARING SHELLS 310 2 1
( Cwis.m.. E ew m n, L.e.s en e e . .. s.. . c ..m., .o ,wi.a v.i.i e ae . e., . **. - s =. t.** sa =i a oei. Y aa sa =i..a
~
Instruction Manual. Section 6. Part D Bearing Shell Position M i T. T u s- ur l s / Record manufacturer's data as et sopea s on bea 'n; s*e
( Side View ' Uppersnen 1 Lower Sne',
=
l Measure ea:h bearing shell in sia pos t ons (ma'.to 'T v w
draengs to the let11. and re:o'd meass'ements i- tv.c t, (m [- - -
-i ea:h measurement pos,teon Use a ba'i m.crometc-1 + ; Sketch bearing surface conditions-note an, ate.: m. t e.
Y .
l l M blo l l
.' e
. i II -
l >.
l Top Shell x
l . ,. .~. C ;
=
(- - j.;.- -
i
~~t. -~~
,r -; -i.
, Perform nondestructive dye check on sit surfaces. includ *;
i '
- .s sides and ends of both shetis Note resu!ts belov.
' 4 -
. a Results
's e !
e
- .* s< -
~ 1 I
v Remarks Bottom Shell TE DATE A DM Searings reused? Yes No Di NN % don 2 F.em E m em ) ( o .$. I h 31021
7, J.
' oncotm1Cu N p a ii 0 nution OnN n Transamenos inspection a,n:d Maintenance Record U Delavel c o . v.v. a r., u o. ... =. s, .. ....
( MAIN BEARING SHELLS 310 2 1 Cues.mee (ew.pensai L.use, e n,.no ed.sei s.'ei wo Cuss.mers Dee esen t ou a n,.n. n. . a since Last sa si a oei in en ci...
aes .ne "*"*******8' Instruction Manual. Section 6, Part D Bearing Shell Position //
Tu s- T ur g s j Record manufacturer's data as it appea 5 on bea' 7 s'e N
Side View Upper Shen
\
1 Lower Shen x
n Measure ea:h bearing she!! in sin positions (ma** ea T' -
w lp\
drawings to the lef t), anc rece'c measse ne . s in conta t,
[- - -
-i nach maassement pos tion use a ba's m.c cmete N ; Sketch be4*ing surfa:e conditions-note an, ser.o ma' :-e.
". I n . f*Id. E E .
. - l
. R- -
. I
_w Top Shell
. -- ~
~ ._ .
).. . . .s
~.m
{
!: - l r_ y
_; _g-
^ l Perform nondestructive d,e check on all surfaces inclui ;
l
~~sides and ends of both shetis Note results be'os.~~
) i
~
Results 6 A i
-t " I
~
~
t w Remarks p Bottom Shell rE DATE OQA y AT E 8 earings reused) No TDi 3 ATE N ^ _ Yes
. .n i at amo Q ek b _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _
sto 2 5
wunco 8 5' e
) Instruction Manual w.e#* 84
+
{ APPENDIX ll!
TABLE OF CLEARANCES i
MODEL R 4 ENGINE C=neamwho== Reawe n'iea 0.e-e., tasas as.th e., e ne. ei er r.we . m s.e.
Croatshe's so Ise.n heisqp . S E74All 3.1784279 --- ---
see teer.at e*'t ta'et aan t sv'ei teertsiefs teinest mass . . 0A224 A33 0.65047&2 CA40 1 05 Repi.ce si neest one Ceanett.a: Ret teerg ie twasswet 0004'0C10 0.1624 254 --- --- See bes eag svl evenaru tg.aei Camdet: 0=<mes se ComeAets leieressetel . O&t4AJ7 0 102/0 178 --- .. -
See t eeres saer en.stan. 4...
Comi.o re t hrust Ad,unmeae . 08041 0C7 0.1024 178 --- ---
Abwi' ei 0 012 o' e.e-Poten t.a eo net teenes . . .* - 8 0004 All 02294 34l 0 020 05;l Patos e.a se Paton . 0 0024A04 0.0514 102 CE. D 12 P toerGeertahapte5hett . SA021A05 03514 127 0 010 0254 8d's Car Tswis to Beecket tenimmed) . . OA044A07 0.102 4 178 --- ---
Rav m s' C 017 se on.
Recter Aem teekeg te $nett . S A04/0 004 0.1024152 0 A?? 0 30's laute Re 6. Arm As, se $4Cese lead sneensatel DA10/2All 02644 535 0 045 1143 to .se Rotter Arm Ane se seConrhasiseweacel SacStA16 0.12'4 381 0130 0 762
! tweeke oas E shoss Toppvis m Guee 00044A04 0 t02/0152 0215 0 lai f e: Toppet in g ede SA03%A05 03764 127 0 012 C 335 Toppet Roine m Rouer gehag 0A024 A04 03584 102 0 A06 0 'b7 Rease 0.sh.as to Pm tvih.as . 3 0C1/1302 0A25/C 051 0 034 0 107 P.r teh.as te Pia S A01/0 0C2 0025.1051 0005 01H An ve.n patea m cas . 00014AC3 0 025/0 376 00;'s CJM Pwte se Leer F'
5 Crema too Lead - Atee fest res Sans - Seerms $wrfsts 0A331050 0 017/0atS 07E2/1.270 0 43210483 fled 4' Cies eate see '.aw eepretew i tga Psion R ng iad Cao
{
ise Cem,re..ea mm. i.e il 0 m,000 . 305, 2.. Om u.;
Compose
~~Res tNo 21. . . CA751A00 IA05.'2Jt6 0 700 S C1';~~
Compresues Reg fNo 31 ! 03604A55 1270/1851 0130 5 02.
Compres.en Reg the 41. 0450.1A6L IJ70/1.851 02C3 5 St3 Od centret Rag fuant) SA35tA60 0309/1524 0 703 5 0e's Od teatre' Res (tower) . SA354 A6C 0300/1.524 0J00 5 :43 Pese R.ae $de Ciewease e Greeve Tes tempreousa Res tte. 81 8A074311 0.170'0279 0 020 0 508 C.mpesien Reg (he 2) . S A051 AJS 0.1274 229 012: 0 508 Compresen nae (me 31. 0A051300 0127/0225 0320 0 5't Compemen Rag (No 4) . . . 0A124419 0 3 E 4 443 0 C3C 0 tt' Dd tenirsl Reg tusperl SA034A07 03764 178 GAN C Et Od centret Ree (tomer) 0A034A07 03704178 G C23 . v.a seeske Vaan tism se Geer . . 8A064 A07 0.127.1 178 0312 33!.
laste Vsen G mee tate: Demees te Cude . 0A074 A11 01705270 CA18 0 405 Dat t.m'eegmei ew Co lniettea Parea Res t ad Cap SA0184 4tl SD464Jtt 0:439 l oin L.e' Ive' ees aei s-'e 1 500 (4 3410 e4 E sheet vain Stem is Cede IUpper? 4GCL9304 01524131 --- ---
See we'w rock eg ter i sheisi b e*w tiem to Gu se f L3=or' . 00584 003 1473r2 C32 --- ---
see vein reches ten Isws' ve'w Resteg tecwmad test C 012.1337 0.305/0 432 C445 1 l'1 See Soci e* 6 Part I te rrN et setog mess veer eat D e me++r 0 e .t c ce p n _, ,.
Lae' Oe'e 17 DOC.17 A05 431 4'4 '.825 17 05C S C2L 433 3.4 T,5f.4 See,mg th.ekaan 15hetti/4 myl " " "'" ' " ' * " " " " "
ase'a Ba'as $hous . OA21'8420 15.775'11 744 0 615 15 571 Leme,then asse seerwg Thrust Rep 5 5154 A13 15 e46a5 570 --- ---
See
~~Creakeets to f a'.n R.es.-~~
Ceanect.ag Red esee Sneit 05214 E20 15.773/15 74t 0 615 15 871 bepee she" Co-ahe*t 6meme sse'u to ersefe:e) OJ084207 5183l 5256 OJ22 5 131 Lewe $se' N Comehe't Seanas Thrist ficase 0211410f $251 5283 --- --- See En*eme*> 7tievi ad..i'*r v i\
t
.._ y OM I 13 e 4 0
..m 7; U.To e u.- . ,. -
g: IN0!W,.
{}/
\,
(
SECTION J CYLINDER LINER INSPECTION GUIDELINES STEP 1 Visually inspect the liner surface and note any conditionr. cr illustrated on the attached inspection forms. Also indicate er the attached forms any blemishes on the interior surface of each liner.
2 Establish and record the micrometer reading reference position in accordance with the attached inspection forms. Take 2 ricreccter readings 90 degrees apart at the reference pesition 1 and position 2 and record these readings on the attached forms.
3 If determined necessary, deglaze cylinder liner in accordance with sheet 6-C-11 (attached). Note on inspection sheet for each liner if deglazing is performed or determined not r.ceessary.
4 Reperform step 2 on any cylinder which has been deglazed and j record on new data sheet, v
5 Compare inspection results against criteric cortained in Appendix III. Replace or rework cylinder liners as determined necessary. ,
6 Cylinder liner inspection complete.
TE Date OQA Date TDT Date o c, =: c A. o 4 11
. -_ l UNCONTP011M
( *1 For [nfoHN "
()
'. Instruction Manual a c.n l f PART C-PISTONS AND RODS (Continued)
LINER DEGLAZING PROCEDURE.
The Sunnen Model AN 815 portable hone with double length stone hoicers, and Sunnen W47.J19 or W47 J47 stnnes in the stone holders has been found to be effective for deglaring. The cutting abihty cf the stones can be improvert by cutting angular slots across the face of the stones. A hacksaw can be used to cut the slots. The slots allow the honing fluid to more easily wash the cuttings from the stones. The honing fluid can be kerosene, solvent or soapy wate Patented honing oils are ava.lable, but are expensive and do not appear to do any better job than the fluids mentioned.
Diesel oil makes a very poor honing fluid.
~~a. Maintain a firm pressure between the stones and the surface of the hner bore to make sure the siones a e cuttmg~~
b. Maintain a steady flow of honing fluid to the stones to wash away the cuttings and to prevent stone glarmg Arrange a sheet meta! trough under the bottom of the cyhnder hner to carry off the fluid and cuttings. Do not allow 11 -
cutting laden fluid to flow over the crankshaft and into the main bearings Lay a series of clean wip.ng rags between the crankshaf t webs and the main bea ing caps to prevent splashed fluid from entering the main bearings Exerc:se ca c when removmg the rags that cuttings do not fali into the main bearings.
~~c. Drive the hone with a powerful, slow turning eiectric air drill motor.The surface speed of the hone ston< ,~~
must be in the range of 25 50 rpm hone speed, and maintain a stroking rate of approximately 30 complete cyclu t e r minute.
CN d After the first minute of honing, remove the hone from the liner and wash the bore surface and dry it
( Inspect the surface carefully to determine if there are any low spots. If low spots are found, measure the bore carefudy
. with inside mierometer to determme if hne' will be useable. or if it must be replaced. )
i
e. Contenue honing until all surface glaze is remove 1 A properly degfazed liner will have a umform satin grav appearance with a good crosshatch pattern. The lines of the crosshatch pattern should intersect at an angle of approm imately 90 degrees.
Note :
Each set of Sunnen stones has an instruction pamphlet which describes the honing procedure.
This is an excellent publication
f. When honing is finished, wash the liner bore well with a stif f scrub brush and hot soap and water. Housenold laundry detergent in hot water can be used Af ter washing. the surface must be dried completely, and oiled w'th engir'c lubricating oil to prevent rust Use an airjet to blow out the lubricator tubes or other hner lubrication fittings to removt.
hone grit which rnay have entered these fittings daring honing ,
.. _ - u .~- a VING CYLINDER LINER. -
If it is detc %ed to be necessary to remove the cylinder liner from the block, first disconnect the lubricating of ,
at the bottom of 1 'ner, includ:ng the elbow. Install a Cyhnder Liner Pulkng Fixture, Part No. 00 59^ " V to the bottom of the liner, and a a chain hoist to the lifting pad on the tool. Pullliner straight the block. It may be necessary to use blocking and a Iic jack to break the liner free of the cylinder ..
INSTALLING CYLINDER LINER.
g Instattation of the liner is the reverse of removal with cert -
al requirements. Use new seahng rings and coat E them with a liquid dishwasning soap, of a tire in - g lubricant befor
~~niing in liner grooves. The bottom sW is~~
/ silicone and should be handled carefull cent tearing or nicking. It is esser > 71 the liners be replaced in ther (7j N
origmal positions in the block.
~~tool, Part No. 02 590-0 at the scribe marks on top of the liner be aligned w.~~
acilitates the instattation of the liner in the block. A split ring devir.
e marks on the block A fits mto the top i e
bore of the bio d allows the liner with seal.ng rings installed to be lowered into the upper bore bio. fler the rings assed through the upper block bore, remove the rings then continue to lower liner until seated in b a ove bner pulling fixture . . _ _ _ _
A e t il Q. p M m I __ _ _ . _ _ _ .
1 l . . . -
UNCONTROl'AU i'
i .. .. Fminto maw C'E
, o , my Transamenos inspection and Maintenance Record -
5 Bolsval
,s.,s o.o.e ,.o .~ e , ,see C-, ..o.e , e,.e
(.
Customer CYLINDER LINERS 315 teveomont Loset.en 1 1
{
Seeme f.o C.stomer's Des.pnei.on Eao.no Moses i
newes s. ace test ea.coci.on ooie vne . ,eci,oa Tom's aeme How's ,
j l
trutruction Manual. Section 6, Part C Cylinder NO./ Bank l M8IE Alb -
I '"
-n.
'p pi# NORM AL CROSSH ATCH b M*?
SCR ATCHES - Long narrow grooves usua't, caused by foreign materiat. Crosshatch
, pattern runs theough.
k..
i" j SCUF FING - Caused by piston and/or ringt e Can start below oil ring and run up throu7 upper compression ring travel s'es Cross
[T hatch pattern cannot be seen.
BRIGHT SPOT - Bearing through crosskatch.
i, Can appear anywhere. Probable cause. Heas, 7 bearrng by build rp above top ring land INTAKE SIDE
ltdcsie blemishes on h1teriot surface 1. Essblah referein enessurement and record. If peton is out of I aee.o if i.ne is of cylincier liner as asen from above- removed from block, wee PREF ERRED REF ERENCE eO$lTION if p. stoa n installed anliner, var ALTERNATE REFERENCE PostTION Take two vesc ain.
~~e 90 des ees sport IA and 81.~~
~~2. Teke readings et Postson 1 and record.~~
a --- i
_ . . .J . , .......~ ~ ' ~ i, C,~ r" 3. Teke raadenes et Posit on 2 and record.
I ee eeee 4ea.as Ahr Mea'as I a e a e met.
' 1 Metnea of hea.as emeloved (e.e , paese menstoe / grit s.aaen nonerstone e*<ti D I e
1
~~r '~~
.m. '
5 4
8'****' g. ,;; .TiVE') 3E a ,
1 - -
Q Q
A = latoard inaneusti side go flyerveel End y A aocu 315 1 '
Form E-267 9/Bo
%n 7
uNCONTROM EC
, for InkimG n S
, W Transamenca inspection and Maintenance Record I (),'- 5 Belsval
~~( .~~
. a . o r . . .... ..... or . . .~., ..e.
\ CYLINDER LINERS 315 1 1 c . .e a e. m t. . a a a.. u,..i s. .. . c . .. o ,. .
v a a. n. . . r. s.a 6 sa ci a o. . v n. sa . .
I a .' -.a= oei mece. a e, instruction Manual, Section 6, Part C Cylinder No./ Bank 2. MM e, .
NORM AL CROSSH ATCH EXHAUST SIDE k lb SCR ATCHES - Long narrow g ooves usuali s 4 ,
caused by foreign material. Crossnatch
! pattern runs through.
k.
Mj SCUFFING - Caused by piston and/or ring-ec Can start below oil ring and run up th'oug*.
upper compression ring travel area Crost hatch pattern cannot be seen.
]
BRIGHT SPOT - Bearing throegs rosshatenc Can appear anywhere. Probable cause Hea.,
bearvng by buildsp above top ring land INTAKESIDE -
/ndicate blemishes on bsterior surface 1. Est.btish reference me.sur.m.mt and record if peton is out of genee. or if line is Of cylinder liner as apen from above-remo d from b6ock, wee PREFERRED REFERENCE POSITION If pistoa is instat6ed in liner, use ALTERNATE R EF ERE NCE POSITION Take svvo re.d np.
, 90 degrees sport IA ered B).
a---
_ i . J . .,, . . . .' 2 Take readings et Poeston t and record 8 3. Take readings et Posit.en 2 and recora ear... M a.ag Arie M.a.as A s A e se -
R.f.
1 2 ,
u.tn.a of h.nens .mpi.yas (6.... pare se t.,tyit s.nn.m h.a./st.a. s'it)
. .ii .,
"*""**' U
, p;t % D n
TDI l> ATE
~~;a T E. DATE 00A DATE~~
~~a. insoore te.sousto aior s.re.rseerune r i~~
k O[ ll Form E.367 s/so gMNOw T
4 Transamenor inspection and Maintenance Record -
u ) .. selsval
..., y re,n c.. . s. sa.ei
( cm neo, o..w. Teve
(', CYLINDER LINERS 315 Eewu a. Losaien 1 1
@o C cweternee 5A, e" Eng.no Messi Sa'er No Customer's Des gmeten f3 ,
C~
Teest Eng no Mow's ,
Mow's Esmse Last snesect on Dete Tn.s :cne.en .
Deze me...eee,
*' mas es
Instruction Manua1. Section 6, Par 1 C Cylinder NO./ Bank 3 MITE &* -
I :
4 NORM AL CROSSH ATCH EXHAUST SIDE w.
~~SCR ATCHES - Long narrow geooves usuan, i~~
3 l#
h caused by foreign material. Crosshater pattern runs through.
k . SCUFFING - Caused by piston and/or ring' e Can start below oil nng and run up th'ovg*
upper compression ring travel stea Cross hatch pattern cannot be seen.
B RIGHT SPOT - Bearing through c'esshatch.
4 Can appear anywt.ere. Psobable cawse Hea. ,
~~bearrng by buildsp above top rang land wV -~~
INTAKE SIDE -
Indicate blemishes on h1terior surface 1. Estebish referorum measurement erud record at paton is own of eine . oe if tiae a of cylinder liner as seen from above' removed t'em block. vee PREF ERRED REF ERENCE POSITION If piston n instelled in liner.use ALTERNATE REF ERENCE POSITION Take two read.ngs.
e 90 dog'ses sport (A orid S t.
y 2 Take readings et Positen 1 erwt record.
_I .,s..,,g...
., _.. L 3. Take read.ngs et Position 2 and record Setore Mening Ahe* Moe.a0 A S I A S ew., s _
a ei.
3 m e .. .,s.ein. - .i. ,ee i... . ,.s. .,e. e,< ,11 swan.a .nern.ae r.o I
e ei e e aeme es- e
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o T'DI DATE o
D AT E OQA DA" a . insenre teen..,srse,oe TE
~~s. rire neer une~~
- * $ e -f (l -
e_...... s7
l l
\
, J , W Transamanca inspection and Maintenance Record 1 .5 Belaval
' f , c o ,.,,, , . .
. .... . .a . ....
( CYLINDER LINERS 315 1 1 -.,
c nwa., a. = :i.. i a gc Lb e .a. ....
s- + e. . c .o a.. . 3E C. -
c: K v.i.is ... .. .
. . s.a tan ea ci a o. . ta. : u ::i... {E i:.?
n.t .ac o.i. n ae, y1 Instruction Manuel. Section 6. Part C ;, .
C Cylinder NoJBank 4 MN O - %,
~~NORM AL CROSSHATCH EXHAUST SIDE~~
?.
? . SCR ATCHES - Long narrow grooves usuali, y csused by foreign rnaterial. Crosshatch i pattern runs through 1' j' SCUFFING - Caused by p ston and/or ring.
Can start below oit ring end run up through i upper oornpression ting travet erea Cross g hatch pattern cannot be seen.
B RIGHT SPOT - Bearing through crosshatch
". . p* Can appear anywhere. Procabie cause Heav, bearrng by buildup above top ring lanc
~~c ,~~
~~INTAKE SIDE~~
~~Indicate blemishes on interior surface~~
1. Estabteh reference en swoment end record if oston is out of sene . oe it line* is of cylinder liner as seen from above' remov.d from block.vos PREF ERRED R EF ERENCE PO5iTION If pistoa .:
enstati.d enline'.ves ALTERNATE REFERENCE POSITION Take two read ass.
t 90 dog'oes sport (A and Bl.
~~2. Tehe re.dirigs et Poestson 1 and record g y a==~~
. . . ." . . . . . .y C, '
~ l 3. Teke readings et Poset en 2.no recore I
.a l
S.t.ee M.a.ag Ah.' M.a'ag ___
A 5 A 9 m.f.
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n TDn .'Dit t e p : r v vls TE DNT E OQA DATC Ao tabeerd (enhausti sede g= forwneet End ,
b Oh ll 3151-1 Form E 367 9/30 bCC%on d n
l . . _ . _ . . . . - . . . _.
r
. . s . ,
, W Transamenos inspection and Maintenance Record li vm-5 Belavel t >
1
,, c.a, i ce . v. e ,e. o r . r.e a~ei eser
\ CYLINDER LINERS 315 2 1 1 l c-i- to. ea 6.. a gA t
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1 i ve=eaa.. ewe-. . noot.s 6 i.e .ea oe , e v . ,, ,,, , ,,,, ~J l
Instruction Manuat, Section 6. Part C Cylinder NoJ8ank 5 M8TE un l
8 m,
" " NORM AL CROSSHATCH l
I ExnausTstDE l
ss , l
+W I
l#
h" SCR ATCHES - Long narrow grooves usuails caused by foreign matersol. Crosshatch pattern runs throug5.
A,wY SCUF FING - Caused by piston and/or ring *.
Can start below oit' ring and run up throug*.
upper compression ring travel erea Cross hatch pattern cannot be seen
( ,/
, dg.e Can
.b B RIGHT SPOT - Bearing throug5 crosshaict appear anywhere. Probable cause Hean
.f bearrng by buildup above top ring land INTAKE SIDE .
%~ .*@#
" " ^
Incticate blemishes on interior surface of cylinder liner as seen from above' 1. Eembish reference enessurement end record 18 psion u out of inne oe it lice .:
removed freen block. wee PREF ERRED REF ERENCE POSITION 88 oistoa is I
instet6ed inliner,uer ALTERNATE REFERENCE POSITION Tome rwo reed r.p.
30 degrees apart (A orus 81.
= ll .I.... 2. Teke road.ngs at Poesten 1 and record.
. . . . . .'~~"
O, 'i ~ 3. Take readings et Position 2 erus tocord.
1 Seiere Hon.ag Ahe.Meaae
l * *
~~l _ , _ _ .~~
Ref.
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3 aseenes hoaine empioved fi o , esame trester/srit svaasa honerreene e .t1 I
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7a u . t. i .t ge,c g n 3
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inspection and Maintenance Record
, h Transamerico 5 Balaval
,1 .
c_,....... . or .~. .~.i ....
. CYLINDER LINERS 315 1 1 ca a. a.a a a .a. u...i s. . *. . c=i.-. .o a.i a , I.-
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5.i.ia . . .
a r. s.a . usi sa ci a o. . Yn. a xi..a yy e.: ~,:
n.. .ac. o.s. a n.. . ,
. Instruction Manual. Section 6. Par 1 C -
1' Cylinder No./ Bank 6 MM E m, 1
NORM AL CROSSHATCH EXHA UST SIDE w.
b' SCR ATCHES - Long narrow grooves usua'i, l#
h caused by foreign rnatersal. Crosshatca pattern runs through.
. SCUF FING - Caused by piston and/or rings W.- ' Can start below oil ring and run up theoug*.
upper compression ring travet area Cross hatch pattern cannot be seen.
/m
\ B RIGHT SPOT - Bearing through crosshatc*..
. %. Can appen' anywhere. Probable cause Hean bearrng by buildup above top ring land INTAKE SIDE.
Indicate blemishes on htterior surface of cylinder liner as seen from above' 1. Estabish reference eneesurement and r. cord if psion is cut of hae.. o'ston 6f lene s
removed from b60ck, u.e PR E F ERRE D R EF ER ENCE POSITION ti p
,inets'6ed in hner.wer ALTERNATE REFERENCE POSITION Teke two v..o.ags.
. 90 dog'ees apart (A and 81.
=
i
.l... .... . - 2. Take re d.n. et Po. ton 1 and record.
~'
C .~ I l" 3. T.te reed' ass et Poe' teen 2 and record f ......a.a.
. .......a.a.
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- ,s T.DI 'D4TE i
DATE OQA DATE A o laboard (enheusti side TF_
go Flywheer Eng ,
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inspection and Maintenance Record
.y ll 5Transamenos Delaval
& , C-oe . ...e i ...e
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\ CYLINDER LINERS 315 1 1 E.
Cw vemee Eewsemeat Loses.en ,[
C Eng ae wese' &*'ai he Cwesome's Des enet.en Q .E tY g.
ie=iaa,..we . , new s.ase Len in eesi.e. o... vn. ene,ecieea E, c -C m e ' ** *asa oete asse.ees e, n Instruction Manuel. Section 6. Part C -[
L Cylinder No./ Bank 7 M% O m
NORM AL CROSSHATCH EXHAUST $!DE A
4 h*5 SCR ATCHES - Long narrow grooves usua".
caused by foreign material. Crosshates I pattern runs through.
is .
k, SCUFFING - Caused by piston and/or rings
.- e Can start below oil ting and run up theou;*
upper compression ring trevet area Cross hatch pattern cannot be seen.
y B RIGHT SPOT - Bearing throug5 erosshat-n
. , '%'. Can appear anywhere Probable cause Hea.,
bestrng by buildup above top ring fan:
INTAKE SIDE .
"" # "O' Indicate bkmishes on interior surface '""*'"
af Cylinder liner as seen from above' *h'*'*"**'"****'*"**'*"*****'*~**'*""**'*'h"***'s'toaa terPoved from teiock, wee PREF ERRED REF EStENCE PostTION ti p instetted en tenet,use ALTERNATE REFERENCE POSITION Toke two ress ar..
90 des ess see'1 (A and Bl.
= q p 2. Teke readings et rootson 1 end record.
~~4. . . . , .. ." .- ." . .~~
= , - i- 2 Te6e road.n ei r .ii.n 2.nd ,ec.,d I
potees woning A*ie. Mea.as A S A B
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aet.
1 3
Mesmos of hen.no amateres 0.e , giete t>' enter /gHt Swanee heaersteae s'atl
=
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A ),lC ?. sA .
S T3)I &
o D AT E OQA DATE A= Inboard (enhaust) side T E.
De firwheel End Oh lf I' $ '1 '
Form E 367 9/So 5CCYOs &
s Transamenos inspection and Maintenance Record -
Delaval
( . - . . . . . . . . ... .. ~. .~., ..e.
CYLINDER LINERS 315 1 1
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Instruction Manual. Section 6. Part C ,-
MM M Cylinder No./ Bank 8 a w NORM AL CROSSHATCH EXHA UST SIDE
'S l SCR ATCHES - Long narrow grooves usual %
4 caused by fore gn maternat. Crosshatch j pattern runs through.
SCUFFING - Caused by piston and/or rings
,' Can start below oil ring and run up theough upper compression ring travel area Cross O hatch pattern cannot be seen.
BRIGHT SPOT - Bearing throug5 crosshatch
., %. Can appear anywhere Probable cause Heav, bearrng by buildup above too ring land INTAKE SIDE -
Indicate bkmishes on interior surface
1. Esimbli.h reference mes.u.ement erus record. If ps,oa is own of ame . o, if line' es Cf ev'!ader liner as seen from above' removed from b6ock. u.e PR EF EP.R ED R E F ERENCE POSITION li pr. ton a instati.e en len.r.use ALTERNATE REF ERENCE POstTION Take ,wo read.ngs.
~~90 deg.a.s esort iA orid BL~~
~~2. Teke reed.ngs et Postson 1 end record-~~
= i ..i... . . . . .
~~
9 C ,~ i~ 3 Teke read.ngs et Po.iteon 2 and record.
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eUNCONTROL W'*
l -
Instruction Manual For informa"" y
( APPENDIX lil TABLE OF CLEARANCES
-l MODEL R 4 ENGINE y C.-eace who n- er..ce a o.,
, leem ternet udlemosyi lachen u.n.nei,rs toge, Cep6shott se atom gesey . 3A07/0All 0.1704 279 --- --- See 6 ear ag se n se smetaan toutes Ceenkshaf t le Tars: Rags . 0 422/0 030 0 669 9 762 0340 let8 Reelece et lessi one i Ceans;tes Ace Searms u Croakene'. 0 0861itt0 0.1524 254 --- --- See hearms see n in.ctaesi egrei Comshe's 8ermes no Cessnett teaynes.atei 00044 007 01924 170 --- --- 8es bee..g enen in. chasee.gueri Censhetifwus Adensimeat 0 A049 007 0.1024 870 --- --- Adn,st at 0 012'eu e.e' Petea P.a se nes tmen.ag 8 0091 A15 02204 301 0020 eles Psiea P.a is P.nu 0 0029 304 04514 102 0405 0 127 saper Gew earwags te 84eh 08029 a05 0461 4 127 0 010 8264
. seer Gene Thrust to Greche'(shamed) . O A04% 007 0 192 4 170 --- ---
neih.m et 0 012 m w Rocker aem S mAmy is saati 88044 006 01024 152 Sall 0 305 sante nect, Are Ame se 5Mw lene susanacal 00109025 0J644 635 0 045 1143 Enheat Roche Arm As, te set Cow ieu cerencel 8 005'0315 01274J41 0A30 0 762 I seeste oas Icnear Teepois a Gwee 00041A06 0 1924 152 0 til 0 3e t F uet teseri m Girse 00031005 0276.9 127 0A12 0 305 Teepet Asier m Refear tuoh*g 0A024A04 0 0514 102 0 406 0 152 Re'iw 0sh.ag to Pia tuskeae 0 0014 002 0 025 4 051 0004 0 102 Pia tash.ag to Pm . 00011 002 0 0251 M1 0 005 0 127 Av ireive Paea m Cos . 00C19 003 0A254 078 0 009 CJ29 P.sioa is tmer Crewe Top Lead (fear.ee: - T os 0D531072 IJ7011129 --- --- ness Ciearsace Crewa Top toad - Asse f st eins O AM t 050 0 75211.270 --- --- Res.ei tieente Sure - Seerag surfere 041710 All 0 43210 483 --- --- Ses new esetacemeat tegee Petea Reas Ied Gap l {} io, Com,re..ea .meme i.
Cem,r-en P , t.e 2> .
Smim Omim imS4 2..
1 A%4 m Om 0m S C.0 Sm
'l Compresen Rme tea 3) . 0 3531 055 IJ7d/1.651 SJ00 5 043 Compree, Ams me el . 0 0604 865 IJ70/t.651 0200 5 000 OsCert'elRmt tuenc) 03354 260 0889/1.524 0 200 5080 0.s tenvel m ag ttement 04354 A60 0A00/1524 0200 5 000 Parem Reg $ ate Classene sa Greew Top Compreessen R.ag me 11 8 A07/0311 0170.9279 0 020 0 504 Comprem ea meg the il . SA059409 0.1274 229 0 020 0.508 Compres.i,a seg me 3. . 0A05/0AC3 01274 220 0320 0 500 Compeessa Aeg me 4) . . 0A124819 0 305 4 403 0830 0 752 0 l Contiel Reg tuppel SAC 11A07 03764 170 0320 0300 De Centrei Ret (Lemed 0 0011 A07 03764 170 0 020 I SC8 6eiste Vale $sem to Gwee . 00061A07 0.1274 170 Sall 0 3C5 satte vain Gese east Oometer se Cwee 0007/0411 0.1784J70 0Att 0 406 Desi lei sas. art sal, Go lanct.en Psion meg Iad Gee OA010/0All 0 040 4 341 00400 1.0 t sei Dini fiel saggi een, i 1300 We 3010 de.
l E shoist va's $iew to Gwee (Useri . 0 0064 ADO O1524 203 --- --- Se sow rectog tesi Eanewet Wow seem se Co.ee (Leew) 0 0681 A00 8473/2032 --- --- See nie rect.g tem E anovi' V w Rece.ag (seewmeatt Test 0.0124 017 0.3% 4 432 0 045 1143 See sen ea 6 Put t te' me Poe of sotme nuesurement Diesesses Dumr/Dut se more leergee 17 A00'17301 438 6/431325 173004 020 433.324 9 300 gas,mg Th.c6are tsbetva ngst ase.a Seereg she'is . . 04214 A20 18 773/16.740 0.015 15 521 Leser sheli Me.a Seersag Thrve Rees S A164 At 3 16 886?16.670 --- --- See "Cepherett ie Tarvet m eg?
e Ceanecie, p od Gesq 5%eit 002180$20 16 773/15 748 0All 15 871 Desc Smet Camine't Seerm; She e t imirmesistet 0J089J07 62011 5258 0207 5 131 Leur 54e's Cemheh Semag Thevet Fleasr 02114 200 5255/ 5203 --- --- $se *Ceesheh ihruse 4dystmai i%
t
,, .- , tr'
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H e 4 ((
h%J -- ._. . _ - - - __
Appendix C-3 t!NCONTROU.E0\ I
-3 Fra fofer.mation Only CRANKSHAFT INSTALLATION i
. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they
,I are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer followed by signoffs from all three.
SECTION A
~~1. Verify base and crankshaf t for cleanliness. Clean as required.~~
~~TE Date OQA Date TDI Date~~
2. Install the lower main bearing shells in place in the base. If old hearings are to be reinstalled, replace the bearing shell back into the base in the saire location as if was removed. All bearing shells were 3r bled to reflect this during removal. If new hearings are to be
' installed replace the old bearinEs and install new coes.
'('N 6
's.,e/ -
TDI Date
~~3. Using a nylon sling and chaninfalls, lift crankshaft.~~
i'E Date OQA Date
~
TDI Date
~~4. Place protective sleeves (oil paper or rubber pad) over the two main bearing studs at each end of the base.~~
Place spacer over back end of rear main bearing. ,
Lubricate lower main bearing shells and crankshaf t with clean engine cil, ensuring both areas are free of dirt.
TE Date OQA Date
( .\
i
(,)I -TDI
~
Date 1 of 8 g ggylg gp j g jgy3
i P
3 Ut?CONTFOLLFO
) r~x for in:armation CA' V) 5. I.ower shaf t into main bearing shells with chainfalls and release
, slings.
! Remove spacer from rear main bearings and protective sleeves from the 2 l main bearing studs at each end of the base.
I Clean and lubricate with 50/50 mixture of clean engine of) and powered graphite all main bearing studs and nuts. I l
l TE Date OQA Date ;
TDI Date i
I 6. Install main bearing studs in engine base with cotter pin.
l TE Date OQA Date l
TDI Date n
(' 7. With the upper bearing shell in place on the bearing cap. position the l
bearing cep over the studs and lower it in position. Assemble locking I
plates and stud nuts. Run nuts down hand tight. Verify mating surface of bearing cap for cleanliness. Perform this for all 11 main bearings.
Rotate crankshdft and check clearance between crankshaft throws and base wall.
Torque the bearing cap nuts to approximately 100 ft. Ibs. Ensure that the bearing cap is properly seated by checking to see that a .002" feeler gauge will not fit between the 2 halfs of the bearing.
i Bearing 1
=
Torque Wrench M&TE No.
l
~ -
TE Dat'e OQA Date TDI iia'te rh i t
\M JIG APPPOVED SEP 1!) $83 2 of 8
. - . .. -. __ = - - - - - ~ . - _ - - . . . . . - - . - - - . . - . _ . .
g I- l UNCONTECl LED l I Fcr internet:en c.A i s .
l i
Bearing 2 i
j Torque Wrench MATE No.
6
. ...- .......... i
~~l TE Date OQA Date i~~
4.
TDI ~~"i)'a'te Bearing 3
. Torque Wrench M&TE No.
ll TE Date OQA Date
i.
TDI ~ ~ i)'a~t e Bearing 4 l~
l Torque Wrench M&TE No. !
i i
i TE Date _OQA Date i
TDI Date Bearing 5 Torque Wrench M&TE No.
l TE Dat~ OQA Date l
TDI Date i
i r
t r
'gg AcPP.0VED SEP I U -
3 of 8 b
. . . -. - . . - . = . . . -- .. . - . __. - . - . . _ - - ._
y
. 1 1
1 UNCONTROLLED For Informatien Cabi
(-s i-Bearing 6 ;
Torque Wrench M&TE No.
TE Date OQA Date 4
TDI ~ 'a't D e :
Bearing 7
~
. _ = . . . . _ _ . _
Torque Wrench M&TE No.
i TE Date OQA Date TDI i)' ate j Bearing 8 -
g Torque Wrench M&TE No.
1 4
TE Date OQA Date TDI Da'te Bearing 9
~ ~ ~ ~ ~ ~
Torque Wrench M&TE No.
TE Date OQA Date Bearing 10 Torque Wrench M&TE No.
i l
TE Date 0QA Date
()
g TDI
_ Date I
i
~
I of 8 lIO bEP 'bvED 5 " '
l
, - . . . . . . ? ,
5 UNCONTROLLED I
To Information 0.YY
,1C L -( Bearing 11 Torque Wrench M&TE No.
i TE Date. . OQA , Date
, TDI Date
8. Torque nuts in 3 increments to 2150 ft. Ibs. See attached sheet for bearing numbering sequence. (Section A. Attachment 1) 4 Bearing 1 , , , , , , , , , _ , , , , , , , , , _ , , , _
Torque Wrench M&TE No.
TE Date OQA Date TDI Date '
Bearing 2 Torque Wrench M&YE No.
_ ...l ............:. .
TE ,
Date OQA Date TDI Date BearinE 3 _
Torque Urench . . . . M&TE . . . . .No. .
TE Date -.OQA Date.
TDI ~~ ~ "D'aE Bearing 4 ,,_,,,,,,,,, , , , , , _
Torque Wrench M&TE No. ,
TE Date OQA Date TDI Date
]
5 of 8 iTG IffE0VD 3Ea i U 1333
~
)
t
)-
UNCONTR0LtFD For informatica Gth
)
Ber. ring 5 , , , , , _ _
__ Torque Wrench M&TE No.
}
l-
? TE Date OQA Date i
i TDI Date
~
Bearing 6 , , _ , _ , , , , _ _
Torque W ench M&TE No.
1 TE Date OQA Date Bearing 7 .__ __._..
Torque Wrench M&TE No.
TE Date OQA Date Bearing 8 _.
s .
Torque. Wrench M&TE No.
1 TE Date OQA Date
,- tTDI -
Date Bearing 9
, Torque Wrench MATE No.
TE Date OQA Date TDI Date Bearing 10 , , , _ _ _,,,,___,_
Torque Wrench M&TE No.
+
TE. Date OQA Date(j f}i'((kk3 b .b O 6 of 8 - 1-
~~. . , . . . , _ _ - , .._ . . . . . A._,_-_ -._; . - . - . , _ , . , ,. _ . . _ _ . . _ - _ _ - _ . - . . . . _ . _ . . . _ . . _ _ _ . _ _. 2 _ _~~
~~r f .,~~
~~.h 3 .'\- t , ) .s ,~~
~~o , UtlCOI4IROV-T ,, P- , 3 a ' t. For intcrr.iL%l * (~~
~~,_ 1 'B$aring 11 , E _~~~
~~1 Torque Wrench M&TI; No.~~
~
~~, . %,. %+ ' ,i h -~~
,k Date Date o g .. ,, TE OQA s s v_ .% i , s l - ,
s
~~+ - - - - - - -~~
~~g7 . Date~~
~~.s#~~
~~g% ., g~~
~
~~9. ' Int tall bearing nut coeter pins.~~
x s' TE . Date OQA Date s 3 TDI , Date -
~~% m . -, 3 . 't s,~~
~~10. Rotate the crankshaf t to check for any obvious bi6 ding'.-~~
~~b),'; 's t m~~
*g .
~~TC - .,Date OQA, Date 3'3~~
~~/3 - - - - - - - - - - - - - -~~
g7 Date" "f-NOTE: The foll,owing readinEs are for informational purposes only. If any abnormal condjt.iens are witnessed by the TDI representative, he shall provids direction and'documentbtion at';this time.
~~11. Take and record on the attached form (Section A, Attachment 1) the cold crankshaft web deflection and end thrust, clearances, s 4 .~~
)
~~wen 4. h~~
~~~ , TE '~~
~~Date ~0QA +. Date~~
- - - -w s TDI ~ Date ~%J, '\_.
~~v. - 3s n~~
~~1 4 v 's~~
~~. - , - s s~~
~~7 of 8 fig N.D. c,.u'. ' ' ' s~~
.\
5 '- s
sec.nou A J . attacheca 1
\
~~Shee} / or I s.o.3 Instruction Manual f mg y a 3 ,:B i (w .~~
/ / UNCONTRCLMI i ' Eor IntOrmation OW t
~~inspection and Maintenance Record T Transamenos Delaval~~
~~-c o.-~~
~~305 1 1 M AIN BE ARING CAPS - Model R E nsne s.. - .s .~~
c. -

s. a. c .- . o - , 2 e.,
~~.s ... o...i... .~~
v .s. . . u a...= o..... Iwi. sat.. he.ket.nn 6. Pa.e O REMARKS: w
~~, O -~~
O
~~@@ c 3~~
a
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~~I i noicvt A.- Y o $.:.s i 1 o Nl l l 5 1 w~~
. O. O W W Cbstv a and raord in the coprosnate soaces below the BE ARING BOLT E LONG ATION. or the TOROUE APPLIED WITH A TOROUE WAENCH tor both disa::,embly and as:cmbly. If a scroue multiplier is used with a toroue wrencn. #aco.d the multipl.cf ratio Bearing caps are numbered, starting from the gaarcase
~~' cnd Torque is to be applied in a criu cross pattern See Engine Namer.,s a te for the cor.cct forout value OlSASSEMBLY (Breakawavi~~
~~. , = .a . .~~
~~n.4. . e,~~
~~, . . e e e is A~~
B C X[X o XC)<] l 1 I i ASSEMBLY a.............a.. i e e .. ..-
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V ASSEMBLY: CYLINDER BLOCK INSTALLATION SECTION B NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual information will be performed by OQA, TDI representatives and the Test Engineer follwed by signoffs from all three. NOTE: All parts removed are to be cleaned, tagged, and or bagged and marked.
~~1. Remove water pump gear.~~
TE Date OQA Date TDI Date ,' 2. Remove idler gear.
~~O(%~~
~~TE Date OQA Date TDI Date~~
~~3. Ensure subbase and cylinder block are clean. Clean as necessary.~~
~~TE Date OQA Date TDI Date~~
~~4. Lubricate thru bolts and nuts with a 50 - 50 mixture of powdered graphite and clean engine oil.~~
~~TE Date OQA Date TDI Date b v~~
~~, , , &h si l of 11 gG fif,iM -~~
~~UNCONTROLi.EU For informr., m 03 O ASSEMBLY: CYLINDER BLOCK INSTALLATION - (continued)~~
~~5. Verify mating surfaces of the block and base are free from burrs. Touch up the surfaces using a flat file as necessary.~~
~~TE Date OQA Date TDI Date~~
~~6. Locate lower.thru bolt nuts in pocket in base.~~
Hang thru bolts in cylinder block with thru bolt set collars. Install corner disc seal and rubber seal. h" f rota - of seal,-fill in void with RTV sealant. TE Date OQA Date - /~% TDI Date
~~7. Slide TDI Lifting Bars through the crankcase doors.~~
~~TE Date OQA Date TDI Date~~
~~8. Lift the engine block and position it over the base.~~
Carefully lower block onto base ensuring that the dowel pins and thru bolts are lined up. Install thru bolts, felt washers, and set collars on exhaust manifold side as the thru bolts.are being lowered. TE Date OQA Date TDI Date () ' jTe4 % U LI' '
UNCONTROLLEG For Information Or.4 O \
~~>/ \,_, ASSEMBLY: CYLINDER BLOCK INSTALLATION - (continued)~~
~~9. Attach a dial indicator to the idler gear shaft and sweep base and block for alignment. Acceptance Criteria is .005".~~
~~Realign as necessary. TE Date OQA Date TDI Date Dial Indicator M&TE No.~~
~~10. Torque the thru bolts in 5 increments to the values listed in Appendix IV (Section B, Attachment 2) and in a criss cross pattern starting from the middle and working outward.~~
~~, Torque Wrench M&TE No.~~
~~TE Date OQA Date~~
~~\_/ TDI Date l 11. Set the thrd bolt set collars as pressure is applied in a l downward direction.~~
( TE Date OQA Date TDI Date ! NOTE: The following readings are for information purposes only. If any abnormal conditions are witnessed by the TDI representative, he shall provide direction and documentation at that time.
~~'12. Take cold crankshaft web deflection readings and record data on the attached form (Section B, Attachment 1) .~~
TE Date OQA Date TDI Date O 3 of 11 bdC SFP : ,,;.)
f... UNCONTRCLLED 7 For inferinaticn Gr/S e i
~~\s!~~
~~ASSEMBLY: CYLINDER BLOCK INSTALLATION - (continued)~~
~~13. Reinstall the idler gear.~~
Reinstall water pump gear. Tighten nut to torque value contained in Appendix IV (Section B, Attachment 2) . i r TE Date OQA Date TDI Date
~~14. Check and set camshaft timing:~~
A. Bar the engine over until the tappet roller for number 1 fuel injection pump tappet is on the base circle of its cam. Set up a one-inch travel dial indicator on the pump base for number one fuel injection pump with the spindle of the indicator bearing on top of the tappet pin for number 1 fuel tappet. Zero the indicator. Dial Indicator M&TE O I ,1 B. Bar the engine.in the direction of normal rotation until the tappet roller for number 1 fuel tappet starts up the lifting ramp of its cam. Continue until the scribe mark for fudl injection for number 1 cylinder is directly in line with the flywheel pointer. This scribe mark is shown on the engine nameplate. C. Observe the dial indicator to determine the lift of the fuel tappet at this point. Lift should be 0.197 in. If the lift is other than 0.197 in., camshaft timing must be corrected in accordance with the following procedure: 1.) Remove 2 fitted bolts that fasten camshaft ring to gear hub. 2.) Loosen remaining 4 bolts and rotate camshaft gear hub within ring gear to raise or lower the tappet as necessary. If there is not enough travel in the slotted holes in the gear hub to allow the required correction, it will be necessary to lift the gear end of the camshaft until cam gear teeth disengage from the idler gear teeth, and slip the mesh one or more teeth as judged necessary. Re-engage the teeth of the cam gear and idler. 3.) Observe dial indicator to find tappet lift after (/) L. correction. Make final correction by rotating the camshaft gear hub with ring gear. 4 of 11 g griJD SP '
4 - - UNCONTROt t.FU '-
~~i. For Intermation OnN~~
(( '%,! ASSEMBLY: CYLINDER BLOCK INSTALLATION - (continued) 4.) When correct tappet lift is obtained, lock up the 4 bolts in the slotted holes and drill and ream for 2 fitted bolts. New holes for fitted bolts should be moved approximately 1 inch from the original holes. 5.) Torque 6 bolts that fasten ring gear to hub to a torque value of 70 ft, lbs. i 20 ft. lbs. as required to align cotter pin holes. Tighten and lock camshaft bearing cap bolts if they were loosened.to slip gear tooth mesh. Torque Wrench M&TE No. TE Date OQA Date TDI Date
~~15. Install the number 1 fuel injection pump torquing capscrews in a criss-cross pattern to a torque value of 80 ft. Ibs.,~~
~~() utilizing 3 increments. TE Date OQA Date TDI Date Torque Wrench M&TE~~
~~16. Perform a gear backlash inspection in accordance with the attached procedure (Section B, Attachment 3).~~
~~TE Date OQA Date TDI Date p d 5 of 11 ;;l' (~~ gpID m -~~
~~.-. __. -- . . _ _ __ . . . . _. _a.~~
1- UNCONTROU FU ' s for inteimatim '"
)
~~J ASSEMBLY: CYLINDER BLOCK INSTALLATION - (continued)~~
17. Clean & lubricate intake header support bolts with a 50-50 mixture of graphite & clean engine oil. Inspect intake header for cleanliness, clean as necessary. Lift in place and tighten bolts in a crisscross pattern to the TDI General' Torque Values.
~~TE Date .OQA Date TDI Date Torque Wrench M&TE~~
~~18. Exhaust manifold installation:~~
A. Remove all protective coverings. B. Inspect manifold for cleanliness, clean as necessary. C. Attach spiral wound gaskets to exhaust manifold flanges () - D.- with masking tape. Clean and lubricate all support capscrews and exhaust flange capscrews with a 50-50 mixture of powdered graphitd and clean engine oil. . Bolt up feet to the TDI General Torque Values in a crisscross pattern in 3 increments. Bolt up exhaust flanges to the TDI General Torque Values in a crisscross pattern. Torque Wrench M&TE No. TE Date OQA Date TDI Date 6 of 11 gGIGTED CE ~ -
UNCDNTF ,# For ink"n" C" ' b Tj ASSEMBLY: CYLINDER BLOCK INSTALLATION - (continued) E. Clean and lubricate the exhaust pipe to turbocharger capscrews with "Never Seez". Tighten capscrews to the TDI' General Torque Values in a crisscross pattern in 3 increments. Torque Wrench M&TE No. TE Date OQA Date TDI Date
~~18. Verify jacket water outlet header for cleanliness, clean as necessary. . Clean &. lubricate the support capscrews with a 50~~
~~- 50 mixture of powdered graphite and clean engine oil.~~
~~Install jacket water outlet header. Tighten to the TDI General Torque Values in a crisscross pattern. _ TE Date 00A Date~~
~~\J TDI Date Torque Wrench M&TE~~
~~19. Clean & lubricate the intercooler inlet and outlet elbow nuts and bolts with 50 - 50 mixture of powdered graphite and clean engine oil. Using new gaskets, install intercooler i~~
inlet and outlet elbows tightening bolts to the TDI General Torque Values in a crisscross pattern. TE Date OOA Date TDI Date Torque Wrench M&TE G
~~.-q 7 of 11 gg gi;4WD S!I~~
\ Sect.LO.4 B Mach uM t / (** *
~~Sher / / t>f l s.oa Instruct, ion Manual -~~
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~~f* O 1. utr0NW w intotmayo% Transemanos inspection and Maintenance Record Delaval~~
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a... o... n e. enstewction mAenust.5euiari 6,8* set D timeses e.th a del andsreios e8hte appse a bee,sA,arske d hows of :;>etdese. httped ed temowetwe e eats ter 6 et entne tea. es sweariere. Il conoceng stati a est.py campass to flyshed and anyme a ysteed se a conscie fevndetee, deced antinction m ces les me 3 as tes to pie (.) ene thesondth et es och in e5 Wests esmee the one ed:sont to stie livw%et. The i>3.id en n..nio DJ'J05 inch te ellem fes d.starten el tM fewsdaise, it sneested as a seat feendeten.sessenesten les thereel datarten e.Il bJ t,aod es loc s .ea are$ teasestwie et f ust and e.1 unas ed.sent to "_ ti deflectace a any crent esmeds OD03 enet.corrorese acten mee to steek Atm. A toise defloaes e on, two ei,ecent tre%s ea:eeds 0203 mch scaverano arten ave to tenen. Esasieas; A .0DO2 m endag e en, eront oth e -0002 m a stie asat se. scene cract et m s a tetel et 0D06 in. defie: tion between thee espam creakat The sampios e.a be e the cas of eas.no scih e sieses conc 2'as terween
. the flywh.e8 said the connectag thef a mouch hose defiermee is seceis et 0303 se.et Paine 3.n the crent edentesi te ene etywhee. es eng eJe enh sehdt, coupled shefsag essmeno deflectee et Peetene 2. 3 m 6 m the crean et,ecost te l'io este.nei spett.pg snuelly en dicetee pool.gnenent bete.se concocteg ehatt and createsert. , $st daherten gauge et tee et Poet.en i.end tura creetafe!1 en deactee el asIrel retsien Pesien 1 fee pleong deflecten se use a ll' ef ter botten cente fw eit et.ns net erd 52' etas sertuni tetten cente fs V4rpe eng"es II:Se'e MV.MVA and GVB e.v,s. .n d.
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~~Instruction Manual !!( U Lg 9,,c.y3 - ' a.s ( APPENDIX IV~~
~~/UNCON Intermatbn N g,q' ED TORQUE TABLES ret~~
Model R-4 Engine The first portion of inis torque table. Special Torque Va!ues. apphes to those nuts, bolts, capSCrews and other thre3ded f asteners for which a specific torque value has been assigned.11 no seecific torque valueis hsted f or a f astener. ref er to the General Torque Values portion of the table.using the torque hsted for the thread size of tr's item in question. All torque values are based upon the use of a thread lubricant consisting of a 50-50 mutve by volume of powdered graphite and engine lubricating oil. A!! torques are hsted in both foot pounds and in kilograms per meter. Where applicable. bolt sizes in the special torque section are shown in parenthes's SPECIAL TORQUE VA1.UES Torque ft-lb kg.m item
~~.. .. ... 1400* ... 193 6 NUT. Foundation Bott (heat treated stcol.1% 8) .~~
29724 NUT. Main Bearing Cap Stud .... ............ ..... . ... .. .. 2150 .. NUT. Cylinder Block to Base Thru-bott First bott on each side (gearcase und) (2%") ..... . . .. . . 3350 .. M/5 3330 415 First bell on each side (gearcase end) (2") ... . . . . ..... .. . ..
. 2800 . 3S55 Intermediate Botts (2%") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ .. .............. . . ....... . . 2500 .. . 345 Intermediate Botts (2") 533 Last bolt on each side (flywheel end) (2%") . ......... .. .. .. 3900 ..
Last bott on each side (flywheel end) (2) ............... . ... . 3503 ... . 484 875 ... . 121 NUT. Connecti'ng Rod Bolt (1%") ...................... . .. .......
~~.. . .... 3600 ..... 497 7 NUT. Cyhnder Head Stud . . . . . . ....................... .~~
75 " . .. 10 37 NUT. Fuelinjection Nozzle Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . Minim u m Maximum 83 .... 11 80 1* NUT. Fuel Pump Stud . . . . . . . . ........... . ....... .... . . . 120 .. . 16 6 CAPSCREW. Fuel Pump Base (Allen) ...... .... .... ... . 200 27 6 CAPSCREW. Camshaft Beanng Cap . . . ... . . . . .. .
.. . .. .. 303 41 43 NUT. Id!er Gear Stub Snaft ..... . .......... 414 5 NUT. Flywheel Bott . . . . .. . . .. ....... . .. .. . . . 3000 1000 139 NUT Cranksha't Counter Weig*.t ....... . . . . . . ..... . . 365 . 50 5 CAPSCREW. Rocker Sha't . . . . . . . . . . . . . - . .
1 E '. CAPSCREW. Sub-Cover to Cyhnder Head . . . . . 120 325 " 4 's CAPSCREW. Cyhnder B!ock Foot to Base .. . . .
~~..... .... . 1800 249'?~~
Camsnatt Gear Retainer Nut . . . 7' CAPSCREW. Air Start valve to Cyhnccr HCad . 150** .
' Heat treated bolts are identacc ry tne f gute "4" starrped on enc c' no't a' ' "Retorque this .te r. every 8 hours c' operation after insta;i-ng new ccpper gassez v til no chr.ge 10tque is CD5erved m-u $ d //
e secrzoa B ahocAmc4 2. 54e t 2 of Z. ._o - .___. Instruction Manual N ll V GENERAL TOROUE VAlus.s The torque values given on the proceding page are for specific applications and are to be used. The
~~following tor::ve values are for general application where no specific values are given. .~~
Bolt Size & Torcue No. Threads (ft-th) (k o-fn) 3/8-16 . . . . . . . . . . . . . . . . 12 . . 1.65 c 3/8-24 . . . . . . . . . . . . . . . . 15 . . . 2.03 tu o
)
1/2-13 . . . . . . . . . . . . . . . 30 . . . 4.15 ae 1/2-20 . . . . . . . . . . . . . . . . 35 . . . 4.74 5/8-n . . .. . . . . . . . . . . . . e0 . . . 8.29 e@S "3 ,5 2 5/8-18 . . . . . . . . . . . . . . . . 70 . . . 9.68 3/4-10 . . . . . . . . . . . . . . . . 100 . . . 13.33 h! 'c3 3/4-16 . . . . . . . . . . . . . . . . 115 . . 15.00 $[ 7/8-9 . . . . . . . . . . . . . . . 1G0 . 22.13 ,P 7/8-14 . . . . . . . . . . . . . . . . 180 . . . 24.83 1-8 . . . . . . . . . . . . . . 24 5 . . 33.78 1-14 . . . . . . . . . . . . . . . 200 . . 40.11 11/8-7 . . . . . . . . . . . . . . . . 335 . . . 46.33 11/8-8 . . . . . . . . . . . . . . 355 . 48.00 1 1/8-12 . . . . . . . . . . . . . . 395 . . . 54.53 11/4-7 . . . . . . . . . . . . . . . 480 . . . 66.39 11/4-8 . . . . . . . . . . . 500 . . . 69.15 i 1 1/4-12 . . . . . . . . . . . . . . . . 550 . . . 76.07 13/B-9 . . . . . . . . . . . . . . 620 . . . 85.75 13/8-8 . . . . . . . . . . . . . . . 680 . . . as.04 1 3/8-12 . . . . . . . . . . . . . . . . 74 5 . . . 103.03 11/2-6 . . . . . . . . . . . . . . . . 735 . . 101.65 11/2-8 . . . . . . . . . . . . . . . . 800 . . . 110.64 1 1/2-12 . . . . . . . . . . . . . . . 665 . . 119.63 5 .L ' : L. , .' bl;
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~~Instruction Manual~~
~~..(_py .//. ,/ // ). .~~
k/ APPENDIX lil-1 - Gb a GEAR SET AND BACKLASH CLEARANCES h MODEL R4 ENGINE 1 e e e cc tu O i f - s
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i BACKLASH l I D ESCRIPTION GPL ens sNCHES CE N' e ut T E p'. ITE M 350 A 0 006/0.010 0 015'O 025 I 1 CAMSHAFT GE AR 0 010f0 015 i T ACHOME TER OMsVE GE AR 402 5 0.004/0 006 l 2 0 020/0 S31 f GOVERNOR ORIVE GE nR 402 C 0.003/0 012 3 4 GOVE RNOR OmtVEPe Gt Am 402 5 ACCESSORY OmiVE GE AR 410 6 DLER CE AR 355 7 CR ANKSM A8 7 GE AR 310 CM ANK TO PUv' GE AR "S
) 8 9 L 0 PukP GE AR C A AR*E p GE An a,0 W ATE A 9QU8 GE A R 425 1 10 .
l _ . - . . l _ . , . . Jib [If bd) b[^ ' . ! .~> 1 l t
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~~y es ' UNCONTROLLEO~~
.Q ASSEMBLY: REAR OIL SEAL INSTALLATION Ecr inforrnation OnW SECTION C NOTE: When verification of cleanliness is required, a visual inspection of the part and it's rating surfaces will be necessary to ensure they are free of dirt, grit and grine films.
~~Visual inspections will be performed by OQA, TDI representatives and the Test Engineer followed by signoffsf from all three.~~
~~1. Verify that all parts are clean.~~
~~
TDI 'D' ate 2.-Inspect and clean mating surfaces on the crankshaft rear cover, the engine base and the cylinder block for crankshaft rear cover installation. G -----....
~~3. Coat the inside diameter of the rear oil seal with molybdenuta disulphide.~~
~~!. TE Date OQA Date l~~
~
TDI ~ hIaIte CAUTION: Do not permit rolybdenum disulphide or any mixture of it to come into contract with any threaded fasteners. The presence of molybdenun disulphide will allow specified terques to overstress the fasteners. All torque values are based on the use of a 50 - 59 mixture of powdered graphite and clean engine oil. ( l i
~~/ \ \/~~
I Cf 4 SfJ li'W ( i.- ,
t UNCCNTPOU ED g Ecr intermden M O
~~4. Lubricate all capscrews using a lubricant consisting of a 50-50 mixture of powdered graphite and clean engine oil.~~
~~TE Date OQA Date TDI Date~~
5. Align and bolt (hand tight), the upper half of the crankshaft rear cover to the upper gasket and cylinder block with a .012" shim stock at the 12 o' clock position between the crankshaft and the oil seal.
Slide the cover until a side clearance of .008" to .010" is achieved. Remove and scrape mating surfaces as needed to provide proper clearance. Apply LOCKTITE #510 to both halves of the upper to lower crankshaft rear' covers mating surfaces.
~~~~~ ~~ ~~~
~~TE D' ate I)QA ~ iia ~te TDI Date lO I-~~
~~6. Align and bolt (hand tight), the lower half of the crankshaft rear cover to the lober gasket, engine base, and upper crankshaft rear cover.~~
Slide the cover until a clearance of .008" to .010" is achieved fron the bottom of the shaft and .008" to .010" is achieved at the sides. Remove and scrape mating surfaces as needed to provide the proper cl ea rances. When proper clearances have been obtained, torque the flange bolts for the upper to lower crankshaft rear cover halves to 60 ft. Ibs. in 3 increments using a criss cross pattern. l Torque Wrench M&TE No. l
~~~ ' ' " " ~~~
4 TE Date OQA Date TDI Date 4 v 2 of 4 2T C !J:id D % ^ or - . . , . -- , - , , , - ,-,a m ,
. UNCONTROLLED l Ecr infomut:en Gnh f-) \"/ 7. Torque all (upper and lower) crankshaft rear cover to es.gine flange bolts to the TDI General Torque Values in 3 incrernents using a criss cross pattern.. ~ " --
~~Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~8. Remove shim stock placed between the crankshaft and the upper crankshaft rear cover installed prior to setting clearances. All clearances will be taken using a feeler gauge.~~
~~Feeler Gauge M&TE No. TE Date OQA Dr.te G~~
~~9. Verify upper oil seal side clearance to be .008" to .010".~~
~~TE Date 0QA Date--- TDI -.Date~~
~~-10. Verify lower oil seal side clearance to be .008" to .010".~~
~~11.' Verify lower oil seal bottori clearara.e to be .008" to .010".~~
~~=..... =...-- =_-.............~~
g, g g, g I r ('% 3 of 4 90g;;;w c,7a
_ _ . _ _ _ _ . . _ _ . - r LINCONTRC' I IU Ecr inletnistian On'V N
~~12. Verify upper oil seal top clearance to be .012".~~
TE Date OQA Date TDI Yate O n .a c . i i .. 4
l
~~) UNCONTR gg CYLINDER LINER INSTALLATION FOf Inf0 M SECTION D Cylinder No.~~
NOTE: When verification of cleanliness is required, a visual inspection of the parr and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and Test Engineer follwed by signoffs from all three. 1.-Verify cylinder liner for cleanliness. Clean as required. TE Date OQA Date TDI Date
~~2. Install new sealing rings in liner grooves using liquid dishwater soap or tire installation lubricant for lubrication.~~
A
~~) TE Date OQA Date l TDI~~
~~Date~~
3. Install a cylinder liner puller fixture (part number 00-590-01-0V) to the bottom of the liner. Using a chain hoist, lower the liner into the block until it is approximately 12 inches from being fully seated.
~~l Brace the cylinder approximately 12 inches above the full seated l pocition using two pieces of wood 12 inches x 12 inches x 1 inch. l l I l n v 1 of 2~~
~~.g( , ,~~
L
UNCONTROUlp,
~~. For informati:n va Cylinder Liner Installation .,~~
~~Cylinder No.~~
~~4. Install new sealing rings in liner grooves from the bottom, using liquid dishwater soap or tire installation lubricant for lubrication.~~
~~TE Date OQA Date TDI Date~~
~~5. Remove blocking and lower the cylinder liner until seated in the block.~~
~~It.is essential that the liners be installed in their original~~
~~-positions in the block and that the scribe marks on the liner be aligned with the marks on the block. Remove the liner pulling fixture.~~
~~TE Date OQA Date TDI Date b~~
\
O 2 of 2 j\C ti- d;;i3 G- ~
I .. _ gNOONTROLLEG
~~'h d CYLINDER LINER INSTALLATION For Iniormaban O SECTION D Cylinder No.~~
NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and Test Engineer follwed by signoffs from all three.
~~1. Verify cylinder liner for cleanliness. Clean as required.~~
~~TE Date OQA Date TDI Date~~
~~2. Install new sealing rings in liner grooves using liquid dishwater soap or tire installation lubricant for lubrication.~~
~~/ O Date (a) TE OQA Date TDI~~
~~Date~~
3. Install a cylinder liner puller fixture (part number 00-590-01-0V) to the bottcm of the liner. Using a chain hoist, lower the liner into the block until it is approximately 12 inches from being fully seated.
~~Brace the cylinder approximately 12 inches above the full seated position using two pieces of wood 12 inches x 12 inches x 1 inch. O 1 of 2 BC !! < . i r ia t a. i - . _, __J~~
~~. .. . - - .= .~~
~~F a 1-tJNCON1'dO7," Cylinder Liner Installation-For lincM<n* " ' Cylinder No.~~
~~4. Install new realing rings in liner grooves from the bottom, using liquid dishwater soap or tire installation lubricant for lubrication, l~~
1 TE Date OQA Date I , TDI Date
~~5. Remove blocking and lower the cylinder liner until seated in the block.~~
It is issential that the liners be installed in their original positions in the block and that the scribe marks on the liner be aligned with the marks on the block. Remove the liner pulling fixture. i TE Date OQA Date TDI Date I 1 O 2 of 2 j" f.; i uiib si
~~~ ,_ ,_ _ _ - _ , . . . - - _ . . - - . _ , _ - . .- __ . . . . . . . _ . _ _ . . , _ . _ . ~ , . . . - _ . . _ . _ . _ . , . _ . - - . . _ . , , _ . . .~~
~~.. _ _ -_.~ .~~
UMCONTRO O For informata]n% V CYLINDER LINER INSTALLATION SECTION D Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and Test Engineer follwed by signoffs from all three.
~~1. Verify cylinder liner for cleanliness. Clean ns required.~~
~~TE Date OQA Date TDI Date~~
~~2. Install new sealing rings in liner grooves using liquid dishwater soap or tire installation lubricant for lubrication.~~
~~O Date Date V TE OQA TDI-Date~~
3. Install a cylinder liner puller fixture (part number 00-590-01-0V) to the bottom of the liner. Using a chain hoist, lower the liner into the block until it is approximately 12 inches from being fully seated.
Brace the cylinder approximately 12 inches above the full seated position using two pieces of wood 12 inches x 12 inches x 1 inch. m 1 of 2 . g ., b - p k r r. " m,, u,a\ ' tun, u .- - - - - - - - - - - - -
i ! c ux;oNTY"[..a pg7 }ntornW ' Cylinder Liner Installation Cylinder No. 3
~~4. Install new sealing rings in liner grooves from the bottom, using liquid dishwater soap or tire installation lubricant for lubrication.~~
~~f TE Date OQA Date l TD1 Date i~~
~~5. Remove blocking and lower the cylinder liner until seated in the block.~~
It is essential that the liners be installed in their original i: positions in the block and that the rcribe marks on the liner be aligned with the marks on the block. Remove the liner pulling fixture. i TE Date OQA Date TDI Date f l w i i l
~~, o,, v. . =, -~~
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4 = ==-.+ - m- r- e I. UN00NTROLt.E0 N Ecr information OW CYLINDER LINER INSTALLATION SECTION D Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and Test Engineer follwed by signoffs from all three.
~~1. Verify cylinder liner for cleanliness. Clean as required.~~
~~TE Date OQA Date TDI Date~~
~~2. Install new sealing rings in liner grooves using liquid dishwater soap or tire installation lubricant for lubrication.~~
~~-TE Date OQA Date TDI~~
~~Date~~
-3. Install a cylinder liner puller fixture (part number 00-590-01-0V) to the bottom of the liner. Using a chain hoist, 1cwer the liner into the block until.it is approximately 12 inches from being fully seated.
Brace the cylinder approximately 12 inches above the full seated position using two pieces of wood 12 inches x 12 inches x 1 inch. l a 1 of 2 jig AFPE0VED SEP 1 b ??.O
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UNCONTprt1 m for IrErmo@r 9 s -Cylinder Liner Installation Cylinder No. 1 i'
~~4. Install new sealing rings in liner grooves from the bottom, using liquid dishwater soap or tire installation lubricant for lubrication.~~
\
~~TE Date OQA Date l TDI Date , t~~
~~5. Remove blocking and lower the cylinder liner until seated in the block.~~
It is essential that the liners be installed in their original positions in the block and that the scribe marks on the liner be aligned with the marks on the block. Remove the liner pulling fixture. TE Date OQA Date TDI Date 1 o L . O 2 of 2 - gg pppgifi[9 5.Ep fj
~~~ - - - . - - - . . . . - - . . . . . . - - - - . .. . - -. .-- - - .~~
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[m ) For IniC@M # CYLINDER LINER INSTALLATION lSECTION D Cylinder No. 5 NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and Test Engineer follwed by signoffs from all three.
~~1. Verify cylinder liner for cleanliness. Clean as required.~~
~~TE Date OQA Date TDI Date~~
~~2. Install new sealing rings in liner grooves using liquid dishwater soap or tire installation lubricant for lubrication.~~
~~/"%~~
~~( TE Date OQA Date i TDI~~
~~Date I~~
3. Install a cylinder liner puller fixture (part number 00-590-01-0V) to the bottom of the liner. Using a chain hoist, lower the liner into the block until it is approximately 12 inches from being fully seated.
~~Brace the cylinder approximately 12 inches above the full seated position using two pieces of wood 12 inches x 12 inches x 1 inch. kA) v I of 2 ;TG f.i:;;Cyij g; , {2 3~~
~~% 5 gJNCONTWIII,aI WM;mati" i' '"~~
~~Cylinder Liner Installation Cylinder No.~~
~~4. Install new sealing rings in liner grooves from the bottom, using liquid dishwater soap or tire installation lubricant for lubrication.~~
l, TE Date OQA Date l TDI Date .
~~5. Remove blocking and lower the cylinder-liner until seated in the block.~~
It.is essential that the liners be installed in their original positions in the block and-that the scribe marks on the liner be aligned with the marks on the block. Remove the liner pulling fixture. TE Date OQA Date TDI Date
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\d CILODER LINER INSTALLATION E0fInt00f'2 ~' 'SECTION D Cylinder No. 6 NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and Test Engineer follwed by signoffs from all three.
~~1. Verify cylinder liner for cleanliness. Clean as required.~~
~~TE. , Date OQA Date TDI Date~~
~~2. Install new sealing rings in liner grooves using liquid dishwater soap or tire installation lubricant for lubrication.~~
~~TE Date OQA Date TDI Date~~
3. Install a cylinder liner puller fixture (part number 00-590-01-0V) to the bottom of the. liner. -Using a chain hoist, lower the liner into the block until it. is approximately 12 inches from being fully seated.
~~> Brace the cylinder approximately 12 inches above the full seated position using two pieces of wood 12 inches x 12 inches x 1 inch.~~
~~1 4 9 4 V JG EM !.U 1 1 of 2 ~ T, J.~~
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Cylinder Liner Installation s C i Cylinder No. U D J .s 4.* Ins'c'all new sealing rings in liner grooves from the bottom, using l ' liquid dishwater soap or tire installation lubricant for lubrication. S . i TE Date OQA Date i a (
- TD1 Date S. Renove blocking and lower the cylinder liner until seated in the block. # -It is essential that the liners be installed in their original -
~~positions in the block cnd that the scribe marks on the liner be . .~~
~~.% 4 . aligned with the nurks on the block. Remove the' liner pulling fixture."~~
~~1, 'TE Date OQA Date~~
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~~! TDI Date I~~
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a - UNCONTROLLED Ear. Information Only U CYLINDER LINER INSTALLATION SECTION D Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and Test Engineer follved by signoffs from all three.
~~1. Verify cylinder liner for cleanliness. Clean as required.~~
~~TE Date OQA Date TDI Date~~
~~2. Install new sealing rings in liner grooves using liquid dishwater soap or tire installation lubricant for lubrication.~~
~~TF Date OQA Date EL Date~~
3. Install a cylinder liner puller fixture (part number 00-590-01-0V) to the bottom of the liner. Using a chain hoist, lower the liner into the block until it is approximately 12 inches from being fully seated.
Brace the cylinder approximately 12 inches above the full seated position using two pieces of wood 12 inches x 12 inches x 1 inch. A 9 itU it> i tJ.IO E ' - 1 of 2 - - I
~
~~I 1 UNCONTROttEU (~'T for informd3 &T V Cylinder Liner Installation Cylinder No. 7~~
~~4. Install new sealing rings in liner grooves from the bottom, using liquid dishwater soap or tire installation lubricant for lubrication.~~
~~TE Date OQA Date TDI Date~~
~~5. Remove blocking and lower the cylinder liner until seated in the block.~~
It is essential that the liners be installed in their original positions in the block and that the scribe marks on the liner be aligned with the marks on the block. Remove the liner pulling fixture. TE Date OQA Date
~~'TDI Date t~~
L
~~~ f%~~
1 i 2 of 2 JIO CIiVfL' S T - ,
l n Ut' M I ,' 91 p.,i W tu! * " CYLINDER LINER INSTALLATION SECTION D Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be r.ecessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and Test Engineer follwed by signoffs from all three. 1.-Verify cylinder liner for cleanliness. Clean as required. TE Date OQA Date TDI Date
~~2. Install new sealing rings in liner grooves using .1.4uid dishwater soap or tire installation lubricant for lubrication.~~
~~G TE Date OQA Date TDI~~
~~Date~~
3. Install a cylinder liner puller fixture (part number 00-590-01-0V) to the bottom of the liner. Using a chain hoist, lower the liner into the block until it is approximately 12 inches from being fully seated.
Brace the cylinder approximately 12 inches above the full seated position using two pieces of wood 12 inches x 12 inches x 1 inch. v 1 of 2 JIG IIFi.CVPJ $ f f' . L ' ; ',
i g;coNTgettr.D O Cylinder Liner Installation w ~ *" ' Cylinder No.
~~4. Install.new sealing rings in liner grooves from the bottom, using liquid dishwater soap or tire installation lubricant for lubrication.~~
~~TE Date 0QA Date TDI Date~~
~~5. Remove blocking and lower the cylinder liner until seated in the block.~~
It is essential that the liners be installed in their original positions in the block and that the scribe marks on the liner be i aligned with the marks on the block. Remove the liner pulling fixture.
~
TE Date OQA Date , t TDI Date - l lO . e b i i e i .~ O 2 of 2 , UC 4.iii,6(fD y - t
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~~ASSEMBLY: PISTON TO CONNECTING ROD SECTION E~~
! l Cylinder No. I i- NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films.
~~Visual inspections will be performed by OQA, TDI representatives and the Test Engineer followed by signoffsf from all three.~~
~~1. Verify all parts for cleanliness prior to installation. Clean as necessary.~~
Ensure that the piston pin bushing is installed in the connecting rod piston pin bore and that the lubricating oil hole is not restricted. TE Date OQA Date TDI Date
~~2. Attach a hoist to the lower end of the piston rod. Lift and position d the rod over the piston.. ,~~
Lower the connecting rod into the piston assembly cnd align the piston pin bore of th5 pis, ton assembly to the piston pin bushing's inside bore of the connecting tod. Coat the piston pin with molybdenum disulphide prior to assembling in piston pin bushing. Use a rag or soft bristle brush. TE Date OQA Date TDI Date CAUTION: Do not permit molybdenum disulphide or any mixture of it to come into contact with any threaded fasteners. The presence of molybdenum disulphide will allow specified torques to overstress the fasteners. All torque values are based on the use of a 50-50 mixture of powered graphite and clean engine cil. O lof 2 J1G UtnGD 3Fr .,
~~, , . . _ _ _ .~~~
~~UNCONTRO!lff Fct Informatkn Od*. O Cylinder No.~~
~~3. Insert the piston pin completely through the bores of the connecting~~
~~- rod (piston pin bushing) and piston assembly.~~
Apply LOCKTITE to the piston pin retaining rings and install a piston pin retaining ring over each end of the piston pin. TE Date OQA Date TDI Date
~~4. Ensure that the connecting rod floats freely inside the piston assembly by movir.g the connecting rod from side to side while holding the piston assembly-stationary.~~
TE Date OQA Date TDI Date O ll l 2of 2 ';I~ jICli:ECi.D
gjMr'ON7#" ' q [,} ggt y> v ASSEMBLY: PISTON TO CONNECTING ROD SECTION E Cylinder No. 2 NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will.be performed by OQA, TDI representatives and the Test Engineer followed by signoffsf from all three.
~~1. Verify all parts for cleanliness prior to installation. Clean as necessary.~~
Ensure that the piston pin bushing is installed in the connecting rod piston pin bore and that the lubricating oil hole is not restricted. TE Date OQA Date TD1 Date
~~2. Attach a hoist to the lower end of the piston rod. Lift and position~~
[] V the rod over the piston. Lower the connecting rod into the piston assembly and align the piston pin bore of thd piston assembly to the piston pin bushing's inside bore of the connecting rod. < Coat the piston pin with molybdenum disulphide prior to assembling in piston pin bushing. Use a rag or soft bristle brush. TE Date OQA Date TDI Date CAUTION: Do not permit molybdenum disulphide or any mixture of it to come into contact with any threaded fasteners. The presence of molybdenum disulphide will allow specified torque; to overstress the fasteners. All torque values are based on the use of a 50-50 mixture of powered graphite and clean engine oil. U lof 2 (G y iDD C; .': -->
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~~3. Insert the piston pin completely through the bores of the connecting rod (piston pin bushing) and piston assembly.~~
Apply LOCKTITE to the piston pin retaining rings and install a piston pin retaining ring over each end of the piston pin. 4 , TE Date OQA Date TDI Date
4. Ensure that the connecting rod floats freely inside the piston assembly by moving the connecting rod from side to side while holding the piston

assembly stationary.
~~TE Date OQA Date TDI Date~~
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~~UNCONTROLLED~~
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ASSEMBLY: PISTON TO CONNECTING ROD SECTION E Cylinder No. 3 NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and the Test Engineer followed by signoffsf from all three. 1.' Verify all parts for cleanliness prior to installation. Clean as necessary. En ture that the piston nin bushing is installed in the connecting rod piston pin bore and that the lubricating oil hole is not restricted. TE Date OQA Date TDI Date f 2. Attach a hoist to the lower end of the piston rod. Lift and position the rod over the piston. Lower the connecting rod into the piston assembly and align the piston pin bore of the piston assembly to the piston pin bushing's inside bore of the connecting rod. Coat the piston pin with molybdenum disulphide prior to assembling in piston pin bushing. Use a rag or soft bristle brush. l TE Date OQA Date l j TDI Date CAUTION: Do not permit molybdenum disulphide or any mixture of it to come into contact with any threaded fasteners. The presence of molybdenum disulphide will allow specified torques to overstress the fasteners. All torque values are based on the use of a 50-50 mixture of powered graphite and clean engine oil. l l n [ V) lof 2 EG;;.319 SFC l . l
~~, , _ - . . - - ~ .~~
~~ty.:CONTRO; 1 ?D~~
- M F; interrxii p i Cylinder No. 3_

3. Insert the piston pin completely through the bores of the connecting rod (piston pin bushing) and piston assembly.
~~Apply LOCKTITE to the piston pin retaining rings and install a piston~~
~~.' pin retaining ring over each end of the piston pin.~~
~~TE Date OQA Date TDI Date~~
4. Ensure that the connecting rod floats freely inside the piston assembly by moving the connecting rod from side to side while holding the piston assembly stationary. -
~~TE Date OQA Date TDI Date D~~
)
t 2of 2 O mm sm r t .
a UNCONTROLtED For (nformatix 0'If h(- ASSEMBLY: PISTON TO CONNECTING ROD SECTION E Cylinder No. NOTE: When verificati'n of cleanliness is required, a visen1 inspection of the part and it's mating surfaces vila be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and the Test Engineer followed by signoffsf from all three.
~~1. Verify all parts for cleanliness prior to installation. Clean as necessary.~~
Ensure that the piston pin bushing is installed in the connecting rod piston pin bore and that the lubricating oil hole is not restricted. TE Date OQA Date TDI Date
~~2. Attach a hoist to the lower end of the piston rod. Life and position (n the rod over the piston..~~
Lower the connecting rod into the piston assembly and align the piston pin bore of the pisten assembly to the piston pin bushing's inside bore of the connecting rod. Coat the piston pin with molybdenum disulphide prior to assembling in piston pin bushing. Use a rag or soft bristle brush. t TE Date OQA Date TDI Date CAUTION: Do not permit molybdenum disulphide or any mixture of it to come into contact with any threaded fasteners. The presence of molybdenum disulphide will allow specified torques to overstress the fasteners. All torque values are based on the use of a 50-50 mixture of powered graphite and clean engine oil. m a lof 2 -
~~' ~ ~ '~~
gg pyGL\TD $Ei
g. i UNCC'<.TPOU ED for inf amai%n CYV i Cylinder No.
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~~3. Insert the piston pin completely through the bores of the connecting rod (piston pin bushing) and piston assembly.~~
r Apply LOCKTITE to the piston pin retaining rings and install a piston pin retaining ring over each end of the piston pin. TE Date OQA Date 551 Date
~~4. Ensure that the connecting rod floats freely inside the piston assembly by moving the connecting rod from side to side while holding the piston assembly stationary.~~
~~TE Date OQA Date TDI Date~~
~~'N v~~
2of 2 jig 11. 4;0iTD $ { ~ l .'.
1 I g g t!T @ 4 gtoptM"3' O ASSEMBLY: PISTON TO CONNECTING ROD SECTION E Cylinder No. 5 NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and the Test Engineer followed by signoffof from all three.
~~1. Verify all parts for cleanliness prior to installation. Clean as necessary.~~
Ensure that the piston pin bushing is installed in the connecting rod piston pin bore and that the lubricating oil hole is not restricted. TE Date OQA Date TDI Date p/ 2. Attach a hoist to the lower end of the piston rod. Lift and position Q the rod over the piston., Lower the connecting rod into the piston assembly and align the piston pin bore of thd piston assembly to the piston pin bushing's inside bore of the connecting rod. Coat the piston pin with molybdenum disulphide prior to assembling in piston pin bushing. Use a rag or soft bristle brush. TE Date OQA Date TD1 Date CAUTION: Do not permit' molybdenum disulphide or any mixture of it to come into contact with any threaded fasteners. The presence of molybdenum disulphide will allow specified torques to overstress the fasteners. All torque values are based on the use of a 50-50 mixture of powered graphite and clean engine oil.
~~. ,m !]1 t.~~
lof 2 .p.m i y QiGiD E
i UMOONIPOII E$' .; for 10:0!WM Cylinder No. h
~~3. Insert the piston pin completely through the bores of the connecting rod (piston pin bushing) and piston assembly.~~
~~Apply LOCKTITE to the piston pin retaining rings and install a piston pin retaining ring over each end of the piston pin. TE Date OQA Date TDI Date~~
~~4. Ensure that the connecting rod floats freely inside the piston assembly by moving the connecting rod from side to side while holding the piston assembly stationary.~~
~~TE Date OQA Date TDI Date i D]~~
~~\~-~~
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v ASSEMBLY: PISTCN TO CONNECTING ROD SECTION E Cylinder No. 6 NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and the Test Engineer followed by signoffsf from all three.
~~1. Verify all parts for cleanliness prior to installation. Clean as necessary.~~
Ensure that the piston pin bushing is installed in the connecting rod piston pin bore and that the lubricating oil hole is not restricted. TE Date OQA Date TDI Date
~~' 2. Attach a hoist to the lower end of the piston rod. Lift and position the rod over the piston..~~
~~Lower the connecting rod into the piston assembly and align the piston~~
~~pin bore of thd piston assembly to the piston pin bushing's inside bore t~~
of the connecting rod. Coat the piston pin with molybdenum disulphide prior to assembling in piston pin bushing. Use a rag or soft bristle brush. l TE Date OQA Date l I TDI Date CAUTION: Do not permit molybdenum disulphide or any mixture of it to come into contact with any threaded fasteners. The presence of
~~molybdenum disulphide will allow specified torques to overstress l~~
~~l the fasteners. All torque values are based on the use of a 50-50 mixture of powered graphite and clean engine oil.~~
~~.[\~~
~~I . l lof 2 ., jM fni:0VfD SF ? 13 5~~
~~l l~~
~~l !' uNCONTROLLEO [c ,;dunn.tLa Onh i~~
~~\ Cylinder No. b i~~
' 3. Insert the piston pic completely through the bores of the connecting rod (piston pin bushing) and piston assembly. Apply LOCKTITE to the piston pin retaining rings and install a piston pin retaining ring over each end of the piston pin. TE Date OQA Date TDI Date
4. Ensure that the connecting rod floats freely inside the piston assembly by moving the connecting rod from side to side while holding the piston

assembly stationary.
TE Date OQA Date TDI Date O e 2of 2 ' GGli'id D U':
F l UNCONTROLif0 i p For Informatica OM V ASSEMBLY: PISTON TO CONNECTING ROD SECTION E Cylinder No. - NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessa.y to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and the Test Engineer followed by signoffsf from all three.
~~1. Verify all parts for cleanliness prior to installation. Clean as necessary.~~
Ensure that the piston pin bushing is installed in the connecting rod piston pin bore and that the lubricating oil hole is not restricted. TE Date OQA Date TDI Date p 2. Attach a hoist to the lower end of the piston rod. Lift and position the rod over the piston.. Lower the connecting rod into the piston assembly and align the piston pin bore of the piston assembly to the piston pin bushing's inside bore of the connecting rod. Coat the piston pin with molybdenum disulphide prior to assembling in piston pin bushing. Use a rag or soft bristle brush. TE Date OQA Date TDI Date CAUTION: Do not permit molybdenum disulphide or any mixture of it to come into contact with any threaded fasteners. The presence of molybdenum disulphide will allow specified torques to overstress the fasteners. All torque values are based on the use of a 50-50 mixture of powered graphite and clean engine oil. (% O lof 2 .3 pg ;F;T.;O U C' -
~~. . . .. . _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ ~ _ _~~
~~l" J UNCONTROU P , For interm<'a f r~~
~~3. Insert the piston pin completely through the bores of the connecting rod (piston pin bushing) and piston assembly.~~
~~Apply LOCKTITE to the piston pin retaining rings and install a piston~~
~~pin retaining ring over each end of the piston pin.~~
~~TE Date OQA Date TDI Date~~
~~4. Ensure that the connecting rod floats freely inside the piston assenbly by moving the connecting rod from side to side while holding the piston assembly stationary.~~
TE Date OQA Date TDI Date O V O 2of 2 jie 3.:' ;i y. c, c ,-
UNCO G N!9 peg lgdotplath 'i N r3
~~) ASSEMBLY: PISTON TO CONNECTING ROD SECTION E Cylinder No.~~
NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representatives and the Test Engineer followed by signoffsf from all three.
~~1. Verify all parts for cleanliness prior to installation. Clean as necessary.~~
Er.sure that the pisten pin bushing is installed in the connecting rod piston pin bore and that the lubricating oil hole is not restricted. TE Date OQA Date TDI Date q 2. Attach a hoist to the lower end of the piston rod. Lift and position t g the rod over the piston.. Lower the connecting rod into the piston assembly and align the piston pin bore of the piston assembly to the piston pin bushing's inside bore of the connecting rod. Coat the piston pin with molybdenum disulphide prior to assembling in piston pin bushing. Use a rag or soft bristle brush. TE Date OQA Date TDI Date CAUTION: Do not permit molybdenum disulphide or any mixture of it to come into contact with any threaded fasteners. The presence of molybdenum disulphide will allow specified torques to overstress the fasteners. All torque values are based on the use of a 50-50 mixture of powered graphite and clean engine oil. i^) c .qq lof 2 iTG MiEIN ~
J ) upCONTC('i '_I D Fo." in u m 4 ' C Cylinder No.
~~3. Insert the piston pin completely through the bores of the connecting rod (piston pin bushing) and piston assembly.~~
Apply LOCKTITE to the piston pin retaining rings and install a piston pin retaining ring over each end of the piston pin. TE Date OQA Date TDI Date
~~4. Ensure that the connecting rod floats freely inside the piston assembly by moving the connecting rod from side to side while holding the piston assembly stationary.~~
~~l TE Date 0QA Date l TDI Date l l l 1 l l l 6 t l n v l i i Ll6: l l~~
~~- -__.2-.-..-.___--...._ _,___m._. _ _ . . _ _ - - _ , . - - - . _ _ _ _ _ . - . _ , . , - - ,~~
n pg.,:grm'T'3 t i pg labi reahv g"5.- V ASSEMBLY: PISTON AND ROD INSTALLATION SECTION F Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grfine films. Visual inspections vill be perforced by OQA, TDI representative and the Test Engineer followed by signoffs from all three.
~~1. Verify all parts for cleanliness. Clean as necessary.~~
~
TE ~ ~~ " ~ifa~t e OQA Date TDI Date CAUTION: The installation procedure is the reverse of the removal procedure. Be careft:1 that rings do not catch on piston ring guide. Exercise particular care not to chip or break oil control (} rings. Damaged rings must be replaced. O 2. Wash the inside diameter of the liner using safety solvent. Use paper or gasket mater,ial to divert the solvent away from the r.ain bearings. TE Date OQA " ~ " ~~ " ~ iial e TDI Date
~~3. Position the crankshaf t web in the proper position (T.D.C.) and coat the crank pin with clean lube oil.~~
~~
~~TE Date OQA " " "'Dat'e~~
~
~~TDI ~ ~ ~ iia ~t e (% 1 of 4 y gi UD BEE i'~~
~~.. n l~~
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por inia. tr.;uu '- - [ Cylinder No. 4._ Position the ring compressor tool and coat the cylinder ifner with clean Jube oil. TE Date OQA Date TDI ~~~~~~~ hate
~~5. Attach piston Iffting fixture to the piston crown, and coat the pisten skirt and piston rings with clean lube oil.~~
~
~~TE Dat'e OQA Date~~
~~
~~TDI Date~~
6. Install the upper connecting rod bearing shell at this time by installing the shell in the connecting rod and tieing clean rags around the bearing shell I.D. and the piston rod. This method holds the hearing in place during transportation and installation of the assembly p
v as a unit. Attach a chain fall to the piston lifting fixture and lift the piston and rod assemb1'y over the cylinder. Position the connecting rod so that the identification numbers stamped on the side of the rod are faced toward the camshaft side.
~
~~TE Date OQA Date TDI DEI~~
~~7. Rotate the piston rings on the piston so that the ring gets are staggered at least every 90 degrees.~~
TE Date OQA Date TDI Date O U . s
i llMCONNy ,, (-] For hihMN' [ Cylinder No.
~~8. Lower the piston and rod assembly into the cylinder liner holding the piston rings in place as they enter the ring compressor tool.~~
Remove the tie down rags and lower the rod until the weight of the piston and rod assembly is being borne by the crankshaf t journal. Install the lower connecting rod bearing shell into the connecting rod
~~. bearing hex and install both bearing shell aligning dowels into the bearing caps.~~
Lubricate the 4 connecting rod bolts with a thread lubricant consisting of a 50-50 mixture by volume of powdered graphite and clean engine lubricating oil. TE Date OQA Date
~
~~TDI iia ~te~~
~~9. Install the connecting rod bearing box using a wooden support located under the cap while bolting the 4 bearing cap bolts.~~
~~O TE Date OQA Date TDI ~ifa~te~~
~~10. Install the 4 connecting rod bolts and nuts and torque the nuts up to approximately 20 - 40 ft. Ibs utfifzing a criss-cross pattern in 3 increments.~~
Remove the connecting rod cap wood lifting supports. TE Date OQA Date Torque Wrench M8TE (G 3 of 4 c p ', v. C 4 gg JyGEM3
i .i. "l-
t.
i-
f
~~! et1C0t4TROlt.!U~~
~~j. For Intermatic 103b' 1,~~
~~cylinder No.- l j 11'. Torque the 4 nuts in a cries cross pattern to a torque value of~~
~~875 ft. Ibs.. Apply torque in 3 increments.~~
i i i ' Torque Wrench M&TE No. i l. i , TE Date OQA Date i-t. I l I l; t l' t i-i i-i l 9 \ . i-I' 9 ..~.
~~. _....-...r 3TG IJ i nt> G Jc c :' ~; " " ' .~~
4 of 4
{ 9 utacotiTeou.m For intermation 04 ASSEMBLY: PISTON AND ROD INSTALLATION SECTION F Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by 0QA, TDI representative and the Test Engineer followed by signoffs from all three.
~~1. Verify all parts for cleanliness. Clean as necessary.~~
l TE Date OQA Date TDI Date CAUTION: The installation procedure is the reverse of the removal r procedure. Be careful that rings do not catch on piston ring l guide. Exercise particular care not to chip or break oil control rings. Damaged rings cust be replaced.
~~2. Wash the inside diameter of the Ifner using safety solvent. Use paper or gasket mater,fal to divert the solvent away from the main hearings.~~
~~TDI Date~~
~~3. Position the crankshaf t web in the proper position (T.D.C.) and coat the crank pin with clean lube oil.~~
l TE Date OQA Date TD1 Date L l I I Y l l 8% 7 b l 1 of 4 FC GnCVfD $[f- UU
l ) f )- UNCONTROi W
~~,O For Infern. atma 0%~~
~~Cylinder No. 2~~
~~4. Position the ring compressor. tool and coat the cylinder ifner with clean lube oil.~~
~~f TE Date OQA Date TDI Dal:e~~
~~5. Attach piston lifting fixture to the piston crown, and cost the piston skirt and piston rings with clean lobe oil.~~
~
~~TE Date OQA ~D~~
~~~ 'a~t'e ~~~
~~TDI Date~~
. 6. Install the upper connecting rod bearing shell at this time 1y installing the shell in the connecting rod and tieing clean rags arm.md the bearing shell I.D. and the piston rod. This method holds the hearing in place during transportation and installatien of the assettbly as a unit. )
s Attach a chain fall to the piston lifting fixture and lift the piston and rod assemb1'y over the cylinder. Position the connecting rod so that the identification numbers stamped on the side of the rod are faced toward the eneshaft side. TE Date OQA Date
~~7. ' Rotate the piston rings on the piston so that the ring gaps are staggered at least every 90 degrees.~~
~~........... ................... 4 V~~
O , ne gn::P (S' " -2
i-I gr. Cylinder No. 2
~~8. Lower the piston and rod assembly into the cylinder liner holding the piston rings in place as'they enter the ring compressor tool.~~
Remove the tie down rags and lower the rod until the weight of the piston and rod assembly is being borne by the crankshaf t journal. Insta)) the lower connecting rod bearing shell into the connecting rod bearing box and install both bearing shell aligning devels into the bearing caps. Lubricate the 4 connecting rod bolts with a thread lubricant consisting of a 50-50 mixture by volume of powdered graphite and clean engine lubricating oil. TE Date OQA Date TDI iia't'e
~~9. Install the connecting rod bearing box using a wooden support located under the cap while bolting the 4 bearing cap bolts.~~
~~TE Date OQA Date TDI ~iiate~~
~~10. Install the 4 connecting rod bolts and nuts and torque the nuts up to Japproximately 20 - 40 ft. Ibs utilizing a criss-cross pattern in 3 l~~
~~. increments.~~
~~R'erove the connecting rod cap vood lifting supports.~~
/
~~l j TE Date OQA Date l ToFqse TTr7ncVF6Y"~"~ l l l~~
~~, 3 of 4 / jTG . tin;CVED $ P' 1 V ' '~~
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~~U Ecr Information orny, ,, v. r)~~
~~., , --- Q ,~~
~~i *' Cylinder.No. C N~~
~~s. p . ,~~
~~m i , _ - 7. 5-S"'~ i%t~~
~~11. Torque the 4 nuts in.a'criss cross pattern to a torque value of je i~~
~~\i , '875 ft. 1bs.. ' Apply torque in 3 increments.~~
! Torque Wrench M&TE No. - mj by ' 1 s,. TE ^r .Date OQA Date g k. i
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~~uncoMTp.0LLFfe pg; mty:N2dOh d' ', t ASSEMBLY: PISTON AND ROD INSTALLATION~~
~~'J SECTION F Cylinder No.~~
NOTE: .When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer followed by signoffs from all three.
~~'l. Verify all parts for cleanliness. Clean as necessary.~~
~~TE Date OQA Date~~
~~~~~~~
TDI Date CAUTION: The installation procedure is the reverse of the removal procedure. Be careful that rings do not catch on piston ring i guide. Exercise particular care not to chip or break oil control rings. Damaged rings must be replaced. V 2. Wash the inside diameter of the liner using safety solvent. Use paper or gasket mater,ial to divert the solvent away from the main bearings.
~~~ " ' ~ ~~~
~~TE Date OQA Date~~
~~3. Position the crankshaft web in the proper position (T.D.C.) and coat ,~~
the crank pin with clean Jube oil. TE Date OQA ~~i)a't e TDI ~ ~D~ 'a't e d.
\
~~(v) 1 of 4 AG.tf G 4D ff -~~
~
s
~~"~l i~~
~~UNCONTRO' I' (n)~~
%/
Cylinder No. 3 ror intorne->' ". L4. Position the ring compressor tool and coat the cylinder liner with clean lube oil. TE Date OQA Date
~~~~~~~
~~TDI Date i~~
~~5. Attach piston lifting fixture to the piston crown, and coat the piston skirt and piston rings with cican lobe oil.~~
TDI ~DIaie 6.-Install the upper connecting rod bearing shell at this time by installing the shell in the connecting rod and tieing clean rags around the bearing shell I.D. and the piston rod. This cethod holds the bearing in place during transportation and installation of the asser.bly as a unit.
~~.%J l~~
Attach a chain , fall to the piston Iffting fixture and lift the piston and rod assembly over the cylinder. Position the connecting rod so that the identification numbers stamped on the side of the rod are faced toward the camshaf t side. i l
~~~ ~ ~ ~ ~ ~~~
~~TE Date OQA Date TDI Date~~
~~7. Rotate the piston rings on the piston so that the ring gaps are~~
~~! staggered at least every 90 degrees. TE Date OQA Date l l b) v~~
~~.~, - . 'O h.1 : bS Nd -~~
t
~
~~,Q LeCG N nw p.g int 0rmd*U \ ,/ Cylinder No.~~
~~8. Lower the piston and rod assembly into the cylinder liner holding the piston rings in place as they enter the ring compressor tool.~~
Remove the tie down rags and lower the rod until the weight of the piston and rod assembly is being borne by the crankshaf t journal. Irstall the lower connecting rod bearing shell into the connecting rod hearing box and install both bearing shell aligning dowels into the bearing caps. 1.ubricate the 4 connecting rod bolts with a thread lubricant consisting of a 50-50 mixture by volume of powdered graphite and clean engine lubricating oil. TE Date OQA Date
~
~~TDI D' ate~~
~~9. Install the connecting rod bearing box using a wooden support located under the cap while bolting the 4 bearing cap bolts.~~
~~TE Date OQA Date TDI ~Date~~
~~10. Install the 4 connecting rod bolts and nuts and torque the nuts up to approximately 20 - 40 ft. Ibs utilizing a criss-cross pattern in 3 increments.~~
Remove the connecting rod cap wood lifting supports. TE Date OQA Date Torque Wrench M&TE " " ~ O (_.) 3 of 4 JIG tih D ED Ci 5 _-
g
\
~~I( OPL,e.,q? '* [s (['i Op's IOI ' Cylinder No.~~
~~11. Torque the 4 nuts in a criss cross pattern to a torque value of 875 ft. Ibs.. Apply torque in 3 increments.~~
~~' Torque Wrench M&TE No.~~
TE Date OQA Date 4 Of 4 jig .if 7.I*) .C [ ~ '
_a i i \
~~"N :~~
v fu ASSEMBLY: PISTON AND ROD INSTALLATION SECTION F Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections wf]l be performed by OQA, TDI representative and the Test Fngineer folJowed by signoffs from all three.
~~1. Verify all parts for cleanliness. Clean as necessary.~~
TDI ~ i)~a~t e CAUTION: The installation procedure is the reverse of the remeval procedure. Be careful that rings do not catch on piston ring guide. Exercise particular care not to chip or break of] control i
~~%); rings. Damaged rings must be replaced.~~
~~2. Wash the inside diameter of the liner using safety solvert. Use paper or gasket material to divert the solvent away from the main bearings.~~
~~TDI Date~~
~~3. Position the crankshaf t web in the proper position (T.D.C.) and coat the crank pin with clean lube oil.~~
~~~~~~~
~~TE Date 0QA D~~~
~~~ ~ 'a~t e = ~------ bag O~~
V
~~-s cr G:~~
1 of 4 F C f ' ' O ',
1 1 (nCONTRO W pg tatormation ON, t
)
~~Cylinder No. g'~~
4. Pesition the ring cumpressor tool and coat the cylinder liner with clean lube oil, t TE Date OQA Date TDI ~i)E

5. Attach piston lifting fixture to the piston crown, and coat tbe pister skirt and piston rings with clean lube oil.
~~
~~TE Date OQA Date~~
~
~~TDI Date~~
6. Install the upper connecting rod bearing shell at this time by installing the shell in the connecting rod and tieing clean rags around the bearing shell I.D. and the piston rod. This method holds the hearing in place during transportation and inr.ta))atien of the assembly
(]) ' \, as a unit. Attach a chain fall to the piston lifting fixture and Ifft the pisten and rod assemb1'y over the cylinder. Position the connecting rod so that the identification numbers starped on the side of the rod are faced toward the camshaft side. TE Date OQA Date
~
~~TDI Date~~
~~7. Rotate the piston rings on the piston so that the ring gaps are staggered at least every 90 degrees.~~
~~TE Date OQA Date m-v~~
.Eis t !] t ([ *
~~2 of 4~~
~~s UNCONTROLLED For Information Only O~~
'- Cylinder No. *
~~8. Lower the piston and rod assembly into the cylinder Ifner holding _the piston rings in place as they enter the ring compressor tool.~~
Remove the tie down rags and lower the rod until the weight of the piston and red assembly is being borne by the crankshaf t journal. Install the lower connecting rod bearing she)) into the connecting rod bearing box and install both bearing shcIl aligning dcwcIs into the bearing caps. Lubricate the 4 connecting rod bolts with a thread lubricant consisting of a 50-50 mixture by voltre of powdered graphite and clean engine lubricating oil. TE Date OQA Date TDI Dati
~~9. Install the connecting rod bearing box using a wooden support located under the cap while bolting the 4 bearing cap bolts.~~
V ........ _ ...- .... ...... TE Date OQA Date TDI Date
~~10. Install the 4 connecting rod bolts and nuts and torque the nuts up to approximately 20 - 40 ft. Ibs utilizing a criss-cross pattern in 3 increments.~~
~~Remove the connecting rod cap wood lifting supports.~~
~
~~TE Date OQA Date Torque Wrench M&TE~~
~~..m-i QE 3 of 4 y y nd.9 "~~
___ _______-___,______._m.-.-____m-__ _ . .
r .-
~~,q l.' .~~
~~I; UNCONTRCld[ Fo- Inictmaur: >'"Y 4 l 9 < Cylinder No. ' l' 11._. Torque the'4 nuts in a criss cross pattern to a torque value of~~
~~~ 875 ft. Ibs.. Apply torque in'3 increr.ents.~~
i ', Torque Wrench M&TE No." "' " "~" " " ' I i .TE Date OQA Date !1 i i + i t l l f i i-G .
*e -4 of 4 .7 J bi M * ^ " >,. - - . . . - q' t
~~r c ..6,. llNCOtMO# s FO Informatica 00W ,~~
]
~~ASSEMBLY: PISTON AND ROD INSTALLATION SECTION F~~
i. Cylinder No. 5 NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grine films. Visual inspections will be performed by OQA, TDI representative and the Test Fngineer followed by signoffs from all three.

1. Verify all parts for cleanliness. Clean ~as necessary.
TE Date OQA Date TDI Date CAUTION: The installation procedure is the reverse of the removal procedure. Be careful that rings do not catch on pisten ring guide. Exercise particular care not to chip or break of] control O rings. Damaged rings must be replaced.-
~~2. Wash the inside diameter of the liner using safety solvent. Use paper or gasket mater,ial to divert the solvent away from the main bearings.~~
~~TE Date OQA Date TDI Date~~
~~3. Position ;the crankshaft web in the proper position (T.D.C.) and coat the crank pin with clean lube oil.~~
~~TE Date OQA Date~~
~~
~~TDI D' ate r_~~
%)
~~1 of 4 ac tme sm - m-~~
~~.-. --_ . - _ . ~ . . - - - . , .-. - . -- - . . - -. -.. -. .~~
~~; 1~~
~~) UNCONTROLLED ! For Information Onth l Cylinder No.~~
~~4. Position the ring con: pressor tool and coat the cylinder ifner with clean Jube o11.~~
~~TE Date OQA Date TDI Date~~
~~5. Attach piston lifting fixture to the piston crown, and coat the piston skirt and piston rings with clean lube oil.~~
~~TE Date OQA Date TDI Date~~
6. Install the upper connecting rod bearing shell at this time by installing the shell in the connecting rod and tieing clean rags around the bearing shell I.D. and the piston rod. This method holds the
~~. hearing in place during transportation and installation of the assembly I i as a unit.~~
b Attach a chain fall to the piston lifting fixture and lift the piston and rod assembly over the cylinder. Position the connecting rod so that the identification numbers stamped on the side of the rod are faced toward the camshaft side. TE Date IfQA Date TDI Date
~~7. Rotate the piston rings en the piston so that the ring gaps are staggered at least every 90 degrees.~~
TE Date OQA Date b_ c, }Ijh . 2 of 4 pgr; g t ? * >>
i I
~~. s UNCONTROLLED . m for intcrmation Ont?~~
~~Cylinder No. 5~~
~~8. Lower the piston and rod assembly into the cylinder liner holding the piston rings in place as they enter the ring cettpressor tool.~~
Remove the tie down rags and lower the rod until the weight of the piston and rod assembly is being borne by the crankshaf t journal. Install the lower connect ing rod hearing shell into the connecting rod bearing box and install both bearing shell aligning dewels into the bearing caps. Lubricate the 4 connecting rod bolts with a thread Jubricant consisting of a 50--50 mixture by volume of powdered graphite and clean engine lubricating oil. TE Date OQA Date
~
~~TDI Date~~
~~9. Insta11 the connecting rod bearing box using a wooden support located under the cap while bolting t'ne 4 bearing cap bolts.~~
~~4 (\ TDI Da'te~~
~~10. Install the 4 connecting rod bolts and nuts and torque the nuts up to approximately 20 - 40 ft. Ibs utilizing a criss-cross pattern in 3 increments.~~
~~Remove the connecting rod cap wood lifting supports. TE Date OQA Date~~
~~~~~~
~~Torque k'rench M&TE r% w,~~
~~'),~~
~~{Q h,'n'((.b5b '~~
~~} !!!;00'CDCli.EO f~;s: Luc:n,i.tian On%~~
~~11. Torque the 4 nuts in a criss cross pattern to a torque value of 875 ft..Ibs.. Apply torque in 3 increments.~~
~~" "" "~" " -Torque Wrench M&TE lio.~~
~~TE Date. OQA Date O~~
~~,s 9- 'n" t ilt ti . . U ,,r u '~~
4 of 4
UNCONTF W :T ASSEMBLY: PISTON AND ROD INSTALLATION Foi informaban onhi SECTION F Cylinder No. b NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensu're they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer followed by signoffs from all three.
~~1. Verify all parts for cleanliness. Clean as necessary.~~
TDI ~~i) ate CAUTION: The installation procedure is the reverse of the removal procedure. Be careful that rings do not catch on piston ring guide. Exercise particular care not to chip or break oil control ringa. Damaged rings must be replaced.
~~2. Wash the inside diameter of the liner using safety solvent. Use paper or gasket inater,lal to divert the solvent away from the rnain bearings.~~
~~TE Date OQA Date , TDI Date 1~~
~~3. Position the crankshaft web in the proper position (T.D.C.) and coat the crank pin with clean lube oil.~~
i TE Date OQA Date l l l l 1 V m~ 1 of 4 RG EAUS !_, . . , , _- . . - . . - . ~ . - , , - - -- -
3
).
~~I UMOGnTRO .,, p.gr Ltdormation Cylinder No. b~~
~~4. Position the ring compressor tool and coat the cylinder liner with~~
~~-clean lube oil.~~
~~TE Date OQA Date TDI ~ ~ ~ ~ ~ iia't e~~
~~5. Attach piston lifting fixture to the piston crown, and coat the piston skirt and piston rings with clean Jube oil.~~
~
~~TDI i)~a~t e~~
6. Install the upper connecting rod bearing shell at this time by installing the shell in the connecting rod and tieing clean rags around the hearing shell I.D. and the piston rod. This method holds the hearing in place during transportation and installation of the assembly D as n unit.
1 Attach a chain fall to the piston lifting fixture and lift the piston and rod assemb1'y over the cylinder. Position the connecting rod so that the identification numbers stamped on the side of the rod are faced toward the camshaft side. TE Date OQA Date TDI Date
~~7. Rotate the' piston rings on the piston so that the ring gaps are staggered at least every 90 degrees.~~
~~__ _ . _ _ . .. b a7~~
~~C -~~
(_ 2 of 4 , g ;. ' , gg t.,, ei.c ~ -
eq l' l UNCON g u-n ,L,, in ya ;p;a.mM ' ' ~ ' Cylinder No. b
~~8. Lower the piston and rod assembly into the cylinder liner holding the piston rings in place as they enter the ring compressor tool.~~
Remove the tie down rags and lower the rod until the weight of the piston and rod assembly is being borne by the crankshaft journal. Install the lower connecting rod bearing shell into the connecting rod bearing box and install both bearing shell aligning devels inte the bearing caps. Lubricate the 4 connecting rod bolts with a thread lubricant consisting of a 50-50 mixture by volume of powdered graphite and clean engine lubricating oil. TE Date OQA Date TDI Date
~~9. Install the connecting rod bearing box using a wooden support Jocated under the cap while bolting the 4 bearing cap bolts.~~
~~[ NI = ............... TE Date OQA Date l~~
~~
~~TDI Date~~
~~10. Install the 4 connecting rod bolts and nuts and torque the nuts up to approximately 20 - 40 ft. Ibs utilizing a criss-cross pattern in 3 l increments.~~
~~Retrove the connecting rod cap wood lifting supports. TE Date OQA Date l~~
~~. Torque Wrench M&TE l~~
l
~~%J 3 of 4 DG 1.i-iTE!ED S ED ' ' ~ - 0~~
~~g l +. s i UNCONTRO!! EIT~~
~~- Cy]inder No.- b-~~
~~11. Torque the_4 nuts in a criss cross pattern to a torque value of '~~
~~875 ft. 3hs.. ' Apply torque in 3 increments. 3 Torque Wrench~ ~ I(~&iTiF'lio~.' E ~~~"~"~~"-~~~
~~.Ty- Date OQA Date.~~
m 4 of 4 ~ + j]G IJFT.CYED $ F I i 3 33 -
UN^ONTF.C'.' ED hs\s) For intacm43 0"h ASSEMBLY: PISTON AND ROD INSTALLATION SECTION F Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer followed by signoffs from all three.
~~1. Verify all parts for cleanliness. Clean as necessary.~~
~~TE Date OQA Date TDI ~~~~~'Date CAUTION: The installation procedure is the reverse of the removal~~
~~. procedure. Be careful that rings do not catch on pisten ring guide. Exercise particular care not to chip or break oil control rings. Damaged rings must be replaced.~~
~~f'J']~~
\
~~2. Wash the inside diameter of the liner using safety solvent. L'se paper or gasket mater,ial to divert the solvent away from the main hearings.~~
~~
~~TE Date OQA Date~~
~
~~TDI Date~~
~~3. Position the crankshaft web in the proper position (T.D.C.) and coat the crank pin with clean Jube oil.~~
~~TE Date OQA Date~~
~
~~TDI iia'tc n-( \' V~~
~~~ ' ~i 1 of 4 E fi?EUID~~
W
\
~~UNCD#, W A O Foi W~~
~~'b Cylinder No. 7~~
~~4. Position the ring compressor tool and coat the cylinder liner with clean lube oil.~~
~~TE Date OQA Date TDI Date~~
~~5. Attach piston lif ting fixture to the pistori croien, and coat the pisten skirt and piston rings with clean lube oil.~~
~~TE Date OQA Date TDI Date~~
6. Install the upper connecting rod bearing shell at this time by installing the shell in the connecting rod and tieing clean rags around the bearing she)) 1.D. and the piston rod. This rnethod holds the hearing in place during transportation and installation of the assembly as a unit.
t/ Attach a chain fall to the piston-lifting fixture and lift the piston and rod assemb3*y over the cylinder. Position the connecting rod so that the identification numbers stenped on the side of the rod are faced toward the camshaft side. TE Date OQA Date
~
~~TDI Date~~
~~7. Rotate the piston rings on the piston so that the ring gaps are staggered at least every 90 degrees.~~
~~TE Date OQA Date en~~
^
2 of 4 ae " Sa sn
v
;)
UNCCNTFOU }_ E o: inior m W o; , h Cylinder No. 7 f II. Torque the 4 nuts in a criss cross pattern to a torque value of 875 ft. Ibs.. Apply torque in 3 increments. Torque Wrench M5 E' To~.~ ~" " ~ ~ ~ ~" ~ ~ ~
~
TE- "~" "~"~Fa~te. ~0QA ~ ~" ~ " ~ ~ ~ " ~ Fa't'e r O O - 4.of 4. 3TC 16i..':. G " ..
t 1 l-UNCONTROI ! EU .' rw For Inionna"
^'
~~Cylinder No. 7~~
~~8. Lower the piston and rod assembly into the cylinder liner holding the piston rings in place as they enter the ring compressor tool.~~
Remove the tie down rags and lower the rod until the weight of the piston and rod assembly is being borne by the crankshaf t journal. Install the lower connecting rod bearing shell into the connecting rod bearing box and install both bearing shell aligning devels into the bearing caps. Lubricate the 4 connecting rod bolts with a thread lubricant consisting of a 50-50 mixture by volume of powdered graphite and clean engine lubricating oil. TE Date OQA Date
~~~ ~~~
~~TDI Da'te~~
~~9. Insta)) the connecting rod bearing box using a wooden support located under the cap while bolting the 4 bearing cap bolts.~~
~~( %. G0 TE Date OQA Date~~
~
~~TDI Date~~
~~10. Install the 4 connecting rod bolts and outs and torque the nuts up to approximately 20 - 40 ft. Ibs utilizing a criss-c - e pattern in 3 increments.~~
~~Remove the connecting rod cap wood lifting supports. TE Date OQA Date~~
~~. Torque Wrench M8TE s~~
~~p,\~~
~~'M 'N g ,, ,~~
RC FiRw cc;. .
y I I ut: CONT 9007. For iniormden #.'?, ( V ASSEMBLY: PISTON AND ROD INSTALLATION SECTION F Cylinder No. 8 NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspectienc will be performed by OQA, TDI representative and the Test Engineer followed by signoffs from all three.
~~1. Verify all parts for cleanliness. Clean as necessary.~~
i TDI ~ ~ ~i)a t e f CAUTION: The installation procedure is the reverse of the removal procedure. Be careful that rings do not catch on piston ring guide. Exercise particular care not to chip or break oil control rings. Damaged rings must be replaced.
~~\ '-) 2. Wash the inside diameter of the liner using safety solvent. Use paper or gasket material to divert the solvent away from the main bearings.~~
~~TE Date OQA Date~~
~~~~~~~
~~TDI Date l~~
~~3. Position the crankshaft web in the proper position (T.D.C.) and coat the crank pin with clean lube oil.~~
~~TE Date OQA Date i i~~
~~~ ~~ ~~~~
~~TDI Date (' I lO m I of 4 f EC f.: ;,CED $ F ' ' ' ~ I I~~
;]
~~(M4M -~~
~~,-s~~
~~('~~) For intonnatim V Cylinder No, b-~~
~~4. Position the ring compressor tool and coat the cylinder liner with clean lube of).~~
~
~~TE ~ ' ~ ~ ~ ~ i)~a t e liQA Date~~
~~5. Attach piston lifting fixture to the piston crown, and coat the piston skirt and piston rings with clean Jube oil.~~
~~TE Date OQA Date~~
~~~~~~~
~~TDI Date~~
6. Install the upper connecting rod bearing shell at this time by installing the shell in the connecting rod and tieing clean rags around the bearing shell I.D. and the piston rod. This rethod holds the hearing in place during transportation and installation of the assenhly as a unit.
v
~~. Attach a chain , fall to the piston lifting fixture and lift the piston and rod assembly over the cylinder.~~
Position the connecting rod so that the identification numbers starped on the cido of the rod are faced toward the camshaft side. ! TE D'aie OQA Date l TDI Date I: 7. Rotate the piston rings _on the piston so that the ring gaps are staggered at least every 90 degrees.
~~- 'gI Q,/ .~~
2 of 4 - - p paiXD N"_,
s } I UNCONTROLLT-S- For informatica OnN Cylinder No. b
~~8. Lower the piston and rod assembly into the cylinder liner holding the piston rings in place as they enter the ring compressor tool.~~
Remove the tie down rags and lower the rod until the weight of the piston and rod assembly is being borne by the crankshaft journal. Install the lower connecting rod bearing shell into the connecting rod bearing box and install both bearing shell aligning dowcIs into the bearing caps. Lubricate the 4 connecting rod bolts with a thread lubricant consisting of a 50-50 mixture by volume of powdered graphite and clean engine lubricating oil. TE Date 0QA Date
~
TDI DatIn 9.. Install the connecting rod bearing box using a wooden support located under the cap while bolting the 4 bearing cap bolts. N] TE Date OQA Date TDI Date
~~10. Install the 4 connecting rod bolts and nuts and torque the nute up to approximately 20 - 40 ft. Ibs utilizing a criss-cross pattern in 3 increments.~~
~~Remove the connecting rod cap wood lifting supports. TE Date OQA Date Torque Wrench M&TE O 3 of 4 r p G J.r~~
~~...a D g p 3 q r ..e ,_~~
, ,. y OM - - .. s , .2-E c ' , . ',4, Cylinder No. 8
~~11. Torque the 4 nuts in a criss cross pattern to a torque value of 875 ft. Ibs.. . Apply torque in 3 increments.~~
~~Torque Wrench M&TE No. TE Date OQA Date O 4 Of 4 ' ~~~
~*
~~j]G [Fii,CYiD SEP I v~~
~~.q A ONCO M na (V) [CT LOWrn4 % '~~
CYLINDER HEAD INSTALLATION SECTION G Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer followed by signoffs from all three.
1. Clean inside of combustion chamber. Bar engine over until piston is at bottom dead center and clean and inspect upper portion of cylinder bore. Clean gasket surfaces of engine block, exhaust pipe, and cylinder head.
TE Date OQA Date TDI Date [ 2. Record head serial no along with the number of cylinder and engine ( installed on. l SERIAL NO. CYLINDER DG TE Date OQA Date l l TDI Date
~~3. Clean and inspect gasket surfaces of cylinder head and exhaust l~~
~~manifold. i l TE Date OQA Date TDI Date 1 of 24 j ; t.c ;,_'lD f.['~~
~~.-]~~
~~1 per.OiF ; ,g~~
~~, r.....d V~~
~~i Cylinder No.~~
~~4. Install new seal rings, o-rings, and grommets on cylinder head consisting of: ,~~
A) (1) F-115-031 Seal Ring - Water - Head to Block B) (1) JE-007-000 Seal Ring - Combustion - Head to Liner C) (2) F-094-097 0-Ring - Push' Rod Tube Seal D) (4) 03-360-05-AE Grommet - Head to Block Water Passage E) (7) 03-360-05-AD Grommet - Head to Blocir Water Passage F) (1) F.-057-009 Flexitallic Gasket Exhaust TE Date 0QA Date TDI Date
~~5. Verify intake elbow and cylinder head for cleanliness. Clean as necessary.~~
~~TE Date OQA Date (,g~~
~~'( ) TDI Date~~
~~6. Attach lifting fixture P/N 00-590-01-BA to cylinder head and hoist head in place over dylinder head studs. Carefully lower head into place, taking care not to damage stud threads, seals, or tubing.~~
Clean and lubricate cylinder head studs, nute,'and washers with a 50-50 mixture of powdered graphite and clean engine oil. l TE Date OQA Date ! TDI Date l I/\ ' 2 of'24 . . . , .
~~. ?>~~
gg ;b ia.nD g . -
UNCONTROU.ED For informaWr. Or?3 s A Cylinder No. I , 51 _.7.1 Torque head bolts-in 3 increments in the sequence shown on the attached
~~,. sheet, (Section G Attachment 2) .~~
~~4 s , 3 (, 1.,, , Torque-Wrench M&TE No.~~
~~n. ji '~~
~"
~~1. .A) :1200 ft. Ibs.~~
~~T ~ '5- -TE Date OQA Date 3)~~
~~-TDI Date y * ;; ;B) 2400 ft. Ibs.~~
~~TE Date OQA Date , , e er 4 y TDI vate 4~~
. c) 3600 ft. lbs. , . TE Date OQA Date , . TDI l Date.
T.' Q .y . q3 8. Remove lifting fixture. 4 1 Inspect and cidan gasket surfaces of intake manifold, inlet elbow, and
~~, s .cylind'er head. '~~
~~! A~~
~~' TE .~~
Date . OQA .Date TDI -Date ~ l- ' 9. Install 2 new gasketson intake elbow.- 03-375-01-0F and 02-375-01-0H. l TE .Date 00a Date (. f .TDI Date
~~10. Place' intake elbow in position.~~
~~-Clean and' lubricate intake elbow capscrews with 50-50 mixture of pc.wdered graphite and clean engine oil.~~
~~s> f -TE-~~
~~) Date' OQA Date 'TDI. Date gr{ l.; ;i;U/O t T D 1 ' 'S 3 of 24~~
~~[ ) _ guccc garm WWr" 9" $ s~~
/^N C linder No. l u- ;g 11. Tighten intake elbow capscrews in 1 equal increments of 10 ft. lbs. in a criss cross pattern. Alternate between head and manifold f1dnSe8 Final torque of.capscrews to be 30 ft. lbs. 's I ;s Torque Wrench M&TE No. '- ,TE Date OQA Date-N .
~~Q,. ' 'j 3 iDI Date~~
~~12. Install a new'flexitallic gasket P/N F-057-009.~~
., y, TE Date OQA Date *. s , . TD1 ~
~~_: Date f] t, 13.' Clean and coat exhaust pipe capscrews with "NEVER-SEZE". Install hand~~
~~'g tight. ,'~~
~~s N TE Date OQA Date~~
.{
~~H' ~. 1 TDI Date~~
~~14. Tighten exhaust pipe capscrewslin 3 increments.in a criss cross pattern. Final torque of capscrews'to be 100 ft. lbs. .~~
~~Torque Wrench M&TE No. 4 , s ,~~
~~. 4 ,~~
~~( TE Date ; OQA Date~~
~~.ft .,\~~
~~v/ - aDI Date y~~
~~t py 15. C.1ean and inspect gasket and sealing surfaces of jacket water outlet 0 <~~
elbow,ficket water discharge header, dresser coupling, cylinder head 5 and spac5'. r "p , l%,[ g~ 1 !;J - *
~~+;'~~
~~llk~~
~~.w) i y, 8~~
~~h( K ,j TE~~
+
~~t Date OQA Date A '~~
~~.j s~~
10
~~- [c h 'i TDI Date 'y- ** p R G FiV;,L;" d) SIG '; . <~~
~~4 of 24~~
~~-w - _ _ - _ _ _ _ --_~~
~~m h UNccMTROU.D For Intermdi:n *,,I~~
~~,e .~~
~~Cylinder No. l~~
~~16. Tighten jacket water outlet capscrews in 3 increments in a criss cross pattern.~~
~~TE -Date OQA Date TDI Date~~
~~17. Verify dresser coupling is tight.~~
Clean and inspect o-ring groove and gasket seats of air start valve and cylinder head air start valve bore. TE Date OQA Date TDI Date g 18. Install a new o-ring P/N B-5692, and gasket P/N 03-359-01-0E on air Q start valve. TE Date 0QA Date TDI DaE
~~19. Clean'and install air start valve taking care not to damage gasket or o-ring.~~
Clean and lubricate capscrews with a 50-50 mixture of powdered graphite and clean engine oil.- Install hand tight and tighten in 50 ft. Ib. increments. Final torque to be 150 ft. lbs. Torque Wrench MTE No. TE. Date OQA Date TDI Date O 5 of 24 g r3,;.i@ d
~~, g ,r.r,~~
~~lTDO' ,,~~
~~I . ., . , t. Cylinder No.~~
~~, 20. Clean top surface of head and bottom gasket surface of subcover.~~
~~TE Date OQA Date TDI Date~~
~~21. Install new gasket P/N 03-362-01-0C on subcover.~~
~~l TE Date OQA Date TDI Date~~
22. Install push rods. I Install subcover on head, taking care not to damage gasket or tubing.
~~Clean and lubricate subcover capscrew heads and shoulders with a 50-50~~
~~- mixture of powdered graphite and clean engine oil. Install capscrews and rundown hand tight.~~
~~TE Date OQA Date TDI Date~~
~~23. Tighten capscrews in a criss crose patter in 3 increments.~~
l I Torque Wrench M&TE No. A)- 40 ft. Ibs. TE Date OQA Date , TDI Date B) 80 ft. Ibs. TE Date OQA Date . TDI Date O r L)
~~.a 6 of 24 ,,C l~~
~~p g; ji'dD M ' i~~
~~----m--~~
9
~~'2 UNCOM gr o.$ ^~~
~~gy latcW, "~~~
/
~~Q] Cylinder No. l~~
~~23. - continued~~
~~'C) 120 ft. Ibs. ~~~
~~TE. Date" 0QA Date TDI Date~~
24. Clean and install (2) starting air pilot lines to subcover bulkhead, and from the subcover bulkhead to the valve. Clean and install the lube oil supply line to the subcover. Blow out the tube with compressed nitrogen or instrument air, which ever is available. Verify lines are dry.
~~TE Date OQA Date TDI Date~~
~~25. Install a new gasket, R-2322, and the injection nozzle holder.~~
~~TE Date OQA Date TDI Date~~
~~26. Clean and lubricate stud and nut threads with a 50-50 mixture of~~
~
~~powdered graphite and clean engine oil. Insta11' nuts on studs hand tight. TE Date OQA Date TDI. Date~~
~~27. Torque the fuel injection nozzle retainer nuts in 3 increments to 85-90 ft. Ibs.~~
~~Torque Wrench M&TE No. TE Date OQA Date TDI Date 7 of 24 2 7 L' , .s ; . ,3 _U~~
\
~~et(coNTPO'.1 ED \ For informction OnN em Cylinder No, i~~
28. Clean and install the new high pressure fuel injection line per E6DCR's F-45709, A, B (Section G Attachment 3) and injection nozzle drain line, taking care to ensure the tube fittings and tube ends are clean, dry and not damaged. Slow out the tube with compressed nitrogen or instrument air, whichever is available. Install tube clamps.
~~TE Date OQA Date TDI Date~~
~~29. Ensure engine is at TDC firing for the cylinder in question.~~
~~Verify tappet sockets for cleanliness. TE Date OQA Date TDI Date~~
~~30. Check rocker arm bolt holes in subcover for excessive lube oil, clean p and install intake and exhaust rocker arms on subcover, ensuring the rocker arm shaft seats properly on the subcover.~~
~~TE Date OQA Date TDI Date~~
~~31. Clean and lubricate the rocker arm shaft capscrews with a 50-50 mixture powdered graphite and clean engine oil.~~
~~TE Date OQA Date TDI Date (8 G 8 of 24 iTC heic/O g :~~
~~. . _ _ . _ . ~ ,~~
~~UNCCNTFftlEO For 1r.tcm'. eden Ct*'~~
~~/~g U ' Cylinder No. i~~
~~32. Tighten the rocker shaft bolts in 3 increments.~~
Torque Wrench M&TE No. A) 120 ft. lbs. TE Date OQA Date TDI Date B) 240 ft. lbs. TE Date OQA Date TDI Date C) 365 ft. lbs. TE Date OQA Date TDI Date
~~33. Clean and install intermediate push rod. Bleed and install lifters.~~
~~Fill lifter cavity with lube oil. TE Date OQA Date TDI Date~~
~~34. Adjust valves to procedure described in Instruction Manual, Section 6 pages 6-B-5 and 6-B-6 (Section C. Attachment 1).~~
~~Torque jam nuts (4) to 130 ft. lbs. Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~'l O~~
~~9 of 24 jh . . ,i) er; ;'~~
~~~:]~~
4
~~. - w,. c ,e .~~
UNCO Gnh h- p,r inMina . Cylinder No. 35.' verify and clean subcover and valve cover gasket surfaces. TE Date OQA Date TDI Date
~~36. Insta11'a new gask'et 03-362-01-0D.~~
TE Date OQA Date ', TDI Date 37.-C1can and install valve cover - tighten valve cover nuts hand tight. c N- TE Date OQA Date I TDI Date
~~38. Verify and clean gasket and sealing surfaces of air start manifold, dresser coupling, air start jumper, head and spacer if used.~~
~~TE Date OQA Date . TDI Date~~
~~39. Install air start jumper with new gasket F-057-019. Tighten dresser coupling hand tight'.~~
~~TE _Date OQA Date TDI Date~~
~~40. Install air start capscrews with a 50-50 mixture of powdered graphite and clean engine oil.~~
~~D \~~
-h IE Date OQA Date TDI. Date /IC flii;UID $U ' .i 10 of 24
_ .. . . _ _ - - _ . . _ .. 1 i. m UNCOS M 3V Ftr Inform /
~~~ Cylinder No. i~~
~~41. Tighten air start capscrews in 3 increments and in criss cross pattern.~~
~~Final torque to be 30 ft. Ibs. Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~42. Tighten dresser coupling for air start jumper.~~
~~TE Date OQA Date TDI Date~~
~~43. Inspect and clean gas inlet blind flange and cylinder head mating~~
~~[ surface. TE Date OQA Date TDI Date~~
~~44. Install new gasket 03-451-01-0D.~~
~~TE Date OQA Date TDI Date~~
~~.45. Install blind flange and gasket. Clean and lubricate bolts with 50-50 mixture of pewdered graphite and clean engine oil. Install hand tight.~~
~~TE Date OQA Date TDI Date~~
~~/"'N YA flG .Ifii,0YED U"' D 1- ;3 11 of 24~~
~~r . .~~
]
~~I t I UNCONTROt W" g f' Fct intor:nstion CO Cylinder No.~~
~~46. Tighten bolts in 3 increments and a criss cross pattern. Final torque to be 30 ft. Ibs.~~
~~Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
47. Retorque exhaust pipe capscrews to 100 ft. Ibs after each I hour run at full load or 3 hours at less than full load, whichever comes first, while the engine is hot. Continue the retorquing process until the capscrews no longer advance on retorquing.
~~TE Date 0QA Date TDI Date Torque Wrench M&TE~~
~~48. Retorque air st' art capscrews to 150 f t. Ibs, after each 12-24 hour run until the capscrews no longer advance on retorquing.~~
~~TE Date OQA Date TDI Date Torque Wrench M&TE No. O~~
~~-\j 12 of 24 jiC !; r i:$'Jrj t-~~
~~L . 3 h-L UNCONTR W '^,,d V ..~~
~~/-. Ecr InterniaW' I~~
D' CYLINDER HEAD INSTALLATION_ SECTION G Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer followed by signoffs from all three.
1. Clean inside of combustion chamber. Bar engine over until piston is at bottom dead center and clean and inspect upper portion of cylinder bore. Clean gasket surfaces of engine block, exhaust pipe, and cylinder head.
~~TE Date OQA Date TDI Dcte~~
~~2. Record head serial no. along with the number of cylinder and engine installed on.~~
~~SERIAL NO.~~
~~CYLINDER DG TE Date OQA Date TDI Date~~
~~3. Clean and inspect gasket surfaces of cylinder head and exhaust '~~
manifold. TE Date OQA Date TDI Date O 1 of 24 JTG G f.C VfD 3 [ o ; y3 s
l - . . . , -) I> i UNCONTPOVIO Fv in'u w"' "N d Cylinder No. 2
~~-4. Install new seal rings, o-rings, and grommets on cylinder head ! consisting of:~~
l A) (1) F-115-031 Seal Ring - Water - Head to Block B) (1) JE-007-000 Seal Ring - Combustion - Head to Liner C) (2) F-094-097 0-Ring - Push Rod Tube Seal D) (4) 03-360-05-AE Grommet - Head to Block Water Passage E) (7) 03-360-05-AD Grommet - Head to Block Water Passage F) (1) F-057-009 Flexitallic Casket Exhaust TE Date OQA Date TD1 Date
~~5. Verify intake elbow and cylinder head fo: cleanliness. Clean as necessary.~~
~~TE Date OQA Date m TDI Date~~
~~6. Attach lifting fixture P/N 00-590-01-BA to cylinder head and hoist head in place over dylinder head studs. Carefully lower head into place, taking care not to damage stud threads, seals, or tubing.~~
Clean and lubricate cylinder head studs, nuts, and washers with a 50-50 mixture of powdered graphite and clean engine oil. TE Date OQA Date TDI Date i O 2 ef 24 >" " SE
0. i i UNCONTR01U.D 7N For Intet x * '* i Cylinder No.
~~. ?~~
~~7. Torque head bolts in 3 increments in the seqttence shown on the attached sheet (Section G, Attachment 2).~~
Torque Wrench M6TE No. A) 1200 ft. Ibs. TE Date OQA Date TDI Date ; B) 2400 ft. lbs. TE Date OQA Date TDI Date C) 3600 ft.-lbs. TE bate- OQA Date , i TDI Date
~~8. Remove lifting fixture.~~
Inspect and cidan gasket surfaces of intake manifold, inlet elbow, and _ cylinder head. l- TE Date Ma Date i l l .TDI Date 9.' Install 2 new gaskets on intake elbow. 03-375-01-0F and 02-375-01-OH. TE Date OQA Date l l .TD1 Date
~
10.-Place intake elbow in position. I Clean and. lubricate intake elbow capscrews with 50-50 mixture of l . powdered graphite and clean engine oil. O TE Date OQA Date TDI Date gre .: r 0 M, _ s - l 3 of 24 1-
i. _ ., . .~ .. _ _ _ ..,,_ _ __._ ___ _. _ , __. _. _ -.,...._. .,._...__. , _....._____. .._..-._ ,,-. _ _. _ .._.. .... _-
}
~~'l UNCONTROt. LED i For intorn: sten OnN Cylinder No.~~
~~11. Tighten intake elbow capscrews in 3 equal increments of 10 ft. lbs. in a criss cross pattern. Alternate between head an' inanifold flanges.~~
~~Final torque of capscrews to be 30 ft. lbs. Torque Wrench M&TE No. TE Date OQA Date TOI Date~~
~~12. Install a new flexitallic gasket P/N F-057-009.~~
~~TE Date OQA Date TDI Date~~
~~13. Clean and coat exhaust pipe capscrews with "NEVER-SEZE". Install hand j tight.~~
~
~~TE Date OQA Date TDI Date~~
~~14. Tighten exhaust pipe capscrews in 3 increments in a criss cross~~
~
pattern. Final torque of capscrews to be 400 ft. Ibs. Torque Wrench M&TE No. TE Date OQA Date TDI Date
~~15. Clean and inspect gasket and sealing surfaces of jacket water outlet elbow, jacket water discharge header, dresser coupling, cylinder head and spacer.~~
A
~~.( TE Date OQA Date TDI Date-3T G fn iiVD $[ ?~~
~~4 of 24~~
~
~~J ,~~
~~-} \ -~~
~~UNCONTPCt LED For Intermaticn On!V O Cylinder No.~~
~~16. Tighten jacket water outlet capscrews in 3 increments in a criss cross pattern.~~
~~TE Date OQA Date TDI DaE~~
~~'17. Verify dresser coupling is tight.~~
~~Clean and inspect o-ring groove and gasket seats of air start valve and cylinder head air start valve bore. TE Date OQA Date TDI Date~~
~~18. Install a new o-ring P/N B-5692, and gasket P/N 03-359-01-0E on air O start valve.~~
~~TE Date OQA Date TDI Date~~
~~19. Clean and install air start valve taking care not to damage gasket or o-ring.~~
Clean and lubricate capscrews with a 50-50 mixture of powdered graphite and clean engine oil. Install hand tight and tighten in 50 ft. Ib. increments. Final torque to be 150 ft. lbs. Torque Wrench M&TE No. TE Date OQA Date TDI Date sj 5 of 24 7: an: p ,
l
~~~ . . . _ _ . _ _ _ _ _ .- - _ i_ E. . ..~~
~~r. UNCONTPOLLEO I- Fcr informatica Oc!S p, V Cylinder No. O L~~
~~20. Clean top surface of head and bottom gasket surface of subcover.~~
~~TE Date OQA Date TDI Date~~
~~21. Install new gasket, P/N 03-362-01-0C on subcover.~~
~~TE Date OQA Date TDI Date~~
~~22. Install push rods.~~
Install subcover on head, taking care not to damage gasket or tubing. Clean and lubricate subcover capscrew heads and shoulders with a 50-50 mixture of powdered graphite and clean engine oil.. Install capscrews and rundown hand tight. O. TE , Date OQA Date TDI Date
~~23. Tighten capscrews in a criss cross patter in 3 increments.~~
Torque Wrench M&TE No. A) 40 ft. Ibs. TE Date OQA Date TDI .Date B). 80 ft. Ibs. TE Date OQA Date TDI Date D b 6 of 24 50 ti:i,CVD q?
1 i- . . l:" UNCONTROt1ED ' For inicrniation only Cylinder No. 2
~~23. - continued C). 120 ft. Ibs.~~
TE Date Date # OQA TDI Date 24.~ Clean and install (2) starting air pilot lines to subcover bulkhead, and from the subcover bulkhead to the valve. Clean and install the lube oil supply line to the subcover. Blow out the tube with compressed nitrogen or instrument air, which ever is available. Verify lines are dry. TE Date OQA Date TDI Date
~~25. Install a new gasket, R-2322, and the injection nozzle holder.~~
~~TE Date 0QA Date TDI Date~~
~~26. Clean and lubricate stud and nut threads with a 50-50 mixture of powdered graphite and clean engir.e oil. Install nuts on studs hand tight.~~
~~TE Date OQA Date TDI Date~~
~~27. . Torque the fuel . injection nozzle retainer nuts in 3 increments to 85-90 fe. Ibs.~~
~~Torque Wrench M&TE No. TE Date OQA Date~~
~~.f -TDI Date Lt 7.of 24 gg ;,. , g j:9 ( r ; ,'~~
~~e I utiCCNTROLQC , For in:ctmet.ca '#2 Cylinder No. 2~~
28. Cican and install the new high pressure fuel injection line per E&DCR's F-45709, A, B (Section G. Attachment 3) and injection nozzle drain line, taking care to ensure the tube fittings and tube ends are clean, dry and not~ damaged. Blow out the tube with compressed nitrogen or instrument air, whichever is available. Install tube clamps.
~~TE Date OQA Date TDI Date~~
~~29. Ensure engine is at TDC firing for the cylinder in question.~~
Verify tappet sockets for cleanliness. TE Date OQA Date TDI Date O 30. Check rocker arm bolt holes in subcover for excessive lube oil. Clean and install intake and exhaust rocker art.; on subcover, ensuring the V rocker arm shaft seats properly on the subcover. TE Date OQA Date' TDI Date
~~31. Clean and lubricate the rocker arm shaft capscrews with a 50-50 mixture powdered graphite and clean engine oil.~~
TE Date 0QA Date TDI Date 8 of 24 ._ i
UNCONTP.CLLED 3 For information Cni? Cylinder No. '2
~~32. Tighten the rocker shaft bolts in 3 increments.~~
Torque Wrench M&TE No. A) 120 ft. lbs. TE Date OQA Date TDI Date B) 240 ft. lbs. TE Date OQA Date TDI Date C) 365 ft. Ibs. TE Date OQA Date TDI Date
~~33. Clean and install intermediate push rod. Bleed and install lifters.~~
~~Fill lifter cavity with lube oil. TE Date OQA Date TDI Date~~
~~34. Adjust valves to procedu e described in Instruction Manual, Section 6 pages 6-B-5 and 6-B-6 (Section G. Attachment 1).~~
Torque jam nuts _ (4) to 150 f c. lbs. Torque Wrench M&TE No. TE Date OQA Date TDI Date J 9 of 24- -,
~~n. i m.: _~~
~~UNCGNTF0LLED o g For inforraation OnN Cylinder No. 2~~
~~35. Verify and clean subcover and valve cover gasket surfaces.~~
~~TE Date OQA Date TDI Date~~
~~36. Install a new gasket 03-362-01-0D.~~
TE Date OQA Date TDI Date 37.' Clean and install valve cover - tighten valve cover nuts hand tight. TE Date OQA Date
~~, TDI Date~~
~~38. Verify and clean gask'et and sealing surfaces of air start manifold,~~
~~. dresser coupling, air start jumper, head and spacer if used.~~
~~TE Date OQA Date TDI Date~~
~~39. Install air start jumper with new gasket F-057-019. Tighten dresser coupling hand tight.~~
~~TE Date OQA Date TDI Date~~
~~40. Install air start capscrews with a 50-50 mixture of powdered graphite and clean engine oil.~~
~~TE Date OQA Date q TDI Date 10 of 24 i: -~~
^I
~~_ .l UNCd G OLLO For Informatica OnVi .-(3 Cylinder No.~~
~~41. Tighten air start capscrews in 3 increments and in criss' cross pattern.~~
~~Final torque to be 30 ft. Ibs. Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~42. Tighten dresser coupling for air start jumper.~~
~~TE Date OQA Date TDI Date~~
~~43. Inspect and clean gas inlet blind flange and cylinder head mating surface.~~
~~s TE Date 0QA - Date TDI Date~~
~~44. Install.new gasket 03-451-01-0D.~~
TE Date OQA Date TDI Date 45.. Install blind flange and gasket. Clean and lubricate bolts with 50-50 mixture of powdered graphite and clean engine oil. Install hand tight. TE Date OQA Date TDI Date A U of 24
~~,. y, a ..~~
~~. -)~~
~~UNCotM C*utM p For information On'.'i 5 Cylinder No.~~
~~46. Tighten bolts in 3 increments and a criss cross pattern. Final torque to be 30 ft. lbs.~~
~~Torque Wren:h M&TE No. TE Date OQA Date TDI Date~~
47. Retorque exhaust pipe capscrews to 100 ft. lbs. after each I hour run at full load or 3 hours at less than full load, whichever comes first, while the engine is hot. Continue the retorquing process until the capscrews no longer advance on retorquing.
~~TE Date OQA Date TDI Date Torque Wrench M&TE~~
~~48. Retorque air start capscrews to 150 ft. lbs. after each 12-24 hour run until the capscrews no longer advance on retorquing.~~
TE Date OQA Date TDI Date Torque Wrench M&TE No. b G 12 of 24 p; C :.e '
UNCONTRCLLE6 ' \ i- For inicrniation CMi b CYLINDER HEAD INSTALLATION SECTION C Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer followed . by signoffs from all three.
1. Clean inside of combustion chamber. Bar engine over until piston is at bottom dead center and clean and inspect upper portion of cylinder bore. Clean gasket surfaces of engine block, exhaust pipe, and cylinder head.
~~TE Date OQA Date TDI Date~~
~~2. Record head serial no. along with the number of cylinder and engine ON . installed on.~~
SERIAL NO. CYLINDER DG TE Date OQA Date L - TDI Date s '3. Clean and inspect gasket surfaces of cylinder head and exhaust manifold. l TE Date OQA Date l l i TDI Date l O . 1 of 24 ._ ._. . ;. 3 q;--- py 6: 4 - . I:
p ... , i i UNCONTRCt'5M For in;armati@ 8 ,
~~.m Cylinder No.~~
~~4. Install new seal rings, o-rings, and grommets on cylinder head consisting of:~~
A) (1) F-115-031 Seal Ring - Water - Head to Block B) (1) JE-007-000 Seal Ring - Combustion - Head to Liner C) (2) F-094-097 0-Ring - Push Rod Tube Seal D) (4) 03-360-05-AE Groamet - Head to Block Water Passage E) (7) 03-360-05-AD Grommet - Head to Block water Passage F) (1) F-057-009 Flexitallic Gasket Exhaust TE Date OQA Date TDI Date
~~5. Verify intake elbow and cylinder head for cicanliness. Clean as~~
~~.necessary.~~
~~TE Date OQA Date A TDI Date -~~
~~6. Attach lifting fixture P/N 00-590-01-BA to cylinder head and hoist head in place over dylinder head studs. Carefully lower head into place, taking care not to damage stud threads, seals, or tubing.~~
Clean and lubricate cylinder head studs, nuts, and washers with a 50-50 mixture of powdered graphite and clean engine oil. TE Date OQA Date TDI Date
~~/O \v/.~~
L ,' . g. *\.
a UNCOMMOV D Fcr Information Cr", (3 V Cylinder No.
~~7. Torque head bolts in 3 increments in the sequence shown on the attached sheet (Section G Attachment 2).~~
Torque Wrench M&TE No. A) 1200 ft. Ibs. TE Date OQA Date TDI -Date B) 2400 ft. Ibs. TE Date OQA Date TDI Date C) 3600 ft. Ibs. TE Date OQA Date /N TD1 Date
~~8. Remove lifting fixture.~~
~~Inspect and cle*an gasket surfaces of intake manifold, inlet elbow, and cylinder head. TE Date OQA Date TDI Date~~
~~9. Install 2 new gaskets on intake elbow. 03-375-01-OF and 02-375-01-OH.~~
~~TE Date OQA Date TDI Date~~
~~10. Place intake elbow in position.~~
Clean'and lubricate intake elbow capscrews with 50-50 mixture of powdered graphite and clean engine oil. (-- q TE Date OQA Date TDI Date . . , ,.
~~, c;- l g 4.. .~~
~~3 of 24~~
~~--,I yt: Cot 1TPOLLEU i~~
~~For inicrmaticn On'.f b~~
~~\j Cylinder No. ,~~
~~11. Tighten intake elbow capscrews in 3 equal increments of 10 ft. Ibs, in a criss cross pattern. Alternate between head and manifold flanges.~~
~~Final torque of capscrews to be 30 ft. Ibs. Torque Wrench M&TE No. TE Date- OQA Date TDI Date~~
~~12. Install a new flexitallic gasket P/N F-057-009.~~
~~TE Date OQA Date TDI Date~~
~~13. Clean and coat exhaust pipe capscrews with "NEVER-SEZE". Install hand O~~
~~l tight. l v l TE Date OQA Date TDI Date~~
~~14. Tighten exhaust pipe capscrews in 3 increments in a criss cross pattern. Final torque of capscrews to be 100 ft. Ibs.~~
~~i l Torque Wrench M&TE No. I l TE Date OQA Date i TDI Date l I~~
~~15. Clean and inspect gasket ar.d sealing surfaces of jacket water outlet elbow, jacket water discharge header, dresser coupling, cylinder head l and spacer.~~
~~.TE Date OQA Date i~~
TDI Date ._ 3iG 6: L IC M ~ 4 of 24
l.
~~..,r;7,t iTROLLG .O g tsumatie ON Cylinder No.~~
~~16. Tighten jacket water outlet capserews in 3 increnents in a criss cross pattern.~~
~~TE Date OQA Date TDI Date~~
~~17. Verify dresser coupling is tight.~~
Clean and inspect o-ring groove and gasket seats of air start valve and cylinder head air start valve bore. TE Date MA Date TDI Date
~~18. Install a new o-ring P/N B-5692, and gasket P/N 03-359-01-0E on air start valve.~~
~~TE.~~
~~Date OQA Date TDI Date~~
~~19. Clean and install air start valve taking care not to daninge gaskei ut o-ring.~~
Clean and lubricate capscrews with a 50-50 mixture of powdered graphite and clean engine oil. Install hand tight and tighten in 50 f t. Ib. ' increments. Final torque to *oe 150 ft. Ibs. Torque Wrench M&TE No. TE Date OQA Date TDI Date
~~) %d 5 of 24 pG l:. ..w." .n cr. ' ~~~
~~9 I l uNCOSFU*h i Fct DdO # 3 (3 Cylinder No. 1~~
~~20. Clean top surface of head and bottom gasket surface of subcover.~~
~~TE Date 00A Date TDI Date~~
~~21. Install new gasket P/N 03-362-01-0C on subcover.~~
~~TE Date OQA Date TDI Date~~
~~22. Install push rods.~~
Install subcover on head, taking care not to damage gasket or tubing. Clean and lubricate subcover capscrew heads and shoulders with a 50-50 mixture of powdered graphite and clean engine oil. Install capscrews and rundown hand tight. TE Date OQA Date TDI Date
~~23. Tighten espscrews in a criFS Cross patter in 3 increments.~~
~~Torque Wrench M&TE No. A) 40 ft, lbs. TE Date OQA Date TDI Date~~
~~' B) 80 ft. lbs. _~~
~~TE Date OQA Date TDI Date f3 V~~
+
~~6 of 24 _~~
~~,_,s, -~~
~~3 , (. .. r~~
~
6 Y %
0 }
+
~~f g;7,0NTROL C ' s~~
~~. For 1r.torma'. ion CrN Cylinder No. D~~
~~23. - continued C) 120 ft. Ibs.~~
TE Date OQA Date TDI Date t 24. C1can and install (2) starting air pilot lines to subcover bilkhead, and from the subcover bulkhead to the valve. Clean and install tl:e lube oil supply line to the subcover. Blov out the tube with compressed nitrogen or instrument air, which ever is available. Verify lines are dry. TE Date OQA Date TDI Date
~~25. Install a new gasket, R-2322, and the injection nozzle holder.~~
~~[ TE Date OQA Date TDI~~
~~Date~~
~~26. Clean and lubricate stud and nut threads with a 50-50 mixture of powdered graphite and clean engine oil. Install nuts on studs hand tight.~~
~~TE Date OQA Date TDI Date~~
~~27. Torque the fusi injection nezzle retainer nuts in 3 increments to 85-90 ft. lbs.~~
~~Torque Wrench M&TE No. TE Date OQA Date~~
~~) .~~
~~t n TDI Date ( \~~
~~- \)~~
7 of 24 "5 g,3 ;,. T4HD C E I' l -
W :i_ y rn " 1. , wt . . . -
~3
[
l
;t .y 3c k / /l s } er fW ; p , , 'i G'"r*r, UNc0NTROLLED \ f{
~~Fci in ormstion On4 I 3rq 4~~
~~$ R Y\ %) J)Y, 0 No.~~
~~1 Cylinder v~~
~~. ?! 28.FC'ean and install the new high pressure fuel injection line per E&DCR's~~
~~?! v F#45709, A, B (Section G, Attachment 3) and injection nozzle drain~~
~~line, taking care to ensure the tube fittings and tube ends are clean.~~
.. dry and not damaged. Blow out the tube with compressed nitrogen or 3 'e instrument air, whichever is available. Install tube clamps. ,r-y, y, ' \
~~JTE OQA Date z j Date). es~~
- TDI Date - )
~~s. 29.~ Ensure engine is at TDC firing for the cylinder in question.~~
i hVerify s k tappet sockets for cleanliness. f * , C i- ,*
~~i-59~~
~~, TE Date OQA Date *% 4' .\t 4~~
[ , TDI s. Date e30. q/Ch'eck rocker arm bolt holes in subcover for excessive lube oil. Clean (]) f , 9 and install intake and exhaust rocker arms on subcover, ensuring the
~~@ ~ tocker arm shaft seats properly on the subcover. , \ ,, '\..! N,, -~~
~~U TE < Date OQA Date TDI Date ,~~
~~31. Clean and lubricate'che rocker arm shaft capscrews with a 50-50 mixture powdered graphite and clean engine oil f.~~
~~r TE Date OQA Date TDI Date e i 8 of 24 ,-- , c-- . a~~
~~'t .~~
r '} f, '..{ t
5
~~} }.~~
1
~~.ONTRO*dD '~ '~~
~~pc lnictmaticn CM l d~ Cylinder No.~~
~~'32. Tighten the rocker shaft bolts in 3 increments.~~
Torque Wrench M&TE No. A)' 120 ft. lbs. TE Date OQA Date TD1 Date B)- 240 ft. Ibs. TE Date OQA Date-TDI Date C) 365 ft. Ibs. TE Date OQA Date TDI Date
~~33. Clean and install intermediate push rod. Bleed and install lifters.~~
~~Fill lifter cavity with lube oil. TE Date OQIs Date TDI Date~~
~~34. Adjust valves.to procedure described in Instruction Manual, Section 6 pages 6-B-5 and 6-B-6 (Section G, Attachment 1).~~
~~' Torque jam nuts (4) to 150 f t. Ibs.~~
~~Torque Wrench . M&TE No.~~
~
~~TE Date OQA Date TDI. Date~~
~~'%d 9 of 24 g. h ii'iO p ,- :~~
~~i; UNCONTROLLEU' i p For information On4 Cylinder No.~~
~~35. Verify and clean subcover and valve cover gasket surfaces.~~
~~TE Date OQA Date TDI Date~~
~~36. Install a new gasker 03-362-01-0D.~~
~~TE Date OQA Date TDI Date~~
~~37. Clean and install valve cover - tighten valve cover nuts hand tight.~~
~~TE Date OQA Date TDI Date~~
~~38. Verify and clean gasket and sealitig surfaces of air start manifold, dresser coupling, air start jumper, head and spacer if used.~~
~~TE Date OQA Date 1 l TDI Date i~~
~~39. Install air start jumper with new gasket F-057-019. Tighten dresser coupling hand tight.~~
TE Date OQA Date i j TDI Date r j 40. Install air start capscrews with a 50-50 mixture of powdered graphite and clean engine oil, p TE Date OQA Date l- Ch (j TDI Date l 1 1 10 of 24 _. cr-l 31 - i
4 .4wme N's 5-'6O h' l-UNCONTROLLED ' 1 for Info:raation Onl1 Cylinder No.
~~. - 41. Tighten air start capscrews in 3 increments and in criss cross pattern.~~
~~i Final torque to be 30 ft. Iba. Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~42. Tighten dresser coupling for air start jumper.~~
~~TE Date OQA Date TDI Date~~
~~43. Inspect'and clean gas inlet blind flange and cylinder head mating l~~
~~surface.~~
~~%J TE ,~~
~~Date OQA Date TDI Date 44._ Install new gasket 03-451-01-0D. l-TE Date OQA Date TDI Date t l~~
~~45. Install blind flange and gasket. ~ Clean and lubricate bolts with 50-50 mixtt.re of powdered graphite and clean engine oil. Install hand tight.~~
~~l TE Date OQA Date TDI Date I v. 11 of 24 3 Tr . i t R' C. i~~
~~. . ..,.:.-. . - ~ . . - - . . . - - - . , )~~
~~h UNCOilW I .c.og.' For intorniacon - v~~
~~-Cylinder No. -~~
~~46. Tighten bolts in 3 increments and a criss cross pattern. Final torque to be 30 f t. Ibs.~~
~~Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
'47. Retorque exhaust pipe capscrews to 100 ft. lbs. after each I hour run at full load or 3 hours at less than full load, whichever comes first, while the engine is hot. Continue the retorquing process until the capscrews no longer advance on retorquing.
~~TE Date OQA Date TD1 Date O' V Torque Wrench M&TE~~
~~48. Retorque air start capscrews to 150 ft. lbs. after each 12-24 hour run until the capscrews no longer advance on retorquing.~~
TE Date OQA Date TDI Date Torque Wrench M&TE No. 12 of 24 f, ( . ,, sr '
1
~~, . . - ~ . ~ , a 3~~
gyr,0NTROLLEU' e Fe infamst;on Cr4 V' CYLINDER HEAD INSTALLATION SECTION G Cylinder No. NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TD1 representative and the Test Engineer followed by signoffs from all three.
1. Clean inside of combustion chamber. Bar engine over until piston is at bottom dead center and clean and inspect upper portion of cylinder bore. Clean gasket surfaces of engine block, exhaust pipe, and cylinder head.
~~TE. Date OQA Date TDI Date~~
~~2. Record head serial no, along with the number of cylinder and engine (W)~~
~~D' installed on. SERIAL NO.~~
~~CYLINDER DG TE Date OQA Date TDI- Date~~
~~3. Clean and inspect gasket surfaces of cylinder head and exhaust manifold.~~
~~TE Date OQA Date TDI Date f~ N)) c' 1 of 24 , , , , q p r. :- g , no -~~
~~i. . .~~
I
\
~~ggccNTROll.fU~~
~~.7,y :n.o:mstia 1 Or1 O Cylinder No.~~
~~4. Install new seal rings, o-rings, and grommets on cylinder head consisting of:~~
A) (1) F-115-031 Seal Ring - Water - Head to Block B) (1) JE-007-000 Seal Ring - Combustion - Head to Liner C) (2) F-094-097 0-Ring - Push Rod Tube Seal D) (4) 03-360-05-AE Grousnet - Head to Block Water Passage E) (7) 03-360-05-AD Grommet - Head to Block Water Passage l F) (1) F-057-009 Flexitallic Gasket Exhaust l 4 TE Date 0QA Date TDI Date
~~'5. . Verify intake elbow and cylinder head for cleanliness. Clean as nececcery.~~
~~TE Date OQA Date A. TDI Date~~
~~6. Attach lifting fixture P/N 00-590-01-BA to cylinder head and hoist head in place over cylinder head studs. Carefully lower head into place, taking care not to damage stud threads, seals, or tubing.~~
Clean and lubricate cylinder head studs, nuts, and washers with a 50-50 mixture of powdered graphite and clean engine oil. TE Date OQA Date TDI Date
)
w/ 2 of 24 pt . iD ( " i
gprranFOLLE0 - poi ti;toondica C:11 s 1
~~' Cylinder.No.~~
~~A 7-~~
~~7. Torque head bolts in 3 increments in the sequence shown on the attached sheet (Section G, Attachment 2).~~
~~Torque Wrench M&TE No. A) 1200 ft. lbs. TE Date OQA Date TDI Date B) 2400 ft. lbs. TE Date OQA Date TDI Date~~
~~'C) 3600 ft. Ibs.~~
~~TE Date OQA Date TDI Date~~
~~8. Remove lifting fixture.~~
~~Inspect and claran gasket surfaces of intake manifold, inlet elbow, and cylinder head.' TE Date OQA Date TDI Date~~
~~9. Install 2 new gaskets on intake elbow. 03-375-01-0F and 02-375-01-OH.~~
~~TE Date OQA Date TDI Date~~
~~10. Place intake elbow in position.~~
Clean and lubricate intake elbow capscrews with 50-50 mixture of powdered graphite and clean engine oil. TE Date OQA Dste TDI Date= ,.. . ,, r+ - ,
~~n. v... s- ,~~
3 of 24
pp(P;!TUS I TE ~ p,y in a. n v U c n C.4 Cylinder No.
~~11. Tighten intake elbow capscrews'in 3 equal increments of 10 ft. lbs. in a criss cross pattern. Alternate between head and manifold flanges.~~
Final torque of capscrews to be 30 ft. lbs. Torque Wrench M&TE No. TE Date OQA Date TDI Date
~~12. Install a new flexitallic gasket P/N F-057-009.~~
TE Date OQA Date TDI Date
~~.p 13. Clean and coat exhaust pipe capscrews with "NEVER-SEZE". Install hand I tight.~~
TE. Date OQA Date TDI Date
~~14. Tighten exhaust pipe capscrews in 3 increments in a criss cross pattern. Final torque of capscrews to be 100 ft, lbs.~~
Torque Wrench M&TE No. TE Date OQA Date TDI Date
~~15. Clean and inspect gasket and sealing surfaces of jacket water outlet elbow, jacket water discharge header, dresser coupling, cylinder head and spacer.~~
~~p TE Date OQA Date N.)~~
~~'TDI Date (L s. ,a: 1 D U ~~~
~~4 of 24~~
)
2
\
~~i [f. GNTROLLEU crmatica Cr4 ~ O Cylinder No.~~
~~16. Tighten jacket water outlet capscrews in 3 increments in a criss cross pattern.~~
~~TE Date OQA Date TDI Date~~
~~17. Verify dresser coupling is tight.~~
~~Clean and inspect o-ring groove and gasket seats of air start valve and cylinder head air start valve bore.~~
~
~~TE Date OQA Date TDI Date~~
~~18. Install a new o-ring ?/N B-5692, and gasket P/N 03-359-01-0E on air O start valve.~~
~~TE Date UQA Date TDI Date~~
~~19. Clean and install air start valve taking care not to damage gasket or o-ring.~~
Clean and lubricate capscrews with a 50-50 mixture of powdered graphite and clean engine oil. Install hand tight and tighten in 50 ft. Ib. increments. Final torque to be 150 ft. lbs. Torque Wrench M&TE No. TE Date IQA Date TDI Date O 5 of 24 ,, cc-
~~- - - _.____________..l___._____ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _~~
~~j sconTpottro fo inturmation On4 ( Cylinder No. AT N./.~~
~~20. Clean top surface of head and bottom gasket surface of subcover.~~
~~TE- Date 0QA Date TDI Date d~~
21. Install new gasket P/N 03-362-01-0C on subcover, TE Date OQA Date TDI Date

22. Install push rods.
Install subcover on head, taking care not to damage gasket or tubing. Clean and lubricate subcover capscrew heads and shoulders with a 50-50 mixture of powdered graphite and clean engine oil, install capscrews and rundown hand tight.
)
~~~ %.J~~
~~-TE Date OQA Date TDI Date~~
~~23. Tighten capscrews in a criss cross patter in 3 increments.~~
Torque Wrench M&TE No. A) 40 ft. lbs. TE Date OQA Date TDI Date B) 80 ft. lbs. TE Date OQA Date TDI Date a 6 of 24 - , . . m.; . . . . u U C. L. .
~~, H s%~~
~~o Cylinder No.~~
~~23. - continued C) 120 ft. lbs.~~
~~TE Date OQA Date TDI Date~~
24. Clean and install (2) starting air pilot lines to subcover bulkhead, and frca the subcover bulkhead to the valve. Clean and install the lube oil supply line to the subcover. Blow out the tube with compressed nitrogen or instrument air, which ever is available. Verify lines are dry.
~~TE Date OQA Date TDI Date~~
~~25. Install a new gasket, R-2322, and the injection nozzle holder.~~
~~TE Date OQA Date TDI Date~~
~~26. Clean and lubricate stud and nut threads with a 50-50 mixture of powdered graphite and clean engine oil. Install nuts on studs hand tight.~~
~~TE Date OQA Date t TDI Date~~
~~27. Torque the fuel injection nozzle retainer nuts in 3 increments to 85-90 ft. lbs.~~
~~Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
.(
L 7 of 24 r, r - y . .-- a. .
a i UNC.cNTROUE , por infon0&WD - O Cylinder No.
28. Clean and install. the new high pressure fuel injection line per E&DCR's F-45709, A, B (Section G, Attachment 3) and injection nozzle drain line, taking carc to ensure the tube fittings and tube ends are clean, dry and not damaged. Blow out the tube with compressed nitrogen or instrument air, whichever is available. Install tube clamps.
~~TE Date OQA Date TD1 'Date~~
~~29. Ensure engine is at TDC firing for the cylinder in question.~~
~~Verify tappet sockets for cleanliness. TE Date OQA Date TDI Date~~
30. Check rocker arm bolt holes in subcover for excessive lube oil. Clean O and install intake and exhaust rocker arms on subcover, ensuring the rocker arm shaft seats properly on the subcover.
~~TE Date OQA Date TDI Date~~
~~31. Clean and lubricate the rocker arm shaft capscrews with a 50-50 mixture powdered graphite and clean engine oil.~~
TE Date OQA Date TDI Date O 8 of 24 7 i l
UNCONTROt LED For inbrm, ticn noto Cylinder No.
~~32. Tighten the rocker shaft bolts in 3 increments.~~
Torque Wrench M&TE No. A) -120 ft. lbs. TE Date OQA Date TDI Date B) 240 ft. lbs. _ _ . TE Date OQA Date TDI- Date C) 365 ft. lbs. TE Date OQA Date TDI Date
~~33. Clean and install intermediate push rod. Bleed and install lifters.~~
~~Fill lifter cavity with lube oil.~~
~~.TE Date OQA Date TDI Date~~
~~34. Adjust valves to procedure described in Instruction Manual, Section 6 pages' 6-B-5 and 6-B-6 (Section G. Attachment 1).~~
Torque jam nuts (4) to 150 f t. lbs. Torque Wrench M&TE No. TE Date OQA Date TDI Date O
~~9 of 24~~
+
~~}' UNCONTROll EP,.c#' for intuim 8'i# ' Cylinder No.~~
~~35. Verify and clean subcover and valve cover gasket surfaces.~~
~~TE Date OQA Date TDI Date~~
~~36. Install a new gasket 03-362-01-0D.~~
~~TE Date OQA Date TDI Date~~
~~37. Cican and install valve cover - tighten valve cover nuts hand tight.~~
~~TE Date OQA Date TDI Date~~
%J
~~38. Verify and clean gasket nnd sealing surfaces of air start manifold, dresser coupling, air start jumper, head and spacer if used.~~
~~TE Date OQA Date TDI Date~~
~~39. Install air start jumper with new gasket F-057-019. Tighten dresser coupling hand tight.~~
~~TE Date OQA Date TDI Date~~
~~40. Install air start capscrews with a 50-50 mixture of powdered graphite and clean engine oil.~~
~~TE Date OQA Date (^)~~
~~.. L/ TDI Date 10 of 24 . g t* Q:.FD U~~
~~i tjNCONT @ I I For litternit '? Cylinder No.~~
~~41. Tighten air start capscrews in 3 increments and in criss cross pattern.~~
Final torque to be 30 ft. Ibs. Torque Wrench M&TE No. TE Date OQA Date TDI Date
~~42. Tighten dresser coupling for air start jumper.~~
~~TE Date OQA Date TDI Date~~
~~43. Inspect and clean gas inlet blind flange and cylinder head mating surface.~~
~~TE Date OQA Date TDI Date~~
~~44. Install new gasket 03-451-01-0D.~~
~~TE Date OQA Date TDI Date~~
~~45. Install blind flange and gasket. Clean and lubricate bolts with 50-50 mixture of powdered graphite and clean engine oil. Install hand tight.~~
~~TE Date OQA Date TDI Date O 11 of 24 i~~
~~, )~~
~~}; l-I UNCONigcLLED ) Ecr Informatico OW b ' Cylinder No.~~
~~46. Tighten bolts in 3 increments and a criss cross pattern. Final torque to be 30 ft. lbs.~~
Torque Wrench M&TE No. TE Date OQA Date TDI Date
47. Retorque exhaust pipe capscrews to 100 ft. Ibs. after each I hour run at full load or 3 hours at less than full load, whichever comes first, while the engine is hot. Continue the retorquing process until the capscrews no longer advance on retorquing.
TE Date OQA Date TDI Date Torque Wrench M&TE
~~48. Retorque air start capscrews to 150 ft. lbs. after each 12-24 hour run until the capscrews no longer advance on retorquing.~~
TE Date OQA Date TDI Date Torque Wrench M&TE No, b d 12 of 24 ,gc , , ~; er
i. 7 , UNCONTF.O W por taioimauca CM,, y/ CYLINDER HEAD INSTALLATION SECTION G - Cylinder No. 5 NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer followed by signoffs from all three.
1. Clean inside of combustion chamber. Bar engine over until piston is at bottom dead center and clean and inspect upper portion of cylinder bore. Clean gasket surfaces of engine block, exhaust pipe, and cylinder head.
~~TE Date OQA Date TDI Date~~
~~2. Record head serial no. along with the number of cylinder and engine installed on.~~
~~SERIAL NO. CYLINDER DG TE Date OQA Date TDI Date~~
~~3. Clean and inspect gasket surfaces of cylinder head and exhaust manifold.~~
TE Date OQA Date TDI Date 1 of 24 '10 SED ; b in i i ii i piii ii i g
_. . _ _ _- . _ . . . _ f UtaCONTROtLEp For Infom3M #,# fm r cylinder No. 5
~~4. Install new seal rings, o-rings, and gron: mets on cylinder head consisting of:~~
A) (1) F-115-031 Seal Ring - Water - Head to Block B) (1) JE-007-000 Seal Ring - Combustion - Head to Liner C) (2) F-094-097 0-Ring - Push Rod Tube Seal D) (4) 03-360-05-AE Grossnet - Head to Block Water Passage E) (7) 03-360-05-AD Grommet . Head to Block Water Passage F) (1) F-057-009 Flexitallic Gasket Exhaust TE Date OQA Date TDI Date
~~5. Verify intake cibow and cylinder head for cleanliness. Clean as necessary.~~
~~TE Date OQA Date~~
~~. f3 t TDI Date~~
~~6. Attach lifting fixture P/N 00-590-01-BA to cylinder head and hoist head in place over dylinder head studs. Carefully lower head into place, taking care not to damage stud threads, seals, or tubing.~~
Clean and lubricate cylinder head studs, nuts, and washers with a 50-50 mixture of powdered graphite and clean engine oil. TE Date OQA Date TDI Date O 2 of 24 Jiu e ' ,4 G CL~ _
~~, ~~~
l -. , I g ) MOON' p On _n p, in na Cylinder No. 5'
~~7. Torque head bolts in 3 increments in the sequence shown on the attached sheet (Section.C, Attachment 2).~~
Torque Wrench M&TE No. A) 1200 ft. Ibs. TE Date OQA Date TDI Date B) 2400 ft. Ibs. TE Date 0QA Date TDI Date C) 3600 ft. Ibs. TE Date OQA Date m TDI Date
~~8. Remove lifting fixture.~~
~~Inspect and cidan gasket surfaces of intake manifold, inlet elbow, and cylinder head. TE Date OQA Date TDI Date~~
~~9. Install 2 new gaskets on intake elbow. 03-375-01-0F and 02-375-01-0H.~~
~~t TE Date OQA Date i TDI- Date~~
~~10. Place intake cibow in position.~~
Clean and' lubricate intake elbow capscrews with 50-50 mixture of powdered graphite and clean engine oil, g TE Date OQA Date TDI Date jic 1; ..c . Q CT . . 3 of 24
):
~
~~UNeonTnouEP O V' Cylinder No. g U p,.,7 utcrnelion ,"~~
~~11. Tighten intake elbow capscrews in 3 equal increments of 10 ft. lbs. in a criss cross pattern. Alternate between head and manifold flanges.~~
~~Final torque of capscrews to be 30 ft. lbs. Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~12. Install a new flexitallic gasket P/N F-057-009.~~
~~TE Date OQA Date TDI Date~~
~~13. Clean and coat exhaust pipe capscrews with "NEVER-SEZE". Install hand tight.~~
TE
~~Date OQA Date TDI Date~~
~~14. Tighten exhaust pipe capscrews in 3 increments in a criss cross pattern. Final torque of capscrews-to be 100 ft. lbs.~~
~~Torque Wrench M&TE No. TE Date' OQA Date TDI Date~~
~~15. Clean and inspect gasket and sealing surfaces of jacket water outlet elbow, jacket water discharge header, dresser coupling, cylinder head and spacer.~~
~~TE Date OQA Date~~
~~.Ys TDI Date JIL !> il i:.3 C. E i 4~~
~~4 of 24~~
~~^' . a . ..: . - . : L. . L , - ' -~~
~~i~ 3 A (. t U . Cylinder No. 5~~
16. Tighten jacket water outlet capscrews in 3 increments in a criss cross

l. pattern.
~~TE Date OQA Date TDI -Date~~
~~17. Verify dresser coupling is tight.~~
Clean and inspect o-ring groove and gasket seats of air start valve and cylinder head air start valve bore. , ,TE Date OQA Date [ TDI~ Date 18.-Install a new o-ring P/N B-5692, and gasket P/N 03-359-01-0E on air i start valve. 1 I TE
~~Date OQA- Date i~~
~~TDI Date~~
~~19. Clean and install air start valve taking care not to damage gasket or o-ring.~~
Clean and lubric' ate capscrews with a 50-50 mixture of powdered graphite and clean engine oil. Install hand tight and tighten in 50 ft. Ib. increments. Final torque to be 150 ft. Ibs. , Torque Wrench M&TE No. TE Date OQA Date TDI Date O 5 of 24 ,7(. , g g -) g.
~~!: , , . . . _ . .- , -_ _ ., _ ca . , ;1.- x- __ _ . , . _ . _ _ . _ _ - _ . _ . . _ .. ._~~
~~tJtsfN@ O3 po; .r.iorD'E, , (V-] Cylinder No. 5~~
~~20. Clean top surface of head and bottom gasket surface of subcover.~~
~~TE Date OQA Date TDI Date~~
~~21. Install new gasket, P/N 03-362-01-0C on subcover.~~
~~TE Date OQA Date TDI Date~~
~~22. Install push rods.~~
Install subcover on head, taking care not to damage gasket or tubing. Clean and lubricate subcover capscrew heads and shoulders with a 50-50 mixture of powdered graphite and clean engine oil. Install capscrews -[^~ and rundown hand tight. (- TE Date OQA Date TDI Date
~~23. Tighten capscrews in a criss cross patter in 3 increments.~~
~~Torque Wrench M&TE No. A) 40 ft. Ibs. TE Date OQA Date TDI Date B) 80 ft. Ibs. TE Date OQA Date TDI Date O~~
~~\_ /~~
~~6 of 24 JTG !E. iiVED t3D , , <; s -- . - .. . s~~
~~.....m......-mm..~~
~~) z ,- For uim" bo V Cylinder No. 5~~
~~23. - continued C) 120 ft. lbs.~~
~~TE Date OQA Date TDI Date~~
24. Clean and install (2) starting air pilot lines to subcover bulkhead, and from the subcover bulkhead to the valve. Clean and install the lube oil supply line to the subcover. Blow out the tube with compressed nitrogen or instrument air, which ever is available. Verify lines are dry.
~~TE Date- OQA Date TDI Date~~
~~25. Install a new gasket, R-2322, and the injection nozzle holder.~~
~~TE Date OQA Date~~
~~-TDI Date~~
~~26. Clean and lubricate stud and nut threads with a 50-50 mixture of powdered graphite and clean engine oil. Install nuts on studs hand tight.~~
~~TE Date OQA Date TDI Date~~
~~27. Torque the fuel injection nozzle retainer nuts in 3 increments to 85-90 ft. Ibs.~~
Torque Wrench M&TE No. TE Date OQA Date TDI Date (/ 7 of 24 JIt ib -; mfd ,CF: ;, ,,
e e%Db.mCA LDon4 g.y tNOWCg,n
~~' Cylinder No.~~
5
28. Clean and install.the new high pressure fuel injection line per E&DCR's F-45709, A, B (Section G, Attachment '3) and injection nozzle drain line, taking care to ensure the tube fittings and tube ends are clean, dry and not damaged. Blow out.the tube with compressed nitrogen or instrument air, whichever is available. Install tube clamps.
~~TE Date OQA Date TDI Date~~
~~29. Ensure engine is at TDC firing for the cylinder in question.~~
~~Verify tappet sockets for cleanliness. TE Date OQA Date TDI Date~~
30. Check rocker arm bolt holes in subcover for excessive lube oil. Clean and install intake and e.xhaust rocker arms on subcover, ensuring the A rocker arm shaft seats properly on the subcover.
~~TE Date OQA Date TD1 Date~~
~~31. Clean and lubricate the rocker arm shaft capscrews with a 50-50 mixture powdered graphite and clean engine oil.~~
~~TE Date OQA Date TDI Date 8 of 24 < J~~
~~;vi:3 Q ,s y 7 , ,,~~
*\
~~l i N UMCOIGN- tk. g yg7 iniorm0000~~
~~'((j - Cylinder No. _v~~
~~32. Tighten the rocker shaft bolts'in 3 increments.~~
Torque Wrench M&TE No. A) 120 ft. Ibs. TE Date OQA Date TDI Date B) 240 ft. Ibs. TE Date OQA Date TDI Date C) 365 ft. Ibs. TE Date OQA Date TDI Date
~~33. Clean and install intermediate push rod. Bleed and install lifters.~~
Fill lifter cavity with lube oil. , TE Date OQA Date TDI Date -
~~34. Adjust valves to procedure described in Instruction Manual. Section 6 pages 6-B-5 and 6-B-6 (Section G Attachment 1).~~
Torque jam nuts (4) to 150 f t. Ibs. 1 Torque Wrench M&TE No. TE Date OQA Date TDI Date O 9 of 24
~
jy tyi'GliiD O -
I
. n .. 5.k. ..-cjgBOLL ET c- ; , ;rf.or m a ~ a O n %
~~wJ Cylinder No. 5~~
~~35. Verify and clean subcover and valve cover gasket surfaces.~~
~~TE Date ' OQA Date 4 s TDI Date. A &~~
~~36. Install a new ga,sket 03-362-01-0D.~~
~~TE Dats OQA Date 1~~
~
TDI Date s w I' 37. Clean and install valve cover - tighten valve cover nuts hand tight.- N s N s TE Date OQA Date l 1.\ . 3
Y
\
~~TDI Date .,~~
~~, \~~
~~s s s,~~
~~.'%/ 38. Verify and clean gasket and sealinh > surf aces 'o'f air start manifold, '~~
dresser coupling, air start jumper, head and spacar if used. ' q w 3 ;% , r 2
\
~~A TE~~
~~Date OQA 3 Date i,~~
~~1 TDI Date~~
~~39. Install air start jumper with '.'.ew gasket F-057-019. :l Tighten dresser coupling hand tight. '~~
~~k., ,z g~~
- TE g i ,Date OQA Date 's i' s S dlate ' s -). ,TDI . %. \
~~40. Install air start capscrewsiuith a 50-50 mixture of powdered graphite 5~~
~~" +' ,ff' and clean engine oil.~~
~~Dj A)t~~
~~.g ,~~
~~a / M .. TE Date OQA Date t-~~
~~,i 4~~
~~c 4 , i~~
~~%) TD1 Date .~~
~~10 of 24 DG A: LOO p'- . l s J~~
~~. i . _ . _ _ . . . .~~
~~i n,tCD d p Cylinder No. 5~~
~~41. Tighten air start capscrews in 3 increments and in criss cross pattern.~~
~~Final torque to be 30 ft. Ibs. Torque french M&TE No. TE Date OQA Date f I' i , ' . TD1 Date~~
~~42. Tighten dresser coupling for air start jumper.~~
~~TE Date OQA Date TDI Date~~
~~43. Inspect and clean gas inlet-blind flange and cylinder head mating surface.~~
O
~~- TE- Date- 0QA Date TDI. Date~~
~~44. Install new gasket 03-451-01-0D.~~
~~b ;. ' q.- ,~~
~~'.I- TE N, , Date OQA Date i- ~,~~
~~I TDI Date~~
~~, i..~~
~~45. Install; blind-flange and gasket. Clean and lubricate bolts with 50-50 I' mixture'of powdered graphite and clean engine oil. Install hand tight.~~
~~? . s 'TE- Date OQA Date t_ s h 't { -]'.=s ,~~
TDI Date L-t w/ . b 11 of 24 u" # k. y r jl 0 tr a ci> g e p e - y j 6, % ' ' ' _; j 1: ' , i
t . ' - 1 y, J l f-
~~-i . ';jf f y,i 'j' .~~
~~YLG p, UN6ygn. .01.0~~
~~' 7 ,e - -~~
~~g r inict0* g , (,;,b,i~~
~~/ ,~~
~~Cylind'er(No. _ 5-~~
~~~"- 46. Tighten bolts in 3 increments'and a criss cross pattern. Final torque ? . ,to be.30 ft. Ibs.~~
~~g jp , -o~~
~~> Y- - '. {- -! -', -J>- , fy 7 g Torque Wrench M&TC No.~~
~~t pd<= .r,~~
~~> ; y,,. ,.<- ,'~~
~~b TE Date CQA Date i,, <~~
~~, .f TDI Date r <.~~
47. ' Retorque exhaust pipe capscrews to 100 f t. Ibs. after each I hour run

st full 1 cad or 3 hours at less than full load, whichever cces first, s t while the engine is bot. Continue'the retorquing process until the vcapscrews no longer advance on retorquing.
~~r TE, Da'e OQA Date~~
~~; t[~~
~~TDI +~~
. 1. : Date Q/- , - v v'<i., Torque Wrench M&TE '
~~( ;ih' t~~
~
~~48. Retorque air start capscrews to 156 ft.-lbs. after each 12-24 hour run until the capscrews'~no longer advance on retorquing. i Idi >~~
~~t TE Date OQA. Date f TDI , Date 1 73~~
~~-Terque Wrench M&TE No.~~
~~f ; '~~
~~e , j- , e It . ..- l q~~
,- i ,. 1 6 .y t
~~4 N~~
.m , ,h ,
~~( \ ,~~
~~'l+ . ,g - 4,4, r/ , ?~~
~~{ 12 of 24~~
~~)$U ,$'.? - .5Y-,, ?c .{ ..~~
~~8 s% s~~
~ -- . _ _ - . - =_ _ ~
~~UI,r.er:<~~
vALE . O $.,;st ,Tu ~ , Ot ,li' CYLINDER HEAD INSTALLATION SECTION G Cylinder No.
NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer folleved by signoffs from all three.
1. Clean inside of combustion chamber. Bar engine over until piston is at bottom dead center and clean and inspect upper portion of cylinder bore. Clean gasket surfaces of engine block, exhaust pipe, and cylinder head.
~~TE Date OQA Date TDI Date~~
~~2. Record head serial no, along with the number of cylinder and engine installed on.~~
SERIAL NO. CYLINDER DG TE Date OQA Date TDI Date
~~3. , lean and inspect gasket surfaces of cylinder head and exhaust manifold.~~
. TE Late OQA Date TDI Date 1 of 24 ')TGfI?UC\ID U D
y ntO RO'.li9
~~'3 "~~
~~[ct I b Cylinder No. b~~
~~4. Install new seal rings, o-rings, and grommets on cylinder head consisting of:~~
A) (1) F-115-031 Seal Ring - Water - Head to Block B) (1) JE-007-000 Seal Ring - Combustion - Head to Liner C) (2) F-094-097 0-Ring - Push Rod Tube Seal D) (4) 03-360-05-AE Grommet - Head to Block Water Passage E)' (7) 03-360-05-AD Grommet - Head to Block Water Passage F) (1) F-057-009 Flexitallic Gasket Exhaust TE Date OQA Date TDI Date
~~5. Verify intake elbow and cylinder head for cleanliness. Clean as necessary.~~
~~TE Date OQA Date TDI . Date~~
~~6. Attach lifting fixture F/N 00-590-01-BA to cylinder head and hoist head in place over cylinder head studs. Carefully lower head into piece, taking care not to damage stud threads, seals, or tubing.~~
Clean and lubricate cylinder head studs, nuts, and washers with a 50-50 mixture of powdered graphite and clean engine oil. TE Date OQA Date TDI Date O 2 of 24 11C /WTC\ID $.t . ,6
3, ggCOMTIiC' E,9q g g{yiniti n V"Y [] V Cylinder No. b
~~7. Torque head bolts in 3 increments in the sequence shown on the attached 4~~
sheet (Section C, Attachment 2). Torque Wrench M&TE No. 4 A) 1200 ft. Ibs. TE Date OQA Date TDI Date B) 2400 ft. Ibs. TE Date OQA Date TDI Date C) 3600 ft. Ibs. TE Date OQA Date i l ( TDI Date
8. Remove lifting fixture. I Inspect end clean gasket surfaces of intake manifold, inlet elbow, and

cylinder head.
~~TE Date OQA Date 4 TDI Date~~
~~9. Install 2 new gaskets on intake elbow. 03-375-01-OF and 02-375-01-0H.~~
~~TE Date OQA Date 1 TDI Date~~
10. Place intake elbow in position. *
-Clean and lubricate intake elbow'capscrews vith 50-50 mixture of powdered graphite and clean engine oil. 'TE Date OQA Date - ^
~~TDI Date g;j g., gyg, y .,~~
~~- 3 of 24~~
~~pgf..,rCOTFOLLEU{n"torma Cylinder No. b~~
~~11. Tighten intake elbow capscrews in 3 equal increments of 10 ft. lbs. in a criss cross pattern. Alternate between head and manifold flanges.~~
~~Final torque of capscrews to be 30 ft. Ibs. Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~12. Install a new flexitallic gasket P/N F-057-009.~~
TE Date OQA Date TDI Date p 13. Clean and coat exhaust pipe capscrews with "NEVER-SEZE". Install hand g tight. TE
~~Date OQA Data.~~
~~TDI. Date~~
~~-14. Tighten exhaust pipe capscrews in 3 increments in a criss cross pattern. Final torque of capscrews to be 100 ft. Ibs.~~
~~Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~15. Clean and inspect gasket and sealing surfaces of jacket water outlet elbow, jacket water discharge header, dresser coupling, cylinder head and spacer.~~
~~l TE Date OQA Date TDI .Date iTC ff ' CUD $p ;3 ,, 4 of 24~~
~~. n .- rg gW.'. 9 A"~~
~~Fl.,.'h'g. cab 3 V Cylinder No. V~~
~~16. Tighten jacket water outlet capscrews in 3 increments in a criss cross pattern.~~
~~TE Date OQA Date TDI Date~~
~~17. Verify dresser coupling is tight.~~
Clean and inspect o-ring groove and gasket seats of air start valve and cylinder head air start valve bore. TE Date OQA Date TDI Date
~~18. Install a new o-ring P/N B-5692, and gasket P/N 03-359-01-0E on air (p start valve.~~
TE
~~Date OQA Date TDI Date~~
~~19. Clean and install air start valve taking care not to damage gasket or o-ring.~~
Clean and lubricate capscrews with a 50-50 mixture of powdered graphite and clean engine oil. Install hand tight and tighten in 50 ft. Ib. increments. Final torque to be 150 ft. Ibs. Torque Wrench M&TE No. TE Date OQA Date TDI Date 5 of 24
~~)TG - li' i y ,~~
~~UNOONTROLLW For Intermation 001 Cylinder No. _b~~
~~20. Clean top surface of head and bottom gasket surface of subcover. ,~~
~~TE Date OQA Date TDI Date~~
~~21. Install new gaskut, P/N 03-362-01-0C on subcover.~~
~~TE Date OQA Date \ TDI Date~~
~~22. Install push rods.~~
Install subcover on head, taking care not to damage gasket or tubing. Clean and lubricate subcover capscrew heads and shoulders with a 50-50 mixture of powdered graphite and clean engine oil. Install capscrews-and rundown hand tight.
~~'%./~~
IE Date OQA Date TDI Date 23.- Tighten capscrews in a criss croso patter in 3 increments. Torque Wrench M&TE No. A) 40 ft. lbs. TE Date 0QA Date TDI Date B) 80 ft. lbs. TE Date OQA Date TDI Date w
~~\. -~~
~~6 of 24~~
~~'2TG?!TGila Cy -~~
~~i I _ _- _ - _ _ _ _ _ _ - _ - _ - _ - - - _ _ _ - - _ _ _ _ _ - -~~
~~..c.nNTROU EU 3,'i,,.$ m ;tiau M O c d Cylinder No. V~~
~~23. - continued C) 120 ft. Ibs.~~
~~TE Date OQA Date TDI Date~~
24. Clean and install (2) starting air pilot lines to subcover bulkhead, and from the subcover bulkhead to the valve. Clean and install the lobe oil supply line to the subcover. Blow out the tube with compressed nitrogen or instrument air, which ever is available. Verify
~~. lines are dry.~~
~~TE Date OQA Date TDI Date~~
~~25. Install a new gasket, R-2322, and the injection nozzle holder.~~
~~() TE Date OQA Date TDI~~
~~Date~~
~~26. Clean and lubricate stud and nut threads with a 50-50 mixture of powdered graphite and clean engine oil. Install nuts on studs hand tight.~~
~~TE Date OQA Date TD1 Date~~
~~27. Torque the fuel injection nozzle retainer nuts in 3 increments to 85-90 ft. Ibs.~~
~~Torque Wrench M6TE No. TE Date OQA Date (O~~
\/
~~TDI Date~~
~~'sTG UTTC.!ig *u :: . r- ,~~
7 of 24
ut4CO*U M y g.g (mum U^^ Cylinder No. _b
28. Clean and install the new high pressure fuel injection line per E&DCR's F-45709, A, B (Section G, Attachment 3) and injection nozzle drain line, taking care to ensure the tube fittings and tube ends are clean, dry and not damaged. Blow out the tube with compressed nitrogen or instrument air, whichever is available. Install tube clamps, a
~~TE Date OQA Date TDI Date~~
~~.29. Ensure engine is at TDC firing for the cylinder in question.~~
~~Verify tappet sockets for cleanliness. TE Date OQA Date TDI Date~~
30. Check rocker arm bolt holes in subcover for excessive lube oil. Clean and install intake and exhaust rocker arms on subcover, ensuring the O's rocker arm shaft seats properly on the subcover.
~~TE Date OQA Date TDI Date~~
~~31. Clean and lubricate the rocker arm shaft capscrews with a 50-50 mixture powdered graphite and clean engine oil.~~
TE Date OQA Da t'e' TDI Date + O s 8 of 24 . JldI.:. . 6'tIl gg7 , l
l ) g p it'GNY ' ,,.t.= O Fct Y*Y'" Cylinder No. b
~~32. Tighten the rocker shaft bolts in 3 increments.~~
Torque Wrench M&TE No. , A) 120 ft. Ibs. TE Date OQA Date TDI Date B) 240 ft. lbs. TE Date OQA Date TDI Date C) 365 ft. Ibs. TE Date OQA Date TDI Date
~~33. Clean and' install intermediate push rod. Bleed and install lifters.~~
~~Fill lif ter cavity with lube oil. TE Date OQA Date TDI Date~~
~~34. Adjust valves to procedure described-in Instruction Manual, Section 6 pages 6-B-5 and 6 B-6 (Section G Attachment 1).~~
Torque jam nuts (4) to 150 ft. Ibs. Torque Wrench M&TE No. TE Date OQA Date TDI. Date O r 1 _v. 9 of 24 S2 !- . :D (;s
~~,,c., , TriOLLEO ! g. h {'t,h;m at!Ori @ 1 r - Cylinder No, b~~
~~35. Verify and clean subcover and valve cover gasket surfaces.~~
~~TE Date OQA Date TDI Date~~
~~36. Instal! a new gasket 03-362-01-0D.~~
TE Date - OQA Date TDI Date 37.-Clean and install valve cover - tighten valve cover nuts hand tight. TE Date OQA Date TDI Date
~~- 38. Verify and clean gasket and sealing surfaces of air start manifold, . dresser. coupling - air start jumper, head and spacer if used.~~
r
~~~TE Date OQA Date TDI Date~~
~~39. Install air start jumper with new gasket F-057-019. Tighten dresser couplfng hand tight.~~
TE Date- OQA Date r TDI Date J40.. Install air start capscrews with a 50-50 mixture of powdered. graphite and clean engine' oil. TE Date OQA Date TDl' Date 10 of 24 U'EE0 ' S EP ~ d 13
7 f-i p,,,'7[c-t TnOu1D[< i md'In O Cylinder No. b
~~41. Tighten air start capscrews in 3 increments and in criss cross pattern.~~
~~Final torque to be 30 ft. lbs. Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~42. Tighten dresser coupling for air start jumper.~~
~~TE Date OQA Date TDI- Date~~
~~43. Inspect and clean gas inlet blind flange and cylinder head mating surface.~~
~~TE , Date- OQA Date TDI Date~~
~~44. Install new gasket 03-451-01-0D.~~
~~TE Date OQA Date TDI Date~~
~~-45. Install blind flange and gasket. Clean and lubricate bolts with 50-50 mixture of powdered graphite and clean engine oil. Install hand tight.~~
~~TE Date OQA Date TDI Date O 11 of 24 5 *. . 7D f f' , I .~~
~~,,(p i-EO Y~~
~~_. c, u.'. [dc e ;c tb0ft Cylinder No. b_~~
~~46. Tighten bolts in 3 increments and a criss cross pattern. Final torque to be 30 ft. Ibs.~~
~~Torque Wrench M&TE No. TE Date 0QA Date TDI Date~~
47. Retorque exhaust pipe capscrews to 100 ft. lbs. after each I hour run at full load or 3 hours at less than full load, whichever comes first, while the engit.e is hot. Continue the retorquing process until the capscrews no longer advance on retorquing.
~~TE Date 0QA Date TDI Date O Torque Wrench M&TE~~
~~48. Retorque air start capscrews to 150 ft. lbs. after each 12-24 hour run until the capscrews no longer advar.ce on retorquing.~~
~~TE Date 0QA Date~~
~
~~TDI Date Torque Wrench M&TE No. (Av ' I 12 of 24 jTG tre :P/D C.J - .~~
~~' ,' . , r, ', ,V M iEO,,'..cn OdV th.,~~
~~{ of - ( ) CYLINDER HEAD INSTALLATION~~
%/
l SECTION G i Cylinder No. 7 i NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer followed by signoffs from all three. 1.' Clean inside of combustion chamber. Bar engine over until piston is at bottom dead center and clean and inspect upper portion of cylinder bore. Clean gasket surfaces of engine block, exhaust pipe, and cylinder head. TE Date OQA Date TDI Date
~~, 2. Record head serial no. along with the number of cylinder and engine installed on.~~
~~SERIAL NO.~~
~~CYLINDER DG TE Date OQA Date TDI Dats~~
~~3. Clean and inspect gasket surfaces of cylinder head and exhaust manifold.~~
TE Date OQA Date TDI Date O NJ l of 24 JR' .! U O ( i 1
I
~~~ UNCOa@ON For infoiC#'~~
o
~~Cylinder No. 7~~
~~4. Install new seal rings, o-rings, and grommets on cylinder head consisting of:~~
A) (1) F-115-031 Seal Ring - Water - Head to Block B) (1) JE-007-000 Seal Ring - Cotr.bustica - Head to Liner C) (2) F-094-097 0-Ring - Push Rod Tube Seal D) (4) 03-360-05-AE Gronunet - Head to Block Water Passage E) (7) 03-360-05-AD Gronenet - Head to Block Water Passage F) (1) F-057-009 Flexitallic Casket Exhaust TE Date OQA Date TDI Date
~~5. Verify intake elbow and cylinder head for cleanliness. Clean as necessary.~~
~~TE Date OQA Date TDI Date u)~~
~~6. Attach lifting fixture P/N 00-590-01-BA to cylinder head and hoist head in place over cylinder head studs. Carefully lower head into place, taking care not to damage stud threads, seals, or tubing.~~
Clean and lubricate cylinder head studs, nuts, and washers wfth a 50-50 m1xture of powdered graphite and clean engine oil. TE Date OQA Date TDI Date e A
~~'s 2 of 24 AL ! ~;CVO S r 3 } q '~~
~~L UNCGHY '~ '* '"..u g,. mic:r,~.0 L O Cylinder No. 7~~
~~7. Torque head bolts in 3 increments in the sequence shown on the attached sheet (Section G Attachment 2).~~
Torque Wrench M&TE No. A) 1200 fe. lbs. TE Date OQA Date TDI Date B) 2400 ft. Ibs. TE Date OQA Date TDI Date C) 3600 ft. lbs. TE Date OQA Date TDI Date
~~8. Remove lifting fixture.~~
Inspect and cidan gasket surfaces of intake manifold, inlet elbow, and cylinder head. TE Date OQA Date TDI Date
~~9. Install'2 new gaskets on intake elbow. 03-375-01-0F and 02-375-01-_0H.~~
~~TE Date OQA Date TDI Date~~
~~10. Place intake elbow in position.~~
Clean and lubricate intake elbow capscrews with 50-50 mixture of powdered graphite and clean engine oil. O l-- G TE. Date OQA Date TDI Dste ~ j IO . ; i. 2 C I 3 of 24
g g 3rm;TROI1 ED 7 ,,, . q . . . . n , /. i J' L '",,*, Cylinder No. 7
~~11. Tighten intake elbow capscrews in 3 equal increments of 10 ft. Ibs. in a criss cross pattern. Alternate between head and manifold flanges.~~
~~Final torque of capscrews to be 30 f t. Ib r, . Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~12. Install a new flexicallic gasket P/N F-057-009.~~
TE Date OQA Date TDI Date p 13. Clean and coat exhaust pipe capscrews with "NEVER-SEZE". tight. Install hand TE Date OQA Date liil Date
~~14. Tighten exhaust pipe capscrews in 3 increments in a criss cross pattern. Final torque of capscrews to be 100 ft. Ibs.~~
~~Torque Wrench M&TE No. TE Date 0QA Date TDI Date~~
~~15. Clean and inspect gasket and scaling surfaces of jacket water outlet elbow, jacket water discharge header, dresser coupling, cylinder head and spacer.~~
I TE Date OQA Date w./ TD1 .Date JI6 lEUIO C.E *I 4 of 24
W tA,e
~~.- n C,U.W- u fct ini"'~~
~~sg ., C H.~~
~~Cylinder No. 7~~
~~16. Tighten jacket water one.let capscrews in 3 increments in a criss cross pattern.~~
~~TE Date OQA. Date TDI Date~~
~~17. Verify dresser coupling is tight.~~
Clean and inspect o-ring groove and gasket seats of air start valve and cylinder head air start valve bore. TE Dete OQA Date TDI Date A 18. Install a new o-ring P/N B-5692, and gasket P/N 03-359-01-0E on air start valve. TE
~~Date OQA Date TDI Date~~
~~19. Clean and install air start valve taking care not to damage gasket or o-ring.~~
Clean and lubricate capscrews with a'50-50 mixture of powdered graphite and clean engine oil. Install hand tight and tighten in 50 ft. Ib. increments. Final torque to be 150 ft. lbs. Torque Wrench M6Tt No. TE Date OQA Date TDI Date
%J 2 6 L'<n.is D f f 5 of 24 I ._ - - _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ - - - _ - _ _ _ _ _ _ _ _ _ - _ _ _ _ - _ _ _ _ _ _ _ _ - _ . _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _
~~JNCOS'iTE'O'\E for itdom'ED #.P.- D Cylinder No.~~
~~20. Clean top surface of head and bottom gasket surface of subcover.~~
~~TE Date OQA Date TDI Date~~
~~21. Install new gasket, P/N 03-362-01-0C on subcover.~~
~~TE Date OQA Date TDI Date~~
~~22. Install push rods.~~
Install subcover on head, taking care not to damage gasket or tubing. Clean and lubricate subcover capscrew heads and shoulders with a 50-50 mixture of powdered graphite and clean engine cil. Install capscrews p and rundown hand tight. U TE Date OQA Date TD1 Date
~~23. Tighten capscrews in a criss cross patter in 3 increments.~~
i Torque Wrench M&TE No. A) 40 ft. Ibs. TE Date OQA Date TDI Date B) 80 ft, lbs. TE Date OQA Date TD1 Date O
~~& ' C ~~~
6 of 24 -
m 81.
'^ .,.c4.p T!Ol lf 0 ,ig,,p r, iJ m t c.r ht ' t '
~~Cylinder No. 7~~
~~23. - continued C) 120 ft. Ibs.~~
~~TE Date OQA Date TDI Date~~
24. Clean and install (2) starting air pilot lines to subcover bulkhead, and from the subcover bulkheed to the valve. C.iean and install the lube oil supply line to the subcover. Blow out the tube with compressed nitrogen or instrument air, which ever is available. Verify lines are dry.
~~TE Date OQA Date TDI Date~~
~~25. Install a new gasket, R-2322, and the injection nozzle holder.~~
~~TE Date OQA Date TDI~~
~~Date~~
~~26. Clean and lubricate stud and nut threads with a 50-50 mixture of powdered graphite and clean engine oil. Install nuts on studs hand tight.~~
~~TE Date OQA Date TDI Date~~
~~27. Torque the f ael injection nozzle retainer nuts in 3 increcents to 85-90 ft. Ibs.~~
~~Torque Wrench M&TE No. TE Date OQA Date~~
~~. (m TDI Date )~~
~~7 of 24 0 t. ..D'i CF'~~
~~..m.. _. . __~~
~~l gMrONIh ,y f or inM*[-f'~~
~~-Cylinder No. 7~~
28. Clean and install the new high pressure fuel injection line per E&DD's F-45709, A, B (Section G, Attachment 3) and injection nozzle drain line, taking care to ensure the tube fittings and tube ends are cican, dry and not damaged. Blow out the tube with compressed nitrogen or instrument air, whichever is available. Install tube clamps.
~~TE Date OQA Date TDI Date~~
~~29. Ensure. engine is at TDC firing for the cylinder in question.~~
~~Verify tappet sockets for cleanliness. TE Date OQA Date TDI Date G I~~
~~30. Check rocker arm bolt holes in subcover for excessive lube oil. Clean and install intake and exhaust rocker arms on subcover, ensuring the rocker arm shaft seacs properly on the subcover.~~
~~TE Date OQA Date IDI Date~~
~~31. Clean and lubricate the rocker arm shaft capscrews with a 50-50 mixture powdered graphite and clean engine oil.~~
~~TE Date OQA Date TDI Date r {~~
~~'s 8 of 24 R r cc';2M <c' _~~
________________________u
g yn;30"!" wu.,.a.m [ Cylinder No. 7
~~32. Tighten the rocker shaft bolts in 3 increments.~~
Torque Wrench M6TE No. A) 120 ft. Ibs. - TE Dcte 0QA Date TDI Date B) 240 ft. Ibs. _ TE Date OQA Date TDI Date C) 365 ft. Ibs. TE. Date OQA Date f i TDI Date
~~33. Clean and install intermediate push red. Bleed and install lifters.~~
~~Fill lifter cavity with lube oil. TE Date OQA Date i-TDI- Date~~
~~34. Adjust valves to procedure described in Instruction Manual, Section 6 l~~
pages 6-B-5 and 6-B-6 (Section-G Attachment 1). Torque jam nuts (4) to 150 ft. Ibs. Torque Wrench M&TE No. 4 TE Date OQA Date TDI Date l l
~~~O u~~
9 of 24 g, , , l
b ) ...c. tC
~~,s UNO7; ,~~
~~cx p or IP.K '")E,,~ (b' ) 7 Cylinder No. I~~
~~35. Verify and clean subcover and valve cover gasket surfaces, t~~
~~TE Date OQA Date TDI Date~~
~~36. Install a new gasket 03-362-01-0D.~~
~~TE Date OQA Date TDI Date~~
~~37. Clean and install valve cover - tighten valve cover nuts hand tight.~~
~~TE Date OQA Date TDI Date ('~'\~~
~~38. Verify and clean gasket and sealing surfaces of air start manifold, dresser coupling, air start jumper, head and spacer if used.~~
~~TE Date OQA Date TDi Date~~
~~39. Install cir start jumper with new gasket F-057-019. Tighten dresser coupling hand tight.~~
~~TE Date OQA Date TDI Date~~
~~40. Install air start capacrews with a 50-50 mixture of powdered graphite and clean engine oil.~~
TE Date OQA Date D TD1 Date 10 of 24 i ..i i ' r
~ . Ul l' '.13 ' ' ' :, i r".a
~~,s v gg gnu.tc d.~~
~~O . Cylinder No.'~~
"7
(
~~41. Tighten air start capscrews in 3 increments and in criss cross pattern.~~
~~Final torque to be 30 ft. lbs. Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
~~42. Tighten dresser coupling for air start jumper.~~
~~TE Date OQA Date TDI Date~~
~~43. Inspect and clean gas inlet blind flange and cylinder head mating n surface.~~
~~-k l TE Date 0QA Date TDI Date~~
~~44. Install new gasket 03-451-01-0D.~~
~~TE Date OQA Date TDI Date~~
~~45. Install blind flange and gasket. Clean and lubricate bolts with 50-50 mixture of powdered graphite and clean engine oil. Install hand tight. !~~
~~TE Date OQA Date TDI Date 1 sv 11 of 24 Ec - T' f ' '~~
-;-rMU'.0LLEU p [gmtdOU t;
~~c Cylinder No. I~~
~~46. Tighten bolts in 3 increments and a criss cross pattern. Final torque to be 30 ft. Ibs.~~
~~Torque Wrench M&TE No. TE Date OQA Date TDI Date~~
47. Retorque exhaust pipe capscrews to 100 ft. Ibs, after each I hour run at full load or 3 hours at less than full load, whichever comes first, while the engine is hot. Continue the retorquing process until the capscrews no longer advance on retorquing.
~~TE Date OQA Date TDI Date ( V) Torque Wrench M&TE~~
~~48. Retorque air start capscrews to 150 ft. Ibs. after each 12-24 hour run until the capscrews no longer advance on retorquing.~~
~~TE Date OQA Date TDI Date Torque Wrench M&TE No. 12 of 24 ,~~ ,~~
~
OF'
l g}NCCI4Ibe.
* (rq O ,, ,,
porinterng.'g."n. CYLINDER HEAD INSTALLATION SECTION C Cylinder No. ( NOTE: When verification of cleanliness is required, a visual inspection of the part and it's mating surfaces will be necessary to ensure they are free of dirt, grit and grime films. Visual inspections will be performed by OQA, TDI representative and the Test Engineer followed by signoffs from all three.
1. Clean inside of combustion chamber. Bar engine over until piston is at bcttom dead center and clean and inspect upper portion of cylinder bore. Clean gasket surfaces of engine block, exhaust pipe, and cylinder head.
TE Date OQA Date , TDI Date (~s 2. Record head serial no. along with the number of cylinder and engine
~~., installed on.~~
~~SERIAL NO. CYLINDER DG TE Date DQA Date 4 TDI Date~~
~~3. Clean and inspect gasket surraces of cylinder head and exhaust ,~~
manifold. , j TE Date OQA Date b TDI Date l N m m see .
~ , s, Ut.c.ntGROgnO,4, Cylin er No. x ; , k;Q
4. Install new seal rings, o-rir.gs, and gromnets on cylinder head' p '3 consisting of: -1 A) (1) F-115-031 SealRibg-Water-HeadtoBlock 3i "
B) (1) JE-007-000 Seal Ring - Combustion - licad to Line#r ' C) (2) F-094-097 0-Ring - hsh Rod Tube Seal ~ w - 'i D) T4) 03-360-05-AE Grommet - Head to Block Water Passag'e - E) (7) 03-360-05-AD Crommet - Head to Block Water Passage F) (1) F-057-009 Flexitallic Garket Exhaust TE Date, OQA Date '
~~?, ~~~
~~x FD1 Date~~
~~5. Verify intake elbow and cylinder head for cleanliness. Clean as necessary.~~
~~TE Date OQA' Date TDI Date '~~
~~6. Attach lifting fixture P/N 00-590-01-BA to cylinder head and hoist Lead ,~~
in place over dylinder head studs. Carefully lower head into place, taking eare not to damage stud threads, seals, or tubing. ,, , ' Clean and lubricate cylinder head studs, nuts, and washers with a 50-50 . mixture of powdered graphite and clean engine oil. ' TE Date OQA Date , s - TDI Date
\ r . ,.>s s )
~~f s-~~
+-
~~e s~~
~~> s s s~~
~~i N- T L. , 3t - , < 2 of 24 %. , e b w . -~~
~~\ n .~~
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.t
~~t. 5 i~~
, ,4 n;TCG ' '-[ ,., 1's ; ,e (,, to.
~~Cy115fer No.' f ?. Torque head bolts in 3 increments in the sequence shown on the attached sheet (Sect.ien G, Attachment 2). s, y~~
~~' , Torque Wrench MSTE No.~~
~~g > s A) 4 ~ 1000 'f t. (1bs.' 4 TE Date 0QA Date~~
, 1 ,,_ 'i s '____- .YJ1 Date \
~~4, B) 2400 ft. Ib s . , TE Date OQA Date~~
\ >s '. .J TDI Date C) 3600 ft. Ibs. ._ , 1, 4
~~TE Date OQA Date 3 ,\~~
~~,' Date TDI s~~
4
~~.'\ 8. Rerove IIfting fixture. 'N'. Inspect and cidan gasket~~
~~surfaces of intake manifold, inlet elbow, and h n cyllader head.~~
~~.s 'h 3,I s g~~
~~TE Date OQA Date~~
~~', TDI Date~~
~~9. Install 2 new gaskets on intake elbow. 03-375-01-0F and 02-375-01-OH.~~
~~t IE Date OQA Date TDI Date~~
~~10. Place intake elbow in position.~~
Clean and lubricate intake elbow capscrews with 50-50 mixture of is po -dered graphite and clean engine oil. (- 8 TE Date OQA Date TDI Date 3 of 24
W !
} , UNr.ONTROIU" - (j~y \ Cylinder No. h for IDk 'r'~M "
~~11. Tighten intake elbow capscrews in 3 equal increments of 10 ft. Ibs. in~~
~~,a ,fa criss cross pattern. Alternate between head and manifold flanges.~~
~~l'/ . Final torque of capscrews to be 30 ft. lbs.~~
?/
Torque Wrench M&TE No. TE Date OQA Date c , TDI Date
~~12. Install a new flexitallic gasket P/N F-057-009.~~
TE Date OQA Date TDI Date g 13. Clean and coat exhaust pipe capscrews with "NEVER-SEZE". Install hand q ,) ' tight. TE
~~Date OQA Date TDI Date~~
~~14. Tighten exhaust pipe capscrews in 3 increments in a criss cross pattern. Final torque of capscrews to be 100 ft. lbs.~~
~~Torque Wrench M6TE No. TE Date OQA Date TDI Date~~
~~-15. Clean and inspect gasket and sealing surfaces of jacket water outlet elbow, jacket water discharge header, dr. esser coupling, cylinder head and spacer.~~
O)
G
.TE Date 0QA Date TDI .Date g,, , t. ~
4 of 24
tiy/'ON'i'- . , [- Cylinder No.
~~16. Tighten jacket water outlet capscrews in 3 increments in a criss cross pattern. .~~
~~TE Date OQA Date TD1 Date~~
~~17. Verify dresser coupling is tight.~~
~~Clean and inspect o-ring groove and gasket seats of air start valve and cylinder head air start valve bore. TE Date OQA Date TDI Date~~
~~18. Install a new o-ring P/N B-5692, and gasket P/N 03-359-01-0E on air G start valve.~~
TE
~~Date OQA Date TDI Date '~~
~~19. Clean and install air start valve taking care not to damage gasket or o-ring.~~
Clean and lubricate capscrews with a 50-50 mixture of powdered graphite and clean engine oil. Install hand tight and tighten in 50 ft. Ib. increments. Final torque to be 150 ft. lbs. Torque Wrench M&TE No. TE Date OQA Date TDI Date O 5 of 24 ; ,
g L l \ UM,t v' TRC4.\ ID
~~., sn t r.'cl x~~
~~pg., gr,t ;ulN ' '~~
s. Cylinder No. U

20. Clean top surface of head and bottom gasket surface of subcover.
~~TE Date DQA Date TDI Date~~
21. Install new gasket, P/N 03-362-01-0C on subcover, iii Date OQA Date TDI Date

22. Install push rods.
Install subcover on head, taking care not to damage gasket or tubing. Clean and lubricate subcover capscrew heads and shoulders with a 50-50 mixture of powdered graphite and clean engine cil. Install capscrews
~~s and rundown hand tight.~~
a
)
~~TE Date OQA Date TDI Date~~
~~23. Tighten capscrews in a criss crosa patter in 3 increments.~~
Torque Wrench M&TE No. A) 40 ft. Ibs. TE Date OQA Date TDI Date B) 80 ft. lbs. TE Date OQA Date TDI Date C) k-/ ( 6 of 24 i *-
t utCIF , M y 7, hvot n
~~Cylinder No.~~
~~'23. - continued C) 120 ft. lbs. .TE Date' OQA Date TDI Date~~
24. Clean and install (2) starting air pilot lines to subcover bulkhead, and from the subcover bulkhead to the valve. Clean and install the lube oil supply line to the subcover. . Blow ;ut the tube with compressed nitrogen or instrument air, which ever is available. Verity lines are-dry. -
~~TE- Date OQA Date TDI- Date~~
~~-25. Install a new gasket, R-2322, and the injection nozzle holder.~~
~~TE . Data OQA Date TDI Date~~
26. Clean and lubricate stud and nut threads with a 50-50 mixture of powdered graphite and clean engine oil. Install nuts on studs hand tight.

TE-
. Date OQA Date TDI Date '27. Torque the fuel injection nozzle retainer nuts in 3 increments to 85-90 ft. Ibs.
~~Torque Wrench M&TE No. TE Date OQA Date A TDI Date~~
~~.t J~~
7 of 24 BC : s
en yyll,0\0 '
-N forif*N)U Cylinder No. , . 28. Clean and install the new high pressure fuel injection line per E&DCR's F-45709, A, B (Section C, Attachment 3) and injection nozzle drain line, taking care to ensure the tube fittings and tube ends are clean, dry and not damaged. Blow out the tube with compressed nitrogen or instrument air, whichever is available. Install tube clamps.
~~TE , Date OQA Date TDI Date~~
~~29. Ensure engine is at TDC firing for the cylinder in question.~~
Verify tappet sockets for cleanliness. TE Date 0QA Date TDI Date fs 30. Check rocker arm bolt holes in subcover for excessive lube oil. Clean
~~-( ) and install intake and exhaust rocker arms on subcover, ensuring the rocker arm shaft seats properly on the subcover.~~
~~TE Date OQA Date TDI Date~~
~~31. Clean and lubricate the rocker arm shaft capscrews with a 50-50 mixture powdered graphite and clean engine oil.~~
~~TE Date OQA Date TDI Date~~
~~./~'T V~~
8 of 24 p. ,< ,
l I opCC @.n\tV' ., b . v
~~,,, u w ~ -~~
p.
~~Cylinder No. b~~
~~32. Tighten the rocker shaft bolts in 3 increments.~~
Torque Wrench M&TE No. A) 120 ft. Ibs. TE Date OQA Date TDI Date B) 240 ft. Ibs. TE Date OQA Date TD1 Date h C) 365 ft. Ibs. IE Date OQA Date
~
~~TDI Date~~
~~33. Clean and install intermediate push rod. Bleed and install lifters.~~
~~Fill lifter cavity with lube oil. TE Date OQA Date TDI Dad~~
~~34. Adjust valves to procedure described in Instruction Manual. Section 6 pages 6-B-5 and 6-B-6 (Section G Attachment 1).~~
Torque jam nuts (4) to 150 ft. lbs. Torque Wrench M&TE No. TE Date OQA Date TD1 Date O 9 of 24 - a s
l VI .C Fv. j , Cylinder No.
~~35. Verify and clean subcover and valve cover gasket surfaces.~~
TE Date OQA Date TDI Date
~~36. Install a new gasket 03-362-01-0D.~~
TE Date OQA Date TDI Date
~~37. Clean and install valve cover - tighten valve cover nuts hand tight.~~
TE Date OQA Date O TDI Date V
~~38. Verify and clean gasket and sealing'eurfaces of air start manifold, dresser couplin,g, air start jumper, head and epacer if used.~~
TE Date OQA Date TDI Date
~~39. Install air start jumper with new gasket F-057-019. Tighten dresser coupling hand tight.~~
5 Date OQA Date TDI Date
~~40. Install air start capscrews with a 50-50 sixture of powdered graphite and clean engine oil.~~
TE Date OQA Date TDI Date 10 of 24 , ,, 1
e
~~O gns -~~
~~j ,,.. , . n 9f 7.,n O Cylinder No. b~~
~~41. Tighten air start capscrews in 3 increments and in criss cross pattern.~~
~~Final torque to be 30 ft. lbs. Torque French M&TE No. TE Date OQA Date TDI Date~~
~~42. Tighten dresser coupling for air start jumper.~~
~~TE Date OQA Date TDI Date~~
~~43. Inspect and clean gas inlet blind flarge and cylinder head mating O surface.~~
~~TE , Date OQA Date TDI Date~~
~~44. Install new gasket 03-451-01-0D.~~
~~TE Date OQA Date TDI Date~~
~~45. Install blind flange and gasket. Clean and lubricate bolts with 50-50 mixture of powdered graphite and clean engine oil. Install hand tight.~~
TE Date OQA D a't e' TDI Date 9 11 of 24 i . l
UNCOMT k onts for\DiOI
~~.<3 Cylinder No. 8 46.-Tighten bolts in 3 increments and a criss cross pattern. Final torque to be 30 ft. lbs.~~
Torque Wrench M&TE No. TE Date 0QA Date TDI Date 47.-Retorque exhaust pipe capscrews to 100 ft. lbs. after each I hour run at full load or 3 hours at less than full load, whichever comes first, while the engine is hot. Continue the retorquing process until the capscrews no longer advance on retorquing. TE Date -0QA Date TD1 Date O Torque Wrench M&TE
~~48. Retorque air st' art capscrews to 150 f t. lbs. after each 12-24 hour run until the capscrews no longer advance on retorquing.~~
TE Date OQA Data TDI Date Torque Wrench M&TE No. rm k,_ - 12 of 24 p,.,., Li
L __. i 1 _ - __._.2 5acrnxv 4 4 C yL. A/0. I thru 8 pg ,,,,,g j Sheet I d'2 uncorn@R. f5 oas e instruction Manua[_p inwn*" b- -
~~.t (PJ 13 *f 2 4 ) -~~
~~h PART B -CYLINDER HEADS AND VALVES (Continued)~~
L l 1 l k lneert a sof t wire in one of the plunger fiti holes then slide the plurvyt out of the barrel *, taking t care not $' >i let the ball dieck valve and the valve retainer drop. Remove the spring from the barrel cavity and wash all items i '
kerosene. Use facquer thinner to remove lacquer and varnish deposits caused by lubricating oil conditions. Do nat prdrg compound or a hard tool to clean the barrel or plunger as this may scratch the surfaces which arefb cioes tolerances. Wipe all parts with a c:ean, lint free ra2- I, l
~~c. The condition of the unit may be best determined by performing a leakdo.vn test. Specifications for a ne,, '~~
urtit require that, with the unit completely assembled and filled with kerosene, the plur.ger should travei 0.125 mch , cne and one half to three seconds when subjected to a 50 pound load. Plungers are not interchangeabfe in the barr j the units are factory assembled for a specific leakdown eate. w ASSEMBLY AND INSTALLATION OF LIFTERS. Assemble lifters in the reversa order of disassembly. Insure that all parts are clean, f ree of dirt or othen forego mattir, and do not stick or tsnd. Fill and purgJ the assembled unit then install in the engine as follows: 3 i Hold 'M check valve off its seat by inserting a soft wire about 3/8 inch into one of the fill holes, thers h
a. j submerge the unit its clean SAE 10 or SAE.20 grade oil. Push in and release the plursger repeatedly until a.r is nn [
~~expelled fron; the assembly. This will purge the unit of air and fill it with oil. j~~
~~b. Remove the wife from the fill hole and remove the assembly from the oil. The plunger should entend 18 inch from the barrel and should not compress when pushed in by hand.~~
~~g 9~~
c. With the rocker arms completely assembled and installed on the cylinder except fer the hydrau!ic r.fn litter assemblies and ad[usting screws (the swivel pad assembly is held in the rocker arm by a roll per 1, fill the ca at / cf the swivel pad with clean oil, f N "
~~Inse*1 the valve lif ter into the swivel pad cavity.The rocker arm must be kept in a near horizontal position~~
.]
d. Sfter the lif ter has t,een inserted to keep the lifter subtrerged in oil. Insta!! the adjusting screw and focknutt f b g ADJUSTMENT. After the litters have been installed, or if a periodic adjustment is to be made, bar the engine over to position the h 3 cylinder being worked on at top dead center on the compresaon stroke and adjust litters by one of the fo!!o.vird methods. The first rnethod (Method "A") irnrolves advancing the adjusting screw until it just contacts the lif ter, bu: } does not compress it, then advancing the screw one additional turn. The siternate method (Method "B") is to crun p'etely collapse the lifter, then back off one full turn from the point where the valve just eats. Either metud if i properly done, will accomplish the same thing. It must be kept in mind, homer, that cold oil will increase tiie time h required fcr the lif ter t , leak down to complete collapse when usirrg the latter rnethod.
~~a. M ETHOD "A" .~~
f Hold the rocker assemblies tight against the pushrods to remove all play, then advance ado :'r7 j (1) screw by hand until the end of the screw just contacts the lif ter under it, taking up all the stack in the vaf ve opero rs ni y l j q geer. Make sure the swivel pad rests souarely on the valva stem. Due to variations in threads, the feel of turrvnq; th 55 g ad;usting screw is not sensitive enough to make an accurate determination as to when all sf ack has been remov fore, the feel for takir.g up the stack has to be on the pushrod or cross (intermediatel rod and the swi e+ pid i n the e M admting screw. Litt each synvel pad by hand to make sure that a'l clearence is remov M betwee the smvel ra the valsr' stem )
)
tm McW G cyLe No.Ithru8 #i% ch,,egy,, j' OS / ghcg7,7gottotmatu.n Sheet 2ol'2 e.a s Instruction Manual m
# ' - (pg /4 o.f 2 4 ) ~
PART B - CYLINDER HEADS AND VALVES (Continued) (2) Turn the adjusting screw one full turn (0.070 trd) with a wrench and tighten the locknut. This will locats the lifter plunger near the midde of its 1/8 frd travel.
~~b. METHOD "8".~~
(1) Advance adjusting screw with a wrench until the volve begins to lift of f its seat,then advance adjusting screw at least two additional carns. - (2) Wait approximamly ten seconds (longer if oil is cold) then back off on adjusting screw untilvalve seats. The point at wwhich the valve seats may be eas.ly felt by the reduced torque required to turn the screw. (3) Note the position of the wrench et the point where the valve just seats, then advance screw at least onw-half tum. (4) Back out adjusting screw until valve just seats. If the rosition of the wrench is the same as (3) above, the litter is fully collapsed. If net, repeat procedure until the position of the wrench is the same each time tha valve seats. (E) Back out adjusting screw one futi turn from position whera valve seated thentighten locknut. p D c. Ewivel pads should now be free 'to be rotated by hand, if they cannot be rotated, the adjusting screwhas collapsed the lifter to the end of its 1/8 inch travel and the valve has been lifted off its seat.
d. Swivel pod clear,mes should be such that the pad cannot be rocked on top of its valve stem. If the sw: vel pad can be rocked it means that the lifter is either fully extended and not at the mid point of its travel, or that it has not been completely purged of air.This may be due to an improper adjustment caused by burrs or dirt on the edjusting screw threads, or because of incomr*,,ie surging of air from the assembly.
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'# 0E 8 0Fh as2:o 498 I . STONE C .WEBSTEft ENGINEERING CORPORATION k T i
~~ENGINEERING. E. DESIGN 2 COORDINATION REPORT . _ . _ ..._l _ . #1 _. M U_ "1 i~~
~~JOB NO P. EoJECT / CLIENT: l~~
~~' SHOREH AM NUCLE AR POWER $1 ATION UNIT t~~
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PROBLEM DESCRIPfl0N: M N l W ')' Q., )f sf 24 ) Ruptured diesel engine high pressure reference fuelLDR injection No. 1140 lines & 11.; 8 . have been documented on two occasions: tube crack propa ;atec Preliminary failurg analysis indicates that a as a result of p f rom a seam locaty on the tut.e inner surf ace, ,
- high cycle fatigue. \- .
~~W g. O - i t .s r_., -~~
~~.L/ c. .u DL D 3 g,p3,js sef [.,p '~~
~~f T E L E C OPY DATES e~~
~~" r. . I h.03 (REQUESTING PAATY)~~
~~C '. . ... ..,N OfiJl J R c v.d~~
. p -,7 . g Dept Or %. "Ttte T a t. ~ 0 e Noeced By iloquested By NN M 9_ TY_ '.' 3 _ _ _ _ . . . _ .
l'ROBLEM SOLUTION: (1) All F. O. Injection lines to be replaced with TDI P/N 02- R5-C5 '. Refer to page 3 fer pr ci . - a shrouded.high pressure fucl 1inc. TDI mar.ual to be updated. { } 1mprovement bul l r't i n . o l) ' (2) Refer to page 4 for shrouded fuel line qualification letter. 6 (3) To insure no tu irements: b t' I.D., seams. P.O. to state the following tubir.g inspection requ Each length"of u ing uhed in the manufacture of the TELECOW DATES ArrtCTs woow usoER spec,rtC AT DN SH h VER*iED Br
~~' ~ -~~
~~Seat: p , ,.d. IMPLEMENTATION VERIFIC TION RE JiRED [l t5~~
~
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Project desegn Ecgr Dole O INFOR L' ATION ONL9 gg - Es AR CH ANGE O v.. 7tN _ _ _ . O ORAWING CHANGE Equipm at Speticlett Tclw .- e CLIENT APPROVAL-O SPECirtCatioN CH ANGE /7.3 g Reaures O N e R'ae XO ENG N4SE RV $ COOL OF WORu CHANGE CHANGE 'g K g ) . Cu, Qual. s.D. orEnD A E.~ Date l Ob'oired O ct e <// , A ; Clio80s will k be latorporated sh the gQ - q g ,,,g,
'r,4 Ng ,'v' w ell mot O f ollomatig dacurrients Meteriets Eegt Date ( =~"~~""}_, , . . . _ . . . _ _ _l CLIE NT 0.$TRIBuT tCN - CLIE '.1#.f A" ".~5'-
~~2 C .g &} Q yz, _ m-Q r:r.w-- - = . _ _ _ _ _ _ _ _ _ n U, Empoonag _ _ . _ _ . . . _ _ E iever AAp' of Pro te [~~
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~~Notteer Sof ety Retoted (Q A Cot 1) LJ*ote~~
~~' - - ~ ~ ~~~
~~d Net kwcteor safety R4fo'ee O QA Cet ET C0 A Cet -_El) lO ft ._ _~~
< J h_f . O. _ __ _ S _T__~.T .~.' _~.' _ . ' $ set n . c o a e, C OP.s t t'[ A 0 0u ART L RS FIELO OtSTRaeuT(ON I
O ch.et E nge - g o..g.ao t or Th' - O Ste tarei . i g /,%. ,-t . .v .s . . i Pr O wec N *,coi . lO . I l k osos EageDas Face _ DCh.et_ DenEegr. _ O ct. eat GA uc+ _ O x i.1 s m /u, . O r,eet.eo, m e s, tas, O sopi Coasi s.., O C...at Coast in , _ _ _ g.. ,gw; :.. L,, w. s _%_ .
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~~\ SECTI ONEV A#ad 3 ~~~
~~i .~~
s h eef 2 af 9 I t]t kk '3 [py / 7 et 24) 9 5 shrouded fuel lines (pressure boundary tube only) to have transverse sample cut from each ,end. Mount sample, polish,
,/
etch, and examine at 100x. both I.D. and O.D. surfaces r.ust meet the requirements of item 4. " Finish", of Design Spec, for TDI P/N 0266 (attached) . , In addition to certificate of compliance to P/N ano SH1-89. inspection reports for each length of tube to be supplied by TDI. This requirement applies to replacement and spare F.O. injection tubes. , L c Copy of E6 DOR to be sent to each holder of TDI instructior. manual R43/13 by re, cord s management. i i : t 1 I MTA0NBC10 E & DG G '..'9.5 = 70"I 0 d i I c-Cy4. AO. l thru 8 ' j , , , , , ,
I i SEc7/CN G *WcN 3 Shoef 3of7 s gege.e and Corrpr: dor Dission y ' ill .1 (Ps 18 *M)sneet 1 at 1
~~/ .~~
OPERATING Product improvement SUPPO RT' BULLET 1 I 1- ::--= _a;_!N ;=- t l *
' SHl10UDED HIGH-PRESSURE l FUEL LINES Nr; Cm. . 'y ' ,-Y ,j \.y, M #
1 S c,r R-4 and RV-4 SERIES l' One of the engine prob: ems mos' watched for by d.esel eng.no opere! ors s leak.ng particularly an the high pressure hneiromineiniectionpu nptotheinjector assemNy An unde'e
~~4. f. leak in this kne is a serious hre l'azwt.and maylead to other adverse consequences Tran b~~
Delavat resultant engine hasroom developed fire. a method of not only detecting such teaks Quickly. but minitti Pump to injector fuel hne feaks are usual'y caused by one or necte of these factors 1. Excessive viscosity. pressure'- ust ally caused by a plugged in:cct.on tip or uncentroi.ed ise. c.1 2. Cavitaten crosion - this ConCitiorus aggravated by Lesvy fuel due to the er a,Oci..ng; of many of its Const;tuents o', 3 Damagea luet hn? t Wheh a leak CCCurs the pressure produced by the in;estion o.smp forces atmosphere. lue... a fire will ensue If the spray mees con:act with any suriace whichis hatterina,tr.eign.t.onge. uni of tt. the r uct oil m t .: tv Fur:hermore, if the leak is attowed to contisive, a combustion pressu e ambalance may deve!op, with potential torsional etters Transamenca Dehval's SHROUDED FUEL INJECTION LINE was deveiopec to be a (wo to's , protection against the effects of heq4 pressure fuelline leans The design cons sts of a soec:al:y. treated steel tube, with both ends suaged to seat in pump and in;ccio" A steel snic:d encloses this high-pressure tube in its entirety. and ettectively prevents tuct trom a suptu'c in tne in;ection tute from reaching a source of ignition Leakage fuelis collecttd m a header and fant which coeta ns an alarm device to indicate such ledage The design has teen approved by the Amentan Barcau et Shippeg. and the shrouded fuellenes are now in successtut operat.on on man y o' cur custo . aengines. few including U S Steel, Amencan President Lmes. and Met.tarf Seat.ft Corrmand. to r.a. .c lhe shrouded fueleniection hnt is as 4ttab'e tot both R.4 and R V-4 atP' r ation'. Il s', rnost acpRatre in the following installations. g
1. Manne unds

2. Units running on heavy fuct V : : . .li.1 5 V 1 Any instat:ation wati an e una'terdec of patent.a ly unatter.ded eng ne r;;ri D" .
~~Th.s product operator support and improvement caucat on - is gus* ort c.a t oi 1ransanierica Oe:aa. s cent.r 7 9 proya A~~
~~, ADNBf, TO o~~
E & DQ ht0,:.gn.e9 1 c.yc.Ndt -l thru 8 surrosii ^*.a smvic- .pi e > 'ifatt'"i"n' "t 'u'^:'~"
~~" 7~~
~~s. ItdilUUlllUIIUM Semw Oclaval~~
, t . g. .,e co,an.mc.c t......on phfled 3 ?ll:,*;;7 su,,s 4 a 9 '- "z Rl 5 Or.ittand, Cal fo eia ut0t i
~~(< 15) 577 74tni jy g/ 2y~~
--t . , o' April 20, 1983 ,, ,d ', Q- .'< ,0 (-'>-
1 Q '" [,,,6 Long Island Lighting Company yo: Shoreham t;oelcar Power Station' P, O. Box 618 Wading River, New York 11792 Attentien: P'r. Nea l _ M. Rudikoff
~~~ "~~
~~Subject:~~
~~Diese'l [Cencrators TDI S/h 7t.010-12~~
~~' Shrouded Fu.l Line Qualification TDI P/N 02-365-05-AL 6~~
~~Agtachment: R&D Te'it Sumary, RV-00 5 - C" 6 Gentlemen; i~~
9 The double vjlled fee) injcqrion 02-365-05-AL, between the fuel pump ar 4 injector was develc, ped f or unat tended engink operation.8 Its function is to contain any g line, TDI Part No.
~~fuel spray resulting from a fjel injection line failure; t he r eh::~~
precluding atriking the exhaust the' possibility of a fire arising from fuel spray piping. The outer tube i, not desis;ned a-a pressure retaining portion of the fuel line and will not s e r v<- as a backup should the primary line fail. This injection line I.as the same high pressure ttibing, tube end style, geometry, and support poants as thc original l i r.e . The only difference is that an additional thin wa)) tube surrrunds the primary tube, and some changes have been made to tne injection line nuts to allow for scaling of the outer tube area. The injection line has been extensively tested, both in pre crerational test inp, (referenced R6D Test attached) and in subsequent marine us<. Tnis testing has shown the tubing functions an designed with no o;trational ' problems ensuin.g from normal hydraulic prc6sorca er vibrations. On the basis of this research and experience, TDI has accepted the - alitouded fuel 1,ine as qualified for nuclear use. If you have any further questions regarding this natter, p l c m.e ! d4 not he.sitate,to contact me. h '
~~? V ty truly yours, ,~~
~~hk'.~~
~~# ' ..ec:Hr.~~
~~Mr. T. Paulantonio R. p att M r . D . k'u l f - I~~
'. " .Lanny ):c hoghm f.ng s r ce r , e /
A
~~' m er G/[% i i~~
~~l": t M. i~~
, f.usto AlTArOffNT T0 se VJ AL finrti g - '! E% nmc mm
_. _ _ --_-- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - ~ ~
T , l' h,$ECMON S GEGch. 3 ENGINE AND .I
~~$Jdof MS */ @[24 9)~~
COMPRESSOR DIV'3 TON *$ (P.9 T.i = % ( hg DESIGN SPECIFICATIO'; nn. : HIGH PRESSUPI PUEL INJECTION jrUBING V g. D5,**" I D l 266 wo. a etsenienow- , I satti
~~) c. p ,, THIS SPECIFICATION COVERS COL p-DRAWN , DEAD SOFI ANI.r Anc.s SEAM 1ISS STEEL PRESSURE TUBING, (115 TO 129 MA7.. EHN).~~
~~I l - L~~
~~1. USE: TO CARRY FUEL OIL FROM THE FUEL INJECTION PUMP TO THE SPRAY N0ZZLE USED ON DIESEL ENGINES AT PRESSUPI AS~~
~~.HIGH AS 14,000 LBS./SQ. IN. WITHOUT YIELDING. . t~~
2. MATERIAL: sap l'1008, OH SAE 1010 STEEL l .
3 TOLERANCES: TUBING TO HAVE THE FOLLOWING TOLERANCES: I.D. PLUS OR MINUS .0025" 0.D. PLUS .005" w MINUS .000"
~
~~4. FINISH: "' U BING ,'f0 BE FINISHED ON A MANDPIL TO INSURE~~
~~,}}~~

ML20083G315

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