SPECIAL Diesel Engine Maintenance Training Manual
CONTENTS
Chapter 1. Troubles: Their Symptoms and Their Causes
A. General Trouble Shooting Procedure
1A1. Recognizing and locating troubles
B. Engine
Fails to Start
1B1. Engine will not crank but can be barred over
1B2. Engine cannot be cranked and cannot be
1B3.
C. Unusual or Erratic Operation
1C1.
1C2.
Engine stops suddenly
1C3.
Engine overspeeds
1C4.
Engine will not carry load (loss of power).
1C5.
Engine will not shut off
1C6.
1C7.
1C8.
Cylinder safety valves pop frequently during engine operation
1C9.
Engine will not reach rated speed
1C10.
Engine hunts (speed varies at constant throttle setting)
D. Noises
1D1. Pounding
1D2. Knocking
1D3. Metallic clicking
1D4. Rattling
E. Instruments — Pressure
1E1. Low lube oil pressure
1E2. High lube oil pressure
1E3. Low fuel oil pressure (in low-pressure fuel supply system)
1E4. Low cooling water pressure (fresh)
1E5. Low cooling water pressure (salt)
1E6. High cooling water pressure (salt)
1E7. Low compression pressure
1E8. Low firing pressure 6
1E9. High firing pressure 6
1E10. Low scavenging air receiver pressure (super-charged engine) 6
1E11. High exhaust back pressure 6
R Instruments — Temperature
1F1. Low lube oil temperature 6
1F2. High lube oil temperature 6
1F3. Low cooling water temperature (fresh) 6
1F4. High cooling water temperature (fresh). 6
1F5. Low cylinder exhaust temperature 7
1F6. High exhaust temperature in one cylinder 7
G. Instruments — Correlation of Cylinder Exhaust Temperature and Cylinder Firing and Compression
Temperatures
1G1. Low firing pressure and low exhaust temperature 7
1G2. Low firing pressure and high exhaust temperature 7
1G3. High firing pressure and low exhaust temperature 7
1G4. High firing pressure and high exhaust temperature 7
1G5. Low compression pressure and low exhaust temperature 7
1G6. Low compression pressure and high exhaust temperature 7
1G7. High compression pressure and low exhaust temperature 7
1G8. High compression pressure and high exhaust temperature 7
H. Instruments — Speed
1H1. Idling speed not normal 7
1H2. Maximum speed not normal 7
I. Presence of Smoke
111. Black exhaust smoke 8
112. Bluish-white exhaust smoke 8
113. Smoke arising from crankcase 8
114. Smoke arising from cylinder head 8
115- Smoke arising from engine auxiliary equipment such as blower, pumps, etc 8
J. Excessive Consumption of Lube Oil, Fuel, or Water
1J1. Excessive lube oil consumption 8
1J2. Excessive fresh water consumption 8
1J3- Excessive fuel oil consumption 8
K. Contamination of Lube Oil, Fuel, or Water
1K1. Fuel oil in lube oil 8
1K2. Water in lube oil 9
1K3. Oil or grease in water 9
1K4. Water in fuel oil 9
1K5. Air or gas in water 9
1K6. Metal particles in lube oil . 9
Chapter 2. Air Intake System
A. Blowers
2A1. Introduction 11
2A2. Turbochargers 12
a. Possible trouble — Damaged shaft or thrust bearings 13
b. Possible trouble — Damaged turbine blading 14
c. Possible trouble — Damaged nozzle ring 15
d. Possible trouble — Damaged blower impeller 16
2A3. Roots type blowers 17
a. Possible trouble — Worn gears 17
b. Possible trouble — Scored rotor lobes and casing 18
c. Possible trouble — Blower shaft oil seals leaking 20
d. Possible trouble — Failure of serrated shafts 21
2A4. Hamilton-Whitfield blowers 21
B. Air Passages
2B1. Troubles in air passages 22
a. Possible trouble — Foreign bodies in manifold 22
b. Possible trouble — Excess accumulation of oil in manifold or air box 23
C. Air Heaters
2C1. Electrical air heaters 24
a. Possible trouble — Failure of electric air heater to operate 24
2C2. Flame primers for air heating 25
a. Possible trouble — Failure of flame primer to operate 25
D. Air Cleaners and Silencers
2D1. Introduction 25
2D2. Dry, or viscous type air cleaner and silencers 25
a. Possible trouble — Clogged and dirty air cleaner 26
b. Possible trouble — Explosion from using volatile solvents for cleaning 26
2D3. Oil bath type air cleaners and filters 26
a. Possible trouble — Excess oil in cleaner causing engine to run away 26
Chapter 3. Exhaust System
A. Manifolds
3A1. Introduction 27
a. Possible trouble — Cracked manifold 27
B. Silencer
3B1. Introduction 28
3B2. Wet type silencers 28
a. Possible trouble — Back flow of water into engine 28
b. Possible trouble — Corrosion of muffler 30
3B3- Dry type silencers 31
a. Possible trouble — Excessive accumulation of oil or soot in the muffler 31
b. Possible trouble — Baffles or end plates broken loose 31
C. Piping and Stacks
3C1. Piping 32
a. Possible trouble — Restricted exhaust piping 32
3C2. Stacks 34
a. Possible trouble — Corrosion of exhaust stack 35
Chapter 4. Fuel Systems
Section 1. Transfer Pumps 37
A. Gear Pumps
4A1. Introduction 37
4A2. General description 37
a. Possible trouble — Leakage at shafts 37
b. Possible trouble— Insufficient discharge. 39
B. Vane Pumps
4B1. General description 39
a. Possible trouble — Insufficient fuel supplied to injector pumps 40
C. Plunger Pumps
4C1. General 41
4C2. The Bosch fuel transfer pump 41
a. Possible trouble — Bosch fuel transfer pump fails to operate 41
4C3. The Excel lo fuel transfer pump 42
Section 2. Injection Pumps and Nozzles 42
D. General
4D1. Functions of the system 42
4D2. Types of fuel systems 42
E. Bosch
4E1. General description 43
a. Possible trouble — Damaged plunger and barrel assembly 45
b. Possible trouble— External leakage from pump 46
c. Possible trouble — Plunger stuck in barrel 47
d. Possible trouble — Control rack sticky or jammed 47
e. Possible trouble— Delivery valve inoperative 48
f. Possible trouble — Backlash (looseness or play) in control rack 49
g. Possible trouble — Pump improperly timed 49
h. Possible trouble — Pumps improperly calibrated (balanced) 50
i. Possible trouble — Broken plunger spring 50
4E2. Spray nozzles and nozzle holders 51
a. Possible trouble — Nozzle opening pressure too high 51
b. Possible trouble — Nozzle opening pressure too low 55
c. Possible trouble — Dribbling (leaky) nozzle 55
d. Possible trouble — Distorted nozzle spray pattern 56
e. Possible trouble — Nozzle fails to chatter 57
f. Possible trouble — Excessive overflow from nozzle leakoff connection 57
g. Possible trouble — Nozzle turns blue after service in engine 58
F. General Motors
4F1. General description 60
a. Possible trouble — Damaged plunger and bushing 60
b. Possible trouble — External leakage from injector 61
c. Possible trouble — Plunger stuck in bushing 62
d. Possible trouble — Rack sticking or jammed 63
e. Possible trouble — Backlash (looseness) of rack 64
f. Possible trouble — Broken plunger spring 64
g. Possible trouble — Dribbling from spray tips 64
h. Possible trouble — Distorted spray pattern 64
i. Possible trouble — Pop pressure too high 65
j. Possible trouble — Pop pressure too low 65
k. Possible trouble — Injectors not balanced 66
I. Possible trouble — Injectors improperly timed 66
G. Excel I o Fuel Injection Equipment Type A Pump
4G1. General description 67
a. Possible trouble— Pump unbalanced 69
b. Possible trouble — Scored plungers and cylinders 70
c. Possible trouble — Sticking plungers 70
d. Possible trouble — System air bound 71
4G2. Exccllo fuel injection nozzle 72
a. Possible trouble — Faulty injector nozzles 72
H. Cummins Fuel System
4H1. General description 73
a. Possible trouble — Scored distribution disk and cover 75
b. Possible trouble — Damaged metering pump plunger and barrel 77
c. Possible trouble — Damaged priming valve 77
d. Possible trouble — Sticky injector plungers 77
e. Possible trouble — Worn or scored injector plungers 78
f. Possible trouble — Clogged injector spray holes 78
g. Possible trouble — Worn injector cup tip 78
I. Atlas Fuel System
411. General description 79
a. Possible trouble — Improper timing of fuel system 82
b. Possible trouble — Clogged spray orifices 83
c. Possible trouble — Leaky nozzle tip 83
d. Possible trouble — Worn spray valve packing 83
c. Possible trouble — Improper functioning of pressure regulating valve 83
J. Cooper-Bessemer Fuel Injection System
4J1. General description 84
4J2. The fuel oil pump 84
a. Possible trouble — Pump fails to operate properly 85
4J3. The accumulator bottle 86
4J4. The fuel injector (distributor) 87
a. Possible trouble — Injector operates improperly 87
4J5. The fuel injection nozzle 90
Section 3- Fuel Links 90
K. Low-Pressure Lines
4K1. General description 90
a. Possible trouble — Threaded pipe joints breaking at root of threads 90
L. High- Pressure Lines
4L1 . General description 91
a. Possible trouble — Broken high pressure fuel lines 91
Section 4. Filters and Strainers 92
M. Filters
4M1. General description 92
a. Possible trouble — Filter clogged before 500 hours' operation 92
b. Possible trouble — Air in filter 94
c. Possible trouble — Leaky filter case 95
N. Strainers
4N1. General description 96
a. Possible trouble — Broken scraping mechanism 96
Section 5. Tanks 97
O. Fuel Oil Tanks
401. Introduction 97
a. Possible trouble — Leaking tank 97
b. Possible trouble — Corrosion of tank interiors 98
c. Possible trouble — Suction and vent lines rusting through 98
Chapter 5- Speed Control System
A. Mechanical Governors
5A1. Introduction 99
5A2. General description 99
5A3. G.M. 71 series mechanical governor 100
a. Possible trouble — Stripped splines on governor drive shaft 100
b. Possible trouble — Broken high or low speed springs 101
c. Possible trouble — Excessive wear of governor parts or external linkage 101
d. Possible trouble — Binding in governor or linkage 101
e. Possible trouble — Low speed spring tension improperly adjusted 102
f. Possible trouble — High speed spring tension adjustment improper 103
g. Possible trouble — Improper gap clearance 103
h. Possible trouble — Buffer screw adjustment improper 103
5A4. Pierce mechanical governor 103
a. Possible trouble — Broken or loose fly- balls 104
b. Possible trouble — Worn shaft bearings . . 105
c. Possible trouble — Worn thrust sleeve face 105
d. Possible trouble — Improper adjustment of pump control rod positioning screw 105
e. Possible trouble — Improper adjustment of speeder spring tension
f. Possible trouble — Improper adjustment of speed droop
g. Possible trouble — Stickiness in governor or external linkage
h . Possible trouble — Stripped or worn drive gears
B. Hydraulic Governors
5B1. Introduction
5B2. Sources of information
a. Possible trouble — Low oil level
b. Possible trouble — Stickiness of governor mechanism or linkage
c. Possible trouble — Governor improperly adjusted
d. Possible trouble — Damaged drive shaft.
e. Possible trouble — Drive gear clearance improper
f . Possible trouble — Leaky oil seals
g. Possible trouble — Foaming of governor oil
C. Overspeed Safety Devices
5C1. Introduction
5C2. Types of speed governors
a. Possible trouble — Trip operates below specified tripping speed
b. Possible trouble — Trip fails to operate at specified tripping speed
Chapter 6. Lubricating System
A. Lube Oil Pumps
6A1. Introduction
a. Possible trouble — Lube oil pump failures
B. Oil Coolers
6B1. Introduction
a. Possible trouble- -Excess scale on cooler tubes
b. Possible trouble—Leakage of oil tubes . .
c. Possible trouble—Corroded zinc plugs and plates
C. Valves
6C1. Introduction
6C2. Line valves
a. Possible trouble — Leaking valve (globe
and angle valves)
b. Possible trouble — Leaking valve (gate valves)
c. Possible trouble — Leaking valve stems.
6C3. Check valves
a. Possible trouble — Leaking check valves
6C4. Pressure regulating valves
a. Possible trouble — Defective pressure regulating valve
6C5. Temperature regulating valves
D. Oil Lines and Passages
6D1. Cleanliness
a. Possible trouble — Plugged lube oil lines
b. Possible trouble — Cracked lube oil lines
E. Centrifuges, Strainers , Filters
6E1. Introduction
6E2. Centrifuges 133
106 a. Possible trouble — Oil discharged from water outlet 133
106 b. Possible trouble— Bent shaft 133
c. Possible trouble — Failure to use and to clean 133
6E3. Strainers 134
107 Possible trouble — Broken scraping mechanism 134
107 6E4. Filters 134
109 a. Possible trouble — Filter clogged prematurely 135
109 Chapter 7. Cooling System
A. General
110 7A1. Introduction 137
112 B. Heat Exchangers
7B1. General 137
115 7B2. Harrison type cooler 138
115 a. Possible trouble — Excessive scale on cooler element 138
116 b. Possible trouble — Clogged cooler element 139
115 c. Possible trouble — Leaky cooler 140
117 7B3. She 11 -and -tube type 140
a. Possible trouble — Excessive scale deny posit on cooler tubes 141
b. Possible trouble — Clogged cooler element 141
c. Possible trouble — Leaky cooler 141
C. Pumps
7C1. General 141
121 7C2. Centrifugal pumps 141
a. Possible trouble — Insufficient discharge. 142
b. Possible trouble — Scored shaft or shaft
121 sleeve 143
c. Possible trouble — Broken shaft 144
123 d. Possible trouble — Clogged impeller 144
126 c . Possible trouble — Worn or broken im- peller 144
127 f. Possible trouble — Corrosion of pump parts 146
128 g. Possible trouble — Shaft seals worn 146
128 h. Possible trouble — Poor condition of shaft bearings 147
128 j. Possible trouble — Excessive wear of wear rings 147
130 7C3. Gear pumps 147
130 a. Possible trouble — Insufficient discharge 147
131 b. Possible trouble— Scored shaft 148
131 c. Possible trouble — Broken shaft 148
131 d. Possible trouble — Damaged pumping gears 149
131 e. Possible trouble — Corrosion of pump parts 150
f. Possible trouble — Shaft seals worn 1 50
132 g. Possible trouble — Poor condition of shaft bearings 150
132 D. Valves
7D1. General 150 7D2. Manually operated valves: general 151
7D3. Manually operated valves; lubricated plug type 151
a. Possible trouble — Valve improperly lubricated 151
7D4. Thermostatic valves: general 152
7D5. Thermostatic valves : automatic temperature regulators 152
a. Possible trouble — Valve improperly adjusted 152
7D6. Thermostatic valves: automotive type thermostat 154
a. Possible trouble — Inoperative thermostat 154
E. Passages and Piping
7E1. General 155
7E2. Passages 155
a. Possible trouble — Excessive scale formation in passages 156
b. Possible trouble — Corrosion of cooling water passages 156
c. Possible trouble — Leaky cooling passages 156
7E3- Piping 157
a. Possible trouble — Clogged water line . . . 158
b. Possible trouble — Leaky water piping. . 158
F. Strainers
7F1. General 161
a. Possible trouble — Clogged strainer basket 161
b. Possible trouble— Corroded strainer basket 162
Chapter 8. Starting Systems
A. Introduction
8A1. General 163
B. Electrical Starting Systems
8B1. General 163
a. Possible trouble — Dirty commutator... 163
b. Possible trouble Burned brushes 164
c. Possible trouble — Weak insulation 164
C. Air Starting Systems
8C1. General 165
8C2. Compressor 166
a. Possible trouble — Compressor overheating 166
b. Possible trouble — Excessive belt wear . 166
c. Possible trouble — Squeaking V-bclts . 167
8C3- Receiver or tank . 167
a. Possible trouble -Sticking safety valve . 167
8C4. Timing mechanisms: general 167
8C5. Timing mechanisms: direct mechanical lift type 167
a. Possible trouble — Improper adjustment 167
8C6. Timing mechanisms: rotary distributor — . 168
a. Possible trouble— Inoperative distributor 168
8C7. Timing mechanisms: plunger type distributor valves 168
a. Possible trouble — Stuck distributor valves 168
8C8. Air starting valves 169
a. Possible trouble — Air valve sticking open — air actuated 169
b. Possible trouble — Leaking air valve — mechanical lift 170
Chapter 9. Electrical Systems
A. Storage Batteries
9A1. General 171
a. Possible trouble — Dead battery 172
b. Possible trouble — Rapid loss of electrolyte level 174
c. Possible trouble — Corrosion of battery terminals 175
d. Possible trouble — Burned terminals 175
e. Possible trouble — Battery explosion ... 176
B. Generators and Generator Control
9B1. Generators 177
a. Possible trouble — Generator not charging — defective generator 177
9B2. Generator controls 179
a. Possible trouble — Generator improperly charging — control unit defective ... . 179
C. Relays and Contactors
9C1. General 181
a. Possible trouble — Burned contacts 181
b. Possible trouble — Magnetic device fails to engage pinion and close circuit 182
D. Wiring
9D1. General 182
a. Possible trouble — Burned insulation 182
b. Possible trouble — Short circuits 183
E. Electrical Remote Control Devices
9E1. General 183
9E2. A.C. Sclsyn motor 184
a. Possible trouble — no response to changes of transmitter 184
9E3. D.C. Selsvn motor 185
a. Possible trouble — Sclsyn fails to operate 185
9E4. A.C, D C. split field motor 185
a. Possible trouble — Motor fails to operate 185
b. Possible trouble — Slip coupling too loose 186
Chapter 10. Engine Frame, Sub-Base, and Mountings
A. Engine Frame
10A1. General 187
a. Possible trouble — Cracked frame 188
b. Possible trouble— Clogged oil passages. 190
c. Possible trouble — Excessive scale formation in passages 191
d. Possible trouble — Dirty air passages .... 191
e. Possible trouble — Crankcasc explosion . . 192
B. Sub-Base
10B1. General 194
a. Possible trouble — Cracked sub-base 194
b. Possible trouble— Warped sub-base 194
C. Mountings
10C1. General 195
a. Possible trouble — Inoperative vibration isolator 197
Chapter 11. Cylinder Assembly
A. Introduction
11A1. General 199
B. Cylinder Liners
11B1. General 199
a. Possible trouble — Cracked or broken liner 201
b. Possible trouble — Scored liner 203
c. Possible trouble — Obstructed liner ports 204
d. Possible trouble — Worn liner 205
C. Cylinder Heads
11C1. General 208
11C2. Parts 209
a. Possible trouble — Cracked cylinder head 210
b. Possible trouble — Burned or corroded cylinder head 211
C. Possible trouble — Distorted cylinder head 212
d. Possible trouble — Fouled combustion chamber 212
D. Cylinder Head Studs
11D1. General 213
a. Possible trouble — Stripped or broken stud 214
E. Cylinder Head Gaskets
11E1. General 217
a. Possible trouble — Leaky gasket 218
Chapter 12. Valve Gear
A. Exhaust Valves
12A1. Mushroom type valves and assembly 221
a. Possible trouble — Exhaust valve sticking open 221
b. Possible trouble — Burned valves 222
c. Possible trouble — Broken valve springs 224
d. Possible trouble — Worn valve keepers and retaining washers 225
e. Possible trouble— Valve head broken off valve stem 227
12A2. Hamilton supercharge valves 228
a. Possible trouble — Supercharge valves do not rotate 228
B. Intake Valves and Ports
12B1. Poppet type valves 230
12B2. Ports 230
a. Possible trouble — Dirty and clogged intake air ports 230
C. Rocker Arms and Push Rods
12C1. Rocker arms 230
a. Possible trouble — Worn bushings 230
b. Possible trouble — Excessive wear on pads and end fittings 230
c. Possible trouble — Tappet adjusting screws worn 231
12C2. Push rods 231
a. Possible trouble — Worn and loose end fittings 231
D. Cam Followers and Lash Adjusters
12D1. Roller type cam followers 231
a. Possible trouble — Worn roller surface . . . 231
b. Possible trouble — Worn cam follower body and guide 232
c. Possible trouble — Worn roller needle bearings 232
12D2. Mushroom type cam followers 232
a. Possible trouble — Worn surfaces 232
12D3. Hydraulic valve lifters or lash adjusters 232
a. Possible trouble — Noisy operation of valve lifter 233
Chapter 13. Piston and Connecting Rod Assembly
A. Pistons
13A1. Trunk type pistons 235
a. Possible trouble — Worn piston, excessive clearance 235
b. Possible trouble — Cracked crown 238
c. Possible trouble — Cracked lands 239
d. Possible trouble — Piston skirt seizure . . 240
e. Possible trouble — Crown and land dragging 241
f. Possible trouble — Ring groove clearance insufficient 241
g. Possible trouble — Clogged oil holes ... . 241
h. Possible trouble — Piston pin bushings worn 242
13A2. Crosshead type pistons 243
a. Possible trouble — Worn and damaged piston skirt band on Hamilton-HOR pistons 243
B. Piston Rings
13B1. General 244
a. Possible trouble — Worn compression rings 245
b. Possible trouble — Worn oil rings 249
c. Possible trouble — Sticking rings 250
d. Possible trouble — Broken rings 251
C. Piston Pins and Piston Pin Bearings
13C1. General 252
a. Possible trouble — Worn piston pins 252
b. Possible trouble — Surface pitting and scoring of pins 253
c. Possible trouble — Worn bushings 254
d. Possible trouble — Worn needle bearings 255
D. Connecting Rods
13D1. General 255
a. Possible trouble — Misaligned rod 255
b. Possible trouble — Cracked rods 256
c. Possible trouble — Defective bolts 257
d. Possible trouble — Plugged oil passages. 28
c. Possible trouble — Bore out-of-round — 258
E. Cross heads and Piston Rods
13E1. Crossheads 259
a. Possible trouble — Broken crosshead .... 261
b. Possible trouble — Damaged crosshead pin and bushings 263
c. Possible trouble — Wiped or pitted babbitt material on slipper 264
13E2. Piston rods 265
a. Possible trouble — Scored piston rod 265
b. Possible trouble — Broken, shattered, bent, or seized piston rod 267
Chapter 14. Engine Shafts
A. Crankshafts
14A1. General 269
a. Possible trouble — Scored journals 269
b. Possible trouble — Broken or bent crankshafts 271
c. Possible trouble — Out-of-round journals 275
B. Camshafts
14B1. General 277
a. Possible trouble — Damaged cams 277
b. Possible trouble— Broken shafts 279
c. Possible trouble — Failed camshaft bearings 280
Chapter 15. Engine Journal Bearings
A. General
15A1. Introduction 281
a. Possible trouble — Journal bearing failures 282
Chapter 16. Anti-Friction Bearings
A. Introduction
16A1. General 295
a. Possible trouble — Dirty bearing 297
b. Possible trouble — Spalled or pitted rollers or races 300
C. Possible trouble — Dented (brinelled) races 302
d. Possible trouble — Failed separator 304
e. Possible trouble — Races abraded on external surfaces 305
f. Possible trouble — Cracked race 305
g. Possible trouble — Worn bearing 306
Chapter 17. Auxiliary Drive Mechanisms
A. Introduction
17A1. General 307
B. Gears
17B1. General 307
a. Possible trouble — Gear failure 309
C. Chains and Belts
17C1. Chains 312
a. Possible trouble — Worn or broken chains 312
17C2. Belts 313
a. Possible trouble — Excessive belt wear 313
b. Possible trouble— Squeaking V-bolts 313
Chaptbr 18 Clutches and Drive Gears
A. Clutches
18A1. Introduction 315
18A2. Friction type clutches 315
a. Possible trouble — Slippage 315
b. Possible trouble— Wear 316
c Possible trouble — Frozen clutch 316
d. Possible trouble — Chattering clutch 316
18A3. Dog type clutches 317
a. Possible trouble — Difficulty in engaging clutch 317
18A4. Falk Airflex clutch 317
a. Possible trouble — Broken airshaft tube. 317
b. Possible trouble — Worn airshaft header and driver 318
c. Possible trouble — Oil clutch facings — slippage 318
d. Possible trouble— Pressure contact maker 319
e. Possible trouble — Clogged air filter 319
f. Possible trouble — Misalignment of reduction gear 319
18A5. Fawick clutch and brake 321
a. Possible trouble — Burned clutch and brake friction blocks 321
18A6. Twin disk clutch 322
a. Possible trouble — Worn clutch disks 322
b. Possible trouble — Grease and oil on clutch surface 323
18A7. Joe's gears 323
a. Possible trouble — Slippage in the ahead position 323
b. Possible trouble — Slippage in the astern position 323
B. Drive Couplings
18B1. Flange type solid coupling 324
a. Possible trouble— Shafts misaligned or coupling bent 324
18B2. Flexible couplings 325
18B3. Hydraulic coupling, quick dump type 325
a. Possible trouble — Dumping under load . 325
C. Reduction and Reverse Gears
18C1. General 326
a. Possible trouble— Pitting 327
b. Possible trouble — Foaming 328
c. Possible trouble— Gear failure 328
Chapter 19. Instruments
A. Pressure
19A1. Bourdon gage 329
a. Possible trouble — Hole in Bourdon tube element 329
b. Possible trouble — Broken cover glass .. . 330
c. Possible trouble — Pointer fails to move. 330
d. Possible trouble — Improper linkage ad- justment 330
e. Possible trouble — Loose linkages and gears 331
f. Possible trouble — Pointer docs not read zero for atmospheric pressure 332
19A2. Manometers 332
a. Possible trouble — Loss of pressure 333
b. Possible trouble — Loss of liquid 333
19A3. Engine indicators 333
a. Possible trouble— Gummed indicator pistons 334
b. Possible trouble — Electrical circuit failure 335
c. Possible trouble — Gummed check valve. 337
d. Possible trouble — Bourdon gage failure 338
e. Temperature
19B1. Liquid in glass thermometer 338
a. Possible trouble — Broken cover glass 338
19B2. Expansion thermometer 338
a. Possible trouble— Bourdon gage failures 339
b. Possible trouble — Inaccurate temperature readings 339
19B3. Pyrometer 339
a. Possible trouble — Pyrometer reads backward for one cylinder only 339
b. Possible trouble — Pyrometer reads backward for every cylinder 340
C. Possible trouble — Incorrect zero or open circuit pointer position 340
d. Possible trouble — Incorrect temperature readings 340
e. Possible trouble — Pointer fails to operate 342
f. Possible trouble — Inaccurate temperature readings 342
19B4. Electrical resistance thermometer 342
a. Possible trouble — Thermometer fails to record 342
b. Possible trouble — Thermometer reads low 342
C. Speed
19C1. Mechanical centrifugal tachometers 343
a. Possible trouble — Fluctuation of pointer 343
19C2. Electrical tachometer 343
a. Possible trouble — Pointer not at zero when engine is secured 344
b. Possible trouble — Pointer reads astern with engine going ahead 344
c. Possible trouble — Fluctuation of pointer 344
d. Possible trouble — Tachometer reads low 344
ILLUSTRATIONS
2-1. Scavenging systems 11
2-2. Turbochargers 12
2-3. Turbine wheel with damaged blade 14
2-4. Roots type blowers 16
2-5. Roots type blower for G.M. 3-268A engine showing helical rotors and timing gears 17
2-6. Checking backlash of rotor gears 18
2-7. Scored blower lobes 18
2-8. Checking clearances of Roots type blower lobes 19
2-9. Shaft oil seals 20
2-10. Failed serrated shaft 21
2-11. Hamilton-Whitfield blower 21
2-12. Air intake manifold 22
2-13. Schematic drawing of an oil separator 23
2-14. Effect of a worn bearing on oil leakage 24
2-15. Flame primer as used on the G.M.-71 series engine. 25
3-1. Cross section of manifold metal 27
3-2. Formation of scale in water jacket 28
3-3. Improper installation of wet type muffler 29
3-4. Use of pipe bend to prevent backflow of water 29
3-5. Use of three-way proportioning valve to regulate water flow to muffler 30
3-6. Use of throttling valve to control flow of water to muffler 30
3-7. Dry type muffler 31
3-8. Force produced in exhaust piping by thermal expansion 32
3-9. Use of flexible expansion joint to absorb thermal expansion 32
3-10. Illustration of pressure drop in exhaust piping and muffler 33
3-11. Types of bends used in exhaust lines 33
3-12. Water trapped due to sagging of elbow 34
3-13. Exhaust stack showing evidence of corrosion 34
3- 14. Revision of stack design to eliminate corrosion 34
4- 1. Schutte and Koerting gear pump 37
4-2. Worn gear pump shafts 37
4~3. Tuthill reversible fuel pump 38
4-4. Packing clamps improperly tightened, cocked 39
4-5. Cover plate of pump shown in Figure 4-4, showing uneven wear of bushing 39
4-6. Vane type fuel oil pumps 40
4-7. Worn and damaged seal on G.M. vane pump 40
4-8. Bosch fuel supply pumps with hand prime feature. . 41
4-9. Excello fuel transfer pump 41
4-10. Schematic diagram of Bosch supply pumps 41
4-11. Sectional views of Bosch type pumps : A — APF pump; B — 3-cylinder APE pump 43
4-12. Pumping principle, one-plunger stroke 44
4-13. Metering principle 44
4-14. Types of plungers 44
4-1 5. Plunger rotating mechanism 45
4-16. Good and bad plungers 45
4-17. APF pump sight window 48
4-18. Typical Bosch spray nozzle 51
4-19. Sectional views of nozzles 51
4-20. Nozzle and nozzle holder 52
4-21. American Bosch nozzle tester in operation 53
4-22. Variations in nozzle holder connections and adjustments 54
4-23. Throttling type pintle nozzle 56
4-24. Good spray from throttling nozzles 56
4-25. Spray patterns from standard pintle nozzles 56
4-26. Types of General Motors injectors 59
4-27. Injection and metering principle 60
4-28. Injector test stand 60
4-29. Sealing surfaces 62
4-30. Type A Excello fuel injection pump 67
4-31. Excello fuel pump drive unit, hydraulic unit, and safety filter 68
4-32. Excello fuel injection nozzle 71
4-33- Exploded view of nozzle tip 72
4-34. Use of special tools to assemble and disassemble nozzle 73
4-35. Cummins fuel system 74
4-36. Cummins fuel injector 75
4-37. Worn and scored distributor disk and cover 76
4 38. Worn and eroded injector cup tip 79
4-39. New injector cup tip 79
4-40. Pressure regulating valve 79
4-41. Atlas fuel system 80
4-42. Spray valve and actuating mechanism 81
4-43. Cutaway view of fuel oil pump 84
4-44. Lapping the plunger and barrel 86
4 45. Lapping the discharge vaive and seat 86
4-46. Square lapping the relief valve seat 86
4-47. Fuel injector 87
4-48. Cutaway view of fuel injector 88
4-49. Lapping the lower valve scat and stem 89
4-50. Sectional view of fuel injection nozzle 90
4-51 Recommended methods for elimination of pipe breakage at root of threads 91
4-52. Duplex system (standard practice) 93
4-53. Duplex fuel filter 93
4-54. Plugging filter for washing 94
4-55. Schematic drawing of a fuel system 95
4-56. Strainer elements 96
4- 57. Tank sampling device for diesel fuel 97
5- 1. Elementary governor mechanisms 99
5-2. G.M. mechanical governor 100
5-3. Governor control mechanism 102
5-4. Pierce mechanical governor 104
5-5. Operating principle of hydraulic governor 108
5-6. Marquette hydraulic governor 113
5-7. Woodward type SI governor 114
5- 8. Simple ovcrspecd trip mechanism 117
6- 1 122
6-2. 124
6-3- Use of the centrifugal pump to clean heat exchangers 125
6-4. Use of hand pumps and plungers to clean heat exchangers 125
6-5. Repairing a strut tube leak. Both ends of tube require scaling 127
6-6. Zinc electrode, before and after use 128
6-7. Line valves 128
6-8. Distortion of valve seat due to excess threads on pipe. 129
6-9. Damaged gate valve, caused by throttling 130
6-10. Tubing splice 133
6-11. Simplex lube oil strainer 134
6- 12. Michiana lube oil filter 135
7- 1. Heat exchangers 138
7-2. Harrison type cooler clement clogged with debris 139
7-3. Attached centrifugal pump 142
7-4. Worn sea-water pump clogged with seaweed 143
7-5. Correct direction of rotation for unidirectional centrifugal pump 143
7-6. Centrifugal pump with fluid sealed stuffing box 144
7-7. Cracked keyway in water pump impeller 145
7-8. Disintegrated key and burred keyway 146
7-9. Location of wear rings on different types of centrifugal pumps 147
7-10. Types of water pumps 148
7-11. Failed neoprene impellers 149
7-12. Mistimed neoprene impellers 149
7-13. Water pump neoprene gear failure through fatigue 150
7-14. Synchronizing gears marked to avoid mistiming 150
7-15. Neoprene gear damaged by burning 150
7-16. Lubricated plug valve 151
7-17. Fulton-Sylphon automatic temperature regulator. . . 152
7-18. Reference for adjustment instruction 153
7-19. Installation of bulb 154
7-20. Commonly used thermostats 155
7-21. Sizing tools 159
7-22. Steps in making a soldered joint 159
7-23- Failure of piping at exposed thread 160
7-24. Bends in copper tubing 160
7-25. Typical sea-water strainer 161
7-26. Clogged sea-water strainer 161
7- 27. Dezincified (corroded) portions of sea-water strainer 161
8- 1. Schematic diagram for checking insulation resistance 165
8-2. Wiring diagram for checking resistance of the insulation, voltmeter method 165
8-3. Checking belt tension 166
8-4. Air pilot valve in Cooper-Bessemer type GSB-8 168
8-5. Hamilton starting air distributor 169
8-6. Sectional view of air starting valve 169
9-1. Cutaway view of lead-acid cell 171
9-2. Typical hard rubber battery case 172
9-3. Typical battery name plate 172
9-4. Corroded and burned battery terminal 175
9-5. Improperly tightened battery terminal and lug 176
9-6. Checking belt tension 177
9-7. Sanding a brush 177
9-8. Testing an armature on the growler 178
9-9. Preparing to test for polarity of field coils 178
9-10. Wiring diagram of current and voltage regulator 179
9-11. Cleaning contact points 179
9-12. Cutout relay adjustments 180
9-13. Voltage regulator adjustments 180
9-14. Current regulator check 181
9-15. Making a wire splice 183
9-16. Diagrammatic sketch of connections for self-synchronous transmitters and indicators 184
9-17. Wiring diagram, sclsyn remote control, a.c 184
9-18. Schematic connection diagram of d.c. solsyn system. 185
9-19. Wiring diagram 185
9-20. A.C. D.C. split field motor 186
10- 1. Cylinder block 187
10-2. Crankcase 187
10-3. Cylinder block for Cooper-Bessemer GSB-8 188
10-4. Engine base with main bearings and bearing caps in position, Cooper-Bessemer GSB-8 188
10-5. Harmon Sav-A-Weld method for repairing cracks 190
10-6. Mctalock process for repairing cracks 190
10-7. Use of cloth patches for cleaning passages 191
10-8. Engine and reduction gear mounted on common sub-base 193
10- 9. Welding in wandering sequence 194
10-10. Generator set secured on flexible mounting 195
10-11. Fundamentals of vibration isolator 195
10-12. Spring type vibration isolator 196
10-13- "Rubber sandwich" type flexible mounting 196
10- 14. Vibration isolator-shock absorber 197
11- 1. Schematic drawing of a cylinder assembly 199
11-2. Cylinder head requiring no gasket 200
11—3- Types of cylinder liners 200
11 4. Wet liner with integral cooling passages 201
11-5. Cracked cylinder liners 202
11-6. Distortion of cylinder due to oversize seal ring 202
11-7. Improper fillet preventing seating 202
11-8. Scored cylinder liners 203
11-9. Effect of scoring on seal between rings and liner 203
11-10. Liner ports before and after stoning 204
11-11. Liner ports before and after cleaning 205
11-12. Measurements of cylinder wear 205
11-13. Measuring a cylinder liner 206
11-14. Common errors in taking inside micrometer readings 206
11 — 15- Trace of moving end of micrometer calipers 207
11-16. Combustion chambers 207
11 17. Typical cylinder heads 208
11-18. Cutaway view of cylinder head 209
1 1-19. Water ferrule assembly 210
11-20. Set-up to test for gas in cooling water 210
11-21. Cracked cylinder head 210
11-22. Cylinder head showing effect of leaking gasket 212
11-23. Cylinder head studs in place 213
11-24. Cylinder head stud designs 213
11-25. Failure at root of thread 214
11-26. Failure in shank 214
11-27. Effect of uneven stud tightening 214
11-28. Use of special stud wrench 215
11-29. Use of two nuts to drive stud 215
11-30. Minimum effective thread length for stud 216
11-31. Two methods for removing a broken stud 216
11-32. Procedure for extracting a broken stud 217
11-33. Use of pilot hole to aid in drilling of stud 217
11-34. Principle of a gasket 218
11-35. Types of cylinder head gaskets 218
11-36. Effect of uneven tightening on a gasket 219
11- 37. Proper order for tightening cylinder head studs 219
12- 1. Exhaust valves 222
12-2. Excessively lapped valves 224
12-3. Exhaust valve springs 225
12-4. Poppet valve assembly 226
12-5. Valve stem cap 226
12-6. Exhaust valves, G.M. 8-268A 226
12-7. Damaged and undamaged cylinder heads 227
12-8. Damaged valves from cylinder head shown in Figure
12-7A. Broken valve that caused damage is not shown 228
12-9. Supercharge valves in HOR engine 229
12-10. Roller type cam followers 231
12-11. Lash adjuster 233
13-1. Typical trunk type piston 236
13-2. Cylinder lubricators, Hamilton diesel 237
13-3- Severe scoring of cylinder walls caused by piston seizure 238
13-4. Piston scored by seizure. Note broken rings 238
13-5. Piston measurements 238
13-6. Piston skirt seizure — galling 241
13-7. Piston ruined by clogged oil holes and seizure 242
13-8. Location of joint in piston pin bushings for piston and connecting rod 243
13-9. Hamilton double-acting crosshead type piston and piston rod 243
13-10. Cylinder lube oil check valve 244
13-11. General types of piston rings 245
13-12. Common types of piston ring gaps 245
13-13. Piston ring nomenclature 245
13-14. Removing and replacing piston rings with piston ring tool 247
13-15. Using metal strips to remove piston rings 247
13-16. Shoulder in ring groove due to wear 248
13-17. Level ring in bore with inverted piston 248
13-18. Installing piston in cylinder bore with funnel type piston ring compressor 248
13-19. Using wire to install piston rings 249
13-20. Checking for stuck rings 249
13-21. Examples of piston pin bearings 252
13-22. Piston pin measurements 253
1 3-23- Reaming tools 253
13-24. Measuring the piston pin and piston pin bushing for wear 254
13-25. Common types of connecting rods 256
13-26. Critical area of a connecting rod 256
13-27. Connecting rod bolts 257
13-28. Incorrect and correct installation of cotter pins 257
13-29. Measuring the bore of a connecting rod for out-of-roundness 258
13-30. Single-acting engine 259
13-31. Double-acting engine 260
13-32. Crosshead and connecting rod assembly 260
13-33. Exploded view of Hamilton HOR assembly 261
13-34. Crosshead guide and crosshead guide gibs 261
13-35- Spherical nut 261
13-36. Crosshead cover nut 262
13-37. Piston cooling linkage 263
13-38. Checking alignment of connecting rods 265
13-39. Stuffing box 266
13- 40. Division cover 266
14- 1. Diesel engine crankshaft 269
14-2. Crankshaft oil passages 270
14-3. Crankshaft with hollow crank pins 270
14-4. Cracked journal 272
14-5. Broken crankshaft 272
14-6. Cracked crank web 273
14-7. Fatigue failure resulting from torsional vibration 274
14-8. Strain gage installed between crank webs 274
14-9- Crankshaft bridge gage 275
14-10. Measurement of crank-pin diameter. 275
14-11. Diesel engine camshaft 276
14-12. Built-up camshaft 276
14-13. Individual cam 276
14-14. Built-up camshaft 277
14-15. Camshaft with adjustable fuel pump cams 277
14-16. Camshaft showing lubrication passageways 277
14-17. Cracked cam 278
14-18. Camshaft key drift 278
14-19. Installing a camshaft 279
14-20. Broken camshaft 280
15-1. Fatigue failure (magnified) 282
15-2. Fatigue failure 282
15-3. Failure due to corrosion 283
15-4. Corroded bearing 283
15-5. Corrosion 284
15-6. Corroded copper-lead bearing 284
15-7. Bearing failure due to inadequate bond 285
15-8. Bond between tin-base babbitt and bronze shell 285
15-9. Embedded foreign particles in a Tri-mctal bearing. . 285
15-10. Defective bond between bronze and steel of a Tri- metal bearing 286
15-11. Failure due to extrusion of bronze back into the connecting rod oil groove 286
15-12. Bearing failure caused by faulty installation 287
15-13. Proper and improper fitting locking lip 288
15-14. Failed bearing 289
15-15. Bearing with ability to carry the load after part of the bearing area has failed 290
15-16. Pitted bearing surface 290
15-17. Wiped bearing 290
15-18. Overheated bearing 291
15-19. Scratched bearing 291
15-20. Proper care of bearings 291
15-21. Use of torque wrench to tighten connecting rod bolt nuts 291
15-22. Gage used to measure stretch in connecting rod bolts . 292
15-23. Measuring stretch in connecting rod bolts 292
15-24. Bearing micrometer 293
15-25. Measuring bearing thickness 293
16-1. Variations in bearing design 295
16-2. Ball and roller bearings 296
Figure Page
16-3. Connecting rod needle bearing 297
16-4. Benches for bearing work 297
16-5. Anti-friction bearing scaling devices 298
16-6. Thimble for mounting flange type seal 299
16-7. Wire basket for cleaning bearings 299
16-8. Cleaning bearing with compressed air 300
16-9. Spalled roller and races 301
16-10. Spalling due to loose adjustment 301
16-11. Spalling due to misalignment 302
16-12. Brinelled races 302
16-13- How to ruin a bearing 302
16-14. Correct methods of bearing removal 303
16-15- Split ring for removal of inaccessible bearings 304
16-16. Failure of separator 304
16-17. Abrasion of external surface of inner race 305
16- 18. Bearing with cracked inner race 306
17- 1. Timing gear train 307
17-2. Camshaft timing gear train 307
17-3. Drive chain assembly 308
17-4. Split crankshaft gear 309
17-5. Pitted metal gear 310
17-6. Checking backlash of rotor gears 310
17-7. Worn fibre gear 310
17-8. Chipped gear tooth 311
17-9. Broken gear tooth 311
17-10. Defective gear determination 311
17-11. Engine gear set 312
17- 12. Chain connection assembly 313
18- 1. Falk Airflcx clutch 317
18-2. Brazing sctscrews into air tubes 318
18-3. Checking angular and parallel alignment of propeller shafts 320
18-4. Cross section of Fa wick reverse gear as used on G.M. engine 321
Figure Page
18-5. Damaged twin-disk clutch disk 322
18-6. Joe's reverse gear 323
18-7. Flange type solid coupling 324
18-8. Flange type solid coupling with shoulder and recess . . 325
18-9. Checking alignment with dial gage 325
18-10. Hydraulic coupling, quick dump type 326
18-11. Farrell-Birmingham single reduction gear 326
18-12. Location of pitch line 326
18-13. Corroded tooth 327
18-14. Pitting due to profile error 327
18-15. Pitting due to improper lead angle 327
18-16. Pitting due to misalignment 327
19- 1. Bourdon gage 329
19-2. Adjustment of Bourdon mechanism 330
19-3. Dead weight tester 331
19-4. U-tube manometer, open type 332
19-5. Premax indicator, model YBC 333
19-6. Bacharach model YRF engine pressure indicator 335
19-7. Poor indicator connection 335
19-8. Good indicator connection 336
19-9. Kienc indicator 336
19-10. Kienc indicator pressure chamber, internal view 336
19-11. Kienc indicator installed on engine 337
19-12. Reconditioning a valve seat (A) and valve (B) 337
19-13. Thermometer 338
19-14. Expansion thermometer 338
19-15. Pyrometer installation 339
19-16. Sectional view of a thermocouple 339
19-17. Comparison of used and unused thermocouple units. 341
19-18. Removing thermocouple unit from engine 341
19-19. Portable pyrometer 342
19-20. Duplex resistance thermometers 342
19-21. Electrical tachometer 343