[
SGML Version See Change Record
]
TECHNICAL MANUAL
DESCRIPTION, OPERATION,
MAINTENANCE
AND ILLUSTRATED PARTS
BREAKDOWN
DIESEL ENGINES
DISTRIBUTION STATEMENT B: DISTRIBUTION AUTHORIZED TO U. S. GOVERNMENT AGENCIES ONLY; ADMINISTRATIVE/OPERATIVE USE OTHER REQUESTS FOR THIS DOCUMENT MUST ME REFERRED TO NAVAL SEA SYSTEMS COMMAND (SEA-09T). WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC. 2751 ET SEQ.) OR THE EXPORT ADMINISTRATION ACT OF 1979, AS AMENDED, TITLE 50 U.S.C., APP 2401, ET SEQ. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH PROVISIONS OF OPNAVINST 5510.161, REFERENCE (JJ).
DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO-SURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT.
TITLE-1 / (TITLE-2 Blank)@@FIpgtype@@TITLE@@!FIpgtype@@ @@FIpgtype@@TITLE@@!FIpgtype@@
PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND
TITLE-2
RECORD OF CHANGES
CHANGE DATE DESCRIPTION OF CHANGE CHANGE NO.
NOTE
THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONIC SOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NO LOEP. ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOT MATCH THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE CONTENT IS EXACTLY THE SAME. ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TM WILL ONLY FIT IN THIS PAGINATED VERSION.
Record of Changes-2
FOREWORD
This Technical Manual is intended to provide operation, maintenance, and repair information for the mod-els 6B5.9-M and 6BT5.9-M diesel engines. The manual contains descriptive and functional information, operat-ing instructions, and maintenance and repair instructions for this system. This manual is one volume subdivided into the following chapters:
CHAPTER 1- GENERAL INFORMATION AND SAFETY PRECAUTIONS CHAPTER 2- OPERATION
CHAPTER 3- FUNCTIONAL DESCRIPTION CHAPTER 4- SCHEDULED MAINTENANCE CHAPTER 5- TROUBLESHOOTING
CHAPTER 6- CORRECTIVE MAINTENANCE CHAPTER 7- ILLUSTRATED PARTS BREAKDOWN CHAPTER 8- INSTALLATION
Ships, training activities, supply points, depots, Naval Shipyards, and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors, Omissions, discrepancies, and suggestions for improvement to NAVSEA technical manuals shall be reported to Commanding Officer, Naval Ship Weapon Systems Engineering Station (Code 5H00), Port Hueneme, CA 93043-5007 on NAVSEA Technical Manual Deficiency/Evaluation Report, Form NAVSEA 9086/10. To facilitate such reporting, three copies of Form 9086/10 are included at the end of this technical manual. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting therefrom. Extra copies of NAVSEA Form 9086/10 may be requisitioned from the Naval Publications and Forms Center, Philadelphia, PA 19120.
FOREWORD-2
TABLE OF CONTENTS
Chapter/Paragraph Page
1 GENERAL INFORMATION AND SAFETY PRECAUTIONS . . . . 1-1 1-1 INTRODUCTION. . . 1-1 1-1.1 GENERAL INFORMATION. . . 1-1 1-1.2 SAFETY PRECAUTIONS. . . 1-1 1-2 EQUIPMENT DESCRIPTION. . . 1-1 2 OPERATION . . . 2-1 2-1 INTRODUCTION. . . 2-1 2-2 NORMAL OPERATING RANGES. . . 2-1 2-3 OPERATING PROCEDURES. . . 2-2 2-3.1 PRE-OPERATIONAL CHECKS. . . 2-2 2-3.2 NORMAL OPERATION. . . 2-3 2-3.3 SHUTDOWN. . . 2-5 2-3.4 EMERGENCY OPERATION. . . 2-6 2-3.4.1 Low Oil Pressure. . . 2-6 2-3.4.2 High Engine Coolant Temperature. . . 2-7 2-3.4.3 Runaway Engine. . . 2-7 3 FUNCTIONAL DESCRIPTION . . . 3-1 3-1 INTRODUCTION. . . 3-1 3-2 GENERAL DESCRIPTION. . . 3-1 3-3 DETAILED DESCRIPTION. . . 3-1 3-3.1 DIESEL ENGINE. . . 3-1 3-3.2 ELECTRICAL STARTING SYSTEM. . . 3-1 3-3.3 AIR INTAKE AND EXHAUST SYSTEMS. . . 3-2 3-3.3.1 Air Intake System. . . 3-2 3-3.3.2 Exhaust System. . . 3-7 3-3.4 FUEL SYSTEM. . . 3-7 3-3.4.1 Fuel Pumps. . . 3-7 3-3.4.2 Fuel Injection Nozzles. . . 3-7 3-3.4.3 Fuel Drain Manifold. . . 3-7 3-3.4.4 Throttle. . . 3-7 3-3.4.5 Fuel Shutoff Valve. . . 3-7 3-3.5 LUBRICATION SYSTEM. . . 3-7 3-3.6 COOLING WATER SYSTEMS. . . 3-7 3-3.6.1 Fresh Water Cooling System. . . 3-7 3-3.6.2 Sea Water Cooling System. . . 3-8 3-3.7 CONTROLS AND INDICATORS. . . 3-8
TABLE OF CONTENTS - Continued
Chapter/Paragraph Page
3-3.7.1 Starter Switch. . . 3-8 3-3.7.2 Electrical Fuel Shutoff. . . 3-8 3-3.7.3 Tachometer. . . 3-8 3-3.7.4 Lube Oil Pressure Switch. . . 3-8 3-3.7.5 Water Temperature Switch. . . 3-8 4 SCHEDULED MAINTENANCE . . . . 4-1 4-1 INTRODUCTION. . . 4-1 5 TROUBLESHOOTING . . . 5-1 5-1 INTRODUCTION. . . 5-1 5-2 TROUBLESHOOTING GUIDE. . . 5-1 5-3 TROUBLESHOOTING PROCEDURES. . . 5-10 5-3.1 ENGINE WILL NOT CRANK. . . 5-10 5-3.2 ENGINE CRANKS BUT WILL NOT START (SMOKE FROM
EXHAUST). . . 5-10 5-3.3 ENGINE STARTS BUT WILL NOT KEEP RUNNING. . . 5-10 5-3.4 ENGINE RUNNING HOT. . . 5-10 6 CORRECTIVE MAINTENANCE . . . 6-1 6-1 INTRODUCTION. . . 6-1 6-2 TOOLS AND EQUIPMENT. . . 6-1 SECTION 1. ADJUSTMENT AND ALIGNMENT . . . . 6-3 6-3 INTRODUCTION. . . 6-3 6-4 TACHOMETER ADJUSTMENT. . . 6-3 6-5 VALVE CLEARANCE ADJUSTMENT. . . 6-3 SECTION 2. REPAIR . . . 6-5 6-6 INTRODUCTION. . . 6-5 6-7 CLEANING AND INSPECTION. . . 6-5 6-7.1 CLEANING. . . 6-6 6-7.2 INSPECTION. . . 6-7 6-8 REPAIR/REPLACEMENT. . . 6-7 6-8.1 GENERAL. . . 6-7 6-8.2 PRELIMINARY PROCEDURES AND SAFETY INFORMATION. . . 6-8 S9233-C9-MMA-010
TABLE OF CONTENTS - Continued
Chapter/Paragraph Page
6-9 STARTER MOTOR. . . 6-9 6-9.1 REMOVAL. . . 6-9 6-9.2 DISASSEMBLY. . . 6-9 6-9.3 CLEANING AND INSPECTION. . . 6-11 6-9.4 REASSEMBLY. . . 6-16 6-9.5 TESTING. . . 6-20 6-9.5.1 Solenoid Engagement Mechanism. . . 6-20 6-9.5.2 Performance Tests. . . 6-21 6-9.5.3 Relay Test. . . 6-22 6-9.6 REINSTALLATION. . . 6-22 6-10 GAUGES. . . 6-22 6-11 AIR CLEANER/SILENCER. . . 6-23 6-11.1 REMOVAL. . . 6-23 6-11.2 REINSTALLATION. . . 6-23 6-12 ALTERNATOR. . . 6-23 6-12.1 REMOVAL. . . 6-23 6-12.2 REPAIR. . . 6-24 6-12.3 REINSTALLATION. . . 6-24 6-13 DRIVE BELT AND BELT TENSIONER. . . 6-24 6-13.1 REMOVAL. . . 6-24 6-13.2 REINSTALLATION. . . 6-25 6-14 FRESH WATER PUMP. . . 6-25 6-14.1 REMOVAL. . . 6-25 6-14.2 REINSTALLATION. . . 6-25 6-15 THERMOSTAT. . . 6-26 6-16 SEA WATER PUMP. . . 6-27 6-16.1 REMOVAL. . . 6-27 6-16.2 DISASSEMBLY. . . 6-27 6-16.3 REASSEMBLY. . . 6-28 6-16.4 REINSTALLATION. . . 6-29 6-17 HEAT EXCHANGER. . . 6-30 6-17.1 REMOVAL. . . 6-30 6-17.2 DISASSEMBLY. . . 6-30 6-17.3 REASSEMBLY/REINSTALLATION. . . 6-31 6-18 MARINE TRANSMISSION OIL COOLER. . . 6-32 6-18.1 REMOVAL. . . 6-32 6-18.2 REINSTALLATION. . . 6-33
TABLE OF CONTENTS - Continued
Chapter/Paragraph Page
6-19 WATER TRANSFER CONNECTION. . . 6-33 6-20 TEMPERATURE TRANSDUCER. . . 6-34 6-21 FUEL LEFT PUMP. . . 6-34 6-21.1 REMOVAL. . . 6-34 6-21.2 REINSTALLATION. . . 6-34 6-22 FUEL PIPING. . . 6-34 6-22.1 REMOVAL. . . 6-34 6-22.2 REINSTALLATION. . . 6-35 6-23 FUEL FILTER AND FUEL/WATER SEPARATOR. . . 6-35 6-23.1 FUEL FILTER. . . 6-35 6-23.2 FUEL/WATER SEPARATOR. . . 6-35 6-24 FUEL DRAIN MANIFOLD. . . 6-36 6-24.1 REMOVAL. . . 6-36 6-24.2 REINSTALLATION. . . 6-36 6-25 FUEL INJECTION NOZZLES. . . 6-36 6-25.1 REMOVAL. . . 6-36 6-25.2 DISASSEMBLY. . . 6-37 6-25.3 CLEANING AND INSPECTION. . . 6-37 6-25.4 REASSEMBLY. . . 6-38 6-25.5 FUEL INJECTION NOZZLE TEST. . . 6-38 6-25.6 REINSTALLATION. . . 6-40 6-25.7 BLEEDING THE FUEL SYSTEM. . . 6-40 6-26 FUEL INJECTION PUMP. . . 6-44 6-26.1 REMOVAL. . . 6-44 6-26.2 DISASSEMBLY. . . 6-47 6-26.3 REASSEMBLY. . . 6-51 6-26.4 PRE-TEST. . . 6-57 6-26.4.1 Pressure Test. . . 6-57 6-26.4.2 Seal Testing. . . 6-58 6-26.4.3 General Testing Procedures. . . 6-58 6-26.4.4 Priming. . . 6-59 6-26.4.5 Pump Output. . . 6-59 6-26.4.6 Shutoff Control. . . 6-59 6-26.4.7 Maximum Fuel Setting. . . 6-59 6-26.4.8 Governor Test. . . 6-60 6-26.4.9 Transfer Pump Setting. . . 6-60 6-26.4.10 Transfer Pump Pressure Adjustment. . . 6-60 6-26.4.11 Pressurized Cam Boxes. . . 6-61 6-26.4.12 Advance Device Test. . . 6-61 6-26.4.13 Timing. . . 6-62 S9233-C9-MMA-010
TABLE OF CONTENTS - Continued
Chapter/Paragraph Page
6-26.5 TEST PARAMETERS. . . 6-63 6-26.5.1 Test Conditions. . . 6-63 6-26.5.2 Test Procedure and Conditions. . . 6-63 6-26.6 REINSTALLATION. . . 6-65 6-27 INTAKE MANIFOLD COVER. . . 6-66 6-27.1 REMOVAL. . . 6-66 6-27.2 REINSTALLATION. . . 6-66 6-28 TURBOCHARGER. . . 6-67 6-28.1 REMOVAL. . . 6-67 6-28.2 DISASSEMBLY. . . 6-68 6-28.3 CLEANING AND INSPECTION. . . 6-70 6-28.4 REASSEMBLY. . . 6-71 6-28.5 REINSTALLATION. . . 6-74 6-29 OIL PRESSURE REGULATOR VALVE. . . 6-75 6-29.1 DISASSEMBLY. . . 6-75 6-29.2 REASSEMBLY. . . 6-75 6-30 OIL COOLER. . . 6-76 6-30.1 REMOVAL. . . 6-76 6-30.2 REINSTALLATION. . . 6-76 6-31 CRANKSHAFT OIL SEALS. . . 6-77 6-31.1 FRONT CRANKSHAFT OIL SEAL. . . 6-77 6-31.1.1 Removal. . . 6-77 6-31.1.2 Reinstallation. . . 6-77 6-31.2 REAR CRANKSHAFT OIL SEAL. . . 6-77 6-31.2.1 Removal. . . 6-77 6-31.2.2 Reinstallation. . . 6-78 6-32 CAM FOLLOWER COVER. . . 6-78 6-32.1 REMOVAL. . . 6-78 6-32.2 REINSTALLATION. . . 6-78 6-33 OIL PRESSURE TRANSDUCER. . . 6-79 6-34 VALVE COVER. . . 6-79 6-35 ROCKER LEVER ASSEMBLY. . . 6-80 6-35.1 REMOVAL. . . 6-80 6-35.2 DISASSEMBLY. . . 6-80 6-35.3 CLEANING AND INSPECTION. . . 6-80 6-35.4 REASSEMBLY. . . 6-81 6-35.5 REINSTALLATION. . . 6-81
TABLE OF CONTENTS - Continued
Chapter/Paragraph Page
6-36 CYLINDER HEAD. . . 6-82 6-36.1 REMOVAL. . . 6-82 6-36.2 DISASSEMBLY. . . 6-82 6-36.3 CLEANING AND INSPECTION. . . 6-82 6-36.4 VALVE SEAT GRINDING. . . 6-83 6-36.5 REASSEMBLY. . . 6-84 6-36.6 REINSTALLATION. . . 6-84 6-37 OIL PAN. . . 6-85 6-38 SUCTION TUBE. . . 6-85 6-39 VALVE TAPPET. . . 6-86 6-39.1 REMOVAL. . . 6-86 6-39.2 CLEANING AND INSPECTION. . . 6-87 6-39.3 REINSTALLATION. . . 6-87 6-40 CAMSHAFT. . . 6-89 6-40.1 REMOVAL. . . 6-89 6-40.2 CLEANING AND INSPECTION. . . 6-89 6-40.3 CAMSHAFT GEAR. . . 6-90 6-40.4 CAMSHAFT BUSHING. . . 6-90 6-40.5 REINSTALLATION. . . 6-91 6-41 LUBE OIL PUMP. . . 6-91 6-41.1 REMOVAL. . . 6-91 6-41.2 DISASSEMBLY. . . 6-92 6-41.3 REASSEMBLY. . . 6-92 6-41.4 REINSTALLATION. . . 6-94 6-42 GEAR HOUSING. . . 6-94 6-42.1 REMOVAL. . . 6-94 6-42.2 REINSTALLATION. . . 6-95 6-43 FLYWHEEL/FLYWHEEL HOUSING. . . 6-95 6-43.1 FLYWHEEL. . . 6-95 6-43.2 FLYWHEEL RING GEAR. . . 6-96 6-43.3 FLYWHEEL HOUSING. . . 6-96 6-44 PISTON AND CONNECTING ROD. . . 6-97 6-44.1 REMOVAL. . . 6-97 6-44.2 DISASSEMBLY. . . 6-98 6-44.3 CLEANING AND INSPECTION. . . 6-98 6-44.4 MEASURE ROD BEARING CLEARANCE. . . 6-99 6-44.5 REASSEMBLY. . . 6-100 6-44.6 CHECKING PISTON RING GAP. . . 6-100 6-44.7 PISTON RING INSTALLATION. . . 6-100 S9233-C9-MMA-010
TABLE OF CONTENTS - Continued
Chapter/Paragraph Page
6-44.8 REINSTALLATION. . . 6-101 6-45 CRANKSHAFT. . . 6-102 6-45.1 REMOVAL. . . 6-102 6-45.2 CLEANING AND INSPECTION. . . 6-102 6-45.3 CRANKSHAFT GEAR REPLACEMENT. . . 6-103 6-45.4 REINSTALLATION. . . 6-103 6-46 CYLINDER BLOCK. . . 6-104 6-46.1 REMOVAL. . . 6-104 6-46.2 CLEANING AND INSPECTION. . . 6-104 6-46.3 REINSTALLATION. . . 6-105 6-47 OIL PAN HEATER. . . 6-105 6-48 START-UP. . . 6-106 7 ILLUSTRATED PARTS BREAKDOWN . . . 7-1 7-1 INTRODUCTION. . . 7-1 8 INSTALLATION . . . 8-1 8-1 INTRODUCTION. . . 8-1 8-2 INSTALLATION. . . 8-1 8-3 START-UP AND CHECKOUT. . . 8-2 8-4 ENGINE OPTION LISTS: . . . 8-2
LIST OF TABLES
Table Title Page
1-1. 6B5.9-M Principal Characteristics . . . 1-2 1-2. 6BT5.9-M Principal Characteristics . . . 1-4 2-1. Normal Operating Ranges . . . 2-1 2-2. Fuel and Lubricating Oil . . . 2-3 5-1. Troubleshooting Guide . . . 5-1 6-1. Special Tools . . . 6-1 6-2. Solenoid Test Data . . . 6-12 6-3. Spring Tension . . . 6-14 6-4. 24-Vdc Starter Test Data . . . 6-20 6-5. Fuel Injection Pump Test Procedures . . . 6-64 6-6. Clearance Measurements . . . 6-106 6-7. Torque Specifications . . . 6-108 6-8. Roller-to-Roller Dimensions . . . 6-110 6-9. Torque for Pipe Plugs . . . 6-110 7-1. Belt Guard . . . 7-3 7-2. Starter Motor . . . 7-5 7-3. V-Belt Tensioner/Alternating Mounting . . . 7-9 7-4. Front Engine Support . . . 7-9 7-5. Alternator . . . 7-11 7-6. Instrument Panel . . . 7-13 7-7. Air Cleaner . . . 7-14 7-8. Expansion Tank Bracket . . . 7-15 7-9. Lifting Bracket . . . 7-16 7-10. Fresh Water Pump . . . 7-17 7-11. Thermostat Housing . . . 7-17 7-12. Vibration Damper . . . 7-18 S9233-C9-MMA-010
LIST OF TABLES - Continued
Table Title Page
7-13. Front Gear Cover/Gear Housing . . . 7-19 7-14. Sea Water Pump . . . 7-20 7-15. Heat Exchanger . . . 7-21 7-16. Water Inlet Connection . . . 7-22 7-17. Marine Transmission Oil Cooler . . . 7-23 7-18. Exhaust Manifold/Intake Cover . . . 7-26 7-19. Exhaust Outlet Connection . . . 7-27 7-20. Turbocharger . . . 7-29 7-21. Oil Level Gauge . . . 7-30 7-22. Lube Oil Pump . . . 7-31 7-23. Lube Oil Cooler . . . 7-32 7-24. Fuel Lift Pump . . . 7-33 7-25. Fuel Piping . . . 7-35 7-26. Fuel Filter . . . 7-36 7-27. Fuel Injection Nozzle . . . 7-37 7-28. Fuel Injection Pump . . . 7-43 7-29. Flywheel . . . 7-46 7-30. Flywheel Housing . . . 7-47 7-31. Cam Follower Cover . . . 7-48 7-32. Valve Covers . . . 7-49 7-33. Rocker Lever . . . 7-51 7-34. Cylinder Head . . . 7-53 7-35. Oil Pan . . . 7-55 7-36. Camshaft . . . 7-56 7-37. Cylinder Block . . . 7-58 7-38. Piston and Connecting Rod . . . 7-59
LIST OF TABLES - Continued
Table Title Page
7-39. Crankshaft and Main Bearings . . . 7-60 7-40. Transmission Mounting Bracket . . . 7-61 7-41. Vibration Isolator . . . 7-62 7-42. Fuel/Water Separator . . . 7-63 S9233-C9-MMA-010
LIST OF ILLUSTRATIONS
Figure Title Page
1-1. Model 6B5.9-M Diesel Engine . . . 1-1 1-2. Model 6BT5.9-M Diesel Engine . . . 1-2 3-1. Electrical Schematic (Sheet 1 of 2) . . . 3-3 3-1. Electrical Schematic (Sheet 2 of 2) . . . 3-5 6-1. Adjusting Tachometer . . . 6-3 6-2. Adjusting Valve Clearance . . . 6-4 6-3. Using Timing Pin to Locate TDC . . . 6-4 6-4. Starter Motor Solenoid . . . 6-12 6-5. Installing Oil Seal . . . 6-14 6-6. Positions of Pole Shoes and Windings . . . 6-15 6-7. Adjusting Forward Movement . . . 6-18 6-8. Adjusting Rear Movement . . . 6-19 6-9. Connecting Starter Terminals . . . 6-21 6-10. Relay Test . . . 6-23 6-11. Installing Thermostat in Housing . . . 6-26 6-12. Cleaning Build-up in Heat Exchanger . . . 6-31 6-13. Flushing Heat Exchanger . . . 6-31 6-14. Cleaning Build-up in Marine Transmission Oil Cooler . . . 6-32 6-15. Flushing Marine Transmission Oil Cooler . . . 6-33 6-16. Checking Injection Nozzle Opening Pressure . . . 6-39 6-17. Leakage Test . . . 6-40 6-18. Energizing Solenoid . . . 6-41 6-19. Venting Fuel Filter and Hand Lever . . . 6-41 6-20. Venting Fuel Injection Pump . . . 6-42 6-21. Venting Fuel Injection Pump through Fuel Drain Manifold . . . 6-43 6-22. Venting High-Pressure Fuel Tubes . . . 6-43
LIST OF ILLUSTRATIONS - Continued
Figure Title Page
6-23. Venting High-Pressure Fuel Lines with Engine Idling . . . 6-44 6-24. Fuel Injection Pump Disassembly . . . 6-45 6-25. Locating TDC for Number 1 Cylinder . . . 6-46 6-26. Loosening Fuel Pump Lock Screw . . . 6-46 6-27. Removing Fuel Pump Drive Gear . . . 6-46 6-28. Governor Linkage Spring Removal . . . 6-48 6-29. Loosening Transfer Pump Rotor . . . 6-49 6-30. Loosening Drive Plate Screws . . . 6-50 6-31. Fitting Corks to Retain Plungers . . . 6-50 6-32. Removing the Drive Hub Seal . . . 6-51 6-33. Rotor Screw Installation . . . 6-52 6-34. Reinstalling Top Adjusting Plate . . . 6-53 6-35. Measuring Roller-to-Roller Dimension . . . 6-54 6-36. Adjusting Link Length . . . 6-56 6-37. Attaching Governor Spring . . . 6-57 6-38. Advancing Device Test Gauge . . . 6-62 6-39. Checking Intake Manifold for Air Leaks . . . 6-67 6-40. Removing Supply Lines to the Turbocharger . . . 6-69 6-41. Seating Piston Ring . . . 6-72 6-42. Aligning Balance Marks . . . 6-72 6-43. Measuring Turbocharger Shaft End Play . . . 6-73 6-44. Measuring Radial Clearance . . . 6-74 6-45. Checking Spring Height . . . 6-75 6-46. Positioning Fastener Devices . . . 6-79 6-47. Cylinder Torque Sequence . . . 6-85 6-48. Retaining Valve Tappets . . . 6-86 S9233-C9-MMA-010
LIST OF ILLUSTRATIONS - Continued
Figure Title Page
6-49. Valve Tappet Removal . . . 6-87 6-50. Inserting Installation Tool into Tappet Bore . . . 6-88 6-51. Pulling Installation Tool/Tappet through Cam Bore . . . 6-88 6-52. Measuring Camshaft Gear Backlash . . . 6-89 6-53. Lube Oil Pump Disassembly . . . 6-92 6-54. Measuring Gerotor Tip Clearance . . . 6-93 6-55. Measuring Gerotor Drive/Gerotor Planetary-to-Port Plate Clearance . . . 6-93 6-56. Measuring Gerotor Planetary-to-Body Bore Clearance . . . 6-94 6-57. Flywheel Cap Screw Torque Sequence . . . 6-96 6-58. Flywheel Housing Torque Sequence . . . 6-97 6-59. Using Plastigauge to Measure Clearance . . . 6-100 6-60. Main Bearing Cap Torque Sequence . . . 6-104 7-1. Belt Guard . . . 7-2 7-2. Starter Motor . . . 7-4 7-3. V-Belt Tensioner/Alternating Mounting . . . 7-8 7-4. Front Engine Support . . . 7-9 7-5. Alternator . . . 7-10 7-6. Instrument Panel . . . 7-13 7-7. Air Cleaner . . . 7-14 7-8. Expansion Tank Bracket . . . 7-15 7-9. Lifting Bracket . . . 7-16 7-10. Fresh Water Pump . . . 7-16 7-11. Thermostat Housing . . . 7-17 7-12. Vibration Damper . . . 7-18 7-13. Front Gear Cover/Gear Housing . . . 7-19 7-14. Sea Water Pump . . . 7-20
LIST OF ILLUSTRATIONS - Continued
Figure Title Page
7-15. Heat Exchanger . . . 7-21 7-16. Water Inlet Connection . . . 7-22 7-17. Marine Transmission Oil Cooler . . . 7-23 7-18. Exhaust Manifold/Intake Cover . . . 7-25 7-19. Exhaust Outlet Connection . . . 7-27 7-20. Turbocharger . . . 7-28 7-21. Oil Level Gauge . . . 7-30 7-22. Lube Oil Pump . . . 7-31 7-23. Lube Oil Cooler . . . 7-32 7-24. Fuel Lift Pump . . . 7-33 7-25. Fuel Piping . . . 7-34 7-26. Fuel Filter . . . 7-36 7-27. Fuel Injection Nozzle . . . 7-37 7-28. Fuel Injection Pump (Sheet 1 of 2) . . . 7-39 7-28. Fuel Injection Pump (Sheet 2 of 2) . . . 7-41 7-29. Flywheel . . . 7-46 7-30. Flywheel Housing . . . 7-47 7-31. Cam Follower Cover . . . 7-48 7-32. Valve Covers . . . 7-49 7-33. Rocker Lever . . . 7-50 7-34. Cylinder Head . . . 7-52 7-35. Oil Pan . . . 7-54 7-36. Camshaft . . . 7-56 7-37. Cylinder Block . . . 7-57 7-38. Piston and Connecting Rod . . . 7-59 7-39. Crankshaft and Main Bearings . . . 7-60 S9233-C9-MMA-010
LIST OF ILLUSTRATIONS - Continued
Figure Title Page
7-40. Transmission Mounting Bracket . . . 7-61 7-41. Vibration Isolator . . . 7-61 7-42. Fuel/Water Separator . . . 7-63
SAFETY SUMMARY
GENERAL SAFETY NOTICES The following general safety notices supplement specific warnings and cautions appearing elsewhere in this manual. General and specific precautions must be understood and applied during operation and maintenance. The Commanding Officer or other authority will issue orders as deemed nec-essary for any situation not covered in the general and specific safety precautions.
KEEP AWAY FROM LIVE CIRCUITS Operating personnel must observe all safety regulations at all times. Do not replace components, make adjustments, or perform internal equipment maintenance without first securing electrical power. Dangerous potential may exist when the electrical power is in the OFF position because of charges retained by capacitors. Before touching, always secure electrical power and discharge the circuit by shorting through a load to ground with a shorting probe.
DO NOT REPAIR OR ADJUST ALONE Under no circumstances should any person reach into or enter equipment enclosures for the purpose of servicing or adjusting equipment except in the presence of personnel capable of rendering aid.
FIRST AID An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.
ENERGIZED EQUIPMENT Before working on energized equipment, ensure against grounding. If pos-sible, make repairs/adjustments with one hand, leaving the other hand clear of the equipment. Never work alone. MOVING EQUIPMENT If equipment must be repaired/adjusted while in motion, a safety watch shall be posted. The safety watch must have a full view of the repair/adjustment operation and immediate access to controls that can stop the equipment in motion.
SPECIFIC SAFETY NOTICES The specific safety warnings and cautions summarized below appear in appropriate chapters of this manual. Each is referenced to the text page on which it appears.
A WARNING is an operating or maintenance procedure, practice, condition or statement which, if not strictly observed, could result in injury or death to personnel.
A CAUTION is an operating or maintenance procedure, practice, condition or statement which, if not strictly observed, could result in damage to, or destruction of, equipment or loss of mission effectiveness.
The following warnings and cautions appear in the text of this volume and are repeated here for empha-sis.
WARNING
To prevent injury or death, exercise extreme caution when working on or around rotating parts of machinery or operating equipment. (Page 2-4)
S9233-C9-MMA-010
WARNING
To prevent injury or death, shut down the engine when unusual noise or vibration occurs. Unusual noise or vibrations may be an indication of equip-ment failure. (Page 2-4)
WARNING
To prevent injury or death, control all oil and fuel leakage immediately. Oil or fuel spraying on hot components is an extreme fire hazard. (Page 2-5)
WARNING
To prevent injury or death, use extreme caution when removing the cap from the expansion tank. Steam formed by the sudden release of pressure from a heated cooling system may force hot coolant through the system’s openings. (Page 2-7)
WARNING
Use of cleaning solvent in a confined area can result in injury or death. Avoid prolonged breathing of fumes and solvent contact with skin or eyes. Avoid use near heat or open flame. (Page 6-5)
WARNING
Never turn a stream of compressed air on anyone. Severe injury or death could result. (Page 6-5, page 6-14, page 6-37, page 6-70, page 6-80, page 6-83, page 6-92, page 6-99, page 6-102, page 6-105)
WARNING
Rotating machinery can cause injury or death. Ensure the engine is shut down before working on equipment and that the starter is tagged OUT-OF-SERVICE. (Page 6-8)
WARNING
To prevent injury or death, ensure extreme care and proper lifting devices are used during handling. The equipment is heavy. (Page 6-8, page 6-82, page 6-102, page 6-106, page 8-1)
WARNING
To prevent injury or death, ensure the engine is securely mounted to the overhaul stand before releasing the lifting sling; engine damage may result if the engine breaks away from the overhaul stand. (Page 6-9)
WARNING
To prevent serious eye injury while removing/installing retaining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove.(Page6-10,page6-17,page6-18,page6-19,page6-28,page6-28,page6-29, page 6-51, page 6-70, page 6-71, page 6-80, page 6-98, page 6-100)
WARNING
To prevent serious eye injury while removing/installing refining ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. (Page 6-10)
WARNING
To prevent injury or death when testing the engagement mechanism, under no circumstances should both main terminals be connected to the supply voltage source. Otherwise the pinion will rotate at high speed when pulled forward and present extreme danger to the operator. (Page 6-20)
WARNING
To prevent serious hand injury while removing/installing the drive belt, keep hands out of the path of the spring-loaded belt tensioner. (Page 6-24, page 6-24)
S9233-C9-MMA-010
WARNING
To prevent injury, exercise extreme care and wear insulated gloves when handling heated components. Heated metal pans can cause serious burns. (Page 6-29)
WARNING
Fuel spray from an injection nozzle can penetrate the skin and cause serious injury. Use the proper equipment and keep hands clear when testing the nozzles. (Page 6-39)
WARNING
Fuel spray from an injection nozzle can penetrate the skin and cause serious injury. Use the proper equipment and keep hands clear when testing the nozzle. (Page 6-43)
WARNING
Do not bleed a hot engine. This action could cause fuel to spill onto a hot exhaust manifold thereby creating a danger from fire. (Page 6-44)
WARNING
To prevent serious eye injury while removing/installing retailing ring(s), wear safety eye protection. Ensure retaining ring(s) is secure in the ring groove. (Page 6-81)
WARNING
To prevent serious eye injury, wear safety eye protection when removing springs under pressure. (Page 6-82, page 6-84)
WARNING
To prevent injury, exercise extreme care and wear insulated gloves when handling heated solutions or metal. (Page 6-90, page 6-96, page 6-103)
WARNING
Wear eye protection when removing the ring gear from the flywheel. Do not use a steel drift pin. (Page 6-96)
CAUTION
To prevent damage to equipment, prime the sea water pumps prior to opera-tion. (Page 2-3)
CAUTION
To prevent damage to equipment, ensure that oil in the engine is at the proper level. (Page 2-3)
CAUTION
To prevent damage to equipment, this entire procedure and the emergency operating procedures must be understood before starting the engine. Rapid automatic sequence of some events without proper operator actions may damage the equipment. (Page 2-4)
CAUTION
To prevent damage to equipment, do not engage the clutch at speeds greater than 850 rpm. (Page 2-5)
CAUTION
To prevent damage to equipment, run the engine at 800 rpm or greater dur-ing extended idle periods. Runndur-ing the engine at idle speed for prolonged periods will dilute oil with fuel and cause sludge build-up. (Page 2-5)
S9233-C9-MMA-010
CAUTION
To prevent damage to equipment, cool the engine before pressing the stop switch. Stopping the engine before it cools down may cause damage to equipment. (Page 2-5)
CAUTION
If excessive oil must be repeatedly drained from the engine, troubleshoot the cause to prevent further damage to the engine. (Page 2-6)
CAUTION
To prevent damage to the timing pin and camshaft gear, disengage the tim-ing pin before rotattim-ing the crankshaft. (Page 6-4)
CAUTION
Do not use harsh abrasives that might scratch, score, or otherwise mar sur-face finishes. (Page 6-5)
CAUTION
Do not allow machined or lapped mating surfaces to contact any surface without protection against nicks, scratches, burrs, etc. (Page 6-6)
CAUTION
Avoid scratching and nicking critical surfaces of balls and rollers in bear-ings; take care to protect surfaces of shaft/ bearing fit. (Page 6-6)
CAUTION
Do not clean bearings ultrasonically; this method can pit bearing surfaces. Do not agitate any other parts longer than five minutes at a time. (Page 6-6)
CAUTION
Ensure that low-pressure air used to dry components is clean and dry. Mois-ture in an air line can cause rust. (Page 6-6)
CAUTION
If polishing is required, avoid leaving deposits of metal dust in and around bearings. (Page 6-6)
CAUTION
To prevent damage to equipment, the diesel engine lifting device should be adjusted so the lifting hooks are vertical. (Page 6-8)
CAUTION
To prevent damage to equipment, a soft-jawed vise, cloth, or cardboard should be used to protect parts. (Page 6-10, page 6-16, page 6-17, page 6-37, page 6-38, page 6-68, page 6-71)
CAUTION
To prevent overheating, do not leave the pull-in winding energized more than 15 seconds. The current draw will decrease as the winding temperature increases. The purpose of the R terminal is to short out the ignition resistor during cranking, thereby providing high ignition coil output. (Page 6-12)
CAUTION
The retaining pad must be removed to prevent oil starvation of the bearing after assembly. On new drive end shields, the retaining pad is fitted in the oil way. (Page 6-13)
CAUTION
To prevent damage to equipment, the starter should always be run in con-junction with a flywheel. If this is not possible, do not operate the starter for more than five seconds. If the starter is allowed to run without a load, the pinion will not be restrained from rotating in the initial stages and will not complete the forward movement necessary to trip the second stage contacts. Under these conditions, the resistor will remain in the circuit and may be damaged by overheating. Prolonged operation on first stage contacts may cause grooving of the solenoid trip mechanism. (Page 6-21)
S9233-C9-MMA-010
CAUTION
Do not scratch the white ceramic surface of the seat. (Page 6-29)
CAUTION
To prevent the fuel injection pump delivery valve holder from turning, use two wrenches. (Page 6-35)
CAUTION
To prevent serious damage to the injection nozzle, ensure the interior of the socket does not come in contact with the fuel drain outlet sealing surface. (Page 6-36)
CAUTION
To prevent damage to the injection nozzle and needle valve, place parts in a suitable bath of clean fuel oil. (Page 6-37)
CAUTION
To prevent damage to equipment, disengage the pin after locating TDC. (Page 6-45)
CAUTION
To prevent damage to equipment and excessive teardown, do not drop the fuel pump drive gear key from the pump shaft when removing the pump. (Page 6-47)
CAUTION
Do not exceed the specified pressure. Excess pressure can cause damage to the shoe assemblies and adjusting plates. (Page 6-63)
CAUTION
Loose connections or cracks in the suction side of the intake pipe on turbo-charged engines can allow debris to be ingested into the turbocharger com-pressor and forced into the engine. (Page 6-66)
CAUTION
Leaks at the intake manifold, unsealed bolt holes, or manifold cover gasket can allow dust and dirt to be ingested into naturally aspirated engines. (Page 6-66)
CAUTION
To prevent damage to equipment, the push rods must be correctly seated in the valve tappets. (Page 6-81)
CAUTION
To prevent damage to the connecting rod and bearing, avoid the use of metal objects during removal. (Page 6-98)
CAUTION
Do not bead blast the pistons. (Page 6-98)
CAUTION
Do not clean the pistons and rods in an acid tank. (Page 6-98)
CAUTION
If a strap-type ring compressor is used to install the piston and connecting rod assembly into the block, ensure the inside end of the strap does not hook on a ring gap and break the ring. (Page 6-101)
S9233-C9-MMA-010
CAUTION
Prior to installing the engine, ensure that all engine mounts and system interfaces are rust-free, clean, complete, and in good working order. (Page 8-1)
CAUTION
When installing the diesel engine, care must be taken to ensure proper alignment of rotating components. (Page 8-1)
xxvi
CHAPTER 1
GENERAL INFORMATION AND SAFETY PRECAUTIONS
1-1. INTRODUCTION.
1-1.1 GENERAL INFORMATION. This manual provides the necessary information to install, maintain, oper-ate, and repair the models 6B5.9-M and 6BT5.9-M diesel engines. The engines are manufactured by the Cum-mins Engine Co., Defense Products, 1000 Fifth Street, P. O. Box 3005, Columbus, Indiana 47201-6574, tel: (800) 343-7357.
1-1.2 SAFETY PRECAUTIONS. Personnel involved with the installation, operation, and repair of the diesel engine shall comply with U.S. Navy Safety Precautions for Operations Afloat, OPNAV 5100 Series. Specific safety precautions are included in the appropriate chapters of this manual. General and specific warnings and cautions are contained in theSafety Summary, which is located in the front matter of this manual.
1-2. EQUIPMENT DESCRIPTION.
The 6B5.9-M is a cylinder, naturally aspirated diesel engine (figure 1-1) and the 6BT5.9-M is a six-cylinder, turbocharged, diesel engine (figure 1-2). Each engine is provided with an instrument panel that moni-tors engine pressures and temperatures.Table 1-1lists the principal characteristics of the 6B5.9-M diesel engine andtable 1-2 lists the principal characteristics of the 6BT5.9-M diesel engine.
Figure 1-1. Model 6B5.9-M Diesel Engine
Table 1-1. 6B5.9-M Principal Characteristics
Item Data
Diesel Engine
Model 6B5.9-M
Manufacturer Cummins Engine Co.
Type 4-cycle, in-line, 6-cylinder
Aspiration Natural
Bore x Stroke 4.02 in. x 4.72 in.
Engine Weight (dry) 855 lbs
Displacement 359 cu. in.
Duty Cycle Medium continuous
Horsepower
Shaft (at 2500 rpm) 112 shp
Brake (at 2500 rpm) 115 bhp
Firing Order 1-5-3-6-2-4
Compression Ratio 18.5:1
Rotation (as viewed from front of engine) Clockwise
Normal Idle Speed 750 rpm
Torque Capacity of Front of Crankshaft (max) 210 lb-ft
Figure 1-2. Model 6BT5.9-M Diesel Engine S9233-C9-MMA-010
Table 1-1. 6B5.9-M Principal Characteristics - Continued
Item Data
Crankshaft End Clearance (range) .0054 to.0104 in.
Engine Speed 2500 rpm
Piston Speed 1969 ft/min
Brake Mean Effective Pressure 101 psi
Standard Flywheel Housing Size SAE No. 3 Lubrication System
High Oil Level Capacity 15 qts
Low Oil Level Capacity 13 qts
Oil Temperature (max) 250° F
Oil Pressure at Idle (min allowable) 10 psi Oil Pressure at Rated (min allowable) 40-60 psi Oil Regulating Valve Opening Pressure 60 psi Differential Pressure to Open Bypass Valve 20 psi Continuous Operational Angularity of Oil Pan
(max)
Front down 45 degrees
Front Up 45 degrees
Side-to-Side 45 degrees
Cooling System
Coolant Capacity (engine only) 13.6 gals
Engine w/Heat Exchange 21.8 gals
Thermostat Range
Starting 180° F
Fully Open 203° F
Pressure 15 psi
External Pressure Loss in Cooling System (max) 5 psi Allowable Coolant Expansion Space of System
Capacity (min)
5 percent Coolant Make-up Capacity (min) 2.7 gals
Engine Water Flow 55 gpm
Fuel Oil System
Fuel Consumption (max) 6.3 gph
Fuel Flow to Pump (max) 8 gph
Allowable Pressure Drop Across Fuel Filter (max) 3 psi Allowable Return Line Restriction (max) 5.0-inHg Restriction to Fuel Pump with Dirty Filter (max) 3.75-inHg
Fuel Supply Hose Size 6
Fuel Return Hose Size 4
Air Supply System
Intake Air Flow 210 cfm
Allowable Intake Restriction at Rated Speed and Load with Dirty Air Filter Element (max)
20-inH2O Allowable Return Line Restriction (max) 20.4-inHg Intake Air Restriction (naturally aspirated) 20-inH2O
Ventilation Area (min) 57 sq. in.
Exhaust System
Exhaust Gas Flow 600 cfm
Table 1-1. 6B5.9-M Principal Characteristics - Continued
Item Data
Exhaust Gas Temperature 1150°F
Exhaust Diameter (min)
Dry 3.0-in.
Wet 3.5-in.
Heat Rejection to Coolant 4500 Btu/min
Heat Rejection to Ambient 800 Btu/min
Sea Water System
Sea Water Flow 23 gpm
Sea Water Pressure (max) 15 psi
Sea Water Pump Inlet Restriction (max) 5 inHg Sea Water Strainer Open Area (min) 6.0-in. Sea Water Pump Initial Suction Lift (max) 10 ft Electrical System
Recommended Battery Capacity (min) Cold soak at 0°F or Above (min/CCA) w/24-Vdc Starter
475 Reserve Capacity Allowable Resistance of Starting
Circuit w/24 volt Starteralign=″right″(max)
.0020 ohms
Table 1-2. 6BT5.9-M Principal Characteristics
Item Data
Diesel Engine
Manufacturer Cummins Engine Co.
Model 6BT5.9-M
Type 4-cycle, in-line, 6-cylinder
Aspiration Turbocharged
Installation Angle (max; up front) 15 degrees
Bore x Stroke 4.02-in. x 4.72-in.
Engine Weight Dry 880 lbs,
Displacement 359 cu. in.
Duty Cycle Medium continuous
Firing Order 1-5-3-6-2-4
Fuel Injection Direct
Engine Torque 378 lb-ft
Valve Clearance (intake) .010-in.
Valve Clearance (exhaust) .020-in.
Horsepower Shaft (at 2500 rpm) 175 shp Brake (at 2500 rpm) 180 bhp Shaft Power High Output 204 shp at 2600 rpm Intermittent 175 shp at 2500 rpm Compression Ratio 17.5:1
Rotation Viewed from Front of Engine Clockwise Rated Speed
High Output 2600 rpm
Intermittent 2500 rpm
S9233-C9-MMA-010
Table 1-2. 6BT5.9-M Principal Characteristics - Continued
Item Data
Standard Flywheel Housing Size SAE No. 3
Normal Idle Speed 750 rpm
Piston Displacement 359 cu. in.
Fuel System Fuel Consumption
High Output 11.2 gph at 2600 rpm
Intermittent 9.7 gph at 2500 rpm
Fuel Flow to Pump 12 gph
Allowable Restriction to Pump with Dirty Filter (max)
3.75 inHg Allowable Injector Return Line Restriction (max) 5.0 inHg Allowable Pressure Drop Across Fuel Filter
(max)
3.0 psi
Fuel Supply Hose Diameter 25-in
Fuel Supply Hose Size 6
Fuel Return Hose Diameter 19-in
Fuel Return Hose Size 4
Air Supply System
Intake Manifold Pressure 43 inHg
Inlet Restriction Filter (max/clean) 15-inH2O Inlet Restriction Filter (max/dirty) 25-inH2O
Allowable dirt Holding Capacity of Air Cleaner (min)
3.0 gpm/cfm
Intake Air Flow 510 cfm
Ventilation Area (min) 138 sq. in.
Heat Rejection to Ambient 7100 BTU/min Lubrication System
Allowable Oil Pressure at Idle (min) 10 psi Allowable Oil Pressure at Rated Speed (min) 40-60 psi Regulating Valve Opening Pressure 60 psi Differential Pressure to Open Bypass Valve 20 psi Oil Capacity
High 15 qts
Low 13 qts
Total System Capacity 16 qts
Continuous Operational Angularity of Oil Pan (Max)
Front down 45 degrees
Front Up 45 degrees
Side-to-Side 45 degrees
Cooling System Engine Water Flow
High Output 56 gpm
Intermittent 55 gpm
Coolant Capacity (engine only) 13.6 gals Thermostat Standard Modulating Range
Starting 180°F
Table 1-2. 6BT5.9-M Principal Characteristics - Continued
Item Data
Fully Open 203°F
Coolant Temperature (max) 210°F
External Pressure Loss in Cooling System (max) 5 psi Static Pressure of Coolant (max; exclusive of
pressure cap)
15 psi Allowable Coolant expansion Space of System
Capacity (min)
5 percent Coolant Make-up Capacity (min) 2.7 gals Sea Water System
Sea Water Flow
High Output 25.5 gpm
Intermediate 23.5 gpm
Sea Water Pressure (max) 15 psi
Sea Water Strainer Open Area (min) 6.0-in. Sea Water Pump Inlet Restriction (max) 5 inHg Sea Water Pump Initial Suction Lift (max) 10 ft Heat Rejection to Coolant 6900 Btu/min
Sea Water Pipe Size (min) 1.25-in.
Exhaust System Exhaust Gas Flow
High Output 1230 cfm
Intermittent 777 cfm
Exhaust Gas Temperature
High Output 835°F
Intermittent 750°F
Heat Rejection to Coolant
High Output 7100
Intermittent 5594
Exhaust Diameter (min; dry) 4.0-in.
Exhaust Diameter (min; wet) 5.0-in.
Electrical System
Recommended Battery Capacity Cold Soak at 0°F or above (min/CCA)
475 Reserve Capacity Allowable Resistance of
Start-ing Circuit w/24-Volt Starter (max)
.0020 ohms S9233-C9-MMA-010
CHAPTER 2 OPERATION
2-1. INTRODUCTION.
This chapter provides procedures to check, prepare, operate, and shut down the diesel engine. These proce-dures are sufficient to enable assigned personnel to operate the engine safely and efficiently. The applicable boat information book (BIB) and the Naval Ship’s Technical Manual (NSTM), Chapters 233 and 541, provide addi-tional information and procedures for various operation conditions.
2-2. NORMAL OPERATING RANGES.
Table 2-1lists the normal operating ranges for the models 6B5.9-M and 6BTS.9-M. Indicator readings out-side the normal operating range may require corrective maintenance to prevent equipment damage. Operating the engine below minimum values or above maximum values will damage the equipment.
Table 2-1. Normal Operating Ranges
Indication Range
6B5.9-M
Air Inlet Restriction (max at rated speed and load)
With Clean Filter Element 20 inH2O
With Dirty Filter Element 20.4 inH2O
Blowby (max; 0.221 in diameter orifice) 4.9 inHg at 2200 rpm; 7.0 at 2500 rpm Coolant Temperature
Standard Thermostat (modulating range) 175 to 195°F
Temperature (max) 210°F
Exhaust Back Pressure at Rated Load and Speed (max) 3 inHg Fuel Inlet Restriction With Clean Filter Element (max) 3.5 inHg
Idle Speed 750 rpm
Injector Return Line Restriction 5.0 inHg
Oil Pressure - Main Oil Passage
Max at rated rpm 60 psi
Min at rated rpm 30 psi
Min at idle rpm 10 psi
Oil Temperature (max) 250°F
6BT5.9-M
Air Inlet Restriction (max at rated speed and load)
With Clean Filter Element 15 inH2O
With Dirty Filter Element 25 inH2O
Blow By (max; 0.221 in. dia. orifice) 4.9 inHg at 2200 rpm 7.0 at 2500 rpm Coolant Temperature
Standard Thermostat (modulating range) 175 to 195°F
Temperature (max) 210°F
Exhaust Back Pressure at Rated Load and Speed (max) 3 inHg Fuel Wet Restriction With Clean Filter Element (max) 3.5 inH2O
Idle Speed 750 rpm
Table 2-1. Normal Operating Ranges - Continued
Indication Range
Injector Return Line Restriction 5.0 inHg
OH Pressure-Main Oil Passage
Max at rated rpm 60 psi
Min at rated rpm 30 psi
Min at idle rpm 10 psi
Oil Temperature (max) 250°F
2-3. OPERATING PROCEDURES.
2-3.1 PRE-OPERATIONAL CHECKS. The following steps shall be used to check and prepare the engine for operation
a. Test the emergency fuel shutdown according to the following steps.
1. Actuate the emergency fuel shutdown lever and ensure the emergency fuel shutdown device operates cor-rectly.
2. Reset the emergency fuel shutdown lever and open the emergency fuel shutdown valve. b. Test the electrical shutdown valve.
c. Ensure the fuel tanks are full of fuel and stripped in accordance with the appropriate BIB or local procedures. If fuel is required, refer to table 2-2 and refuel in accordance with the NSTM, Chapter 541, and the appro-priate BIB.
d. Check and drain the fuel strainer. e. Drain the fuel/water separator.
f. Open the fuel supply shutoff valves, as required, to supply fuel from the on-service fuel tank to engine. g. Open the fuel return shutoff valves, as required, to ensure that fuel spill from the engines returns to on-service
fuel tank only.
h. Check the fuel piping, hoses, fittings, and valves for leaks. If leaks are found, refer tochapter 5 and trouble-shooting.
i. Check the starting motor and batteries; ensure the battery charge is sufficient to start the engine. j. Check the air silencer for dirt and clogging. Remove any foreign material. Clean as required. k. Operate compartment ventilation, as required, for engine operation.
l. Remove the cap from the expansion tank assembly and check the coolant level. At normal operating tempera-ture, the coolant level should be about two inches below the top of the filler neck; add engine coolant, as required. Replace the cap.
m. Check the fresh water pipes, hoses, and fittings for leaks. If leaks are found, refer to chapter 5 and trouble-shoot.
n. Close the sea water drain and vent connections. o. Clean and inspect the sea water stainer.
p. Open the sea water manual valves, as required, for engine operation S9233-C9-MMA-010
Table 2-2. Fuel and Lubricating Oil
Type Usage
Primary
Fuel, Naval Distillate (MIL-F-168834) Use when ambient temperature is consistently above 30°F.
Secondary
Turbine Fuel, Aviation, Grade JP-5 (MIL-T-5624) Use when ambient temperature is consistently below 30°F.
Primary
Lubricating Oil, Internal Combustion Engine, Diesel (MIL-9000G, Sym 9250)
Use with ambient temperature above 20°F. Secondary
Lubricating Oil, Internal Combustion Engine, Diesel (MIL-L-2104)
Ambient temperature consistently below 20°F.
CAUTION
To prevent damage to equipment, prime the sea water pumps prior to opera-tion.
q. If necessary, prime the sea water pump.
CAUTION
To prevent damage to equipment, ensure that oil in the engine is at the proper level.
r. Ensure oil in the engine is at the high level mark on the dipstick.
1. Remove the dipstick from the oil pan and check the level. The oil level should be at the full mark. 2. If the level is low, refer totable 2-2. Remove the oil fill cap from the valve cover and add lubricating oil,
as required, to bring the level to the full mark. 3. Reinstall the oil fill cap.
4. If the level is high, excess oil can be removed from the oil sump with the sump pump. Dispose of oil in accordance with the NSTM, Chapter 593.
5. Reinstall the dipstick in the dipstick tube.
s. Ensure the marine transmission is prepared for operation, if equipped. Also, ensure the clutch is disengaged. t. Ensure the auxiliary driven equipment and associated systems are prepared for operation.
u. Ensure the engine rotating components are unobstructed. v. Place the start switch in the OFF position.
w. Ensure the oil pressure and alternator warning lights are on. x. Set the engine control lever in the idle position.
2-3.2 NORMAL OPERATION. The following steps shall be used for normal operation. This procedure covers electrical starting for cold and warm weather.
CAUTION
To prevent damage to equipment, this entire procedure and the emergency operating procedures must be understood before starting the engine. Rapid automatic sequence of some events without proper operator actions may damage the equipment.
a. Review this entire procedure and the emergency engineering operating procedures (EEOP) before performing any steps. This will ensure undemanding of required actions during rapid automatic sequence of events. Where conflicts exist, the EEOP takes precedence.
b. Ensure the pre-operational checks have been performed. Refer toparagraph 2-3.1. c. Place throttle in the idle position.
d. When the ambient temperature is 40°F or less and the engine is cold, start the engine using the cold start pro-cedures contained in the BIB.
e. When the ambient temperature is greater than 40°F or the engine is warm, start the engine with the electrical starting system.
WARNING
To prevent injury or death, exercise extreme caution when working on or around rotating parts of machinery or operating equipment.
1. Ensure the area around the engine is clear of personnel and loose equipment
NOTE
The start switch has three positions: OFF, RUN, and START. OFF and RUN are continuous contact positions and START is a momentary contact position.
2. Place the switch in the RUN position and observe that the engine’s gauges and instruments are energized. The temperature gauges should read normal temperatures and the alternator and low oil pressure warning lights should be lit.
3. Place and hold the switch in the START position to activate the starter motor and crank the engine. Pro-ceed to step f.
4. If the engine does not start after 30 seconds, return the switch to the OFF position. Wait two minutes between unsuccessful attempts.
5. Repeat steps 1 through 4. If the engine does not start after four attempts, refer to chapter 5 and trouble-shoot.
WARNING
To prevent injury or death, shut down the engine when unusual noise or vibration occurs. Unusual noise or vibrations may be an indication of equip-ment failure.
S9233-C9-MMA-010
f. Within 10 to 15 seconds after the engine starts, the alternator warning light and the low oil pressure warning light should go out, and the oil pressure gauge should indicate at least 10 psi. If this does not occur, place the switch in the OFF position and shut down the engine. Refer tochapter 5 and troubleshoot.
g. If abnormal noises or vibrations are present in the engine or any driven equipment, shut down the engine according to the EEOP.
WARNING
To prevent injury or death, control all oil and fuel leakage immediately. Oil or fuel spraying on hot components is an extreme fire hazard.
h. Periodically check the engine, attached piping, and hoses for oil, fuel, coolant, and sea water leakage. 1. If oil or fuel is spraying, shut down the engine according to the EEOP.
2. If the oil or coolant levels cannot be maintained, shut down the engine according to the EEOP. 3. If fuel is leaking, shut down the engine according to the EEOP.
4. If sea water is leaking and the coolant temperature is above 190°F and rising, shut down the engine. If the temperature reaches 210°F, shut down the engine according to the EEOP.
i. Periodically monitor all engine indicators and record readings. Ensure the monitored parameters are within operating limits. Refer totable 2-1.
j. Run the engine at idle speed for one minute.
CAUTION
To prevent damage to equipment, do not engage the clutch at speeds greater than 850 rpm.
k. With the boat moored to the dock, engage the clutch and run the engine at partial load for five minutes.
CAUTION
To prevent damage to equipment, run the engine at 800 rpm or greater dur-ing extended idle periods. Runndur-ing the engine at idle speed for prolonged periods will dilute oil with fuel and cause sludge build-up.
l. Operate the engine, as required, for boat operations; maintain 800 rpm or greater when operating. Ensure the clutches are not engaged at speeds greater than 850 rpm.
2-3.3 SHUTDOWN. Shut down the engine according to the following steps.
CAUTION
To prevent damage to equipment, cool the engine before pressing the stop switch. Stopping the engine before it cools down may cause damage to equipment.
a. To cool down the engine, run the engine for five minutes at idle speed with the clutch disengaged. b. Move the start switch to the OFF position; ensure the engine stops.
c. If the engine does not stop, actuate the emergency manual shutdown lever. If the emergency fuel shutdown lever does riot stop the engine, determine and correct the cause. Refer to chapter 5and troubleshoot.
d. If the engine does not stop, actuate the emergency fuel shutdown lever for the on-service fuel tank. Ensure the engine stops in about 10 seconds. Determine and correct the cause of the stop switch not stopping the engine.
e. If actuated, reset the emergency fuel shutdown lever and open the emergency fuel shutdown valve. f. Close the fuel supply shutoff valve supplying fuel from the on-service fuel tank to the engine. g. Close the fuel return shutoff valve which allows fuel spill to return to the on-service fuel tank. h. Close the sea water manual valves that were opened for engine operations
i. Open the sea water vent and drain connections.
j. After the engine has been stopped for 20 minutes, ensure oil in the engine is at the proper level. 1. Remove the dipstick from the oil pan and check the level. The oil level should be at the full mark. 2. If the level is low, remove the oil fill cap from the valve cover and add lubricating oil, as required to bring
level to full mark. (Refer totable 2-2.) Reinstall the oil fill cap on the cover.
CAUTION
If excessive oil must be repeatedly drained from the engine, troubleshoot the cause to prevent further damage to the engine.
3. If the level is high, pump oil from the oil pan into an appropriate disposal container. Dispose of oil in accordance with the NSTM, Chapter 593.
4. Reinstall the dipstick in the dipstick tube.
k. Refer to table 2-2and fill the fuel tanks with fuel in accordance with the NSTM, Chapter 541, and the BIB. l. Perform required engine maintenance.
2-3.4 EMERGENCY OPERATION. Emergency operation is necessary when the equipment malfunctions. If the equipment malfunctions, refer to chapter 5 and troubleshoot. Ensure equipment repair/replacement is per-formed as soon as possible.
2-3.4.1 Low Oil Pressure.
a. If the warning light indicating low oil pressure comes on, check the oil pressure gauge.
b. If the oil pressure gauge indicates greater than 10 psi, determine and correct the cause of the malfunctioning warning light. Refer to chapter 5 and troubleshoot.
c. If the oil pressure gauge indicates 10 psi or less, stop the engine.
d. If operation of the engine is not absolutely required, shut down the engine (refer to paragraph 2-3.3.). S9233-C9-MMA-010
e. If the engine operation is required and low oil pressure is due to oil leakage, operate the engine while per-forming the following steps.
1. Remove the dipstick from the oil pan and check the level.
2. Remove the oil fill cap from the valve cover. Add lubricating oil (table 2-2), as required, to bring the level to the full mark. Reinstall the oil fill cap on the cover.
3. Reinstall the dipstick in the oil pan.
4. Continuously repeat steps 1 through 3 while the engine is running.
5. If the oil level cannot be maintained between the low and full marks on the dipstick or the oil pressure cannot be maintained greater than 10 psi, shut down the engine according toparagraph 2-3.3.
f. Determine and correct the cause of low oil pressure. Refer tochapter 5 and troubleshoot.
2-3.4.2 High Engine Coolant Temperature.
a. If the warning light indicating high engine coolant temperature comes on, check the water temperature gauge. 1. If the water temperature gauge indicates 210°F or greater, shut down the engine to determine and correct
the malfunction. Refer tochapter 5 and troubleshoot.
2. If the water temperature gauge indicates 200°F or greater, decrease engine speed to attempt cooling of the engine. Refer to chapter 5and troubleshoot.
b. If engine operation is required and high engine coolant temperature is due to coolant leakage, operate the engine as follows:
1. Allow the engine to cool as long as possible.
WARNING
To prevent injury or death, use extreme caution when removing the cap from the expansion tank. Steam formed by the sudden release of pressure from a heated cooling system may force hot coolant through the system’s openings.
2. Using extreme caution, remove the cap from the expansion tank. 3. Add coolant, as required, to bring the tank to the proper level.
4. Operate the engine; refer to paragraph 2-3.2. Continuously monitor the tank and add coolant, as required, to maintain the proper level.
5. If the coolant level cannot be maintained, shut down the engine according to the EEOP. 6. When engine operations are complete, reinstall the cap on the tank.
c. Determine and correct the cause of a high engine coolant temperature. Refer tochapter 5 and troubleshoot.
2-3.4.3 Runaway Engine. If oil is introduced into the cylinders, the engine will become uncontrollable and may overspeed. Excessive oil level in the oil pan will cause a runaway engine. If a runaway engine is suspected, pro-ceed as follows:
a. Shut down the engine according to the EEOP.
b. If the engine speed is quickly approaching 2600 rpm, actuate the emergency manual shutdown lever. c. Determine and correct the cause of a runaway engine. Refer tochapter 5 and troubleshoot.
S9233-C9-MMA-010
CHAPTER 3
FUNCTIONAL DESCRIPTION
3-1. INTRODUCTION.
This chapter provides a detailed functional description of the diesel engine.
3-2. GENERAL DESCRIPTION.
The diesel engine converts chemical energy into mechanical energy, which is used for propulsion and to pro-vide power for boat accessories. The model 6B5.9-M diesel engine is a six-cylinder, four-cycle internal combus-tion engine that also drives its own accessory equipment and the model 6BT5.9-M diesel engine is a six-cylinder, four-cycle, internal combustion, turbocharged diesel engine. Each of the engines consists of an electric starting system, an air intake and exhaust system, a fuel system, lubrication system, cooling system, and various controls and indicators.
3-3. DETAILED DESCRIPTION.
3-3.1 DIESEL ENGINE. The engine is a four-cycle, internal combustion engine that includes an intake air cleaner/silencer, six pistons and connecting rod assemblies, a crankshaft assembly, idler gear, camshaft assembly, cylinder head assembly, cylinder block assembly, and an accessory drive assembly. The piston and connecting rod assemblies convert the heat energy released by fuel combustion into mechanical energy to rotate the crank-shaft assembly. Crankcrank-shaft assembly rotation is then transmitted by the idler gear to the camcrank-shaft assemblies through a gear train. The camshaft assemblies actuate the cylinder head assemblies to inject fuel into and con-duct exhaust gases out of the cylinders in the required timed sequence. The cylinder head assembly forms the top enclosure for the cylinders and provides for cooling, lubrication, fuel injection, and exhaust gas removal. (The model 6BT5.9-M includes a turbocharger to increase intake air volume and pressure.) The cylinder block assem-bly supports and aligns the diesel engine components and provides internal passages for oil, coolant, and air flow. Various diesel and non-diesel accessory equipment is driven by the accessory drive assembly.
3-3.2 ELECTRICAL STARTING SYSTEM. The electrical starting system includes a starting circuit, 24-volt battery bank, starting motor, and an alternator. A deposition toggle switch (OFF, RUN, START) is included for engine control. The OFF position closes the fuel supply to the injection pump. The RUN position energizes the engine gauges, instruments, warning lights, and control devices, and also opens the fuel supply valve. The START position is a momentary contact. When held closed, the solenoid switch on the starter motor is closed to supply full battery power to the starter motor for cranking the engine. When released the switch returns to the RUN position where it remains until it is moved to the OFF position. An electrical interlock, which is included in the engine throttle and clutch control, prevents starting the engine unless the transmission is in neutral.
The alternator includes a solid-state, integral voltage regulator. A positive battery lead supplies power for ini-tial excitation of the alternator field. An alternator failure warning light is fed by the same line. As soon as the alternator begins to generate voltage, that voltage matches the battery voltage to the regulator and turns out the alternator failure warning light, and the alternator becomes self-excited. The voltage regulator senses battery con-dition and maintains alternator output voltage at an appropriate level throughout the full range of engine running speeds. When the alternator output stops, battery power returns to the warning light.
3-3.3 AIR INTAKE AND EXHAUST SYSTEMS.
3-3.3.1 Air Intake System. The air intake system provides clean air to the cylinders at atmospheric pressure for the model 6135.9-M, and above atmospheric pressure for the model 6BT5.9-M. The model 6B5.9-M intake sys-tem includes air cleaner/ silencer piping and an intake manifold and intake valves, through which clean, cool air is admitted into the engine cylinders. The model 6BT5.9-M is equipped with an exhaust-driven turbocharger, which increases the intake air volume and pressure to the cylinders via the intake manifold and intake valves. S9233-C9-MMA-010
Figure 3-1. Electrical Schematic (Sheet 1 of 2)
3-4
Figure 3-1. Electrical Schematic (Sheet 2 of 2)
3-6
3-3.3.2 Exhaust System. The exhaust system includes those components used to expel the engine’s exhaust gasses. It starts with the exhaust valves, one valve for each of the six cylinders. Each cylinder expels its exhaust gas into the manifold: in the model 6B5.9-M, the exhaust passes through a sea water-cooled exhaust elbow fit-ting, through a 2-1/2-inch to 3-inch piping, a muffler, and more piping to the atmosphere. The path of the exhaust gasses for the model 6BT5.9-M is the same from the cylinder exhaust valve to the exhaust manifold, but in this model, the exhaust gasses are used to drive the turbocharger. From the turbocharger, the exhaust gas passes through the sea water-cooled elbow, piping, muffler, and additional piping before it is discharged to the atmo-sphere.
3-3.4 FUEL SYSTEM. The fuel system consists of a fuel lift pump, injection pump, fuel drain manifold, throttle, shutoff valve, fuel injection nozzles, and fuel lines.
3-3.4.1 Fuel Pumps. The fuel lift pump is attached to the side of the engine block. The lift pump pulls fuel from the supply tank and supplies low-pressure fuel (3 to 5 psi) to the fuel filter head, through the filter, then to the fuel injection pump. The fuel injection pump increases fuel pressure and routes the high-pressure fuel to each Injection nozzle.
3-3.4.2 Fuel Injection Nozzles. Fuel is supplied through the high-pressure lines to the fuel injection nozzles in the cylinder head. When the high-pressure fuel reaches the injection nozzles, the pressure lifts the needle valve against spring tension and allows fuel to enter the combustion chamber. A common drain line returns unused fuel to the supply tank.
3-3.4.3 Fuel Drain Manifold. Any leakage past the fuel injection needle valve enters the fuel drain manifold. The fuel drain manifold routes controlled venting from the injection pump and leakage from the nozzles back to the main fuel tank.
3-3.4.4 Throttle. The throttle provides a means for the operator to manually control engine speed above idle, as required, by varying operating conditions of speed and load.
3-3.4.5 Fuel Shutoff Valve. The injection pump is equipped with an electrical shutoff valve. This solenoid-operated valve blocks the supply of fuel to the high-pressure pumping and distribution components. The valve is designed to be closed when there is no electrical power to the solenoid.
3-3.5 LUBRICATION SYSTEM. The engine is pressure-lubricated by a gerotor-type lube oil pump driven by the front crankshaft gear located in the oil pan at the front of the engine. A pressure regulator is mounted in the block to control pressure. Filters and screens are provided in the lubricating system to remove impurities in the oil. A bypass valve is provided in the full-flow oil filter head to continue lubrication if the element becomes clogged. The engines lube oil capacity at full level holds 15 quarts of oil.
3-3.6 COOLING WATER SYSTEMS.
3-3.6.1 Fresh Water Cooling System. Coolant in the fresh water cooling system consists of a mixture of fresh water and antifreeze. The engine fresh water cooling system includes an engine block, cylinder head, heat exchanger, fresh water pump, thermostat, expansion tank, and piping; it has a coolant capacity of 21.8 gallons. The coolant is pressurized up to 15 pounds psi when the diesel engine is running at normal operating speed (2500 rpm) by the fresh water pump. Coolant output from the fresh water pump empties into the oil cooler cavity of
the cylinder block. The coolant circulates around each cylinder and crosses the cylinder block to the fuel injec-tion pump side of the engine. As the coolant flows through the cylinder head and block toward the thermostat, it provides cooling for the fuel injection nozzles. When the engine is below operating temperature, the thermo-stat is closed and coolant flow bypasses the heat exchanger, trapped air goes to the water pump inlet via drilled passages in the block and head. When the operating temperature is reached, the thermostat opens, thereby block-ing the bypass passage to the fresh water pump and openblock-ing the outlet to the heat exchanger. Coolant flowblock-ing through the heat exchanger to the fresh water pump is cooled by a counterflow of sea water pumped through the heat exchanger. Sea water exits from the heat exchanger via a sea water connection at the upper rear end of the heat exchanger. The expansion tank provides make-up coolant for the closed coolant system and provides a place for hot coolant to expand.
3-3.6.2 Sea Water Cooling System. The sea water cooling system furnishes sea water, which is used to cool oil passing through the transmission’s oil cooler, fresh water coolant passing through the heat exchanger, and exhaust gas passing through the exhaust manifold elbow to the muffler. The water pump, which has a maximum suction lift of 10 feet, draws sea water through a strainer with a minimum open area of six square inches. The sea water pump discharges coolant at a maximum pressure of 15 psi.
3-3.7 CONTROLS AND INDICATORS. Various controls and indicators are provided with the diesel engine installation to start, operate, and shut down the diesel engine and to monitor diesel engine parameters during operation. Seefigure 3-1for an electrical schematic of the engine controls.
3-3.7.1 Starter Switch. When the starter switch is activated, 24-Vdc is supplied to the solenoid, completing the circuit to the starter motor on the engine.
3-3.7.2 Electrical Fuel Shutoff. The fuel shutoff is installed on the fuel injection pump. Its purpose is to stop the engine under normal operating conditions by stopping the fuel flow to the nozzles when the start switch is moved to the OFF position.
3-3.7.3 Tachometer. The tachometer is electrically connected to a sender attached to the engine. It converts mechanical motion to electrical impulses to cause the tachometer to indicate engine speed (rpm).
3-3.7.4 Lube Oil Pressure Switch. The lube oil pressure switch is a break-type switch set to actuate when the lube oil pressure drops to eight psi. This completes the low lube oil alarm circuit to the control panel to activate the engine warning light. The switch is located on the fuel pump side of the block.
3-3.7.5 Water Temperature Switch. The water temperature switch, which is located on the cylinder head, is operated by a high cooling water temperature condition. When the cooling water temperature exceeds 225°F, the switch closes a set of contacts that causes the engine warning light at the control panel to activate.
S9233-C9-MMA-010
CHAPTER 4
SCHEDULED MAINTENANCE 4-1. INTRODUCTION.
Required preventive maintenance procedures to be performed on a scheduled basis are provided in the Planned Maintenance System (PMS) documentation OPNAVINST 4790.4 describes this system, which also cov-ers departmental and work center record keeping, as well as the Maintenance Index Page (MIP) and Maintenance Requirements Cards (MRC’s). MRC’s cover scheduled inspection and lubrication procedures for the diesel engine. The extensive and comprehensive scheduled maintenance provided by PMS MRC’s eliminates the need for any coverage within this chapter. Specific corrective maintenance (adjustment, alignment, and repair) is cov-ered inchapter 6 of this manual.
4-2
CHAPTER 5 TROUBLESHOOTING
5-1. INTRODUCTION.
This chapter provides information for troubleshooting unsatisfactory operation or failure of the diesel engine. The procedures have been prepared for the operators rather than the more experienced and better equipped per-sonnel in maintenance facilities. However, some of the diagnostic and corrective action procedures may require personnel assistance and/or tools or other equipment not available onboard the craft.
5-2. TROUBLESHOOTING GUIDE.
The troubleshooting guide (table 5-1) is provided as an aid to locate and correct any malfunctions of the die-sel engines. At the first sign of trouble, isolate the problem and evaluate before removing any components.Table 5-1represents a list of potential problems, their probable causes, and suggested corrective actions.
Table 5-1. Troubleshooting Guide
Problem/Malfunction Probable Cause Corrective Action
Engine will not crank. a. Loose or corroded battery cables.
a. Clean and tighten battery connections.
b. Loose or corroded connections in the starting circuit
b. Clean and tighten connec-tions.
c. Battery charge low. c. (1) Inspect battery for dead cell. Replace defective battery. (2) Inspect alternator output. Replace defective alternator. d. Faulty solenoid or starting
motor.
d. Temporarily cross-connect the starter solenoid terminals If the starter does not crank, replace the starter motor. e. Faulty auxiliary magnetic switch. e. Temporarily connect starter
solenoid terminal P to S. if the engine does not crank, replace the switch.
f. Faulty starter switch. f. Temporarily connect termi-nals I to S on the start switch. If the starter cranks, replace the switch.
