Professional Documents
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DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION
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30 NOV 1988
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CHANGE RECORD
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B 17 JUL 91 ADDED ISOTTA FRASCHINI INSPECTION
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PREFACE
This handbook is divided into two parts: Part I will provide you, the Diesel Inspector, with the
requirements and procedures for properly conducting a Diesel Engine Inspection. Part II will give
you a background on the design, construction, operation, and maintenance of the various Diesel
Engines in naval shipboard use. Part II is not intended to replace or duplicate any specific Diesel
Engine technical manual, NSTM, or operational procedure. It is intended to provide you with a
technical resource that enables you to better understand and evaluate Diesel Engines and their related
systems.
COMMANDING OFFICER
ATTN: CODE 9325
NSWCCD-SSES
5001 S BROAD ST
PHILADELPHIA PA 19112-5083
Preface
TABLE OF CONTENTS
Chapter/Paragraph Page
Change F i
TABLE OF CONTENTS (Continued)
ii
TABLE OF CONTENTS (Continued)
H5 DDA 16V 149 DIESEL ENGINES OPERATIONAL TEST DATA SHEET ..........H5-1
Change F
iii
TABLE OF CONTENTS (Continued)
iv
CHAPTER 1
ROLE OF THE INSPECTOR
Let your professionalism show – in your bearing, your uniform, your manner, your attitude.
Remember, you may be inspecting the engine, but the crew is inspecting you.
Show courtesy to the ship by planning your inspection. If you communicate with the ship, give the
crew a plan of action before your arrive, you will avoid the unexpected in scheduling. Showing up
on the quarterdeck to inspect the diesel engine with no prior planning, however, will always start the
process badly.
Do your homework before you go on board. No one can master every engine the Navy uses, but if
you are well prepared to inspect a particular engine your knowledge will be apparent to the ship’s
engineering department and will instill in them the confidence that you know what you’re doing.
You may be a very competent inspector with good understanding of diesel engine theory, but if you
don’t know, for example, the compression or firing pressure of a particular engine you have to
inspect, you had better give yourself a few hours of careful preparation before you begin your
inspection. Take Notes when you do your research; take them on board with you; and, most
important, use them: You will gain the confidence of the crew and help yourself. If you know the
limits of an engine you can do a better job of gathering data. If you know what the compression is
supposed to be and the reading fall outside the specifications, you’ll be able to identify the problem
immediately. No matter how through your inspection is, it will be disregarded if your data are
incomplete or inaccurate.
• Assisting other naval activities in diesel engine related quality assurance issues
• Conducting training sessions for ship’s force on topics like diesel operation, maintenance, engine
performance tests, water treatment, lube oil analysis program and other diesel engine related
subjects.
• However varies your role as an inspector might be, you must be aware that although inspecting
the engine properly is your highest priority, you must also set the standard for:
1-1
• Safety
• Leadership
• Training
1-2 SAFETY
It is not enough to set a good example for safety. You must do as you say. This means that you do
not cut corners on safety, those whom you inspect will do the same after you have completed the
inspection and have left the ship. Because they view you as the expert, the crewmembers will
conclude that if the inspector does it this way and cuts corners, it’s acceptable for them to do the
same. Display the right example by being familiar with and following current safety practices.
1-3 LEADERSHIP
As a diesel inspector you must realize your position of leadership within the diesel engine
community. You should be able to evaluate any engine problem, identify the corrective action
needed, and provide the necessary guidance to implement the corrective action. To accomplish this
you need a thorough knowle dge of the engine and its installation. This will enable you to lead the
ship’s crew and will increase its confidence in your ability to manage the course of the
inspection/investigation.
Since you, the inspector, are constantly exposed to the fleet’s diesel engines, you are in the leadership
position and can set an example for the crew in making recommendations and identifying errors in
published procedures. Failure to question any area of concern permits erroneous data or procedures
to affect the fleet’s diesel engines. The Navy’s diesel engine population can be improved materially
by the leadership the diesel engine inspector provides to the fleet as the eyes and ears of NAVSEA
the LCM, the Type Commander and the technical community.
1-4 TRAINING
Inspecting an engine is only half the job. Teaching and training the crew is equally important. You
will often find that the younger sailors don’t know what the inside of their engine looks like. They
are eager to learn and are interested in what you do and what you know. Explain in detail what you
are looking for, how to look at various components, and how to determine that one part is normal and
another part isn’t. Explain why you’re taking a measurement. Don’t leave the impression that “it’s
because PMS requires it.” Show the crew how to take the measurements and then have the crew take
them. Don’t teach short cuts. Obtain the appropriate PMS MRC and take measurements exactly
according to the procedures. Once you have demonstrated a measurement procedure or a
maintenance action, the ship’s force will know how to perform the maintenance action correctly.
Insist that the crew use PMS and the engine technical manual during the inspection. Show by
example that the ship’s force need not be embarrassed about using the technical manual. Always
strive to leave the crew with a better understanding of how to operate and maintain the engine than it
had when you came aboard.
1-2
CHAPTER 2
You must prepare for the inspection. Brief the crew on what the inspection entails, and review past
inspection report, logs, engine performance, PMS, maintenance records, and oil analysis reports.
Obtaining information from the Deck Plate Level is often helpful. Study past inspection reports to
see if there are recurring problems. If there are, find the cause and offer recommendations. Listing
discrepancies is only one part of the inspection process; listing them with references and repair
recommendations is also required. The crew should never have to ask, “What instruction says I have
to do that?” You must have the reference that supports your findings at your fingertips. A
debriefing with the ship’s Captain and Chief Engineer is neither the time nor the place to say you’ll
“look up” a particular reference.
Remember: Credibility is established before; during, and after each inspection you perform. And
tell the Commanding Officer and Engineering Officer all the good things you find the engineering
department has done. Be sincere and professional; don’t make up positive
Statements just to be nice.
As the number of inspections increases, you will discover that not all ships are exactly the same.
Procedures, level of knowledge, pride, and cleanliness will vary. Avoid stereotyping a ship class.
Saying that “this whole class of ships is screwed up” will alienate the crew. The crew won’t work
with you if it feels you have little regard for the ship. Offer firm, corrective criticism in a positive
manner.
Be diplomatic when inspecting one of your own past ships. Accept it when the procedures are
different from the ones you followed. Also, be aware of any favoritism, intended or not. Inadvertent
favoritism can be shown to a class of ship, a type of engine, ex-shipmates, or a prior superior.
You will become more confident as you complete each inspection. Don’t feel you have to know the
answer to every question asked. When you don’t know the full, correct answer, say so, and then find
the answer before the next day. Use the help available to track down the answer. Other diesel
inspectors, NAVSEA PHILADELPHIA, FTSC’s, and NAVSEA are only a few sources of technical
data. When you conduct an inspection, always have on hand small notebook to write down the
question(s): It’s easy to forget what was asked after a hectic day. After a while, the notebook will
become invaluable to you.
Debriefing the ship is as important as the inspection itself. Make every effort to hold the debriefing a
day or two after the inspection. This extra time will allow you to collect your data and review it for
accuracy. Shooting from the hip during a debriefing will only embarrass you. Be sure that those
attending the debriefing understand what you’re saying, not what you think you’re saying. Before
leaving the ship try, to answer all questions you’ve been asked. Be sure to allot enough time in the
debriefing for both you and the ship to fully express your viewpoints. You’ll be able to leave the
crew with mutual respect. Use the worksheets for your debriefing and provide the ship with a copy.
2-1
The inspection process is incomplete until the final report has been written, serialized, and received
by the ship. Fill out the report thoroughly, remembering that usually it will be mailed to the ship.
The report must be able to stand-alone. Don’t assume that the crew understands or knows what
you’re referring to. Make sure the report is technically correct and grammatically correct, with
attention paid both to spelling and to written procedures. Inspectors that say they’re “snipes", not
“English majors", are both wrong and unprofessional. Take time to be sure that your findings are
documented and that each discrepancy noted has a recommendation for repair. Long after the
inspection has been completed your report will be reviewed and commented on. The inspection
report is a ready reference for future technical assists and forthcoming diesel inspections. Write it
accordingly. You are the written report and the written report is you. If you’re a new inspector,
understand that being a good inspector does not comes overnight or with the NEC, but only through
hard work and through continuously striving for Improvement.
By following the standard diesel inspection procedures and providing a detailed report of diesel
engine discrepancies, you can contribute significantly to the overall improvement of the diesel
engine.
• Representative engine operating logs (list your minimum number of log sheets per
engine)
Using such a form will reduce the time you have to wait while the crew locates the documentation
and equipment. Type Commander or the Type Commanders representative should specify the format
for the pre-inspection checklist.
The arrival meeting on board the ship should establish the plan of action for the diesel inspection. It
should include the proposed end date and a proposed schedule for debriefing the Commanding
Officer. Convey to the crew that the intent of your inspection is not only to inspect the engines, but
2-2
also to provide the crew with training and any assistance required to improve the maintenance and
reliability of the diesel engines. The Engineering Officer and/or Commanding Officer should be
notified immediately if any major discrepancy is discovered during the inspection. The Senior
EN/MM shall accompany the inspector during the inspection.
• If heavy parts must be removed, be sure that chain falls and straps are weight tested
and tagged.
• Be conscious of barring the engine when personnel are working inside it.
• Observe approved methods for handling and disposing of treated jacket water.
• If “hot work” is required, be sure that the ship has approved and posted a gas-
free/hot-work chit.
• Never allow any part of your body to pass under a large; heavy, unsupported engine
part, not even for a “quick look".
All special tools required for an inspection must be on board the ship. Use the PMS cards, NAVSEA
technical manual, and the inspection worksheets provided in appendix D to determine if the special
tools are available. Those special tools requiring calibration, such as micrometers, dial indicators,
and crankshaft deflection gages, should also have a current calibration sticker indicating that they
have been certified for use. Once again, do not set just a “good” example; set the right example. Use
shipboard special tools and instruments, but don’t use special tools that are out of calibration for the
sake of completing the inspection.
To evaluate the engine in the safest, most consistent manner, conduct the diesel inspection in the
following sequence.
2-3
1. Phase 1 - Administrative Review.
The administrative review phase shall not be graded.
The diesel inspector should remove and copy engine-specific blank Secured Phase Inspection
Worksheets (Appendix D), Tolerance Measurement Data sheets (Appendix G), and Operational Test
Data Sheets (Appendix H) to complete during the inspection. The Administrative review
discrepancies will be brought to the attention of the ship's crew during the administrative review
and again during the debriefing.
The administrative review will provide you with initial information about the particular engine’s
performance and condition. The following items must be reviewed:
• Special tools
Reviewing these records, particularly the Engine performance data, will give you insight into what to
inspect during the secured and operational phases. Examine the ship’s force during this phase to
ensure that they understand and how to use this information. Understanding and technical accuracy
are much more important than neatness and format. Use your notebook as you progress through the
administrative review, making appropriate entries. Analyze all data entries for correct or out-of-
parameter readings. All data should be technically correct and should be within the limits specified
by current technical documentation (PMS, engine technical manual, and EOSS). Note all
unanswered questions, questionable data, or abnormal readings in your notebook so that you can find
the answers during the other phases of the inspection. Administrative review remarks are not to be
included in the Diesel Inspection Report, but you should provide your findings to the ship during the
review and again during the ship debriefing.
2-4
NOTE
Follow guidance and make appropriate entries on the worksheets in Appendix D to accomplish the
secured inspection. The requirements specified in Appendix D represent the minimum to be
accomplished in the secured phase. Keep TEARDOWN TO THE ABSOLUTE MINIMUM
required. Be sure parts are available for reassembly before starting teardown. List discrepancies
from the secured inspection on the Engine Discrepancy Data Sheet, Appendix F2. List tolerance
measurements on the appropriate Tolerance Measurement Data Sheet, Appendix G, and tolerance
discrepancies on the Engine Discrepancy Data Sheet. Secured inspection worksheets are not to be
included in the Diesel Inspection Report, but should be retained by the you for your records, with a
copy provided to the ship during the ship debriefing. It is essential that the inspection report indicate
the “As found” condition of the engine. Corrected conditions may be indicated under “comments",
repaired during the inspection.
If the secured phase inspection results indicate that no unsafe condition exists, continue the
inspection to the operational phase. The operational phase of the inspection is necessary for
thoroughly evaluating the engine’s condition and performance and should substantiate the findings of
the secured inspection. Your conclusions are based on what you observed in the secured phase and
are supported during the operational phase. The diesel engine should be able to achieve operational
standards specified by the appropriate NAVSEA technical manual or the appropriate PMS
performance card. Operating data such as compression and firing pressure readings should reinforce
the findings of all the inspection phases. During the operational phase of the inspection, use the
appropriate Engine Operational Test Data Sheet, found in Appendix H. List the discrepancies found
during the operational inspection on the Engine Discrepancy Data Sheet, Appendix F2. Operational
safety checks shall be completed in accordance with PMS as part of the operational phase.
2. If the Engine Performance Test PMS does not require operation at 100 percent load and
speed, conduct an additional operational test. Complete a separate Operational Test Data
Sheet for each test.
1. Operate the diesel generator in accordance with Engine Performance Test PMS.
2-5
2. If the Engine Performance Test PMS does not require operation at 100 percent or the
maximum attainable load, conduct an additional operational test. Complete a separate
Operational Test Data Sheet for each test.
2. If the Engine Performance Test PMS does not require operation at 100 percent or the
maximum attainable load, conduct an additional operational test. Complete a separate
Operational Test Data Sheet for each test.
Compare the results of the Operational Engine Performance Test PMS to shipboard records and list
inconsistencies on the Engine Discrepancy Data Sheet, Appendix H. If Engine performance Test
PMS requires 100 percent or maximum attainable load, only one operational test is required and only
one operational test data sheet per engine must be completed. Otherwise, complete separate
operational test data sheets for Engine Performance Test PMS and full load tests on each engine.
2-6
CHAPTER 3
b. Engine Discrepancy Data Sheet, Appendix G (one for each engine inspected)
c. Tolerance Measurement Data Sheet, Appendix G (one for each engine inspected)
d. Operational Test Data Sheet, Appendix H (one for each engine inspected and test
conducted)
The cover letter format electronically or manually will be specified by Type Commander or the Type
Commander representative but will typically include the following; (one cover letter for each engine
inspected)
e. Assigned grades
f. Required action
You may be required to prepare the cover letter for your Type Commander or the Type Commander
representative, but the LCM, (NAVSEA-PHILADELPHIA) NAVSEA, or OPNAV does not dictate
this.
3-1
3-2.2 Diesel Inspection Report Data Sheet
The Diesel Inspection Report Data Sheet, appendix E, serves as the front page of your report and
provides the basic data for the inspection and the engines inspected. Include one sheet of data for
each engine inspected.
List discrepancies found during the administrative review, secured, and operational phases of the
inspection on the Administrative Review Sheets and Engine Discrepancy Sheets, Appendix F.
Categorize discrepancies (column 1) as Repair Before Operation, major and minor. List all engine
discrepancies noted on the Secured Phase Worksheet, Tolerance Measurement Data Sheet,
Operational Test Data Sheet, and any other engine discrepancies on the Engine Discrepancy Data
Sheet, Appendix F2 (a separate sheet for each engine inspected). Tolerance measurement data shall
be compared with previous data. Although the data may be within maximum and minimum
specifications, any measurement, which has changed 0.0025 inch or more, must be discussed on the
Engine Discrepancy Data sheet.
Use the “category” column in the engine discrepancy data sheets to specify the discrepancy category
or severity. Discrepancies shall be Categorized in one of the categories Repair Before Operation
(RBO), Major, or Minor. Repair Before Operation discrepancies include those for which continued
operation could endanger personnel and/or cause serious damage to the engine or associated
equipment such as but not limited to:
• Readings that exceed the limits of PMS or manufacturer specifications that in the
judgment of the inspector are unsafe
• Uncontrollable oil leaks, NSTM Chapter 233 Diesel Engines provides guidance
for lube and fuel oil leaks.
• Fuel leaks
• Evidence of serious internal failure (bearing, connecting rod, crankshaft, or piston failure)
When you identify a “REPAIR BEFORE OPERATION “ (RBO) discrepancy notify the
Commanding Officer and Engineering Officer immediately. Continue the inspection after
3-2
debriefing them on the RBO discrepancy. The Diesel Inspector should make every effort to
clear the (RBO) before the completing the inspection. If you cannot clear the (RBO) make
recommendations to clear the (RBO) based on current references and offer advice on personnel
hazards and/or possible damage to the engine should the engine be operated before the (RBO) is
cleared. The Commanding Officer, should he elect to operate the diesel engine, bears the
ultimate responsibility for any personnel or machinery casualties. A certified inspector shall re-
inspect all areas of the diesel engine that were categorized as “REPAIR BEFORE
OPERATION”. Inspect the discrepancy and clear it if it has been properly corrected.
MAJOR: discrepancies include those that require prompt action but that pose no immediate
personnel or equipment hazard:
The Engine Discrepancy Data Sheet “component” or “system” column should specify the faulty
component or engine system that is deficient. The “description column in engine data sheets should
contain a complete, concise, and accurate description of the discrepancy. This description should be
as specific and quantitative as possible avoiding adjectives such as “severely: and “excessively”.
Include references whenever possible. The final columns, “recommended corrective action” and
“repair recommendation", should provide concise instructions on how to correct the problem, citing
references. Fill in all blocks on the Operational Test Data Sheets. Mark those blocks that do not
apply to the particular engine as N/A.
3-3
It is essential to complete all phases and requirements of the inspection. An inspection is incomplete
if you have failed to:
3-4
OPNAVINST 9220.3
N763
1. Purpose
3. Discussion
A-1
all levels of command is required to achieve the desired standards
and to maintain overall fleet readiness.
A-2
is provided in Table 2. SGPI will accompany the NSWCCD-SSES LCEM
inspector as delineated in Table 2.
A-3
TYPE INSPECTION EQUIPMENT SCHEDULE DATE SCHEDULER
Five Year Strength Boiler/ § Normal interval 60 months TYCOM
And Integrity Catapult § No earlier than 48 months (Coordinate
(1) § Not to exceed 72 months. with LCEM)
§
Start of Boiler/ § At start of availability/ Naval Shipyard
Availability Catapult overhaul in conjunction with or SUPSHIP
Overhaul (SAI/SOI) strength and integrity.
(1)
Industrial Support/ Boiler § During availability/overhaul. Naval Shipyard
Visit (ISV) only or SUPSHIP
(2)
Completion of Boiler/ § To be conducted before re- Naval Shipyard
Availability/ Catapult assembly of equipment and final or SUPSHIP
Overhaul (CAI/COI) hydrostatic test
(1)
Newly constructed Boiler/ § Prior to delivery. NAVSEA
ship Acceptance Catapult § In conjunction with the open- Acquisition
Inspection and-inspect phase of the Board Manager
of Inspection and Survey
(INSURV) acceptance trials.
§ For catapult accumulators,
initial strength & integrity
inspection shall be accomplished
6 months after vessel is placed
in service and prior to
expiration of the ships
guarantee period.
Inactivation/ Boiler § Prior to final action and INACTSHIPFAC
Reactivation only disposition. Naval Shipyard
or SUPSHIP
(1) The cognizant TYCOM SGPI inspector shall accompany the NSWCCD-SSES LCEM
Inspector.
(2) The Industrial Support Visit (ISV) is normally provided during major overhaul
and/or repair assignments. These ISVs may be deleted by the LCEM with TYCOM
concurrence for any short duration availability or any availability with no major
repair assignments.
A-4
a. Military Enlisted Personnel candidates:
(5) SGPI candidates must graduate from one of the “C” schools
listed in reference (f) for the applicable course to include
graduation from all pre-requisite courses.
d. All candidates:
A-5
(1) Physically capable of entering confined areas such as
boiler steam and water drums, uptakes, stacks, engine enclosures
and plenums.
7. Certification
A-7
8. Action
A-8
(1) Identify and designate those fleet activities that have
inspection responsibilities and maintain a base of certified
inspectors within those activities.
A-9
(1) Ensure that all enlisted personnel assigned to
inspector certification instruction course billets hold the proper
Navy Enlisted Classification (NEC), are currently certified, and
have at least 3 years prior experience as an inspector.
Distribution:
SNDL A1J1F (PEO SURFACE STRIKE)
A1J1L (PEO THEATER SURFACE COMBATANTS)
A1J1M (PEO MUW)
A1J1N (PEO SUB)
A1J1P (PEO EXW)
A1J1Q (PEO CARRIERS)
21A (Fleet Commanders in Chief)
24 (Type Commanders)
25A (COMINEWARCOM)
26A (Amphibious Group)
26B3 (Naval Surface Reserve Force Commander)
26E (Amphibious Unit)
26H (Naval Coastal Warfare Group)
26J (Afloat Training Group and Detachment)
26Z (Shore Intermediate Maintenance Activity)
28 (Squadron Division and Group Commanders – Ships)
29 (Warships)
31 (Amphibious Warfare Ship)
32 (Auxiliary Ships)
36 (Service Craft)
41A (Commander Military Sealift Command)
50D (COMNAVSPECWARCOM CORONADO CA)
FA8 (Fleet Technical Support Center Lant)
FB8 (Fleet Technical Support Center Pac)
FJA3 (COMNAVPERSCOM)
FKA1G (COMNAVSEASYSCOM)
FKP4E (Naval Surface Warfare Center Divisions)
FKP7 (Shipyard)
FKP8 (Supervisor, Conversion and Repair, USN)
FK4P16 (Ship Systems Engineering Station) A-11
FT1 (CNET)
FT24 (Fleet Training Center)
FT30 (SERVSCOLCOM)
(Add SPECWARCOM)
OPNAV (N1, N3/5, N7, N75, N76, N77, N78, N79, N80, N81,
N09B)
A-12
REFERENCE LIST
B-1
REFERENCE LIST (CONTD).
B-2
ADMINISTRATIVE PHASE
REVIEW WORKSHEET
NOTE:
USS________________________________
Date________________________________
NOTE:
THE DIESEL ENGINE REPORT GENERATOR (DERG) WILL DISPLAY CORRECT APL AND
TECHNICAL MANUAL
3. Operating Logs
Comments: ___________________________________________________
C-1
NOTE:
NSTM 'S ON CD IS ACCEPTABLE, PAPER COPY NOT REQUIRED.
NOTE:
LIST DISCREPANCIES ONLY DO NOT ASSIGN A GRADE.
Engine No. Serial No. Model No. Hrs. Since Ovhl. Hrs. Since Comm.
C-2
NOTE
NOTE
ENSURE ENGINE SERIAL NUMBERS AND MODEL NUMBERS MATCH THE DIESEL
ENGINE REPORT GENERATOR (DERG) CORRECT DATA AS REQUIRED
C-3
ALCO ENGINES
SECURED-PHASE INSPECTION WORKSHEET
USS_______________________________
DATE______________________________
ENGINE NO.________________________
A. SPECIAL TOOLS
NOTE
6. Dial indicator.
Comments: ___________________________________________
D1-1
12. Holset coupling slugging wrench.
Comments: ___________________________________________
b. 0.640 midrange
Comments: ___________________________________________
D1-2
c. 0.860 idle
Comments: ___________________________________________
B. VISUAL INSPECTION
1. Crankcase and block. Isolate expansion tank and hydrostatically test jacket water system
according to PMS if any of the following conditions exist; that is, rust, excessive water
and chemic al makeup, water streaks, obvious external/internal leaks, and NOAP results.
a. Inspect engine foundation bolts and chock blocks/wedges for correct installation
(wedges must be welded together: no shims are allowed).
Comments: ___________________________________________
b. Check forward engine foundation feet shear blocks for proper installation (must have
at least 80% contact with engine feet).
Applies to MPDE only.
D1-3
NOTE
Bolts must be installed with flat side of each head butted together.
Comments: ___________________________________________
h. Verify that there are no broken or missing cotter pins on connecting rod
bolts.
NOTE
Cotter pins are required on bolts with 0.015-inch stretch only, not
on bolts with 0.206-inch stretch. Caps and rods are marked for
0.026-inch stretch.
Comments: ___________________________________________
i. Verify that matching “O” marks on each connecting rod and cap face outward for
each bank.
Comments: ___________________________________________
j. Verify that there are no broken or missing cotter pins on main bearing castellated
nuts (upper) and that washers have been installed with main bearing nuts
(lower).
Comments: ___________________________________________
k. Check main bearing and connecting-rod bearing edges for proper installation
or looseness of bearing shell.
Comments: ___________________________________________
o. Barring engine over, with pistons near TDC, inspect liners from beneath
for signs of scoring, galling, and dull spots.
NOTE
Comments: ___________________________________________
D1-4
2. Crankshaft.
a. Check vibration damper for freedom of movement (10 degrees either direction, which
is approximately 1-1/2 to 2 inches total movement).
Comments: ___________________________________________
b. Measure crankshaft deflection at crank web closest to the drive end according to
PMS. Record on data sheet.
Comments: ___________________________________________
e. Inspect flywheel ring gear teeth and air starter motor pinion for cracking and
excessive wear.
Comments: ___________________________________________
NOTE
Comments: ___________________________________________
h. Inspect accessory drive and crankshaft gears for broken teeth, unusual wear pattern,
excessive wear, proper lock wiring, and proper lubrication.
CAUTION
Comments: ___________________________________________
i. Run prelube pump and check for oil leaks and adequate lubrication of running gear
assemblies and power pack assemblies.
Comments: ___________________________________________
D1-5
3. Camshafts. (From crankcase, either use inspection mirror or feel surfaces with
hand.) Flame hardening on camshafts is normal.
a. Inspect camshaft lobes for excessive pitting, flat spots, and galling.
Comments:___________________________________________
b. Inspect camshaft drive gears for broken teeth and excessive wear.
Comments:___________________________________________
d. Verify that the camshaft gear nut locking screw has been lock wired.
Comments:___________________________________________
a. Inspect bushings for signs of spinning or movement in or out of the bushing bore.
For further details see ALCO MI 11249A.
Comments:___________________________________________
b. Inspect drive gears for broken teeth, unusual wear pattern, and excessive wear.
Comments:___________________________________________
5. Fuel injection pump crosshead assembly (from crankcase, use inspection mirror or feel
surfaces with hand).
Comments:___________________________________________
b. Inspect fulcrum-to-support locking-plate bolts and ensure that the lock wire is in
place.
Comments:___________________________________________
d. Check valve pushrod cam rollers for excessive wear or flat spots.
Comments:___________________________________________
e. Check pushrod lifter roller pins for correct retaining clips (round vice flat).
Comments:___________________________________________
f. If any problem are evident during inspections 5a through 5e, remove the fuel pump
crosshead assembly and check for excessive looseness and wear.
Comments:___________________________________________
D1-6
6. Running gear assemblies.
c. Spot-check valve clearances (at least two on each bank). (Intake and exhaust should
be according to PMS).
Comments:___________________________________________
NOTE
Comments:___________________________________________
7. Cylinder heads.
a. Inspect for broken or damaged cylinder head nuts and for correct installation.
NOTE
Comments:___________________________________________
b. Inspect the nozzle strong back for correct installation and the retaining nuts for proper
torque.
NOTE
With both nuts hand tightened, torque only inboard nut to 50 ft-lb.
Comments:___________________________________________
D1-7
e. run prelube pump and check for oil leaks and adequate lubrication of running gear
assemblies and power pack assemblies.
Comments:___________________________________________
a. Check uniformity of rack settings. (Use governor tail rod jack to position rack to full
load gap.)
Comments:___________________________________________
b. Check freedom of movement on all racks, linkage, and control shafts. (Disconnect
governor linkage.)
Comments:___________________________________________
c. Check fuel injection pump pointer setscrew tightness and be sure that the pointer
reading meets current PMS requirements.
Comments:___________________________________________
d. Check all linkage for lost motion with clevis pin nuts securely tightened against
shoulders and all cotter keys in place.
Comments:___________________________________________
e. Work each spring lever and ensure that it returns to its original position with no
evidence of binding.
Comments:___________________________________________
f. Check governor oil level and for oil leakage around base of governor.
Comments:___________________________________________
i. Ensure that fuel rack limiter stop bolt is adjusted correctly and lock wired and that the
governor top (lid) is lock wired.
Comments:___________________________________________
j. Ensure that fuel injection pump control rack latches and retainers have been installed.
Comments:___________________________________________
D1-8
9. Jacket and raw water pumps.
a. Check for any leakage observed out of the telltale hole and miscellaneous piping
(leakage from telltale holes indicates defective mechanical seals). Check telltale
holes for blockage.
Comments: ___________________________________________
a. Check for any leakage of oil out of pipe connections and flanges (to be observed from
operational test).
Comments: ___________________________________________
c. Remove and open one lube oil filter element per engine (lower one if installed) and
inspect for types of contamination.
Comments: ___________________________________________
NOTE
No sock-type filters.
Comments:___________________________________________
f. Check lube oil sampling valves for proper location, hand wheels, and caps.
Comments: ___________________________________________
h. Shift lube oil strainer to check shifting chain for freedom of movement and material
condition.
Comments: ___________________________________________
j. Check lube oil filter and strainer vent valves for proper operation.
Comments: ___________________________________________
D1-9
k. Ensure that valves in the lube oil system that could obstruct the flow of oil to the
engine have been locked fully open with proper locking devices.
Comments: ___________________________________________
l. Check for completed PMS on testing of lube oil system relief, bypass, and pressure-
regulating valves.
Comments: ___________________________________________
m. Ensure that all sump drain valves are locked closed and capped.
Comments: ___________________________________________
11. Turbocharger.
a. Inspect turbocharger compressor rotating assembly for damage and/or oil seal
leakage.
Comments: ___________________________________________
c. Inspect external surface of the turbocharger for evidence of exhaust gas and jacket
water leaks.
Comments: ___________________________________________
d. Remove cover and inspect turbocharger after cooler for dirt, fin damage, oil
contamination, and jacket water leaks.
Comments: ___________________________________________
e. Verify that the 1/16-inch shims have been installed for proper adjustment of
turbocharger to exhaust manifold height.
Comments:___________________________________________
c. Inspect fuel oil booster pump drive shaft oil seal for evidence of leakage.
Comments: ___________________________________________
D1-10
d. Ensure that strainer T-handle turns freely.
Comments: ___________________________________________
a. Inspect flexible hoses for cracks, fraying, rubbing, swelling, and deterioration.
Comments: ___________________________________________
NOTE
Fuel and lube oil systems are not permitted to have galvanized
fittings.
a. Inspect filter element for cleanliness and completeness; ensure that filter element is
firmly seated in housing.
Comments: ___________________________________________
c. Inspect air ducting from filter-to-turbocharger air inlet for cracks, missing sections,
loose or missing nuts, bolts, and rivets.
Comments: ___________________________________________
a. Ensure that label plates for remotely operated safety devices identify correct engine
and function.
Comments: ___________________________________________
D1-11
b. Check low lube oil pressure and high jacket water temperature alarms for audibility
by using test button.
Comments: ___________________________________________
c. Remotely operate the emergency trip (inspect for frayed wire and improper
connection.)
Comments:___________________________________________
d. Check manual trip stop lever cap screw for tightness and retainers for wear.
Comments:___________________________________________
b. Check ferobestos bushing bolts for proper installation and correct type.
Comments:___________________________________________
c. Check axial locking device for freedom of movement and ensure that it is lubricated
and welded according to current PMS requirements.
Comments:___________________________________________
d. Ensure that grease fittings have been removed and plugs installed on modified clutch
and brake assemblies.
Comments:___________________________________________
e. Check Sier-bath coupling for air leaks according to current PMS requirements.
Comments:___________________________________________
f. Ensure that Sier-bath coupling has been greased according to current PMS
requirements.
Comments:___________________________________________
g. Check clearance between Holset coupling spider and flywheel according to current
PMS requirements.
Comments:___________________________________________
h. Inspect pedestal bearings for oil leaks and ensure that foundation bolts have been
torqued to required specifications.
Comments:___________________________________________
D1-12
NOTE
i. Inspect clutch and brake shoes and drums for excessive wear and for cleanliness.
Comments:___________________________________________
j. Inspect clutch and brake shoe torque bars and side plate holes for wear and
elongation.
Comments:___________________________________________
k. Check Holset coupling rubber blocks for cracks, elongation, chafing, and melting
(overheating).
Comments:___________________________________________
a. Visually inspect engine exhaust system in space for leaks during operational test.
Comments:___________________________________________
b. Check engine exhaust muffler for baffle separation and deterioration (if applicable).
Comments:___________________________________________
c. Inspect spring hangers for material condition, proper tension, and indications of
movement.
Comments:___________________________________________
e. Inspect the generator exhaust silencer hand hole covers for leaks.
NOTE
Comments:___________________________________________
f. Inspect generator exhaust silencer mounting pads for wear and deterioration.
Comments:___________________________________________
g. Check exhaust pipe/silencer drain valves for freedom of movement and clogging.
Comments:___________________________________________
D1-13
18. Intake and exhaust manifolds.
a. Inspect air and exhaust elbows for proper securing devices, installation, and leaks.
Comments:___________________________________________
b. Inspect jacket water Amot valve manual/automatic levers for proper operation.
Comments:___________________________________________
c. Inspect lube oil Amot valve manual/automatic levers for proper operation (applies
only to SSDG).
Comments:___________________________________________
f. Ensure that zinc maintenance is being performed on the jacket water cooler and
generator air cooler according to current PMS requirements.
Comments:___________________________________________
a. Check for proper operation, installation, and calibration during operational test.
Comments:___________________________________________
D1-14
EMD ENGINES
SECURED-PHASE INSPECTION WORKSHEET
USS________________________
DATE______________________
ENGINE NO.________________
A. SPECIAL TOOLS
NOTE
6. Dial indicator.
Comments:___________________________________________
D2-1
12. Test valve wrench.
Comments:___________________________________________
D2-2
28. Lash adjuster test stand (110 volt).
Comments:___________________________________________
D2-3
44. Piston pulling eyebolt.
Comments:___________________________________________
D2-4
60. Main bearing cap-lifting tool.
Comments:___________________________________________
B. VISUAL INSPECTION
1. Remove oil pan inspection hand-hole covers and air box hand-hole covers, and open top
deck covers.
2. Isolate expansion tank and hydrostatically test the jacket water system according to PMS
if any of the following conditions exist; that is, rust, water streaks, obvious
external/internal leaks, and NOAP results.
a. Check cleanliness of lube oil sump. Check for broken parts or other contamination.
Comments:___________________________________________
b. Check for missing or loose bolts between crankcase and oil pan. Check foundation
bolts and chocks for proper installation.
Comments:___________________________________________
e. Check flywheel pointer gage accuracy in order to proceed with the inspection.
Comments:___________________________________________
f. Open cylinder test valves (indicator cocks) and prelubricate engine before attempting
to bar over. Engage barring device, then align cylinder No. 1 at top dead center.
Comments:___________________________________________
D2-5
4. Follow the one-revolution-inspection sequence given below for each applicable EMD engine:
Starting with cylinder No. 1, a single revolution of the crankshaft from 0 to 360 degrees
will align the following areas for inspection: Compression rings will be visible through
the liner ports for one cylinder moving upward and another cylinder moving downward,
the piston cooling oil pipe alignment check for two cylinders at once, the piston skirt
inspection for two cylinders at once, and an inspection of the liner for any one cylinder.
D2-6
16-Cylinder CCW rotation.
16-Cylinder CW rotation.
D2-7
a. Check condition of compression rings that are visible through liner ports. Use
wooden stick to push ring for resiliency check; if broken, the ring will not push back.
A ring in good condition will have a bright surface, but a broken ring will usually
turn black. Vertical brown streaks will indicate blow-by.
Comments: ___________________________________________________
NOTE
Comments:___________________________________________
d. Check visible areas of liners through ports for signs of scoring, galling, dull spots, or
port framing.
Comments:___________________________________________
g. Measure crankshaft deflection at crank web closest to the drive end according to
PMS. Record on data sheet.
Comments:___________________________________________
D2-8
k. Check connecting-rod bolts and nuts for proper installation. Check for presence of
incorrect silver-alloy piston pin bearings by shaking connecting rod or by feeling the
surface finish of the bearing edge (a smooth surface finish is acceptable).
NOTE
Comments:___________________________________________
CAUTION
Comments:___________________________________________
m. Check match marks on rod caps and rods for correct installation.
Comments:___________________________________________
o. Inspect drive gears for broken teeth or excessive wear. Inspect flywheel ring gear
teeth and air starter motor pinion.
Comments:___________________________________________
D2-9
c. Inspect camshaft coupling bolts and nuts and ensure that securing lock wire is in
place (if applicable).
Comments:___________________________________________
d. Check cylinder head crab nut and plate positioning. Check torque if suspect.
Comments:___________________________________________
NOTE
3 4 5
645 645E3C 4 5
4 5 645E3B
Comments:___________________________________________
D2-10
6. Visually inspect turbocharger/blower.
b. Inspect turbocharger compressor for damaged vanes, leaking oil seal or corrosion due
to ingestion of seawater.
Comments:___________________________________________
c. Rotate turbocharger rotor by hand to ensure that the rotor is not binding.
Comments:___________________________________________
e. Measure clearance between impeller and casing in accordance with PMS. Record on
data sheet.
Comments:___________________________________________
f. Inspect blower rotors for signs of contact with casing through air box.
Comments:___________________________________________
g. Inspect blower rotor and casing for dirt or overheating through air box.
Comments:___________________________________________
NOTE
NOTE
7. Exhaust system.
NOTE
a. Visually inspect exhaust pipes and expansion joints in engine room and exhaust
stacks for leaks during operational test.
Comments:___________________________________________
D2-11
b. Check engine exhaust muffler for baffle separation and deterioration (if applicable).
Comments:___________________________________________
c. Inspect spring hangers for material condition, proper tension, and indications of
movement.
Comments:___________________________________________
e. Check exhaust pipe/silencer drain valves for freedom of movement and clogging.
Comments:___________________________________________
NOTE
Fuel and lube oil systems are not permitted to have galvanized
fittings.
Comments:___________________________________________
a. Check freedom of movement of all racks, linkages, and control shafts. With clevis
pin nuts securely tightened and cotter keys in place, check all linkages for lost
motion.
Comments:___________________________________________
b. Use applicable power piston jack to check uniformity of rack settings from idle to full
speed.
Comments:___________________________________________
c. Check governor oil level and ensure that no oil leakage around base of governor
exists.
Comments:___________________________________________
D2-12
11. Inspect fuel system.
a. Check fuel pump flexible coupling spider insert for uneven wear.
Check drive shaft oil seal for leakage.
Comments:___________________________________________
b. Ensure that filter and strainer shift handles, drain, and installed vent valves operate
correctly.
Comments:___________________________________________
a. Check lube oil system and engine attached piping for leakage.
Comments:___________________________________________
c. Inspect cleanliness of lube oil filter. Pull the lower filter element out, cut it apart, and
inspect it for contamination.
Comments:___________________________________________
d. Check for completed PMS on testing of lube oil system relief, bypass, and pressure-
regulating valves.
Comments:___________________________________________
NOTE
If turbocharger inlet oil filter is dirty the main lube oil pressure
will drop.
Comments:___________________________________________
f. Operate prelube pump and ensure that all rocker arm assemblies have an adequate
flow of lube oil.
Comments:___________________________________________
D2-13
13. Inspect jacket water system.
b. Check for leakage from the telltale hole indicating defective seal on engine attached
jacket water pump.
Comments:___________________________________________
Inspect lube oil separator screen for correct installation and check for excessive
oil accumulation. Ensure that the orifice has been installed.
Comments:___________________________________________
Check for leakage from the telltale hole indicating defective seal on engine
attached seawater pump. Check telltale hole for blockage.
Comments:___________________________________________
a. Inspect clutch, shoe, and drum for cleanliness and for excessive wear. Check clutch
shoe torque bars and side plate holes for wear and elongation.
b. Check pedestal bearings for oil leakage and ensure that foundation bolts are tight.
Comments:___________________________________________
Visually check generator windings to ensure that they are not oil soaked.
Comments:___________________________________________
D2-14
19. Safety devices.
a. Ensure that label plates for remotely operated safety devices identify the correct
engine and function.
Comments:___________________________________________
b. Activate and test all alarms for audibility by using test button.
Comments:___________________________________________
d. Remotely operate the emergency trip (inspect for frayed wire and improper
connections).
Comments:___________________________________________
e. Check manual trip lever for wear; that is, pins, bushings, and fasteners, for proper
tightness.
Comments:___________________________________________
D2-15
FAIRBANKS MORSE ENGINES
SECURED-PHASE INSPECTION WORKSHEET
USS__________________________
DATE_________________________
ENGINE NO.___________________
A. SPECIAL TOOLS
NOTE
NOTE
NOTE
2. Torque wrenches.
D3-1
5. Dial indicator.
Comments:____________________________________________
14. Fuel pump stroke and plunger timing gage (8-1/8 only).
Comments:____________________________________________
D3-2
* 21. Main bearing cap puller.
Comments:____________________________________________
b. Two I-bolts.
Comments:____________________________________________
d. Crankpin cover.
Comments:____________________________________________
D3-3
b. Two I-bolts.
Comments:____________________________________________
44. Fuel pump stroke gage (for engines equipped with gasket less fuel
pumps only).
Comments:____________________________________________
1. Air box and exhaust belt areas. Isolate the expansion tank, and hydrostatically test the
jacket water system according to PMS if any of the following conditions exist; that is,
D3-4
rust, excessive water and chemical makeup, water streaks, obvious external/internal
leaks, and NOAP results.
e. Check condition of rings, pistons, and liners. Inspect for broken rings, blow-by, etc.,
on both sides of the engine.
Comments:____________________________________________
h. Check for missing, broken, or improperly installed lock wire on blower bolts.
Comments:____________________________________________
2. Crankcase:
a. Check for missing, broken, or improperly installed cotter pins and lock wire.
d. Check all upper and lower main bearing lube oil jumper lines for leakage and lock
wire.
Comments:____________________________________________
e. Check connecting rod and main bearing edges for evidence of bearing failure.
Comments:____________________________________________
D3-5
NOTE
Comments:____________________________________________
NOTE
Comments:____________________________________________
CAUTION
The 0.002-inch feeler gage may slip into the parting line of a
perfectly normal 5-1/4 thrust bearing because of a 0.020-inch,
plus or minus 0.010-inch, relief machined at the parting line of
the thrust flanges.
Comments:____________________________________________
NOTE
NOTE
Comments:____________________________________________
D3-6
f. Check crankshaft lead. Verify pointer (zero degrees).
Comments:____________________________________________
g. Check lower crankshaft deflection in accordance with PMS. Record on data sheet.
Comments:____________________________________________
i. Measure upper and lower crankshaft thrust in accordance with PMS. Record on data
sheet.
Comments:____________________________________________
j. Visually inspect all drive gears for signs of overheating, galling, pitting, and unusual
wear patterns. Take backlash readings if necessary.
CAUTION
Comments:____________________________________________
k. Prelube engine and ensure that lube oil flows to all moving parts.
Comments:____________________________________________
3. Vertical drive.
a. Check for missing or loose bolts and broken Falk coupling grids (5-1/4 only).
Comments:____________________________________________
D3-7
4. Timing chain.
a. Inspect timing chain for proper installation, tension, and excessive wear.
Comments:____________________________________________
NOTE
A new timing chain is 96.250 inches long. The maximum length of an in-service
chain is 97. 500 inches long
a. Check uniformity of fuel oil pump rack setting (trip fuel control rack).
NOTE
Comments:____________________________________________
b. Check freedom of movement of all racks, linkage, roller support, guide rods, and
governor shafts (disconnect governor linkage).
Comments:____________________________________________
c. Check governor oil level and check for external oil leaks.
Comments:____________________________________________
d. Check fuel pump timing and stoker on No. 1 cylinder (both pumps on double
pumpers) and run a random check on one additional pump(s).
Comments:____________________________________________
e. Ensure that fuel control rod stop bolt has been lock wired and/or locknut installed.
Comments:____________________________________________
f. Using a magnet check to ensure fuel oil crossover lines are steel, copper (no
Bundyweld piping is allowed) and rubber hoses are not authorized. If crossover piping
must be changed use, pipe assembly Fairbanks-Morse Part Numbers 16 608 646
or crossover assembly Part Number 16 205 456.
Comments:_____________________________________________
D3-8
The following is a Safety Item (Mandatory Inspection)
Note: The following inspection is applicable only to those engines with two (2)
injection pumps per cylinder.
f. Remove the front cover’s center inspection plate, visual inspect the right-hand fuel
control rod insert (viewed from the drive end of engine) for sufficient interference fit.
If there is any evidence of the insert pull-out (0.050” or more the fuel control rod with
the insert shall be replaced. Refer to Figure 1.
1. With the shutdown cocked and the control arm against the rack stop,
adjust the adjusting screw to a clearance of 0.010” to 0.030”
between the screw and shutdown lever button. Refer to Figure 1.
2. Remove and discard any 3/8” thick washers behind the shutdown
spring.
CAUTION
If the washers are removed, the rack must be inspected at shutdown to assure
injection pumps on both sides are at “ 0 “or less.
3. With the shutdown released, adjust the clearance between the stop
nuts on the shutdown stem and the reset lever to 0.060”.
D3-9
Figure 1
Comments:_____________________________________________________
a. Inspect flexible hoses for cracks, fraying, rubbing, swelling, and deterioration.
NOTE
Galvanized fittings are not permitted in the lube oil or fuel oil systems.
Comments:___________________________________________
b. Inspect all pipe hangers and flexible hose supports for correct installation.
Comments:___________________________________________
D3-10
7. Camshaft.
9. Engine fuel oil and generator bearing scavenging lube oil pumps during operational test.
d. Check oil separator and vacuum breaker for contamination and deterioration.
Comments:___________________________________________
NOTE
Comments:___________________________________________
D3-11
11. Air intake system.
NOTE
a. Visually inspect exhaust pipes and expansion joints in engine room and exhaust stacks
for leaks during operational test.
Comments:___________________________________________
b. Check engine exhaust muffler for baffle separation and deterioration (if applicable).
Comments:___________________________________________
c. Inspect spring hangers for material condition, proper tension, and indications of
movement.
Comments:___________________________________________
e. Check exhaust pipe/silencer drain valves for freedom of movement and clogging.
Comments:___________________________________________
a. Check for any leakage of oil from pipe connections and flanges (to be observed during
operational test.)
Comments:___________________________________________
c. Remove and open one lube oil filter element per engine (lower one if installed) and
inspect for types of contamination.
Comments:___________________________________________
D3-12
d. Inspect filter elements for correct type and installation.
NOTE
No sock-type filters.
Comments:___________________________________________
e. Ensure that valves in the lube oil system that could obstruct the flow of oil to the
engine have been locked fully open with proper locking devices.
Comments:___________________________________________
f. Check for completed PMS on testing of lube oil system relief, bypass, and pressure-
regulating valves.
Comments:___________________________________________
g. Ensure that all sump drain valves are locked closed and capped.
Comments:___________________________________________
b. Check for completed PMS on testing of fuel oil system relief, bypass, and pressure-
regulating valves.
Comments:___________________________________________
Check for proper operation, installation, and calibration during operational test.
Comments:___________________________________________
D3-13
17. Safety devices.
a. Ensure that all label plates for remotely operated safety devices identify the correct
engine and function.
Comments:___________________________________________
b. Activate and test all alarms for audibility by using test button.
Comments:___________________________________________
d. Remotely operate the emergency trip (inspect for frayed wire and improper
connections.)
Comments:___________________________________________
e. Check manual trip lever for wear; that is, pins, bushings, and fasteners, for proper
tightness.
Comments:___________________________________________
c. Measure rotor shaft drop reading at pedestal bearing against stamped reading in
accordance with PMS.
Comments:___________________________________________
D3-14
COLT-PIELSTICK
SECURED-PHASE INSPECTION WORKSHEET
USS ________________________
DATE_______________________
ENGINE NO._________________
A. SPECIAL TOOLS:
NOTE
D4-1
12. Tools for removing connecting rod.
Comments:___________________________________________
D4-2
28. Jackscrew for exhaust valve removal.
Comments:___________________________________________
35. Test stand assembly for PC2.5 injection nozzle and cylinder head safety valve
(pop tester).
Comments:___________________________________________
40. Support for dial indicator assembly for setting valve lash.
Comments:___________________________________________
D4-3
44. Special wrench, Allen 10 mm.
Comments:___________________________________________
53. Impact socket, 2-inch 8-point, with sliding T-handle, 1-inch drive.
Comments:___________________________________________
58. Long flat chisel 15-1/2 to 18 inches long, 7/8-inch across flats.
Comments:___________________________________________
D4-4
60. Wrench 9/16-inch, single end flare nut, 12-point.
Comments:___________________________________________
65. Eyebolt.
Comments:___________________________________________
67. Wrench-open-end double – 6-7, 8-9, 10-11, 12-13, 14-15, 16-17, 19-22,
24-27, 30-32 mm
Comments:___________________________________________
D4-5
76. Screwdriver (large) standard blade 0.075 inch.
Comments:___________________________________________
82. Wrench-torque multiplier (4:1) 3/4-inch sq female dr, 1-inch sq male drive.
Comments:___________________________________________
83. Tool for tightening cylinder head nuts (socket impact 2-1/2 inch with 1-1/2 drive.
Comments:___________________________________________
D4-6
92. Torque adapter, 26 mm 1/2-inch drive.
Comments:___________________________________________
103. Borescope.
Comments:___________________________________________
D4-7
B. VISUAL INSPECTION
a. Check for missing or lose bolts, block to base. Inspect chocks for shifting and
cracked welds.
Comments:___________________________________________
b. Remove crankcase inspection covers and check internals for discoloration or signs of
overheating. Check crankcase for foreign particles and indications of jacket water
leakage. Spot check for mismatched connecting rod and connecting rod caps. Check
for serial number and orientation.
Comments:___________________________________________
c. Inspect all connecting-rod bolts for proper installation and lock wire (PMS).
Comments:___________________________________________
d. Inspect lock washer, securing cap screws, and lock plates on all main bearing caps for
proper installation (PMS).
Comments:___________________________________________
e. Check connecting rod and main bearing edges for evidence of bearing failure (PMS).
Comments:_ __________________________________________
f. Check visible areas of all liners for scoring, scuffing, and abrasion. Check for
indications of jacket water leakage. Some polishing will exist and is considered
normal for this engine (PMS).
CAUTION
Comments:___________________________________________
h. Inspect crankcase inspection covers and cover relief valves for loose or missing
gaskets and fasteners.
Comments:___________________________________________
i. Remove inspection plates on both sides of engine and inspect crankshaft gear for
broken teeth, unusual wear pattern, excessive wear, and improper lubrication.
Comments:___________________________________________
D4-8
CAUTION
Comments:___________________________________________
j. Inspect all auxiliary drive gears, including camshaft drive, for broken teeth, unusual
wear pattern, or excessive wear.
CAUTION
Comments:___________________________________________
a. Remove all camshaft covers and inspect camshaft lobes for excessive wear, galling,
flat spots, or discoloration (PMS). Inspect fuel cams for excessive pitting and sliding
contact surface damage. Relatively small pits, widely dispersed over the fuel cam
and roller contact surface are acceptable for continued use. Moderate shallow pitting
of single areas not exceeding 1/4 inch in diameter are acceptable for continued use.
Pitted cams shall be re-inspected at six moth intervals to determine if pitting has
progressed or if surface damage has increased. Cams with severely spalled surfaces
or deep pits shall be replaced. Questionable cam surface damage shall be referred to
NSWCCD-SSES for replacement criteria.
Comments:___________________________________________
D4-9
b. Check for any evidence of fuel or water leakage around the outside of the cylinder
head area and inside the valve cover.
Comments:___________________________________________
c. Inspect camshaft thrust bearing cover and thrust bearing housing for looseness. If a
loose assembly is found, remove cover and inspect camshaft castle nut and cotter pin
for looseness. Measure camshaft thrust at 16,000 engine hours or as situation
requires.
Comments:___________________________________________
d. Inspect camshaft supplemental support bearing cap screw IAW NAVSEA Technical
Manual S9233-A8-MMO-010 Change G 28 July 1995 and NAVSURFWARCEN
SHIPSYSENGSTA PHILADELPHIA PA MESSAGE DTG 172020Z JUN 02. This
inspection is mandatory every 500 hours of engine operation for all Engines that have
not been repaired.
f. Check for any excessive looseness in the rocker arm assemblies (PMS).
Comments:___________________________________________
g. Check and record valve clearances on at least two cylinders on each bank (PMS).
Comments:___________________________________________
h. Ensure that sump tank is filled with oil to normal non-operating level and heated to
100°F minimum/140°F maximum. Operate main lube oil standby/prelube pump.
Check for adequate oil circulation from all main, connecting- rod, and camshaft
bearings, pistons, injection pump rollers, and gears.
Comments:___________________________________________
3. Turbocharger.
a. Visually inspect oil level and condition of oil through sight glasses.
Comments:___________________________________________
c. Ensure that turbocharger surge control system operates properly. Statically test
bypass and waste gate valves (PMS).
Comments:___________________________________________
D4-10
4. Exhaust system.
NOTE
a. Visually inspect exhaust pipes and expansion joints in engine room and exhaust
stacks for leaks during operational test.
Comments:___________________________________________
b. Check engine exhaust muffler for baffle separation and deterioration (if applicable).
Comments:___________________________________________
c. Inspect spring hangers for material condition, proper tension, and indications of
movement.
Comments:___________________________________________
e. Check exhaust pipe/silencer drain valves for freedom of movement and clogging.
Comments:___________________________________________
5. Intake System.
a. Remove free end cover of each intake manifold and inspect for lube oil and debris.
Comments:___________________________________________
b. Ensure that all intake filter elements are installed and firmly seated in the housing.
Inspect elements for cleanliness and deterioration.
Comments:___________________________________________
c. Inspect air ducting within the machinery space for cracks, missing sections, and loose
or missing fasteners.
Comments:___________________________________________
d. Ensure that blow-in door operates properly and closes completely when reset.
Comments:___________________________________________
1. Ship's air supply pressure regulator to the Valve shall be set at 100 PSI IAW
MPDE T/M NAVSEA S9233-A8-MMO-010, Fig. 3-3.
D4-11
2. Valve shall close within 25 +10 / -5 seconds IAW MPDE T/M Fig. 3-3 and
(revised) MRC 6WMJ N. (TFBR LSD 48 Ser 0056-02).
3. Corrective action for Valve closure not IAW 25 +10 / -5 seconds time delay
requires Kidde Time Delay Cylinder modification by OEM/FMED to comply with
new FMED Drawing P12619832.
Comments:______________________________________________
f. Check the forward and aft space bars supporting the intercoolers. Refer to figure
F7-52 in the NAVSEA Technical Manual S9233-A8-MMO-010. Ensure that the
space bars and locknuts at each end cannot be rotated by hand. If the bar is not tight
or turns freely or if locknuts are loose, contact NAVSEA-Philadelphia, Code 9325
for direction.
Comments:________________________________________________
6. Flexible hoses.
a. Inspect flexible hose for cracks, fraying, rubbing, swelling, and deterioration.
Comments:___________________________________________
a. Check and record injector fuel pump timing on at least two cylinders on each bank.
Comments:___________________________________________
b. Check governor oil level and oil leakage around base of governor. Visually inspect
oil condition through sight glass.
Comments:___________________________________________
c. Check all racks, linkages, and control shafts for loose or missing fasteners.
Comments:___________________________________________
d. Check freedom of movement of all racks, linkages, and control shafts (use the
manual stop lever to move racks through full range of travel).
Comments:___________________________________________
e. Check uniformity of rack settings (use manual stop lever to move rack to full load
position). Ensure that rack stop has been set at 39 mm. Ensure that lead seal on rack
stop adjusting screw is intact.
Comments:___________________________________________
8. Fuel system.
a. Operate fuel oil standby pump and inspect fuel oil jumper liner and connections for
leakage. Check flange shields for fuel soaking, indicating flange connection leakage
(perform this inspection after injector fuel pump timing checks).
Comments:___________________________________________
c. Check operation of hand priming pump. (Ensure that standby pump is off.)
Comments:___________________________________________
d. Ensure that fuel filter shift handle operates correctly.
Comments:___________________________________________
D4-13
e. Inspect filter vent and drain valves for correct operation.
Comments:___________________________________________
f. Inspect one filter element for excessive contaminants and correct installation (PMS).
Comments:___________________________________________
g. Using a feeler gauges, check the clearances between the upper flange and the fuel
injection pump body in five places, the nominal clearance is 0.065 to 0.075. The
clearance shall be within 0.003 of the nominal clearance. All pumps must be
checked.
a. Check operation of hand priming pump (ensure that standby pump is off).
Comments:___________________________________________
b. Drain rocker lube oil reservoir. Inspect one rocker lube oil strainer basket for
excessive contaminants and correct installation (PMS). Ensure that reservoir sight
glass indicates that reservoir refills when main lube oil standby pump is operated.
Comments:___________________________________________
c. Operate main lube oil standby/prelube pump and inspect lube oil manifold for
leakage. Inspect lube oil cooler for external leaks. Check flange shields for oil
soaking, indicating leakage of oil from flange connections.
Comments:___________________________________________
d. Operate the rocker lube oil standby pump and ensure that all rocker arm assemblies
are getting lube oil. Check piping system for leakage.
Comments:___________________________________________
e. Inspect main lube oil strainer interlock and shift mechanism for loose and missing
fasteners and correct operation.
CAUTION
f. Inspect main lube oil strainer vent and drain valves for correct operation.
Comments:___________________________________________
g. Inspect one main lube oil strainer basket for excessive contamination and correct
installation.
Comments:___________________________________________
D4-14
h. Inspect main lube oil filter vent and drain valves for correct operation.
Comments:___________________________________________
i. Inspect one main lube oil filter element for excessive contaminants and correct
installation (PMS).
j. Check lube oil sampling valves for hand wheels and caps. Record specific location
of sampling valve in system (examples: upstream of filter, at standby pump casing
vent, etc.).
Comments:___________________________________________
k. Inspect each MPDE attached lube oil pump for loose thrust bearing assembly lock
washers and locknuts, and loose or damaged roller bearings. Isolate and tag-out the
affected portion of the lube oil system. Remove pump relief valve. Visually inspect
the condition of the upper and lower pump shaft drive end roller bearings visible
through the forward relief valve port in the pump body. The outer races of the roller
bearings should be flushed with the face of the front head housing and should be
secured in the housing by the socket heat capscrews, washers and lock wire. Ensure
cap screw lock wire is in place. The inner races of the roller bearings should be even
with the outer races and be in contact with the shaft shoulder on both the upper and
lower shafts. If a gap exists between the shaft shoulder and the aft end of the inner
roller bearing race, the bearing is migrating off the pump shaft and shall be
repaired/replaced. Remove nuts from studs and remove only the rear head cover.
Clean gasket from rear head. Visually inspect the toothed lock washer for damage to
locking tabs, and ensure that one lock tab is completely and properly secured in a
locknut slot. Check that locknut is tight against lock washer No. 43 and thrust
bearing spacer sleeve. Check for evidence that locktite has been applied to the
locknut.
CAUTION
Replacement gasket for rear head must be made from .007-inch thick material.
Use of any other gasket material will affect the pump thrust bearing clearance.
b. Operate the jacket water standby pump. Check for leakage from the attached pump
telltale hole (leakage indicates defective mechanical seal).
Comments:___________________________________________
c. Ensure that the constant vent has been installed on the attached pump case.
Comments:___________________________________________
D4-15
d. Ensure that attached pump suction and discharge local gages have been installed and
calibrated.
Comments:___________________________________________
e. Inspect jacket water cooler and injector cooler for external leaks.
Comments:___________________________________________
a. Operate the jacket water keep warm pump. Check pump, piping, heater, and heater
relief valve for leaks.
Comments:___________________________________________
a. Ensure that seawater system has been pressurized. Check for leakage form the
attached pump telltale hole (leakage indicates defective mechanical seal).
Comments:___________________________________________
b. Ensure that attached pump has a vent valve on the pump case and that it operated
correctly.
Comments:___________________________________________
c. Ensure that attached pump suction and discharge local gages have been installed and
calibrated.
Comments:___________________________________________
d. Manually cycle the Leslie three-way control valve (shut off the air supply and bleed
pressure from diaphragm). Check for free movement through full valve stroke.
Check material condition of valve, stem packing, etc. Reconnect air supply and
ensure that air pressure regulators to Leslie temperature pilot and volume booster
have been set to correct pressure.
Comments:___________________________________________
e. Manually cycle the emergency cooling water valves (shut off the air supply and bleed
pressure from diaphragm). Check for free movement through full valve stroke.
Reconnect air supply.
Comments:___________________________________________
f. Open both sea chest strainer baskets. Check for excessive blockage and marine
growth.
Comments:___________________________________________
D4-16
g. Measure seawater pump drive thrust and wear ring diametric clearance (PMS).
Comments:___________________________________________
a. Ensure that lube oil separator and piping loop seals have been filled to the correct
level with engine lube oil.
Comments:___________________________________________
b. Perform static check of overspeed trip mechanism. Ensure that rack returns to no-
fuel position (PMS).
Comments:___________________________________________
e. Ensure that emergency fuel shutoff valves operate properly (local and remote).
Comments:___________________________________________
Check for proper operation, installation and calibration during operational test.
Comments:___________________________________________
D4-17
DDA 16V 149 DIESEL ENGINES
SECURED PHASE INSPECTION WORKSHEET
USS:__________________________________________
DATE_________________________________________
ENGINE NO.___________________________________
A. SPECIAL TOOLS
NOTE
3. Dial indicator.
Comments:___________________________________________________________
8. Hand tools.
Comments:___________________________________________________________
D5-1
12. Cylinder liner installing tool.
Comments:___________________________________________________________
D5-2
B. VISUAL INSPECTION
b. Check condition of flappers. Visually check flapper resilient mount for through-bolt
configuration and condition.
Comments:____________________________________________
e. Ensure that all remotely operated safety device label plates have been properly
installed.
Comments:____________________________________________
2. Blowers.
d. Inspect turbo adapters, intercoolers, and flange connections for evidence of oil,
contamination, and water leaks (also check performance).
Comments:____________________________________________
D5-3
f. Check turbocharger-rotating assembly for freedom of movement without binding.
Comments:____________________________________________
NOTE
g. Check that pop up gages air filters are of the correct one, installed, and function.
NOTE
Comments:____________________________________________
h. Inspect air ducting from filters to blowers for cracks, missing fasteners, and air leaks
(also check operation).
Comments:____________________________________________
a. Thrust camshafts in order to check camshafts and thrust assemblies for excessive
wear and proper lubrication. Refer to tolerance Measurement Data Sheet, Appendix
G5.
Comments:____________________________________________
NOTE
Comments:____________________________________________
b. Check exhaust valves and springs for proper installation. Check spring retainers and
valve locks for proper seating.
Comments:____________________________________________
D5-4
d. Check to ensure that fuel injector screw plugs are fully seated and engaged into the
body of the injector.
NOTE
Comments:____________________________________________
e. Check jumper lines for proper installation and for leaks and torque. Use special
torque wrench only.
Comments:____________________________________________
f. Check injector control tubes for proper installation and freedom of movement
Comments:____________________________________________
h. Spot check (2 per side) valve clearances and fuel injector timing. (Refer to previous
operational logs to determine past performance and that variations of exhaust
temperatures from cylinder to cylinder and bank-to-bank are/are not within
specification.)
Comments:____________________________________________
5. Air box.
6. Cylinder liners.
NOTE
Comments:____________________________________________
D5-5
7. Pistons and piston rings.
b. Inspect rings for scuffing, fracture, and abnormal sticking and carbon deposits.
Comments:____________________________________________
8. Exhaust manifolds.
a. Inspect main bearings and connecting rod bearings for proper installation.
Comments:____________________________________________
b. Inspect bearing connecting rod bolts and nuts for correct installation.
Comments:____________________________________________
Inspect the outer casing for dents, nicks, bulges, or evidence of fluid leakage.
Comments:____________________________________________
a. Inspect oil pump drive gear and crankshaft gear for unusual wear patterns or
discoloration. Inspect whole gear train if there is evidence of further damage.
Comments:____________________________________________
NOTE
D5-6
c. Check backlash or jacket water pump gear and idler gear (refer to Tolerance
Measurement Data Sheet, Appendix G5).
Comments:____________________________________________
a. Inspect the barring device safety switch for proper installation and adjustment.
Comments:____________________________________________
a. Check foundation bolts for proper installation, and check for tightness and torque.
Comments:____________________________________________
b. Inspect the vibration mounts and vibration isolators for proper installation,
deterioration, and date of installation.
Comments:____________________________________________
a. Inspect the generator T-ring for cracks, distortions, and the proper installation of the
reinforcing ring (i.e., an excessive number of holes drilled in the aluminum T-ring.).
Comments:____________________________________________
b. Inspect the generator housing and windings for oil accumulation and the inner
generator bearing seals for leakage.
Comments:____________________________________________
b. Inspect he zincs in the generator air cooler, engine jacket water cooler and the fuel oil
cooler for proper installation (refer to MRC).
Comments:____________________________________________
c. Inspect the jacket water temperature-regulating valve for proper operation and for
evidence of leakage.
Comments:____________________________________________
a. Inspect the lube oil strainer for contaminants and the strainer elements for integrity
(proper assembly).
Comments:____________________________________________
D5-7
b. Inspect strainer basket top oil seal (square) integrity and condition.
Comments:____________________________________________
c. Inspect the lube oil filter for contaminants (break one filter element open).
Comments:____________________________________________
a. Inspect one filter element for excessive contaminants and correct installation.
Comments:____________________________________________
b. Inspect filter assembly housing for missing fasteners, brackets, and mounting shields.
Inspect for fuel leaks inside the filter housing assembly. Ensure that the fuel valve
handle turns freely.
Comments:____________________________________________
c. Inspect the fuel strainer for fuel leaks. Ensure that the strainer T-handle turns freely.
Inspect the strainer shield assembly and cover. Inspect to ensure proper strainer
support mounting.
Comments:____________________________________________
d. Inspect the complete fuel system on the engine for oil leaks, missing brackets,
standoffs, missing spiral wrap, and hose/tube deterioration.
Comments:____________________________________________
18. General.
Visually check condition of all hoses, tube and pipe assemblies, spiral wraps,
standoff brackets fittings, and elbow joints. Check for:
c. Proper installation.
NOTE
D5-8
19. Exhaust system.
NOTE
a. Visually inspect exhaust pipes and expansion joints in engine room and exhaust
stacks for leakage during operation test.
Comments:____________________________________________
b. Check engine exhaust muffler for baffle separation and deterioration (if applicable).
Comments:____________________________________________
c. Inspect spring hangers for material condition, proper tension, and indications of
movement.
Comments:____________________________________________
e. Check exhaust pipe/silencer drain valves for freedom of movement and clogging.
Comments:____________________________________________
C. HELPFUL INFORMATION.
1. Left bank 1-8 on EPCC pyrometer readings and right bank 9-16 on EPCC pyrometer
readings.
DIAGRAM
1R 2R 3R 4R 5R 6R 7R 8R
FRONT REAR
1L 2L 3L 4L 5L 6L 7L 8L
RIGHT-HAND ROTATION
D5-9
SMALL, HIGH-SPEED DIESEL ENGINE
SECURED-PHASE INSPECTION WORKSHEET
USS_________________________
DATE_______________________
ENGINE NO._________________
A. SPECIAL TOOLS
NOTE
4. Dial indicator.
Comments:____________________________________________
9. Ring compressor.
Comments:____________________________________________
D6-1
12. Ring expander.
Comments:____________________________________________
22. J-tools:
Tool Number Description
J 23410 Torque multiplier
J 1264-01 Torque wrench 0-200 ft-lb
J 23775 Torque wrench 100-600 ft-lb
J 24407 Torque wrench 10-250 ft lb
J 8398 Torque wrench 0-500 ft-lb
J 25310 Tube bender
J 8051-01 Tubing flare kit
J 9708-01 Valve lash feeler gage set
Comments:____________________________________________
D6-2
B. VISUAL INSPECTION
NOTE
c. Inspect main bearing and connecting-rod bolts and nuts for broken or missing cotter
pins.
Comments:____________________________________________
d. Validate that with twin units (tandem) both engines trip at the same time.
Comments:____________________________________________
f. Check visible areas of liners for scoring, galling, and dull spots. Inspect rings for
excess carbon and/or broken rings. (Bar engine over for this operation.)
Comments:____________________________________________
h. Inspect accessory drive and crankshaft gear for broken teeth, unusual wear pattern,
excessive wear, and improper lubrication.
CAUTION
Comments:____________________________________________
D6-3
i. Inspect drive gears for broken teeth, unusual wear pattern, or excessive wear.
Comments:____________________________________________
NOTE
a. Check vibration damper for dents or bulges in the damper case; check mounting bolt
torque after removing cover.
Comments:____________________________________________
b. Check flywheel ring gear teeth and air start motor pinion for cracking or pitting.
Inspect attached pulleys if installed.
Comments:____________________________________________
3. Camshaft.
b. Check lube oil sample and, if required (i.e., diluted), pressurize engine fuel system to
determine source of leakage.
Comments:____________________________________________
NOTE
Comments:____________________________________________
b. Check to ensure that control racks and settings are properly adjusted and that linkage
arm, pins, and clips are properly set.
Comments:____________________________________________
D6-4
c. Check for any evidence of fuel or water leakage near the cylinder head.
Comments:____________________________________________
b. Check all linkages for lost motion with clevis pin nuts securely tightened against
shoulders and all cotter keys in place.
Comments:____________________________________________
7. Salt- and freshwater pumps. Remove the end plate on JABSCO pump and inspect
impeller for wear and cracks.
a. Check for any leakage from the telltale hole and miscellaneous piping (leakage from
telltale holes indicates defective seals).
b. Ensure that all vent valves and gages have been installed.
Comments:____________________________________________
b. Ensure that turbocharger rotor does not bind when rotated by hand.
Comments:____________________________________________
d. Inspect turbocharger after cooler for dirt, oil, contamination, and jacket water leaks.
Comments:____________________________________________
D6-5
10. Flexible hoses, flexible pipe, and fittings.
a. Inspect flexible hose for cracks, crimping, fraying, rubbing, swelling, and
deterioration. Check for improper bend radii.
Comments:____________________________________________
c. Inspect pipe hangers for tightness and correct settings, and inspect flexible pipes for
freedom of movement.
Comments:____________________________________________
a. Inspect filter elements for cleanliness, completeness; ensure that filter element is
firmly seated in housing and that differential gage has been installed and calibrated.
Comments:____________________________________________
b. Inspect air ducting from filter to turbocharger air inlet for cracks, missing sections,
loose or missing nuts, bolts, and rivets.
Comments:____________________________________________
a. Remotely operate the emergency trip (inspect for frayed wire and improper
connectors).
Comments:____________________________________________
b. Check the manual trip stop lever cap screw for tightness.
Comments:____________________________________________
c. Check flange shields and spray shields for proper installation and condition.
Comments:____________________________________________
NOTE
D6-6
14. Exhaust system.
NOTE
a. Visually inspect exhaust pipes and expansion joints in engine room and exhaust
stacks for leaks during operational test.
Comments:____________________________________________
b. Check engine exhaust muffler for baffle separation and deterioration (if applic able).
Comments:____________________________________________
c. Inspect spring hangers for material condition, proper tension, and indications of
movement.
Comments:____________________________________________
e. Check exhaust pipe/silencer drain valves for freedom of movement and clogging.
Comments:____________________________________________
a. Inspect one filter element for excessive contaminants and correct installation.
Comments:____________________________________________
b. Check lube oil sampling valves for hand wheels and caps.
Comments:____________________________________________
D6-7
b. Check heat shields for proper installation.
Comments:____________________________________________
D6-8
ALL ABOVE VIEWS FROM REAR OF ENGINE
D6-9
Model Description, Rotation, and Accessory
Arrangement
General Specifications
6V 8V 12V 16V
Type 2 Cycle 2 Cycle 2 Cycle 2 Cycle
Number of Cylinders 6 8 12 16
Bore (inches) 4.25 4.25 4.25 4.25
Bore (mm) 108 108 108 108
Stroke (inches) 5 5 5 5
Stroke (mm) 127 127 127 127
Compression Ratio (Nominal) 17 to 1 17 to 1 17 to 1 17 to 1
(Standard Engines)
Compression Ratio (Nominal) 18.7 to 1 18.7 to 1 18.7 to 1 18.7 to 1
(“N” Engines)
Total Displacement - cubic inches 426 568 852 1136
Total Displacement - liters 6.99 9.32 13.97 18.63
Number of Main Bearings 4 5 7 10
D6-10
TABLE D6-1. General Specifications
6V 8V 12V 16V
Type 2 Cycle 2 Cycle 2 Cycle 2 Cycle
Number of Cylinders 6 8 12 16
Bore (inches) 4.25 4.25 4.25 4.25
Bore (mm) 108 108 108 108
Stroke (inches) 5 5 5 5
Stroke (mm) 127 127 127 127
Compression Ratio (Nominal) 17 to 1 17 to 1 17 to 1 17 to 1
(Standard Engines)
Compression Ratio (Nominal) 18.7 to 1 18.7 to 1 18.7 to 1 18.7 to 1
(“N” Engines)
Total Displacement - cubic inches 426 568 852 1136
Total Displacement - liters 6.99 9.32 13.97 18.63
Number of Main Bearings 4 5 7 10
D6-11
GENERIC MEDIUM-SPEED DIESEL ENGINE SECURED-PHASE
INSPECTION WORKSHEET
USS
DATE
ENGINE NO.
A. SPECIAL TOOLS
NOTE
2. Torque wrenches.
a. 1/2-inch drive up to 350 ft./lb.
Comments:
4. Dial indicator.
Comments:
D7-1
9. Cylinder pressure gage (Kie ne indicator).
Comments:
B. VISUAL INSPECTION.
a. Isolate expansion tank and hydrostatically test jacket water system according to PMS
if any of the following conditions exist: rust, excessive water and chemical makeup,
water streaks, obvious external/internal leaks, and NOAP results.
Comments:
D7-2
b. Inspect engine foundation bolts for correct installation.
Comments:
e. Check condition of rings, pistons, and liners, Inspect for broken rings, blow-by etc.
on both sides of engine.
Comments:
D7-3
CATERPILLAR DIESEL ENGINES SECURED-PHASE
INSPECTION WORKSHEET
USS
DATE
ENGINE NO.
A. SPECIAL TOOLS
NOTE
6. Dial indicator.
Comments:
D8-1
11. Ring compressor.
Comments:
B. VISUAL INSPECTION.
NOTE
D8-2
c. Inspect main bearing and connecting rod bolts and nuts.
Comments:
d. Check connecting rod and main bearing edges for evidence of bearing failure.
Comments:
f. Check visible areas of liners from beneath for scoring, galling, and dull spots. (Bar
engine over for this operation.)
Comments:
h. Run prelube pump and check to ensure that oil lines to the engine are tight. Check to
ensure that oil is reaching all rocker arm assemblies.
Comments:
i. Inspect accessory drive and crankshaft gear for broken teeth, unusual wear pattern,
excessive wear, and improper lubrication.
CAUTION
Comments:
j. Inspect drive gears for broken teeth, unusual wear pattern, or excessive wear.
Comments:
a. Check condition of the vibration damper for dents or bulges in the damper case.
Comments:
b. Check flywheel ring gear teeth and air start motor pinion for cracking or pitting.
Comments:
3. Camshaft.
D8-3
4. Fuel injection pump and fuel lines.
5. Cylinder head.
a. Check for any evidence of fuel or water leakage around the cylinder head area.
Comments:
b. Thrust crankshaft and record (refer to the Tolerance Measurement Data Sheet,
appendix G8).
Comments:
b. Check all linkage for lost motion with clevis pin nuts securely tightened against
shoulders and all cotter keys in place.
Comments:_____________________________________________
c. Check governor oil level and oil leakage around base of governor.
Comments:_____________________________________________
D8-4
8. Sea (raw) and jacket water pumps.
a. Check for any leakage from the telltale hole and associated piping (leakage from
telltale holes indicates defective seals).
Comments:______________________________________________
b. Ensure that all vent valves and gages have been installed.
Comments:______________________________________________
a. Check for any leakage of oil out of pipe connections and flanges.
Comments:______________________________________________
10. Turbocharger(s).
b. Ensure that turbocharger rotor does not bind when rotated by hand.
Comments:______________________________________________
c. Inspect external surface of the turbocharger for evidence of exhaust leaks.
Comments:______________________________________________
d. Inspect turbocharger after cooler for dirt, oil, contamination, and jacket water leaks.
Comments:______________________________________________
a. Inspect flexible hose for cracks, crimping, fraying, rubbing, swelling, and
deterioration.
Comments:______________________________________________
c. Inspect pipe hangers for tightness and flexible pipes for freedom of movement.
Comments:______________________________________________
a. Inspect filter elements for cleanliness, completeness; ensure that filter element is
firmly seated in housing and that the pop-up indicators have been installed.
Comments:______________________________________________
D8-5
b. Inspect air ducting from filter to turbocharger air inlet for cracks, missing sections,
loose or missing nuts, bolts, and rivets.
Comments:______________________________________________
a. Remotely operate the emergency trip (inspect for frayed wire and improper
connectors).
Comments:______________________________________________
b. Check the manual trip stop lever cap screw for tightness.
Comments:______________________________________________
c. Check flange shields and spray shields for proper installation and condition.
Comments:______________________________________________
NOTE
D8-6
e. Check exhaust pipe/silencer drain valves for freedom of movement
and clogging.
Comments:______________________________________________
b. Check lube oil sampling valves for hand wheels and caps.
Comments:______________________________________________
D8-7
WAUKESHA DIESEL ENGINES
SECURED-PHASE INSPECTION WORKSHEET
USS
DATE
ENGINE NO.
A. SPECIAL TOOLS
NOTE
5. Hand tools.
Comments:
D9-1
11. Water inhibitor test kit.
Comments:
13. Accessory drive gear puller and adapters (standard Navy puller tool).
Comments:
B. VISUAL INSPECTION.
NOTE
a. Inspect engine foundation for cracks and separations from the engine.
Comments:______________________________________________
b. Sound the engine hold down bolts. Inspect for loose or missing bolts.
Comments:______________________________________________
c. Inspect for cracked or missing chock fast and other bearing materials used between
engine and foundation.
Comments:______________________________________________
D9-2
e. Damper end of engine and power take-off end—Inspect all accessory hold-down
bolts for tightness. Inspect for oil, water, and fuel leaks. Inspect for chafed lines and
integrity of hold-down retaining devices.
Comments:______________________________________________
NOTE
Comments:______________________________________________
g. Inspect all water, fuel, oil, air, and hydraulic lines for leakage and chafing. Inspect
rubber and flexible lines for wear and deterioration.
Comments:______________________________________________
NOTE
Correct fuel and lube oil leaks immediately, and cite water leaks
that are minor to the responsible engineering personnel. Correct
leaks before operation.
2. Viscous damper.
a. Inspect viscous damper for indications of bulges, cracks, elongated boltholes, and bolt
tightness.
NOTE
Dents in the viscous damper or oil leaks are cause for rejection.
Comments:______________________________________________
3. Turbocharger.
a. Check the turbocharger for oil, air, and exhaust leaks. Remove air filter and inlet
silencer and inspect the inlet of the turbocharger for dirt, damage, and abnormal
conditions. Check turbochargers for damaged vanes, leaking oil seal, freedom of
movement.
Comments:______________________________________________
D9-3
4. Air inlet shutdown device.
a. Check to be sure that all air cleaners have been securely mounted and all connections are
tight.
Comments:______________________________________________
b. Open drain petcocks in air cleaners (MCM) and air intake manifolds (L1616DSIN) to
check for presence of water.
Comments:______________________________________________
c. Inspect air ducting (inlet to turbocharger) for cracks, missing sections, loose or
missing fasteners.
Comments:______________________________________________
6. Engine Instrumentation.
7. Lower Crankcase.
Lower crankcase inspection (engines with hand-hole covers). Remove hand-hole covers
from each side of engine. Conduct the following inspection procedures:
a. Thrust crankshaft and record total thrust (end play). (Refer to Tolerance
Measurement Data Sheet, appendix G9.)
Comments:______________________________________________
c. Inspect lower portion of cylinder liners for abnormal wear. Record results.
Comments:______________________________________________
e. if warranted (i.e., oil analysis) inspect main bearings. If only one main bearing is
inspected, it should be no. 4.
Comments:______________________________________________
D9-4
f. Measure and record L.O. pump backlash (refer to Tolerance Measurement Data
Sheet, appendix G9).
Comments:______________________________________________
a. Check timing.
NOTE
Comments:______________________________________________
b. Conduct intake and exhaust valve clearance check. Measure clearances and record.
Comments:______________________________________________
d. Inspect the control shaft flexible coupling and rack return springs for proper
installation or settings.
Comments:______________________________________________
e. Check installation of all rack stops and rack movement. All rack stops must be the
same width.
Comments:______________________________________________
f. Check the actuator arm linkage (MSO) and that the cross-rod adjustment is correct
according to the technical manual. (Refer to the Tolerance Measurement Data Sheet,
appendix G9.)
Comments:______________________________________________
9. Fuel system.
c. Open the drain petcock on the fuel oil strainer to check for water from the separator.
Check the window screen for cleanliness.
Comments:______________________________________________
D9-5
d. Check and record fuel oil pump backlash. (Refer to the Tolerance Measurement Data
Sheets, appendix G9).
Comments:______________________________________________
a. Manually start the prelube system from local and remote control to check operation.
Check lights (prelube is on).
Comments:______________________________________________
b. Check for any oil leaks at the pipe connections and flanges.
Comments:______________________________________________
NOTE
Comments:______________________________________________
b. Check the operation of the temperature control manual override on the surge tank.
NOTE
Comments:______________________________________________
c. Check the flange shields and spray shields for proper installation and condition.
Comments:______________________________________________
12. General.
a. Validate the alignment of the prime mover if warranted (last PMS readings, vibration
problems, etc. may dictate this requirement).
Comments:______________________________________________
b. Check the backlash of the generator oil scavenging pump gear. (Refer to the
Tolerance Measurement Data Sheet, appendix G9.)
Comments:______________________________________________
c. Check the condition of the epoxy chocks below the engine rails for damage and
cracking.
Comments:______________________________________________
D9-6
d. Check the engine foundation bolts for tightness, missing bolts, or improper
installation.
Comments:______________________________________________
NOTE
a. Visually inspect exhaust pipes and expansion joints in engine room and exhaust
stacks for leaks during operational test.
Comments:______________________________________________
c. Inspect spring hangers for material condition, proper tension, and indications of
movement.
Comments:______________________________________________
C. IDENTIFICATION/NUMBERING
1. Establish the right and left sides of the engines by standing at the rear or flywheel
end and facing the engine.
2. Cylinders are numbered one to six in each bank, starting from the front gear
cover, so any reference should designate either right or left bank (for example: 1R, 2R,
3R, 4R, 5R, and 6R for the right bank, and 1L, 2L, 3L, 4L, 5L, and 6L for the left bank).
D9-7
3. Front and rear are designated as antiflywheel (front) and flywheel (rear) ends.
CAUTION
4. CW rotation is clockwise rotation as viewed facing the flywheel end of the engine;
CCW rotation is counterclockwise rotation as viewed facing the flywheel end of the
engine.
5. Firing order
D9-8
ISOTTA FRASCHINI (IF) SPECIAL TOOLS CHECK SHEET
USS
DATE
A. SPECIAL TOOLS
D10-1
14. Extractor drive shaft coupling half inj pump 185000057A01
Comments: __________________________________________
D10-2
30. Feeler gages (short)
Comments: __________________________________________
a. Check for missing or loose bolts, block to rails, and rails to sub base.
Comments: __________________________________________
b. Check for oil leaks at gasket area between block and oil pan.
Comments: __________________________________________
c. Check for cracks on sub base in the area between engine and generator.
Comments: __________________________________________
NOTE
f. Check for visible areas of liners for scoring, galling, dull spots, and glazing.
Comments: __________________________________________
g. Check all lube oil piping and brackets for looseness and cracks.
Comments: __________________________________________
h. Check the condition of piston cooling tubes for possible contact with connecting rods.
Comments: __________________________________________
NOTE
i. Inspect lube oil pump drive gears for broken teeth, unusual wear pattern, excessive
wear, signs of nitriding, spalling, and evidence of improper lubrication.
Comments: __________________________________________
l. Inspect crankshaft gear for broken teeth, unusual wear pattern, excessive wear, signs
of nitriding, spalling, and evidence of improper lubrication.
Comments: __________________________________________
CAUTION
Use extreme care, as engine must be barred over to fully inspect gear.
a. Check vibration damper for dents or bulges in the dampener case. (Also check for oil
leaks at seams of case.)
Comments: __________________________________________
b. Check flywheel ring gear teeth and air start motor pinion for excessive wear, cracking
or pitting.
Comments: __________________________________________
a. Inspect fuel supply pump for leaks. Check tell-tale line for signs of fluid.
Comments: __________________________________________
b. Check lube oil sample and, if required (i.e., diluted), determine source of leakage.
Check seal area of engine mounted primary fuel oil pump along with having fuel
nozzle tested.
Comments: __________________________________________
4. Cylinder heads.
a. Check for evidence of fuel, water, and lube oil or combustion gas leakage around area
of cylinder heads.
Comments: __________________________________________
c. If warranted, by either hours IAW class advisory for checking valve recession or
PMS not being completed within periodicity for checking valve lash, conduct a set of
valve recession readings and check guide post height readings. Record results.
Comments: __________________________________________
D10-4
d. Remove fuel injection nozzles and perform borescope inspection of all cylinders,
check the condition of cylinder liners, piston crowns and heads. If evidence of water
intrusion is suspect, conduct a jacket water system hydro and re-borescope.
Comments: __________________________________________
CAUTION
NOTE
b. Check all linkages for ease of motion with clevis pin nuts securely tightened against
shoulders.
Comments: __________________________________________
NOTE
a. Check for any leakage on the jacket water pump from the tell-tale hole. (Leakage
from tell-tale hole indicates defective mechanical seals.)
Comments: __________________________________________
b. Ensure all gages and gage cut out valves have been installed.
Comments: __________________________________________
c. Inspect salt water pump drive and belt in accordance with current PMS.
Comments: __________________________________________
D10-5
7. Turbochargers.
b. Ensure that turbocharger rotor does not bind when rotated by hand.
Comments: __________________________________________
c. Inspect external surface of the turbocharger for evidence of exhaust leaks, oil leaks or
housing cracks.
Comments: __________________________________________
a. Inspect filter elements for cleanliness and completeness. Ensure that filter element is
firmly seated in housing and that manometer gage has been installed.
Comments: __________________________________________
b. Inspect air ducting from filter to turbocharger air inlet for cracks, missing sections,
loose or missing nuts, bolts, and clamps.
Comments: __________________________________________
a. Inspect air and exhaust manifolds for evidence of blown out gaskets.
Comments: __________________________________________
b. Ensure that air manifold/intercooler tell-tale drilled plugs are unobstructed. Check
for signs of excessive oil tell-tale plugs.
Comments: __________________________________________
NOTE
If water is leaking from tell-tale plug, hydro jacket water system and borescope
intercooler.
c. Check turbocharger heat shields and exhaust system lagging for proper installation.
Comments: __________________________________________
NOTE
D10-7
a. Visually inspect exhaust pipes and expansion joints in the engine room and exhaust
stacks for leaks during operational test.
Comments: __________________________________________
c. Check exhaust pipe/silencer drain valves for freedom of movement and clogging.
Comments: __________________________________________
a. Inspect flexible hoses for cracks, crimping, fraying, rubbing, swelling, and
deterioration. Check inspection tags ensuring hoses are within current guidance for
periodicity.
Comments: __________________________________________
a. Remotely operate the emergency trip (inspect for frayed wire and improper
connections).
Comments: __________________________________________
b. Check flange shields and spray shields for proper installation and condition.
Comments: __________________________________________
c. Validate that by moving AMOT valve manual operation lever through both detents
proper shutdown operation of the injection pump control rack and air flaps is
achieved.
Comments: __________________________________________
a. Cut open filter elements and inspect for excessive contaminants. Ensure new filter
elements are installed correctly.
Comments: __________________________________________
b. Inspect duplex filter and Salamini fuel/water separator filter drain valves for freedom
of movement.
Comments: __________________________________________
D10-8
c. Inspect filter elements for excessive contaminants and correct installation.
Comments: __________________________________________
d. Ensure Salamini filter water indicator ball is in bottom of sight glass (ball only floats
in water).
Comments: __________________________________________
NOTE
NOTE
Comments: __________________________________________
a. Inspect drive gears for broken teeth, unusual wear pattern, excessive wear and signs
of nitriding spalling. Check backla sh between gears.
Comments: __________________________________________
NOTE
D10-9
c. Inspect camshaft lobes for excessive pitting, flat spots or wear. Measure camshaft
endplay.
Comments: __________________________________________
D10-10
PAXMAN VALENTA (16RP200M)
SECURE PHASE INSPECTION WORKSHEET
USS
DATE _____
A. SPECIAL TOOLS
NOTE
D11-1
11. Metric tool set open end, box end and sockets for routine maintenance.
Comments: __________________________________________
B. VISUAL INSPECTION
d. Inspect crankcase covers for missing bolts, loose fasteners, or missing gaskets.
Comments: __________________________________________
e. Inspect crankcase relief valves cover springs for distortion and collapse.
Comments: __________________________________________
f. Inspect connecting rod and main bearing edges for signs of bearing failure.
Comments: __________________________________________
a. Inspect flywheel gear teeth and both starter pinion gear teeth for cracking, pitting, and
excess wear.
Comments: __________________________________________
b. Inspect raw water pump and engine pulleys for dents or cracks.
Comments: __________________________________________
D11-2
c. Inspect pulley vee belts for cracks and deterioration.
Comments: __________________________________________
3. Cylinder Head.
d. Inspect lube oil drain ferrules (no paint and properly greased).
Comments: __________________________________________
e. Inspect for evidence of water and fuel leakage around cylinder heads.
Comments: __________________________________________
f. Check tappet clearance using a feeler gauge. Note: Tappet adjustment indicating
should be used to indicate Piston TDC compression stroke. Record on data sheet.
Comments: __________________________________________
4. Fuel System.
NOTE
b. Check all fuel injection pump return springs for security and distortion.
Comments: __________________________________________
D11-3
f. Inspect freedom of movement of all rack linkages and control shafts.
Comments: __________________________________________
g. Inspect under fuel injection pump bellows for leakage from the control rod oil seals.
Comments: __________________________________________
i. Examine the fuel reservoir stages for deposit or foreign matter and the air bleed slot
between compartments for obstruction.
Comments: __________________________________________
j. Inspection fuel oil reservoir relief valve; ensure that the valve slides smoothly in the
carrier bore and the relief spring is not collapsed or distorted.
Comments: __________________________________________
5. Exhaust System.
d. Inspect air filter element for cracks, welding failure, cleanliness, and completeness;
ensure that filter is firmly seated in housing.
Comments: __________________________________________
e. Inspect condensate drain valves and spring for dirt, corrosion and deterioration.
Comments: __________________________________________
f. Inspect charge air cooler for dirt, fin damage, oil contamination, and water leaks.
Comments: __________________________________________
7. Turbocharger.
D11-4
b. Inspect turbocharger compressor rotating assembly for oil seal leakage.
Comments: __________________________________________
c. Check turbocharger inducer to blower inlet casing clearance. Record on data sheet.
Comments: __________________________________________
d. Inspect external surface of turbocharger for evidence of lube oil, exhaust gas and
jacket water leaks.
Comments: __________________________________________
b. Remove and inspect lube oil filter for contaminants such as metal particles.
Comments: __________________________________________
c. Run prelube pump and ensure that the lube oil reaches the turbocharger oil supply
inlet.
Comments: __________________________________________
e. Check lube oil level in sump after engine has been shutdown for at least 20 minutes.
Maintain at "max static" mark on dipstick.
Comments: __________________________________________
9. Cooling System.
NOTE
b. Inspect jacket water pump telltale line for leakage or blockage. (Leakage from
telltale lines indicate defective mechanical seals.)
Comments: __________________________________________
D11-5
c. Check heat exchanger and lube oil cooler for coolant leakage.
Comments: __________________________________________
a. Inspect coupling for signs of wear. Refer to Paxman Valenta 16RP200M Technical
Manuals S9233-E1-MMC-010 and S9233-E1-MMC-020 for inspection criteria.
Comments: __________________________________________
a. Inspect the vibration mounts and isolators for proper installation and deterioration.
Comments: __________________________________________
c. Check distance from alignment arm to sole plate (Should match distance on mount
foot). Record on data sheet. Refer to Paxman Valenta 16RP200M Technical
Manuals S9233-E1-MMC-010 and S9233-E1-MMC-020.
Comments: __________________________________________
b. Ensure that all electrical cables are supported (electrical cables should not be laying
on the engine).
Comments: __________________________________________
D11-6
13. Safety Devices.
a. Ensure that all label plates for remotely operated safety devices identify the correct
engine and function.
Comments: __________________________________________
b. Check low lube oil pressure and high jacket water temperature alarm.
Comments: __________________________________________
d. Inspect all remotely operated cables for frayed wire and proper connections.
Comments: __________________________________________
a. Inspect flexible hoses for cracks, crimping, fraying, rubbing, swelling, and
deterioration. Check for improper bend.
Comments: __________________________________________
c. Inspect pipe hangers for tightness and correct settings, and inspect flexible pipes for
freedom of movement.
Comments: __________________________________________
D11-7
CATERPILLAR TOOLS AND EQUIPMENT CHECKLIST
USS (______________)
DATE
A. SPECIAL TOOLS
6. Dial indicator.
Comments:
D12-1
14. Ring expander.
Comments:
D12-2
29. 9U5335 cylinder liner press (2EA).
Comments:
D12-3
CATERPILLAR DIESEL ENGINES
SECURED PHASE INSPECTION WORK SHEET
USS (______________)
DATE
NOTE
B. VISUAL INSPECTION.
d. Check connecting rod and main bearing edges for evidence of bearing failure.
Comments:
f. Check visible areas of liners from beneath for scoring, galling, and dull spots. (Bar
engine over this operation.)
Comments:
h. Run prelube pump and check to ensure that oil lines to the engine are tight. Check to
ensure that oil is reaching all rocker arm assemblies.
Comments:
D12-4
i. Inspect accessory drive and crankshaft gear for broken teeth, unusual wear pattern,
excessive wear, and improper lubrication, as accessible on 3600 series.
Comments:
j. Inspect drive gears for broken teeth, unusual wear pattern, or excessive wear, as
accessible on 3600 series.
Comments:
a. Check condition of the vibration damper for dents or bulges in the damper case.
Comments:
b. Check flywheel ring gear teeth and air start motor pinion for cracking or pitting,
mandatory 3600 series.
Comments:
3. Camshaft.
5. Cylinder head
a. Check for any evidence of fuel or water leakage around the cylinder head area.
Comments:
D12-5
6. Fuel control linkage and governor assembly.
b. Check all linkage for lost motion with clevis pin nuts securely tightened against
shoulders and all cotter keys in place.
Comments:_____________________________________________
c. Check governor oil level and oil leakage around base of governor.
Comments:_____________________________________________
a. Check for any leakage from the telltale hole and associated piping (leakage from
telltale holes indicates defective seals.)
Comments:______________________________________________
b. Ensure that all vent valves and gages have been installed.
Comments:______________________________________________
a. Check for any leakage of oil out of pipe connections and flanges.
Comments:______________________________________________
10. Turbocharger(s).
b. Ensure that turbocharger rotor does not bind when rotated by hand.
Comments:______________________________________________
d. Inspect turbocharger after cooler for dirt, oil, contamination, and jacket water leaks.
Comments:______________________________________________
D12-6
e. Inspect shutdown gate orifice hole, located cooler side, 3600 series.
Comments:
a. Inspect flexible hose for cracks, crimping, fraying, rubbing, swelling, and
deterioration.
Comments:______________________________________________
c. Inspect pipe hangers for tightness and flexible pipes for freedom of movement.
Comments:______________________________________________
a. Inspect filter elements for cleanliness, completeness; ensure that filter element is
firmly seated in housing and that the pop-up indicators have been installed.
Comments:______________________________________________
b. Inspect air ducting from filter to turbocharger air inlet for cracks, missing sections,
loose or missing nuts, bolts, and rivets.
Comments:______________________________________________
c. Inspect air intake manifold on 3600 series engines. Manifold will be wet with
approximately 1 inch of oil at low point due to intake manifold lubricators.
Comments:
a. Remotely operate the emergency trip (inspect for frayed wire and improper
connectors).
Comments:______________________________________________
b. Check the manual trip stop lever cap screw for tightness.
Comments:______________________________________________
c. Check flange shields and spray shields for proper installation and condition.
Comments:______________________________________________
D12-7
15. Exhaust system.
NOTE
b. Check lube oil sampling valves for hand wheels and caps.
Comments:______________________________________________
D12-8
18. Inspect intake and exhaust manifolds.
D12-9
MTU MODEL 396TE94
SECURED PHASE INSPECTION WORKSHEET
A. SPECIAL TOOLS.
6. Torque wrench, 1/2-inch dr. 210 mm (150 ft. lbs.) with extension.
Comments:
8. Dial gauge and measuring jig for TDC, P/N YA 272995, YA 0002727.
Comments:
9. MTU general hand tool kits, P/Ns, 820, 589 11 59/00 and 550 589 03 99/00.
Comments:
10. Emergency fuel line, P/N 558 070 5273 or 558 070 6678.
Comments:
11. MTU kit for water treatment, P/N 560 589 14 99/00 and lube oil analysis kit NSN,
6630-01-096-4792 (see Notes 1 and 2). Water treatment to be conducted as per latest
class advisory.
Comments:
D13-1
B. VISUAL INSPECTION
1. Inspect flywheel gear teeth for damage or excess wear. (MTU G3-1).
Comments:
C. CYLINDER HEADS
4. Inspect for evidence of water, oil and fuel leakage around cylinder heads.
Comments:
5. Spot check valve clearances. (Record on data sheet.) (MTU G11-311, MRC)
Comments:
8. Check compression pressure. (As required for troubleshooting only) (MTU G5-19)
Comments:
D13-2
D. FUEL SYSTEM.
5. Inspect external fuel piping system and high-pressure engine attached fuel lines for leaks.
Comments:
E. EXHAUST SYSTEM.
2. Inspect air filter housing for cracks, seam welding failure, cleanliness, and completeness;
ensure the filter is firmly seated in the housing.
Comments:
3. Inspect air filter restriction indicator for dirt, corrosion, and deterioration. (MTU G10-
211).
Comments:
4. Inspect freedom of movement of all turbocharger control linkages and control shafts for
ease of movement. (MTU G10-401).
D13-3
G. TURBOCHARGER.
1. Inspect turbocharger rotor for ease of movement. Measure thrust only if turbo binds
during spin test. (MTU G9-101).
Comments:
2. Drain oil filter, check for metallic residue. Remove and inspect lube oil filter.
(MTU G16-121, MRC).
Comments:
3. Inspect external lube oil system piping, transfer lines and lube oil pump out system for
evidence of leakage.
Comments:
I. COOLING SYSTEM.
1. Inspect jacket water and raw water pumps telltale hole for leakage or blockage. (MTU
G13-112, MRC).
Comments:
4. Check coolant level. Coolant level must be between the min and max marks
on the expansion tank sight glass.
Comments:
NOTE:
A small quantity of water is only condensate. A slight discharge
of oil is also normal. If a large quantity of water is discharged,
the intercooler is leaking. (MTU G10-181).
Comments:
D13-4
6. Inspect jacket water return strainer.
NOTE:
Comments:
1. Inspect the engine mounts and foundation for proper installation. Check for cracking
or deterioration of chock fast.
NOTE:
Comments:
2. Inspect foundation bolts for proper installation, locking devices and condition.
(MRC)
Comments:
1. Inspect the LOCOP for proper installation and operation. (Lamp test).
Comments:
2. Ensure that all electrical cables are supported in cableways and have chaffing protection.
Comments:
3. Inspect the engine attached PT-1000 sensors, pressure sensors and canon plugs for frayed
or broken wiring. (MTU G86 321 01)
Comments:
L. SAFETY DEVICES.
1. Ensure all label plates for remotely operated safety devices identify the correct engine
and function.
Comments:
2. Check low lube oil pressure and high jacket water temperature alarms.
(MTU E531 403/00 E Section 3.6).
Comments:
D13-5
3. Inspect all remotely operated trips for proper operation.
Comments:
4. Inspect all remotely operated cables for frayed wire and proper connections.
Comments:
5. Inspect the engine manual throttle control device bolt is tight and has safety seal is in
place.
Comments:
6. Check operation of the air shutdown flaps. (MTU G10 151 01)
Comments:
1. Inspect flexible hoses for cracks, crimping, fraying, rubbing, swelling, and deterioration.
Check for improper bending and hydrostatic test data. (Refer to latest MK V advisory).
Comments:
2. Inspect engine attached pipe sections and isolation boots for cracks or leakage.
Comments:
3. Inspect pipe hangers for tightness and correct settings, and inspect flexible pipes for
freedom of movement.
Comments:
D13-6
3100 CATERPILLAR ENGINE
SECURED-PHASE INSPECTION WORKSHEET
HULL NUMBER _________________________
DATE __________________________________
A. SPECIAL TOOLS
NOTE:
NOT ALL SPECIAL TOOLS ARE HELD BY THE BOAT DETACHMENTS (DETS).
ENGINE REPAIR WORK IS ACCOMPLISHED BY THE SPECIAL BOAT UNIT (SBU)
ENGINE SHOP PERSONNEL OR BY A OUTSIDE CONTRACTORS. ONLY THE TOOLS
REQUIRED FOR PMS ARE LISTED.
NOTE:
2. Feeler gages.
Comments: ______________________________________________
B. VISUAL INSPECTION.
NOTE
D14-1
1. Crankcase and block.
4. Cylinder head:
Fuel timing.
NOTE:
Before the fuel setting is checked, the injectors must be correctly synchronized. Either
9U7305 or 1U6680 Governor And Fuel Adjusting Tool Groups can be used for testing
and adjusting. Ensure the procedures being used are the correct ones for the Tool
Group available.
6. Check fuel timing, synchronization, and fuel setting (check fuel setting on No. 1
injector rack bar).
Comments: ___________________________________________
D14-2
a. Check for any leakage from piping and seal areas.
Comments: ___________________________________________
8. Turbocharger.
D14-3
14. Lube oil filter.
16. Coolers.
17. Gauges.
Ensure all gauges on panel are operable and within normal parameters.
(During operational phase.)
Comments: ______________________________________________
D14-4
DIESEL INSPECTION REPORT DATA SHEET
(ONE FOR EACH ENGINE INSPECTED)
S9233-CJ-HBK-010
E-1
CHANGE E
DISCREP COMPONENT
CAT OR DESCRIPTION REPAIR RECOMMENDATION
SYSTEM
S9233-CJ-HBK-010
F-2
S9233-CJ-HBK-010
ALCO ENGINES
TOLERANCE MEASUREMENT DATA SHEET
USS _________________________
DATE _______________________
NOTE
SPEC ACTUAL
1. Crankshaft measurements
______________ q______________
_______________ ______________
2. Turbocharger measurements
G1-1
3. Pump timing measurements
4. Valve clearances
NOTE
If there are any unusual wear patterns in the gear train, take the
following measurements:
G1-2
S9233-CJ-HBK-010
G1-3
EMD ENGINES
TOLERANCE MEASUREMENT DATA SHEET
USS _________________________
DATE _______________________
NOTE
All tolerance measurements are to be obtained in accordance with
current PMS Maintenance Requirement Cards (MRCs) and
current printed instructions .
Spec: _________________________
Cylinder No. 1 2 3 4 5 6 7 8
Clearance
Cylinder No. 9 10 11 12 13 14 15 16
Clearance
Spec: _________________________
______________ q______________
_______________ ______________
NOTE
G2-1
S9233-CJ-HBK-010
Cylinder No. 1 2 3 4 5 6 7 8
Sat./Unsat
Cylinder No. 9 10 11 12 13 14 15 16
Sat./Unsat
G2-2
S9233-CJ-HBK-010
USS _________________________
DATE _______________________
NOTE
SPEC ACTUAL
1. Crankshaft measurements.
a. Thrust bearings
1) Upper ______________
2) Lower ______________
______________ q______________
_______________ ______________
NOTE
G3-1
SPEC ACTUAL
2. Vertical drive measurements (if taken)
a. Gear backlash
3A. Auxiliary drive gear assembly (if taken) FM 8 1/8 ______ _______
4. Engine timing.
G3-2
S9233-CJ-HBK-010
MIN ACTUAL
NOTE
7. Blower readings.
NOTE
NOTE
SPEC ACTUAL
d. Rotor thrust*
Gate rotor _______ ________
Main rotor _______ ________
*Mandatory reading
G3-3
NOTE
GATE ROTOR TIP TO MAIN ROTOR BODY, PRESENT AND PREVIOUS READINGS
TABLE 1
G3-4
S9233-CJ-HBK-010
COLT-PIELSTICK ENGINES
TOLERANCE MEASUREMENT DATA SHEET
USS _________________________
DATE _______________________
NOTE
SPEC ACTUAL
1. Crankshaft.
3. Seawater Pump.
G4-1
4. Web Deflections and Bearing Presses
FREE DRIVE
BRG END END
1 ______
2
3
4
5
6
7
8
9 ______
G4-2
S9233-CJ-HBK-010
WEB DEFLECTIONS
G4-3
CHART FOR CRANKSHAFT WEB DEFLECTION CALCULATIONS AND RECORDS
m4
m2
dh = m2 – m4
d – DIFFERENCE
VERTICAL #1 & 2 NEW 0.06mm/IN SERVICE 0.06 mm HORIZONTAL ALL WEBS NEW LESS THAN 0.03 mm
DEFLECTION #2 THRU #8 NEW 0.03mm/IN SERVICE 0.06 mm DEFLECTION ALL WEBS IN SERVICE LESS THAN 0.06 mm
LO SUMP TEMP _____°F JACKET WATER TEMP _____°F AMBIENT TEMP ____° F
G4-4
S9233-CJ-HBK-010
USS _________________________
DATE _______________________
NOTE
All tolerance measurements are to be obtained in accordance with
current PMS Maintenance Requirement Cards (MRCs) and
current printed instructions.
SPEC ACTUAL
1. Crankshaft measurements. _______ _______
Crankshaft thrust readings _______ _______
3. Turbocharger measurements.
4. Camshaft thrust.
5. Backlash.
G5-1
6. Blowers.
NOTE
G5-2
S9233-CJ-HBK-010
USS _________________________
DATE _______________________
NOTE
All tolerance measurements are to be obtained in accordance with
current PMS Maintenance Requirement Cards (MRCs) and current
printed instructions.
SPEC
MIN MAX ACT
1. Crankshaft thrust. _____ _____ ______
G6-1
S9233-CJ-HBK-010
USS _________________________
DATE _______________________
NOTE
SPEC ACT
NOTE:
The sign on the No. 3 position (bottom) must be a minus.
______________ q______________
_______________ ______________
G8-2 G7-1
S9233-CJ-HBK-010
NOTE
G7-2
S9233-CJ-HBK-010
USS _________________________
DATE _______________________
NOTE
SPEC
MIN MAX ACT
1. Crankshaft thrust. _____ _____ ______
______________ q______________
_______________ ______________
G8-1
S9233-CJ-HBK-010
WAUKESHA ENGINES
TOLERANCE MEASUREMENT DATA SHEET
USS _________________________
DATE _______________________
NOTE
SPEC
MIN MAX ACT
1. Crankshaft thrust. _____ _____ ______
G9-1
S9233-CJ-HBK-010
USS _________________________
DATE _______________________
NOTE
SPEC ACTUAL
1. Crankshaft thrust. 0.____"/0._____" 0.____"
0.____"/0._____" 0.____"
0.____"/0._____" 0.____"
0.____"/0._____" 0.____"
0.____"/0._____" 0.____"
0.____"/0._____" 0.____"
0.____"/0._____" 0.____"
0.____"/0._____" 0.____"
G10-1
CHANGE D
S9233-CJ-HBK-010
USS _________________________
DATE _______________________
NOTE
1. Deflection readings.
SPEC ACT
______________ q______________
_______________ ______________
DRIVE END
NOTE
G11-1
CHANGE D
S9233-CJ-HBK-010
SPEC ACT
NOTE
3. Valve Clearances.
NOTE
SPEC ACTUAL
SPEC ACTUAL
CHANGE D
G11-2
S9233-CJ-HBK-010
USS _______________________________________(____________)
NOTE
MIN/MAX ACTUAL
1. Crankshaft thrust. 0.____"/0._____" 0.____"
0.____" 0.____"
CCW
0.____" 0.____"
0.____"
G12-1
CHANGE D
S9233-CJ-HBK-010
NOTE:
All tolerance measurements are to be obtained in accordance with
current PMS Maintenance Requirement Cards (MRCs) requirements
and current printed instructions.
1. Valve Clearances.
NOTE:
Engine is viewed from the Power Take Off (PTO) end. (** As required).
A BANK 1 2 3 4 5 6
Intake
Exhaust
B BANK 1 2 3 4 5 6
Intake
Exhaust
3. Measure shut down flap proximity switch clearance. (MTU B84 620)
G13-1
S9233-CJ-HBK-010
ALCO ENGINES
OPERATIONAL TEST DATA SHEET
Exhaust Temperature
Cylinder No. 1L 2L 3L 4L 5L 6L 7L 8L
Ex. Temp*
Fi. Press*
Com. Press*
Rack Pos*
Cylinder No. 1R 2R 3R 4R 5R 6R 7R 8R
Ex. Temp*
Fi. Press*
Com. Press*
Rack Pos*
Pressures: Temperatures
Crankcase vacuum: ___________________ J.W. to engine: _________________
Fuel header press: ____________________ J.W. from engine: _______________
L.O. pump disch: ____________________ L.O. to engine: _________________
J.W. pump disch: ____________________ L.O. from engine: _______________
S.W. pump disch: ____________________ S.W. in: ______________________
Generator brg—fwd: __________________ S.W. overboard:________________
Generator brg—aft: ___________________ Generator brg—fwd: ____________
L.O. strainer DP: _____________________ Generator brg—aft: _____________
L.O. filter DP: _______________________
Air box press/turbo: __________________ Overspeed Trip Setting: __________
H1-1
S9233-CJ-HBK-010
H1-2
S9233-CJ-HBK-010
EMD ENGINES
OPERATIONAL TEST
DATA SHEET
Exhaust Temperature
Cylinder No. 1 2 3 4 5 6 7 8
Ex. Temp
Fi. Press
Cylinder No. 9 10 11 12 13 14 15 16
Ex. Temp
Fi. Press
NOTE
H2-1
S9233-CJ-HBK-010
Pressures: Temperatures:
Crankcase vacuum: ___________________ J.W. to engine: ____________________
Fuel pump disch: ____________________ J.W. from engine: __________________
L.O. header press: ___________________ L.O. to engine: ____________________
L.O. pump disch: ____________________ L.O. from engine: __________________
J.W. pump disch: Right / Left S.W. overboard: ___________________
S.W. pump disch: ____________________ Generator bearing—fwd: ____________
Scavenging air press: _________________ Generator bearing—aft: _____________
Generator brg—fwd: __________________ Combined exhaust (stack): ___________
Generator brg—aft: ___________________
L.O. strainer DP: _________________
L.O. filter DP: ___________________
Fuel filter DP: ___________________
H2-2
S9233-CJ-HBK-010
Cylinder No. 1 2 3 4 5 6
Ex. Temp*
Fi. Press*
Com. Press*
Rack Pos*
Inbd
Outbd
Cylinder No. 7 8 9 10 11 12
Ex. Temp*
Fi. Press*
Com. Press*
Rack Pos*
Inbd
Outbd
H3-1
S9233-CJ-HBK-010
Pressures: Temperatures
H3-2
S9233-CJ-HBK-010
COLT-PIELSTICK ENGINES
OPERATIONAL TEST
DATA SHEET
Low Lube Oil Pressure Standby Pump Start Alarm Engine Shutdown
Low Speed=175-290 rpm
Med Speed=291-370 rpm
High Speed=371-520 rpm
NOTE
Cylinder No. 1 2 3 4 5 6 7 8
Ex. Temp*
Fir. Press
Rack Pos*
Cylinder No. 9 10 11 12 13 14 15 16
Ex. Temp*
Fir. Press
Rack Pos*
*Note: Take temperature readings simultaneously with firing pressures. Readings should be
taken at EOSC. Fuel rack position readings must be taken at each injection pump.
Note: Check the fuel leak off sight glasses, the maximum leak off is 5 drops per minute.
H4-1
CHANGE F
S9233-CJ-HBK-010
MAX.
HIGH LOW AVERAGE DIFF.
Cylinder firing pressures ______ ______ __________ ________
Cylinder exhaust temperatures ______ ______ __________ ________
Fuel rack position ______ ______ __________ ________
Pre-turbo exh temp LB/RB ______/_______ Post-turbo exh temp LB/RB _______/_____
Pressures: Temperatures:
Lube oil disch press: _______________ Lube oil temp to engine: ____________
Lube oil press to engine: ____________ Lube oil temp to cooler: ____________
J.W. pump suct press: ______________ J.W. water temp to engine: __________
J.W. pump disch press: _____________ J.W. water temp from engine: ________
J.W. press to engine: _______________ Injector clg wtr outlet temp: __________
S.W. pump suct press: ______________ Rocker lube oil temp: _______________
S.W. pump disch press: _____________ S.W. injection temp: _______________
Lube oil filter DP: ______/___________ S.W. inlet temp to intercooler:
Lube oil strainer DP: _______________ Left bank/right bank:______/_______
Rocker lube oil press: ______________ S.W. outlet temp from intercooler:
Turbo disch press: _________________ Left bank/right bank: _____/_______
Left bank/right bank: _____________ Intake air manifold temp:
Rocker lube oil strainer DP: __________ Left bank/right bank: _____/_______
Fuel pump suct press: ______________
Fuel pump disch press: ______________
Fuel filter DP: _____________________
Fuel press to engine: ________________
Crankcase vacuum (H2O) ____________
H4-2
S9233-CJ-HBK-010
DETROIT DIESEL
MODEL 16V 149TI ENGINES
OPERATIONAL TEST DATA SHEET
Cylinder No. 1L 2L 3L 4L 5L 6L 7L 8L
Cylinder No. 9 10 11 12 13 14 15 16
Air filter ∆P: No. 1 ________ No. 2 ________ No. 3 ________ No. 4 _______
DISENGAGED ENGAGED
FWD AFT
H5-1
S9233-CJ-HBK-010
SAT UNSAT
H5-2
S9233-CJ-HBK-010
Cylinder No. 1L 2L 3L 4L 5L 6L 7L 8L
Exhaust Temp
Cylinder No. 9 10 11 12 13 14 15 16
Exhaust Temp
Fuel oil press to filter: _________________ Jacket water press to engine: ____________
Fuel oil press to engine: _______________ Jacket water temp. to engine: ____________
Lube oil pump disch. press: _____________ Jacket water temp. from engine: _________
Lube oil press at engine: _______________ Raw water press to cooler: _____________
Lube oil temp to engine: _______________ Raw water injection temp: ______________
Lube oil temp from engine: _____________ Raw water overboard temp: _____________
Lube oil filter DP: ____________________ Crankcase pressure (H2O): ______________
Lube oil strainer DP: __________________ Crankcase vacuum (H2O): ______________
Gen lube oil alarm: ___________________ Air box press:________________________
Overspeed RPM: _____________________
Lube oil alarm: _______________________
H6-1
S9233-CJ-HBK-010
GENERIC MEDIUM-SPEED
DIESEL ENGINE
OPERATIONAL TEST
DATA SHEET
Cylinder No. 1 2 3 4 5 6 7 8
Ex. Temp*
Fi. Press*
Com press
Rack Pos*
Inbd
Outbd
Cylinder No. 9 10 11 12 13 14 15 16
Ex. Temp*
Fi. Press*
Rack Pos*
Inbd
Outbd
H7-1
S9233-CJ-HBK-010
Pressures Temperatures
H7-2
S9233-CJ-HBK-010
Cylinder No. 1L 2L 3L 4L 5L 6L 7L 8L
Cylinder No. 1R 2R 3R 4R 5R 6R 7R 8R
Fuel oil press to filter: _________________ Jacket water press to engine: ____________
Fuel oil press to engine: _______________ Jacket water temp. to engine: ____________
Lube oil pump disch press: _____________ Jacket water temp. from engine __________
Lube oil press at engine: _______________ Raw water press. to cooler: _____________
Lube oil temp to engine: _______________ Raw water injection temp: ______________
Lube oil temp from engine: _____________ Raw water overboard temp: _____________
Lube oil filter DP: ____________________ Crankcase pressure (H2O): ______________
Lube oil strainer DP: __________________ Crankcase vacuum (H2O): ______________
Low lube oil alarm: ___________________ Turbocharger disch. press:______________
FWD AFT
Generator bearing oil press: ____________ ______________
Generator bearing oil temp: ____________ ______________
H8-1
S9233-CJ-HBK-010
H8-2
S9233-CJ-HBK-010
Cylinder No. 1L 2L 3L 4L 5L 6L
Cylinder No. 1R 2R 3R 4R 5R 6R
H9-1
S9233-CJ-HBK-010
Fuel oil press. to filter: ___________________ Jacket water temp to engine: ____________
Fuel oil press. to engine: __________________ Jacket water temp. from engine: _________
Fuel oil filter DP: _______________________ Salt water injection temp: ______________
Lube oil pump disch. press.: _______________ Salt water overboard temp: _____________
Lube oil press. to engine: _________________ Lube oil temp. from engine: _____________
Turbocharger lube oil press.: _______________ Lube oil temp. to engine: _______________
Lube oil filter DP: _______________________
Lube oil strainer DP: _____________________
Jacket water press. to engine: ______________
Salt water press. to cooler: _________________
Crankcase vacuum (H2O): _________________
Scavenging air press.: _____________________
Air filter DP: ____________________________
H10-1
CHANGE D
S9233-CJ-HBK-010
SHIP NAME: _____________ ENGINE No.: ___________ TOTAL ENGINE HRS. _______
HRS SINCE LAST TREND: __________ SEA STATE: __________ DATE _____________
HRS SINCE OVERHAUL: __________ DATE SINCE LAST OVERHAUL: ______________
SHIP DRAFT: ______________
Time
Engine Speed (RPM)
Engine Load (%)
Shaft Speed (RPM)
Lube Oil Pressure (PSI)
Lube Oil Temperature (F)
Jacket Water Temp (F)
Raw Water Temp (F)
Fuel Oil Pressure (psi)
Jacket Water Pressure (psi)
Crankcase Pressure (in H2O)
Exhaust Back Pressure (in H2O)
Air Manifold Press (psi) (Boost)
Bylinder exhaust Temp B1 A1
B2 A2
B3 A3
B4 A4
B5 A5
B6 A6
B7 A7
B8 A8
Exhaust Temp After turbo (F)
Lube oil filter DP (in H2O)
Governor Lever
Fuel rack position
CHANGE D H11-1
S9233-CJ-HBK-010
PAXMAN VALENTA
OPERATING CHECKS WORKSHEET
2. Inspect all external fuel lines, unions, and coupling fuel leaks.
Comments: _____________________________________________
3. Check for leaks at exhaust stack, exhaust manifold gaskets, expansion bellows and
turbocharger exhaust inlet.
Comments: _____________________________________________
4. Inspect for air leaks at intake manifold to heads and joints at air delivery casing to manifolds.
Comments: _____________________________________________
6. Inspect jacket water and raw water pump telltale orifice for leakage or blockage. (Leakage
from telltale lines indicates defective mechanical seals).
Comments: _____________________________________________
H11-2
CHANGE D
S9233-CJ-HBK-010
Temp
Temp
Temp
Temp
CHANGE D H12-1
S9233-CJ-HBK-010
Generator brg oil press. fwd: ______Generator oil temp. fwd: ______
Generator brg oil press. aft: ______Generator oil temp. aft: ______
Sea state (MPE only): ______Ships draft (MPE only): ______
Ft./% of pitch (MPE only): ______Shaft RPM (MPE only): ______
Shaft torque (MPE only): ______
H12-2
CHANGE D
S9233-CJ-HBK-010
DATA SHEET
NOTE:
1. Start engine in accordance with craft operation procedures. Conduct pre-underway checks.
Overspeed trip test, record results. (MTU E531 399/00 E Chapter 7.5)____________
2. Conduct underway operation of engines at full engine rpm and record engine data at
LOCOP.
OPERATING DATA:
A. Engine RPM
E. Turbo Speed A
F. Turbo Speed B
H13-1
CHANGE E
S9233-CJ-HBK-010
H13-2
CHANGE F
S9233-CJ-HBK-010
DATE: _______________________
DATA:
H14-1
CHANGE F
I-1
I-2
I-3
I-4
I-5
I-3
I-6
I-7
I-8
I-9
I-10