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