CHAPTER 14 ENGINE  ASSEMBLY  AND  COMPONENTS  REPAIR  INSTRUCTIONS Section  I.  ENGINE  ASSEMBLY 14-1.   General. The   engine   assembly   provides   the   mechanical power   to   drive   the   main   generator.   It   consists   of a   six-cylinder,   turbocharged,   diesel   engine;   battery- charging   alternator,   speed   switch,   electric   starter and  fuel  pump. In   addition,   on   precise   generator sets,   a   hydraulic   pump   is   provided.   Maintenance instructions   for   the   components   of   the   engine   assembly are  provided  in  Sections  II  through  XVII. 14-2.    Removal. Refer  to  paragraph  2-13  and  remove  the  engine  as- sembly,  if  required  for  the  repair  action  to  be  taken. 14-3.   Disassembly. a.   Place   engine   assembly   on   an   engine   stand   utili- zing   engine   stand   adapter   plate   and   spacers. b.   Disassemble   the   engine   to   the   extent   required by  following  procedures  given  in  Sections  11  through XVII. 14-4.   Inspection   and   Repair. Inspect  and  repair  engine  assembly  assemblies, subassemblies,   and   components   as   described   in Sections II through XVII. 14-5.    Reassembly. Reassemble  the  engine  assembly  by  following  the procedures  provided  in  Sections  II  through  XVII. 14-6.  Testing. a.  Service  engine  lube  oil  and  fuel  systems  with proper  oil  and  fuel. (Refer  to  Operator  and  Organi- zational    Maintenance    Manual.) b.   Connect   engine   assembly   to   a   suitable   engine dynamometer  equipped  with  a  cooling  system  and means   of   monitoring   engine   oil   pressure,   coolant temperature,   and   engine   rpm. c.   Pre-run   Checks. (1)  Manually  turn  engine  over  a  minimum  of two  revolutions  and  check  for  binding  and  mechanical interference.  Correct  cause  of  any  binding  or  inter- ference  prior  to  starting. (2)  With  the  fuel  injection  pump  solenoid de-energized,   crank   the   engine   until   oil   pressure   ap- pears   on   the   oil   pressure   gauge.   Crank   the   engine an  additional  15  seconds  to  insure  061  is  in  all  parts of  the  lube  oil  system. (3)  Recheck  oil  level  and  top  off  lube  oil  sump. d.   Engine  Oerational   Check (1)  With  the  dynamometer  throttle  set  to  the idle  position  and  the  fuel  injection  pump  solenoid energized,   crank   the   engine  until   the   engine   starts. (2)  Allow  the  engine  to  run  at  idle  for  30 seconds,  shut  down  engine  and  inspect  for  signs  of leakage. (3)  Restart  engine  and  allow  to  run  at  low  idle for   10   minutes. NOTE Monitor   oil   pressure   and   coolant   tem- perature   at   all   times   during   this   test, also  check  for  unusual  noise  or  vibra- tions.   If   at   any   time   the   oil   pressure falls   below   20   psi,   the   coolant   tempera- ture  exceeds  222°  F,  or  if  noise  or vibrations  occur,  discontinue  test  run. (4)  Operate  engine  at  1800  rpm  at  1/2  load  for 30   minutes. (5)  Operate  the  engine  at  1800  rpm  at  full  rated load  for  1  hour. (6)  Check  to  see  that  the  engine the   following   brake   horsepower. 1500   rpm   - 100 bhp 1800   rpm   - 120 bhp 2000   rpm   - 130 bhp will   produce (7)  Operate  the  engine  with  no  load  for  five minutes  at  1800  rpm. (8)  Shut  down  and  inspect  engine  for  coolant, oil  and  leaks. 14-7.   Installation. Refer   to   paragraph   2-14   and   install   the   engine   as- sembly   in   the   generator   set. Change 6 14-1