Figure 7-12. Valve Seat Replacement

Figure 7-13. Cylinder Head Bolt Tightening Sequence

TM-5-6115-585-34 Generator Set Diesel Engine Driven Tactical Skid Mtd 5 KW 1 Phase 2 Wire 1 Phase-3 Wire 3 Phase-4 Wire 120 120/240 and 120/208 Volts Manual
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TM5-6115-585-34 NAVFAC P-8-623-34 TO-35C2-3-455-2 TM-05684C/05685B-34 Be careful not to cut into counterbore bottom. See figure 7-12. Thoroughly clean valve seat counterbore and remove’ any burrs from the edges. Drive new valve seat inserts into place. Be certain that each seat rests solidly on bottom of counterbore at all points. To make installation easier, heat cylinder head in an oven at 325°F (163°C) for about l/2-hour. Face each new seat to a 45° angle. The finished seat face should contact approximately center of the valve face. Use Prussian Blue on each valve face to check this. Make any corrections on the seat, not the valve face. When new seats are installed and faced, insert valve into each seat and check clearance from valve head to the face of cylinder head. This must be at least 0.030 inch. If it is not, regrind the seat. (4) Valve Springs. Check valve springs (5, figure 7-1 1) on a compression scale. Valve spring data is given in the table 1-2. Replace any spring that is weak, cracked or pitted or has ends out of square. (5) Push Rods. Check that push rod is absolutely straight. Replace bent or worn push rods. e. Reassemble. (1) Push a valve stem oil seal assembly (4) onto each intake valve guide (6, figure 7-11). Then oil in- side surface of each seal. (2) Oil the stem of each valve (8 and 10, figure 7-11) and insert each in its own guide (6 and 9). If in- take valve (8) is removed with seal in place on guide, wrap sharp edge of valve notch with cellophane tape to protect seal bore. (3) Check each valve for a tight seat. (4) Using a valve spring compressor (see figure 7-10), compress each valve spring and insert the valve spring retainer (3, figure 7-11) and retainer locks (2). Install valve rotator (l). f. Install (see figure 7-9). (1) Place head assemblies (8) and gaskets (10) on cylinder block (9). Install springs (18), washers (19) and packings (16) on push rod shields (17) and install assembled push rod shields in cylinder block. Lift back side of cylinder head and place push rod shields in place, lower cylinder head in place. Use an anti-sieze compound on head bolt threads and thread bolts (4 and 6) and washer (7) into cylinder block (9). Do not tighten head bolts at this time. (2) Refer to Operator and Organizational Maintenance Manual and install intake manifold. Torque bolts 13-15 ft-lbs (see table l-l). Bend over lock tabs. Now tighten head bolts 44 to 46 ft-lbs (see table 1- 1) following the sequence in figure 7-13. Figure 7-12. Valve Seat Replacement (3) Refer to Operator and Organizational Maintenance Manual and install mufflers. CAUTION I n s t a l l p u s h r o d w i t h l o n g e r s h o u l d e r ed end toward rocker arm. (4) Install push rods (15, figure 7-9), rocker arms (3), rocker arm balls (2) and rocker arm nuts (l). (5) Set valve clearance per Operator and Organizational Maintenance Manual. (6) Refer to Operator and Organizational Maintenance Manual and install air shutter assembly and shroud assembly. NOTE After the first 50-hours of operation, valve clearance. 7-10. PISTON AND CONNECTING ROD. read just a. General (see figure 7-14). Each piston (7) is fitted with three compression rings and an oil control ring (4). Full floating piston pins connect the piston to the connecting rod. The pins are held in place with a retaining ring (5) at each end. The lower end of each connecting rod contains half shell, precision bearings (11) and the upper end contains reamed bushings (13). Change 4 7-13

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