DATE _____
ENGINE NO. ______________________________ A. SPECIAL TOOLS
NOTE
Inspect a minimum of 25 percent of the following tools.
1. Fuel injection pump gap gauge.
Comments: __________________________________________ 2. Fuel rack calibration setting pins.
Comments: __________________________________________ 3. Heel type pinch bar for injector removal.
Comments: __________________________________________ 4. Fuel injector nozzle cleaning kit.
Comments: __________________________________________ 5. Fuel pump camshaft timing adjuster.
Comments: __________________________________________ 6. Dummy nozzle for top dead center check of piston.
Comments: __________________________________________ 7. Special feeler gauge 0.005 for intake tappet clearance.
Comments: __________________________________________ 8. Special feeler gauge 0.020 for exhaust tappet clearance.
Comments: __________________________________________ 9. Torque wrench 10 to 50 lb/ft. Comments: __________________________________________ 10. Torque wrench 50 to 250 lb/ft. Comments: __________________________________________ D11-1
11. Metric tool set open end, box end and sockets for routine maintenance. Comments: __________________________________________ 12. Internal and external circlip pliers.
Comments: __________________________________________
B. VISUAL INSPECTION
1. Crankcase and block.
a. Inspect block for missing or loose bolts.
Comments: __________________________________________ b. Inspect internals for discoloration and signs of overheating.
Comments: __________________________________________ c. Inspect for foreign material in crankcase.
Comments: __________________________________________
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: __________________________________________ g. Inspect forked connecting rod bolts for proper stretch.
Comments: __________________________________________ h. Check the balance weights for security.
Comments: __________________________________________ i. Check crankcase deflections (drive end). Record on data sheet.
Comments: __________________________________________ j. Inspect for crankcase block cracks.
Comments: __________________________________________ 2. Ring gear and pulleys.
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: __________________________________________
c. Inspect pulley vee belts for cracks and deterioration.
Comments: __________________________________________ 3. Cylinder Head.
a. Inspect for missing, damaged and loose valve spring circlip.
Comments: __________________________________________ b. Inspect for broken valve springs and valve bridges.
Comments: __________________________________________ c. Inspect for loose or damaged cylinder head bolts.
Comments: __________________________________________ 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: __________________________________________
g. Inspect cylinder heads for cracking.
Comments: __________________________________________ 4. Fuel System.
NOTE
To inspect fuel pump camshafts for proper timing, a dummy injector and timing tool must be used.
a. Inspect fuel pump camshafts for proper timing.
Comments: __________________________________________ b. Check all fuel injection pump return springs for security and distortion.
Comments: __________________________________________ c. Inspect coalescer and duple x filters for signs of leakage.
Comments: __________________________________________ d. Ensure that the Duplex fuel filter-shifting device operates properly.
Comments: __________________________________________ e. Inspect uniformity of fuel rack setting.
Comments: __________________________________________
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: __________________________________________
h. Check internal of coalescer and duplex filter for contamination. 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.
a. Inspect expansion bellows for pinholes, cracks, and burning.
Comments: __________________________________________ b. Inspect heat shields for proper installation and deterioration.
Comments: __________________________________________ 6. Air Intake System.
a. Inspect air intake clamp bands for proper fit or deterioration.
Comments: __________________________________________ b. Inspect ends of air pipes for wear, fretting, or cracking.
Comments: __________________________________________ c. Inspect for proper operation of air shutdown valve.
Comments: __________________________________________
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.
a. Ensure Turbocharger inducer blades are not binding.
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: __________________________________________ e. Inspect turbocharger blade for deterioration.
Comments: __________________________________________ 8. Lube Oil System.
a. Inspect duplex filter shifting handle for freedom of movement. 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: __________________________________________ d. Ensure hand operated lube oil priming pump is operational.
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
To inspect fuel pump camshafts for proper timing, a dummy injector and timing tool must be used.
a. Inspect raw water pump drive belts for proper tension.
Comments: __________________________________________
b. Inspect jacket water pump telltale line for leakage or blockage. (Leakage from telltale lines indicate defective mechanical seals.)
Comments: __________________________________________
c. Check heat exchanger and lube oil cooler for coolant leakage. Comments: __________________________________________ d. Inspect all external coolant lines and flanges for leaks.
Comments: __________________________________________ e. Inspect heat exchanger zinc anodes for deterioration.
Comments: __________________________________________ 10. Vulkan Coupling.
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: __________________________________________
b. Inspect rubber element for plastic deformation.
Comments: __________________________________________ c. Inspect rubber element for cracking, rippling and peeling.
Comments: __________________________________________ 11. Engine Mounts.
a. Inspect the vibration mounts and isolators for proper installation and deterioration. Comments: __________________________________________
b. Inspect foundation bolts for proper installation.
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: __________________________________________ d. Check rebound clearance of mounts. Record on data sheet.
Comments: __________________________________________ 12. Gauges and Instruments.
a. Inspect the gauge for proper installation and calibration.
Comments: __________________________________________
b. Ensure that all electrical cables are supported (electrical cables should not be laying on the engine).
Comments: __________________________________________ c. Check static readings of all gauges.
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: __________________________________________ c. Inspect all remotely operated trips for proper operation.
Comments: __________________________________________ d. Inspect all remotely operated cables for frayed wire and proper connections.
Comments: __________________________________________ e. Inspect condition of spray shields.
Comments: __________________________________________ f. Inspect jacking gear start limit switch for proper operation.
Comments: __________________________________________ 14. Flexible hoses, flexible pipe, and fittings.
a. Inspect flexible hoses for cracks, crimping, fraying, rubbing, swelling, and deterioration. Check for improper bend.
Comments: __________________________________________ b. Inspect pipe sections for cracks or leakage at flanges.
Comments: __________________________________________
c. Inspect pipe hangers for tightness and correct settings, and inspect flexible pipes for freedom of movement.
Comments: __________________________________________