ENGINE MAINTENANCE

Keeping an internal combustion engine (diesel or gasoline) in good operating condition demands a well-planned procedure of periodic inspection, adjustments, maintenance, and repair. If inspec-tions are made regularly, many malfunctions can be detected and corrected before a serious casualty results. A planned maintenance program will help to prevent major casualties and the occurrence of many operating troubles.

The Maintenance and Material Management (3-M) System provides a logical and efficient approach to many maintenance problems. It produces a large reservoir of information about equipment disorder and indicates what corrective steps must be taken to prevent them.

Another aspect that must be considered in connection with maintenance problems is the safety requirement aboard ship. On some ships, the 3-M System includes safety requirement cards. A safety requirement card provides guidelines and periodicity for the inspection of selected areas not covered in the regular maintenance schedule. Complete information about the 3-M System is contained in the Maintenance and Material Management (3-M) Manual, OPNAVINST 4790.4.

There may be times when service requirements will interfere with a planned maintenance pro-gram. In such event, routine maintenance must be performed as soon as possible after the specified interval of time has elapsed. All necessary corrective measures should be accomplished as soon as possible. Repair jobs should not be allowed to accumulate, otherwise hurried and inadequate work will result.

Since the Navy uses many models of internal combustion engines, it is impossible to specify a detailed overhaul procedure that would be adaptable to all models. However, there are several general rules which apply to all engines.

They are:

1. Detailed repair procedures are listed in manufacturers instruction manuals and in maintenance pamphlets. Study the appropriate manuals and pamphlets before attempting any repair work. Pay particular attention to tolerance limits, and adjustments.

2. Observe the highest degree of cleanliness in handling engine parts during overhaul.

3. Before starting repair work, be sure that all required tools and replacements for known defective parts are available.

4. Keep detailed records of repairs. Such records should include the measurements of parts, hours in use, and the names of the new parts in-stalled. Analyses of such records will indicate the hours of operation that may be expected from the various engine parts. This knowledge is helpful as an aid in determining when a part should be renewed in order to avoid a failure.

Since maintenance cards, the manufacturers maintenance manuals, and the various types of instructions discuss repair procedures in detail, this chapter will be limited to general information on engine inspections, adjustments, and maintenance, as well as some of the troubles encountered during overhaul, the causes of such troubles, and the methods of repair to be used.