1.0 ABSTRACT 1.1 This item describes the 30,000 hour overhaul of the ship's service diesel generator diesel engine number 3. 2.0 REFERENCES/ENCLOSURES 2.1 References: 2.1.1 NAVSEA Technical Manual No. T9233-AN-MMC-010, Ship Service Diesel Generator Engine, Model KVGB-16. (available onboard vessel) 3.3 Enclosures: 2.2.1 List of Government Furnished Material (GFM) 3.0 ITEM LOCATION/DESCRIPTION 3.1 Location/Quantity: 3.1.1 One (1) diesel engine (No. 3), engineroom, 4-60-0. 3.2 Description: 3.2.1 Diesel Engine Mfr: Bergen Diesel Model: KVGB-16 16 Cylinder V-Type Turbocharged Diesel Engine Bore: 250 mm Stroke: 300 mm Speed: 900 rpm MCR: 2630 kw, 3580 bhp 4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES: 4.1 MATERIAL: None 4.2 SERVICES: Manufacturer's Technical Field Service Representative 5.0 NOTES 5.1 Contractor to provide all necessary special tools required under this work item. 6.0 QUALITY ASSURANCE REQUIREMENTS 6.1 All work shall be performed to the satisfaction of the attending ABS Surveyor, MSC Port Engineer, Chief Engineer, and the manufacturer's technical field service representative and shall be in accordance with reference 2.1.1. 7.0 STATEMENT OF WORK REQUIRED 7.1 All work on this item to be accomplished under the direct supervision of a Government furnished manufacturer's authorized field service engineer and in accordance with ref. 2.1.1. 7.2 Accomplish all inspections and adjustments as outlined in ref. 2.1.1 under 30,000 hour maintenance table 4.1 to the No. 3 SSDG. 7.3 Prior to commencing work and upon completion, take and record crankshaft deflection readings in the presence of MSC Port Engineer, Chief Engineer, and the manufacturer's representative. 7.3.1 Submit two (2) copies of all readings to the MSC Port Engineer. 7.4 Remove all cylinder heads from both No. 3 engine and transport from ship to shop. 7.4.1 Crate and ship, via traceable means, the removed cylinder heads to the manufacturer's facility as follows: ULSTEIN USA, INC. 200 James Drive West St. Rose, LA 70087 Phone:
+1 (555) 000-0000 Fax:
+1 (555) 000-0000 7.4.2 Submit two (2) copies of shipping and receiving documents to the Port Engineer. 7.4.3 Transport the Government Furnished reconditioned cylinder heads to the vessel and install on the engine. 7.5 Remove and recondition fuel injectors and replace injector nozzle tips. Set and test each injector to manufacturer's specifications. Reinstall all fuel injectors. 7.6 Disconnect and remove two (2) pistons, conrods, and associated components on the engine and clean all components. Pistons to be designated by the ABS Surveyor. Layout for inspection by the MSC Port Engineer, Chief Engineer, and ABS. 7.6.1 Take readings on liners, sleeves, pistons and pins to ensure tolerances are within manufacturer's specifications. Polish conrod journals and hone liners to remove all imperfections. 7.6.2 Reassemble components with new piston rings, o-rings, snap rings, and seals and reinstall in engine. 7.7 Remove two (2) main crankshaft bearings (to be designated by ABS) as per reference 2.1.1, clean and layout for inspection by the MSC Port Engineer, Chief Engineer, and ABS Surveyor. Dress bearings and polish journals removing all scores, ridges, discolorations, and other imperfections. 7.7.1 Measure and record main bearing clearances as per manufacturer's instructions. Submit report of same to the MSC Port Engineer. 7.7.2 Reinstall main bearings. 7.8 Conduct inspection of all fuel injection pumps and drives as outlined in reference 2.1.1. 7.8.1 Check the pre-injection angle on all fuel injection pumps and correct as needed. 7.8.2 Remove sixteen (16) fuel injection pumps from No 3 SSDG, disassemble, inspect for wear and overhaul utilizing provided GFM Submit report of inspection findings to the Port Engineer. 7.8.3 Reassemble and reinstall the sixteen (16) pumps with new gaskets, seals, and o-rings. 7.9 Rocker Arm Lube Oil Circuit: clean oil tank and replace filter elements for No 3 SSDG. 7.10 Main Lube Oil Circuit: clean sumps and replace filter elements for No 3 SSDG. Inspect regulating valves. 7.11 Conduct inspection and measure backlash on all gear drives for camshafts, engine driven pumps, and governors to include the following: fuel oil booster pump, lube oil pumps, jacket water pumps, and start air distributor drives. Inspect camshaft drive chain assemblies. Inspect drive chain and tension as per manufacturer's specifications. 7.11.1 Replace camshaft drive chain assemblies on No 3 SSDG with new chain. 7.12 Conduct inspection of camshafts, cams, rollers, pushrods, and bearings. Check the timing between the camshafts and crankshaft, correct as needed. 7.13 Reassemble engine in accordance with ref. 2.1.1 replacing with new all gaskets, o-rings, seals, and new fasteners as required. Make all necessary adjustments and tighten all bolting to proper torque values as outlined in ref. 2.1.1, leaving engine ready for operation. 7.13.1 Prior to crankcase closure, conduct inspection to ensure all tools, rags, dirt, and other debris have been removed. MSC Port Engineer and the manufacturer's representative to conduct inspection. 7.13.2 Check and set all intake and exhaust valve lash. 7.14 Coat all fasteners with anti-seize compound prior to installation. 7.15 Remove from the vessel all dirt and debris resulting from this work item on a daily basis and leave work area in good order. 7.16 Reinstall all insulation and lagging pads removed during the performance of this work item as original. 7.17 Inspection/Test: 7.17.1 Conduct eight (8) hour operational test during dock trials, under load, in the presence of the MSC Port Engineer, Chief Engineer, ABS surveyor and the manufacturer's Representative. Take and record all firing pressures and temperatures. 7.18 Replace the vibration dampers on both #3 and #4 SSDG's. Rubber elements (PN: UBE-46252) and Buffers (PN: UBE-22528) provided as GFM. 7.18.1 Conduct crankshaft alignments check before and after the rubber elements and buffers have been replaced. Notify Port Engineer and Chief Engineer immediately of any alignment discrepancies. Provide two (2) copies of the alignment report. 7.19 Manufacturer's Representative: 7.19.1 Provide by government. 7.20 Preparation of Drawings: none. 8.0 GENERAL REQUIREMENTS: None additional. ? Item Description Part No. Qty. 1. Cylinder head unit exchange N/A 16 2. Gasket Set, Cylinder Head 401701 16 3. O-Ring, Cyl. Head Stud 10171 64 4. Nozzle, Injector 22991 16 5. Big End Bearing Shell 17553 4 6. Piston Ring Set 404837 2 7. Door Gasket Kit 900023 1 8. Gasket, Banjo Fitting 10028 64 9. Gasket, Copper, Erosion Plug 23466 32 10. Lock Wire, 1.25 MM 11553 0.50 11. Shim Kit, Fuel Inj. Pump 405577 2 12. Gasket, Cooling Water Pump 90766 1 13. Element, L.O. Filter 20710 6 14. O-Ring 10220 2 15. Element, Rocker Arm Filter 24538 2 16. O-Ring 24546 2 17. Main Bearing Shell 21299 2 18. Main Bearing Shell, L/P 21298 2 19. O-Ring Set, Fuel Inj. Pump 407087 2
