TB 11-6115-741-24
checked for proper dimensional tolerances. Journals may be ground if scored or out of dimension.
Upon acceptance, each journal and/or lobe shall be micro-polished. Ra surface finish on journals
shall be within OEM specifications. Crankshaft and camshaft shall also be demagnetized as
required.
4.2.7 Turbocharger shall be remanufactured and tested in accordance with the OEM Technical
Manual.
4.2.8 Cooling System. Thermostat and fan belts shall be replaced. The water pump shall be
remanufactured in accordance with OEM Technical Manual or replaced.
4.2.9 Fuel System. Replace or remanufacture and test fuel injectors and fuel injection pump.
4.2.10 Lubrication System. Filters, gaskets, seals, O-rings, and fluids shall be replaced. Oil pressure
regulating and bypass valves shall be inspected and replaced as required. The oil pump shall be
remanufactured in accordance with OEM Technical Manual or replaced.
4.2.11 Air Intake and Exhaust System. Exhaust clamps, gaskets, seals, filters, and check valve shall be
replaced. Heater devices and glow plugs shall be tested and replaced as required.
4.2.12 Electrical System. The starter and battery-charging alternator shall be replaced or remanufactured
and tested to OEM specifications/requirements. During remanufacture, replace all brushes and bearings.
Replace diodes and other internal components as required.
4.2.13 Repainting. Engine shall be repainted after remanufacture original OEM color or as otherwise
specified. Do not paint OEM nameplate, fuel line hoses, water connections, electrical terminals, pulley
grooves, belts, glow plugs, exhaust manifold, heaters, electronic sensors and switches, and flywheel
mating surfaces. All openings shall be sealed or capped during repainting.
4.2.14 Engine Dynamometer Testing. Testing of completed engines will be in accordance with the OEM
Technical Manual and shall be as follows. Test reports shall be completed by engine serial number and
provided with each engine. For engines rebuilt, engine manufacturer's break in oil shall be used as
applicable. A tag shall be secured to the engine and to the S1, engine start switch, stating that the engine
contains break in oil and specifying when the first oil change should be performed based on the generator
set hour meter reading.
CAUTION
If engine will idle longer then 5 minutes, stop the engine.
a)
Break-In: Start engine and run at loads and speeds shown in the following chart for
the time limits given.
b)
850 rpm at no load for 2 minute.
c)
Fast idle at no load for 3 minutes.
d)
Rated speed at load for 60 minutes.
e)
Rated speed at load for 40 minutes.
f)
Rated speed at full load for 15 minutes.
g) Run engine 2 minutes at 1500 rpm with no load before shutdown.
h) Retorque the head and reset the valves as specified by the applicable Technical Manual.
4-2