M.I.

1730
Rev. D

MAINTENANCE INSTRUCTION

INDUSTRIAL, DRILL RIG, AND MARINE POWER EQUIPMENT STORAGE

Changes in Revision D are indicated by the box D in the margin of the affected text.

 Copyright 2008 Electro-Motive Diesel, Inc. All rights reserved. Neither this document, nor any part thereof, may be reprinted without the express written consent of Electro-Motive Diesel, Inc. Contact EMD Service Publications Office.

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TABLE OF CONTENTS
1.0 2.0 GENERAL..................................................................................................... 4 MATERIAL LIST ........................................................................................... 6

3.0 PREPARATION FOR STORAGE ................................................................. 7 3.1 ENGINE COOLING SYSTEM............................................................................. 7 3.2 AIR STARTING MOTOR .................................................................................... 7 3.3 ENGINE FUEL SYSTEM..................................................................................... 7 3.4 ENGINE GOVERNOR ......................................................................................... 7 3.5 MARINE REDUCTION AND REVERSE GEAR BOX...................................... 8 3.6 DRILL RIG GEAR BOX....................................................................................... 8 3.7 ENGINE LUBE OIL SYSTEM............................................................................. 8 4.0 STORAGE .................................................................................................... 9 4.1 ENGINE COOLING SYSTEM............................................................................. 9 4.2 ENGINE FUEL SYSTEM..................................................................................... 9 4.3 ENGINE LUBE OIL SYSTEM............................................................................. 9 4.4 ENGINE GOVERNOR ....................................................................................... 10 4.5 ENGINE............................................................................................................... 10 4.6 AIR STARTING MOTOR .................................................................................. 10 4.7 ELECTRIC STARTING MOTOR ...................................................................... 10 4.8 LOAD REGULATOR ......................................................................................... 11 4.9 DRILL RIG GEAR BOX..................................................................................... 11 4.10 MAIN GENERATOR OR ALTERNATOR ....................................................... 11 4.11 EXCITERS .......................................................................................................... 12 4.12 DRIVE MOTORS................................................................................................ 12 4.13 DRIVE MOTOR BLOWERS.............................................................................. 12 4.14 BATTERIES ........................................................................................................ 13 4.15 ELECTRICAL CABINETS................................................................................. 13 4.16 ELECTRICAL EQUIPMENT LOCATED OUTSIDE OF ELECTRICAL CABINETS .......................................................................................................... 13 4.17 MISCELLANEOUS ............................................................................................ 13 5.0 INSPECTION .............................................................................................. 14 6.0 PREPARATION FOR EXPORT SHIPMENT .............................................. 14

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1.0 GENERAL
Storage and shipment preparation of power equipment and its associated components are divided into four main categories as follows: 1. Preparation for storage. 2. Storage. 3. Inspection. 4. Preparation for export shipment. Storage requirements are predicated on the availability of inside storage facilities, with heating equipment capable of maintaining temperature above the dew point. If adequate storage facilities are not available, construction of a simply structured housing with heating and dehumidification facilities to protect the equipment from the elements will provide ample protection foe extended periods. Regardless of the storage interval involved, inspection of the equipment by EMD authorized personnel will be required when the equipment is placed in service before warranty provisions become effective for subsequent service. A copy of this procedure should be placed in a conspicuous place with the stored equipment so that anyone deprocessing a unit will be alerted to remove all materials used in processing. Original packing material should be removed upon receipt of shipment so that equipment can be inspected for shipping damage. Bags and boxes used for shipment purposes are not intended for, nor do they provide, adequate protection for outside storage even for relatively short periods. It is advisable to perform any maintenance necessary on equipment that has been in service before storage preparations are made. Carbonaceous deposits often form in the oil pan and the top deck of engines that have been in service and when such engines are stored, the rust preventatives used tend to loosen such deposits. These deposits may peel away and clog important oil passages when the engine is again placed in service. To prevent this, the areas involved should be sprayed with diesel fuel oil to break up the deposits and then the oil system should be carefully flushed to remove this material. Follow the flushing instructions given in M.I. 1757. The material recommended for storage will not cause deterioration of seals or other equipment and the equipment can be put back into service without washing out protective fluids, provided the engine is pre-lubed and the turbocharger auxiliary lube oil pump (when the engine is so equipped) is actuated and allowed to pump oil to the turbocharger bearings for its full timed period before barring over the engine or a starting attempt is made.

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Use Vapor Corrosion Inhibitor (VCI) paper to enclose where instructed, applying in a manner as recommended by the VCI manufacturer. The technology that applies the VCI chemical to the paper will do so one side, meaning one side of the paper is more loaded with VCI. Performance as a corrosion inhibitor is therefore dependant on proper orientation relative to the subject area under protection. Typically the side without printing is the more VCI active surface, but the manufacturer of the specific VCI product should be consulted for proper VCI paper application. Some designations for packaging and preservative materials are abbreviated in the text, but are more fully described in the materials list that follows. A vendors name is provided for certain materials, and a military standard materials or their equivalent can be obtained from any protective packaging material company.

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2.0 MATERIAL LIST

Product Nalco 41RR Vendor or Specification Nalco Co. Naperville, Illinois www.Nalco.com Daubert-Cromwell Corporation, Alsip, Illinois www.daubertcromwell.com

VCI impregnated foam and emitters

Tectyl 823 EM

Daubert Chemical Company, Chicago, Illinois www.daubert.com CAUTION: Use only Tectyl 823 bearing the EM suffix letters.

VCI paper (Vapor Corrosion Inhibitor) MIL-P-3420 Class 3, Style A, form b (Daubert-Cromwell VW 35H fills this requirement.) Diesel Fuel Oil Lubrication Oil EMD Maintenance Instruction 1750 EMD Maintenance Instruction 1752 (MI 1761 for Export) EMD Maintenance Instruction 1764 AAR Specification 914-66 MIL-B-131

Governor Oil Air Brake Cylinder Grease Barrier Material Water-vapor proof, Flexible Barrier Material Greaseproof, Waterproof Flexible VCI polyethylene Corrosion Preventive Coating Grade 4, (P-19) Tectyl 846, Dabuert Chemical Co. Tape, Waterproof, Pressure Sensitive Petroleum Jelly

MIL-B-121

VCI 2000, Northbrook, Illinois MIL-C-16173

PPP-T-60 b M Tartan

NOTE: The referenced MIL specification material is for a guide only. Equivalent material may be used if meets the MIL spec standard. M.I. 1730 Rev D Page 6 of 15 2/10/2009

3.0 PREPARATION FOR STORAGE

To adequately circulate preservative fluids to all internal engine parts and components of the cooling system, it is necessary to run the engine at idle speed for a short interval. It is suggested that the preliminary preparations listed be followed in order to process them simultaneously during a single short run of the engine.

3.1

ENGINE COOLING SYSTEM

1. Drain cooling system.

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2. Prepare an engine coolant solution using Nalco 41RR and cold water. The concentration should be 1.2 to 1.8 fluid ounces of Nalco 41RR per gallon of cold water. The solution can be adequately mixed by first putting the preservative in the expansion tank and then filling the system. (See Maintenance Instruction 1748 for basic coolant guidelines.) 3. Fill system completely so that entire system, including the expansion tank, will be preserved.

3.2

AIR STARTING MOTOR

1. Drain any condensate present in the air strainer. 2. Pour some Tectyl 823EM into air intake of motor.

3.3

ENGINE FUEL SYSTEM

1. If a good grade of fuel has been used as recommended in Maintenance Instruction 1750, it will provide the necessary protection for the injectors, fuel pump, and other system components. 2. If fuel grade is not considered satisfactory, drain tank and add a sufficient quantity of high quality fuel for use during the short engine run period. 3. If engine can not be run, prime fuel system with high quality fuel.

3.4

ENGINE GOVERNOR

1. If the governor has been operating with turbine type oil recommended in Maintenance Instruction 1764, the oil will provide adequate rust and oxidation prevention properties. 2. If governor oil is not considered satisfactory, drain and fill to normal operating level with Tectyl 823EM.

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3.5

MARINE REDUCTION AND REVERSE GEAR BOX

Refer to manufacturers recommendations for equipment storage.

3.6

DRILL RIG GEAR BOX

1. Drain lubricating oil. 2. Charge lube system with Tectyl 823EM 3. If engine can not be run, drain lubricating oil and spray gears and inside of gear box with Tectyl 823EM.

3.7

ENGINE LUBE OIL SYSTEM

1. Drain lube oil system, including filter element and housings and engine strainer housing. It is not necessary to replace filter element with new elements. 2. Charge the lubricating oil system with Tectyl 823EM as would normally be done at lube oil change. Make certain that the strainer housing is full and that the turbocharger filter and auxiliary filter housings are filled with preservative oil. NOTE: If engine cannot be operated, charge the system with preservative oil Tectyl 823EM by first pumping oil into the piston cooling oil pump discharge elbow until that system is purged. Then pump the oil into the main lube oil pump discharge elbow until the entire pressure system us purged as evidenced by full flow of preservative oil from the accessory end camshaft bearings. After oil shows at these bearings, open cylinder test valves and bar the engine over one full turn with the purging pump still operating. On turbocharged engines, the small check valve in the turbo filter housing should be removed prior to purging the pressure system. After purging, the check valve should be replaced and the turbo soak-back filters and housings drained. CAUTION: Under no circumstances should a turbocharged engine be started or run unless connected to a generator, reduction gear box, or equipped with the proper flywheel. The low inertia of a bare engine can allow the engine to accelerate at such a rapid rate that the turbocharger can be damaged. 3. Start the engine and run at idle speed for approximately 15 minutes without load to properly circulate the protective fluids throughout the engine lube oil system. The engine should remain relatively cool during the circulating run. 4. Stop the diesel engine.

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4.0 STORAGE
The following storage procedures are applicable to both long and short term storage. If equipment is to be stored for a period of six months to two years, perform all the steps of the procedure, but if the storage period is for less than six months, disregard any procedural steps which are marked with an asterisk (*). In case where the storage period will exceed two years, all procedures contained in PREPARATION FOR STORAGE and STORAGE must be repeated at two year intervals.

4.1

ENGINE COOLING SYSTEM

Drain the engine cooling system. After draining is completed, ensure that drain, supply, return, and vent valves are left open, or sealing material covering openings is punctured to allow continued drainage of the system. CAUTION: Do not reuse the Nalco 41RR solution to charge another cooling system.

4.2

ENGINE FUEL SYSTEM

1. Drain the fuel tank and piping. Remove filter caps and spray Tectyl 823EM into the tank. 2. Replace filter caps and plug fuel tank vents. 3. Purge fuel system with Tectyl 823EM. 4. When Tectyl flows from the fuel return line at the engine mounted fuel filters, bar the engine over one complete revolution. 5. Allow fuel lines to drain. 6. Remove filter elements. Drain and clean filter housings. Spray filter housing with Tectyl 823EM, and replace filter elements, filter housing, and covers.

4.3

ENGINE LUBE OIL SYSTEM

1. Drain the Tectyl 823EM from the lube oil system, including filter elements and housings and the strainer housing. NOTE: If the preservative oil is to be used on more than one engine, it must be filtered or strained before reuse. 2. Disconnect and drain oil pressure line to governor, if applicable. 3. If the lube oil cooler is equipped with a vent, wrap the vent with VPI-B and secure with pressure sensitive tape. M.I. 1730 Rev D Page 9 of 15 2/10/2009

4.4

ENGINE GOVERNOR

1. Drain oil or Tectyl 823EM from governor.

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2. Wrap the entire governor with MIL-B-131 barrier material. Make certain the governor is completely covered and the wrap as air tight as possible. Seal with pressure sensitive tape.

4.5

ENGINE

1. Spray each airbox with Tectyl 823EM. 2. Spray each cylinder liner bore with a mist of Tectyl 823EM as the ports of each liner are uncovered by barring the engine over. 3. Close airbox covers and check seals for proper position. Check that cylinder test valves are closed. 4. Remove oil pan covers and spray lower end of cylinder liners with mist of Tectyl 823EM. Replace covers. 5. Coat all parts under the engine top deck covers with a stream or spray of Tectyl 823EM. 6. Fasten the top deck covers securely and tape all edges with pressure sensitive tape. Apply plywood exhaust stack covers and seal withMIL-B-131 barrier material and pressure sensitive tape. 7. Cover entire air intake filter units with MIL-B-131 barrier material and secure with pressure sensitive tape. On units shipped without filters, cover blower intakes with plywood covers securely bolted in place and sealed around the edges with pressure sensitive tape. On turbocharged engines, completely cover the air intake with MILB-131 barrier material secured with pressure sensitive tape. 8. Coat all external unpainted machined surfaces such as the coupling, cylinder test valves, and injector control shaft linkage bearings with MIL-C-16173, Grade 4 or equivalent.

4.6

AIR STARTING MOTOR

Coat Bendix pinion and lead screw with Tectyl 823EM.

4.7

ELECTRIC STARTING MOTOR

Coat pinion gear with Tectyl 823EM.

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4.8

LOAD REGULATOR

1. Drain oil from vane motor and governor oil connection piping. 2. On commutator type load regulators, remove cover, place MIL-B-121 between brushes and commutator and replace cover. Wrap entire unit with MIL-B-131 barrier material and seal with pressure sensitive tape. 2. On face plate type load regulators, cover entire unit with MIL-B-131 barrier material and seal with pressure sensitive tape.

4.9

DRILL RIG GEAR BOX

1. Drain Tectyl 823EM from box. 2. Seal all gear box openings with pressure sensitive tape.

4.10 MAIN GENERATOR OR ALTERNATOR

1. Coat all unpainted external steel surfaces with MIL-C-16173, Grade 4 or equivalent. 2. Raise brushes and place a sheet of MIL-B-121 barrier material between brushes and commutator or slip rings.
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3. Place 1 VCI foam pad inside the generator door with tape. The foam pad is removed before generator operation. 4. Wrap shaft between generator and generator coupling with VCI paper and secure with pressure sensitive tape. The paper is removed before generator operation 5. Enclose entire coupling end of the generator, using MIL-B-131 barrier material and seal with pressure sensitive tape. 6. On DC generators with the lower brush holder area open, wrap the entire brush holder end of the generator with MIL-B-131 barrier material and seal with pressure sensitive tape. 7. On generator with an airbox and blowers, cover each blower intake ith MIL-B-131 barrier material and seal with pressure sensitive tape. Seal airbox access panels with pressure sensitive tape.

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4.11 EXCITERS
1. Raise brushes and place a sheet of MIL-B-121 barrier material between brushes and commutator or slip rings.
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2. Place one VCI foam pad under inspection covers, one on each side. 3. Cover both ends of exciter with MIL-B-131 barrier material and seal with pressure sensitive tape. 4. Coat all unpainted external steel surfaces with MIL-C-16173, Grade 4 or equivalent. 5. Wrap VCI paper around shaft between exciter and engine and seal with pressure sensitive tape.

4.12 DRIVE MOTORS

1. Coat all unpainted steel surfaces with MIL-C-16173, Grade 4 or equivalent. 2. Cover the air inlet with MIL-B-131 barrier material and secure with pressure sensitive tape. 3. Cover air outlets with MIL-B-131 barrier material and secure with pressure sensitive tape.
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4. Suspend 1 VCI foam pad inside the commutator with tape and inspection cover and secure to the cover so as to hang clear of the commutator. 5. Raise the brushes and place a sheet of MIL-B-121 barrier material between the brushes and the commutator. 6. Replace covers and seal with pressure sensitive tape. 7. Wrap entire drive end of motor with VCI paper and seal with pressure sensitive tape. 8. Seal drain holes on commutator end with pressure sensitive tape.

4.13 DRIVE MOTOR BLOWERS

1. Place VCI paper over intake of blower and seal with pressure sensitive tape. 2. Cover outlet opening with plywood and seal with pressure sensitive tape. 3. Wrap plug connectors with MIL-B-131 barrier material and seal with pressure sensitive tape.

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4.14 BATTERIES
1. Disconnect and insulate battery leads at the battery. Secure the ends. 2. Grease all terminals with petroleum jelly. 3. Batteries should be fully charged, and should be checked and charged at inspection intervals.

4.15 ELECTRICAL CABINETS

1. Remove and package all fuses in MIL-B-131 barrier material and seal with pressure sensitive tape. 2. Open all switches and circuit breakers. 3. Protect all exposed contact tips with a thin film of petroleum jelly. 4. Wrap resistors with MIL-B-131 barrier material and seal with pressure sensitive tape.
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5. Attach VCI emitters inside at various points inside the electrical cabinet, and seal all openings with pressure sensitive tape. Seal openings where cables come through from the outside with pressure sensitive tape.

4.16 ELECTRICAL EQUIPMENT ELECTRICAL CABINETS

LOCATED

OUTSIDE

OF

1. Protect contact tips with a light coat of petroleum jelly. Wrap with MIL-B-131 barrier material and seal with pressure sensitive tape. 2. Wrap switches and resistors with MIL-B-131 barrier material and seal with pressure sensitive tape.

4.17 MISCELLANEOUS
1. Spray couplings with Tectyl 823EM, wrap with VCI paper, and seal with pressure sensitive tape. 2. Cover all gauge glasses with MIL-B-131 barrier material and seal with pressure sensitive tape. 3. Plug all air piping. 4. Cover air starting motor exhaust openings with VPI-B and secure with pressure sensitive tape.

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5.0 INSPECTION
The following inspection procedures must be performed on stored equipment at 6 months intervals. 1. Inspect engine top deck, air box, and oil pan for initial signs of corrosion. Usually a spray of Tectyl 823EM is all that is necessary to terminate progressive corrosion before it reaches serious proportions. CAUTION: Do not bar engine over during this inspection. 2. Inspect VCI material and replace if material color so indicates. 3. Check fluid level and charge batteries. 4. Replace all sealing materials disturbed during this inspection. Do not reuse original material.

6.0 PREPARATION FOR EXPORT SHIPMENT

1. Perform procedures described in PREPARATION FOR STORAGE. 2. Perform procedures for long term storage as described in STORAGE. 3. It is recommended than any further packing for physical and environmental; protection of equipment be performed by an experienced and reputable export packaging firm.

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(DE-L) Electro-Motive Diesel, Inc La Grange, Illinois 60525 USA Telephone: 708-387-6000 Website: www.emdiesels.com 2008 Electro-Motive Diesel, Inc. All rights reserved. Neither this document, nor any part thereof, may be reprinted without the express written consent of Electro-Motive Diesel, Inc.. Contact EMD Customer Publications Office.

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