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FLOW PROCESS CHART OF POWER PACK

POWERPACK FROM

LRS

TG ENGINEBLOCK

ENGINEBLOCK

TRACTIONMACHINE SHOP HEAVY MACHINE SHOP

STRIPPINGSECTION

ENGINEBLOCK ONMANUPULATOR

POWER PACK ASSY.

POWERPACKTESTINGON TESTBED

POWER PACK TO LRS



POWER PACK SHOP (P.P.S.)

In this shop th po! " p#$% is !ho&&' (is)#nt& ( #n( *+i&t, th n s t to

L.R.S. -o" -it) nt on th Lo$o. Wh n th &o$o)oti $o)p& t s /0 &#%hs %)on th t"#$% o" "+n -o" th 12 ' #"s th n it is n $ ss#"' to " *+i&( th

&o$o)oti . A no")#& &i- sp#n o- th &o$o)oti is 34 ' #"s #-t " 4 ' #"s o-

s " i$ o" "+nnin5 2 &#%h %)s #n o "h#+& $#n * 5i n to th n5in . So

#-t " 12 ' #"s o- s " i$ " *+i&(in5 o- th &o$o)oti is " 6+i" (. Th

-+n$tion o- th shop $#n * *"o#(&' $&#ssi-i ( into -o&&o!in5 t'p s 78

Dis)#nt&in5, R $on(itionin5 #n( Ass )*&in5 o- po! " p#$%.

Lo#( t stin5, sp $i-i ( -+ & $ons+)ption t stin5 #n( oth " t'p o-

t stin5.

For this purpose there are many Sections in the Po er Pac! Shop. These are "i#en $e%o &'

• St"ippin5 s $tion

• R $on(itionin5 s $tion

• T+"*o s+p " $h#"5 " s $tion

• V#& & " #ss )*&' s $tion

• F+ & in9 $tion p+)p "oo)

• Go "no" "oo)

• Piston #n( h #( s $tion

• B&o$% Ass )*&' s $tion

• Ass )*&' s $tion



• L+* oi& p+)p s $tion

• S+* #ss )*&' s $tion

• Po! " p#$% t stin5 s $tion

STR PP * SECT O &

Po! " p#$% $o) s -"o) th &o$o st"ippin5 s $tion. St"ippin5 o- po! " p#$%

(on in # s 6+ n$ . Fi"st&' :h#+st pip , !#t ", &+* oi& #" " )o (. Th n

$o "s o- -+ & p+)p ; -+ & p+)p s+ppo"t, $'&in( " h #(, th n -+ & p+)p,

-+ & p+)p s+ppo"t #" " )o (. Cont"o& sh#-t, $'&in( " h #(, t+"*o s+p "

$h#"5 ", t+"*o $h#"5 " s+ppo"t, 5o "no", CC )oto", $#)sh#-t 5 #", $"#n%

sh#-t 5 #", i*"#tion (#)p " ; +pp " $o " #" " )o (. Th n :t nsion

sh#-t, * #"in5 $#ps, $"#n%sh#-t, piston8$onn $tin5 "o( #ss )*&' #" " )o (.

Th n th n5in *&o$% is " )o ( -"o) th s+)p. A&& th s p#"ts #" s n( to

th $on$ "nin5 s $tion. Ch $% is+#&&' #&& th s p#"ts -o" #n' (#)#5 ;

$& #n #&& th s p#"ts. Us#*& p#"ts #" +s ( #5#in ; (#)#5 ( p#"ts #" s n(

to $on(o) s $tion. n5in *&o$% is s n( to H.M.S. -o" " 8)#t$hin5. S+$h

p#"ts &i% $"#n%sh#-t $#)sh#-t, piston, t+"*o $h#"5 ", 5 #" ; -+ & p+)pin9 $to" #&& th s #" " p&#$ !ith n ! p#"ts.

P STO SECT O

In this s $tion pistons #" $h $% ( ; p" p#" ( -o" +s . pistons #" )#( into

t!o p#"ts i. . +pp " ; &o! " p#"t. Upp " p#"t is st & $#p. In th $#s o- #n'

(#)#5 o- th piston )#' s# th oth " p#"t o- th piston i. . &o! " p#"t * $#+s this &o! " p#"t is #si&' $h#n5 (. Piston "in5s #" (i-- " nt t'p s.

Co)p" ssion "in5s, oi& p" ss+" "in5s, #" +s ( to )#int#in th p" ss+" in

th $h#)* " ; $ont"o& & #%#5 .



CA+SHAFT SECT O .

In $#) sh#-t s $tion #" $h $% ( ; p" p#" ( -o" +s . In /4<<hp &o$o # sin5&

pi $ $#)sh#-t is +s ( *+t in 33<<hp &o$o th sti-- " $#)sh#-t is +s (. Sti-- "

$#)sh#-t ) #ns not # sin5& pi $ *+t into s)#&& 2 pi $ s. Th s 2 pi $ s #"

9oin ( to5 th " *' s)#&& n+t *o&ts. It is #s' to -it ; " )o -"o) th n5in

*&o$%. In $#s o- #n' (#)#5 it is #s' to $h#n5 on pi $ th#n th !ho&

sh#-t.

C,L -ER HEA- SECT O

In this s $tion $'&in( " h #(s #" " p#i" ( ; " 8*+i&(. Th o+t " -"#) o- th$'&in( " h #( is s#) *+t inn " p#"ts &i% op "#tin5 #& #" " p&#$ ( !ith

n !. St+(s, sp"in5s, "o$% " #") #" n !. C'&in( " h #( $o " is p#int ( #-t "

$& #nin5.

CO ECT * RO- SECT O

Conn $tion "o( is +s ( to 9oin th piston ; $"#n%sh#-t. Conn $tin5 "o( is)#n+-#$t+" ( in th L.M.S. shop. Th s #" )#5n ti= ( (+"in5

)#n+-#$t+"in5. In this s $tion th s #" ( )#5n ti= ( !ith th )#$hin .

C,L -ER L ER SECT O

C'&in( " &in " #" #&so )#n+-#$t+" ( in D.M.W. ; p" p#" ( to +s in

$'&in( " &in " shop. C'&in( " &in " is -itt ( in th *o" s o- th n5in *&o$%.

E * E LOCK / S0+P SECT O

F"o) H.M.S. th n5in *&o$% $o) s in this s $tion. Th *&o$% is $h $% (

#5#in *' D.P.T. t stin5. A-t " th#t #&& th p#"ts #" -itt ( on th *&o$% ; p+t it

on th s+)p.



CRA KSHAFT SECT O

C"#n%sh#-t is i)po"t#nt -"o) ALCO $o)p#n'. In this s $tion it is $& #n (

!ith (i s & ; $h $% ( *' (' p n t"#tion t st. A-t " th#t it is +s ( in LOCO.

Th $ost o- $"#n%sh#-t is #*o+t /< to /3 &#%hs. In $#s o- #n' (#)#5 it is

not #$$ pt (.

T0R O CHAR*ER SECT O

Th " #" t!o t'p o- t+"*o s+p " $h#"5 ". On is GE t!in pip i. . t!o

o+t& ts #" 5i n to th s'st ). With this $oo&in5 is -- $ti 5oo( ; h #t&oos s #" " (+$ (. S $on( is. Whi$h h#s sin5& o+t& t. Th t+"*o s+p "

$h#"5 "s #" i)po"t ( -"o) oth " $o)p#ni s. Both t'p s o- t+"*o $h#"5 "s

#" +s (.

*O1ER OR SECT O

Go "no" is th $ont"o&&in5 p#"t o- th po! " p#$%. F+n$tion o- th 5o "no" is $ont"o& th sp ( !.".t. $h#n5in5 &o#( ; -+ & s+pp&' to th s'st )

#$$o"(in5 to sp ( o- th LOCO. Th s ttin5 o- th -i"in5 o"( " is #&so

( p n( on th 5o "no". Th " #" t!o t'p s o- th 5o "no"s. On is

) $h#ni$#& ; oth " is & $t"i$#& 5o "no".

F0EL P0+P SECT O

F+ & p+)p is )#in p#"t o- th -+ & s+pp&'. F+ & p+)p $onsist o- (i-- " nt

p#"ts &i% , -+ & in9 $to", no==& , o+t " $#sin5, no==& $#p, "#$%, shi)s t$. #&&

th s p#"ts #" +s to $ont"o& -+ & s+pp&' in th $h#)* ". It p&#'s #n

i)po"t#nt "o& to s+pp&' -+ &.



P PE SECT O

Th " #" (i-- " nt t'p s o- pip s +s ( in po! " p#$%. E:h#+st pip , !#t "

o+t& ts, -+ & pip s, &+*"i$#tin5 oi& pip s, #i" in& ts ; o+t& ts. Li% :h#+st

pip it is )#( in s)#&& (i-- " nt p#"ts ; 9oin ( *' n+ts ; *o&ts. On th

:h#+st pip th " #" &*o!s #" )#( , * $#+s (+"in5 :h#+st th 5#s s

#" "' hot, th :h#+st pip !i&& 5 t :p#n( ( ; si= )#' * $h#n5 (. So

-o" th#t " #son &*o!s #" )#( on th :h#+st pip .

CO TROL SHAFT SECT O

Cont"o& sh#-t is to $ont"o& th -+ & s+pp&' in th s'st ). It is )#( into t!o p#"ts !ith th h &p o- $o+p&in5. It is #s' to " )o -"o) th *&o$% (+"in5 in

th sh ( +n( " s " i$ in #n' $#s o- th (#)#5 . F+n$tion o- th $ont"o&

sh#-t to $ont"o& th s+pp&' in in9 $tion p+)p.

+A ASSE+ L, SECT O

In th )#in #ss )*&' s $tion #&& th p#"ts o- th po! " p#$% #-t " " 8p#i"in5t stin5 o" $h $%in5 th ' #" s n( to th #ss )*&' s $tion. H " #&& th s

p#"ts #" -itt ( #$$o"(in5 to th p"o$ (+" o- -ittin5. F"o) s)#&& p#"ts >n+ts,

*o&ts, !#sh "s, t$? to &#"5 " p#"ts >5o "no", t+"*o $h#"5 " t$.? #&& th s #"

-itt (. A-t " th#t it is s n( to t stin5 s $tion.

TEST * SECT O

A-t " #ss )*&' o- th po! " p#$% it is s n( to th t stin5 s $tion. In this

s $tion th " #" t!o t st * (s. T!o po! " p#$%s #" t st ( si)+&t#n o+s&'.

Th " #" th" :$it ( )oto"s #" $onn $t ( to th #&t "n#to" si( . Th

& $t"i$#& s+pp&' is 5i n to th s :$it "s ; th ' st#"t th #&t "n#to". Fi"st&'



th ' st#"t th po! " p#$% !itho+t &o#( -o" so) ti) on th i(& sp ( i. .

3@< ".).p. A-t " th#t th ' p+t &o#( on th po! " p#$% !ith t!o "o(s (ipp (

into th !#t ". On in$" #sin5 sp ( &o#( !i&& in$" #s *' (ippin5 "o(s in th

!#t " #t )o" ( pth. L #%#5 is $h $% ( ; p "-o")#n$ o- th po! " p#$% is $h $% ( on th i(& sp ( i. . it sh+t (o!n o" not. An' t'p o- & #%#5 ;

h #tin5 o- po! " p#$% is t st (. A-t " $o)p& t insp $t ( it is s n( to th

L.R.S. shop.

- FFERE T S0 ASSE+ L ES ARE AS FOLLOWS &'

F+ & In9 $tion Ass )*&' V#& & " #ss )*&'

Yo% #ss )*&'

Cont"o& sh#-t

L+* oi& p+)p #ss )*&'

E:t nsion sh#-t #ss )*&'

C"#n% sh#-t C"#n%sh#-t i*"#tion (#)p "

C#) sh#-t

C#) sh#-t i*"#tion (#)p "

C"#n% $#s :h#+st "

T"#$tion 5 n "#tion

B"i - ( s$"iption o- s & $t ( )#$hin s +s ( in th !ho& o- th shop7

2) H,-RA0L C +A P0LATOR&

A h'("#+&i$ )#nip+&#to" is inst#&& ( in th shop. M#nip+&#tion o- n5in

*&o$% is (on on it.



3) +. . ELO *ATOR&

A h'("#+&i$ too& is +s ( -o" &on5#tion o- )#in * #"in5 st+(s.

4) WOO- WOR- *O1ER OR TEST * STA -&

A s+it#*& o- 5o "no" t stin5 is * in5 +s (. This -#$i&it' is p#"ti$+&#"&'( si5n (, -o" !oo( !o"( 5o "no"s. O&( 5o "no"s #" " $on(ition ( #n(

" $h $% ( o " th " .

5) F. .P CAL RAT * +ACH E&

This )#$hin is +s ( -o" $#&i*"#tion o- -+ & in9 $tion p+)p. As th -+ &

in9 $tion is on o- th p" $ision #n( i)po"t#n$ th " -o" this #$ti it' is

$#""i ( o+t $#" -+&&' #n( ) ti$+&o+s&'.

6) 7ECTOR TEST * STA -&

In9 $to" is tho"o+5h&' :#)in ( #n( t st ( o " h " . Di-- " nt #sp $ts o-

t stin5 i. . s+pp&', sp"#' p#tt "n, & #%#5 , no==& t$. o- in9 $to" #" t st (

h " .

8) *EAR TEST * +ACH E&

On this )#$hin #"io+s 5 #"s #" t st ( -o" o+t " (i#., pit$h (i#., p"o-i& ,

#(( n(+), ( ( n(+).

9) PROCESS CLEA * PLA T

REASSE+ L, OF THE POWER PACK FRO+ A T O

2. Fitment at the :ree en; o: the cy%in;er $%oc! :rom H.+.S.

#. :t nsion sh#-t #n( $"#n%sh#-t #n( i*"#tion (#)p " *. LOP ; WP.

$. TSC s+ppo"t AC.

(. F" n( oi& s #& !#t " -ipin5

. TSC -ittin5.



-. F+ & -i&t ", p"i)#"' #n( s $on(#"'.

5. L+* oi& p+)p

3. TOP E -#. C'&in( " h #( st+(.

*. C'&in( " h #(

$. Ai" -i&t "

(. E:h#+st pip

. W#t " o+t& t -&#n5

-. V#& & " #ss )*&'

5. W#t " 9+)p "

h. T#pp t -#$in5

4. S -E

#. $#) *+sh

*. C#)sh#-t $#) 5 #" -it TDC t"#ns- ".

$. C#) 5 #" *#$%&#sh

(. FP s+ppo"t #n( &i-t "

. B#&#n$ FP s+ppo"t

-. F+ & - (in5 $#&i*"#tion

5. F+ & in9 $tion p+)p inst#&& (

h. HP t+*in5

i. C#) sh#-t t $ho5 n "#to"

9. Go "no" 5. OTTO+

#. &+* oi& - ( " s'st )

*. -i&t "

$. sh#-t to t st * (



R EF -ESCR PT O OF THE +A

CO+PO E TS 0SE- POWER PACK&

2) P STO &

Piston +s ( is o- positi -&o!, oi& $oo& (, t"+n% t'p )#( o- #&+)in+).

L+*"i$#tin5 oi& is ( &i " ( to th piston $oo&in5 5"oo s -"o) th $"#n%sh#-t

*' ) #ns o- # ho& th"o+5h th $onn $tin5 "o( #n( piston pin. Es$o"ts M#h&

s+pp&i s th pistons. A st & $#p is -itt ( on th piston.

3) P STO P &

Th piston pin h#s # -&o#tin5 -it in th piston #n( "+nnin5 -it in th st & *#$% (, *"on= &in ( $onn $tin5 "o( *+shin5. A "o&& ( s& is inst#&& ( in

th pin *o" to s #& in th $oo&in5 oi&. Sp $i#& sn#p "in5s #" p"o i( ( #t #$h

n( o- th pin to ho&( it in p&#$

5) P STO R *S&

Th "in5s #" !ho&&' " p&#$ (. Th ' )#int#in th $o)p" ssion in th

$'&in( " piston n$&os+" . V#"io+s t'p s o- "in5s #" s6+#" , t#p ", #n(

$on-o")#*& #n( s$#"p ". S6+#" #n( t#p " "in5s #" $#st.

6) CO ECT * RO-

Th $onn $tin5 "o( is # hi5h st" n5th #&&o' st & -o"5in5 !ith th

$on ntion#& "o( $#p. P" ss ( into th piston n( o- th "o( is # st & *#$% (,

*"on= &in (, spi&t piston pin *+shin5. Th $"#n% sh#-t n( o- th "o( is

p"o i( ( !ith +pp " #n( &o! " p" $ision8t'p $o#t ( * #"in5 sh &&s !hi$h

#" h &( in position *' &o$%in5 t#*s. Th &o! " sh && h#s # -+&& 5"oo -o"

&+*"i$#tion th +pp " on h#s # p#"ti#& on . oinin5 *oth n(s o- th "o( is #

("i&& ( p#ss#5 -o" p" ss+" - ( &+*"i$#tion. Th "o( $#p is #&i5n ( to th "o(

*' # sho"t #n( &on5 (o! & #n( is s $+" ( *' -o+" *o&ts #n( n+ts.4

6) C,L -ER L ER&



Th ' -it in th $'&in( " *&o$% !ith # ) t#& to ) t#& -it. E#$h &in " h#s #

$o&&#" on its +pp " n( !hi$h s #ts in th $'&in( " *&o$%. On s #& "in5 in #

5"oo n #" th top o- th &in #n( t!o s #& "in5s in th 5"oo n #" th

*otto) o- th &in " s #& th -its * t! n th &in " #n( $'&in( " *&o$%. M t#&to ) t#& 9oints o- th -&#t t'p -"o) th $o)p" ssion s #& * t! n th &in "

#n( $'&in( " h #(s.

8) HEA-ER< WATER O0TLET A - EL OWS

In(i i(+#& !#t " o+t& t &*o!s #" #tt#$h ( to #$h $'&in( " h #(. Th !#t "

o+t& t h #( " is #tt#$h ( to th !#t " o+t& t *' ) #ns o- U st"#ps. A

5#s% t is +s ( * t! n th h #( " #n( !#t " o+t& t &*o!. A 5#s% t is #&so

+s ( * t! n th !#t " o+t& t &*o! #n( $'&in( " h #(.

9) C,L -ER HEA-

Th $'&in( " h #( is s $+" ( to th $'&in( " *&o$% *' s n st+(s. In(i i(+#&

!#t " 9+)p "s -"o) th $'&in( " *&o$% to #$h $'&in( " h #(, $on(+$t !#t "

-"o) th $'&in( " *&o$% to !#t " $oo&in5 p#ss#5 s in th $'&in( " h #(s. Th

$oo&in5 !#t " (is$h#"5 -"o) #$h h #( is $#""i ( to th !#t " o+t& t h #( "

*' in(i i(+#& &*o! $onn $tions.

Co" ( p#ss#5 s p ")it th #()ission o- s$# n5in5 #i" #n( :p+&sion o-

:h#+st 5#s s.

M t#&8to8) t#& 9oints to th -&#t &#p t'p -o") th 5#s s #& * t! n th

$'&in( " h #(s #n( $'&in( " &in "s #n( p" nt th s$#p o- 5#s s -"o) th

$'&in( "s. No 5#s% t is " 6+i" ( * t! n $'&in( " h #( #n( &in ".E#$h h #( h#s s+it#*& $h#)* "s -"o) t!o #i" in& t #& s, t!o :h#+st

#& s #n( # -+ & in9 $tion no==& .

Th #& & " *"#$% t #ss )*&', $onsistin5 o- # *"#$% t #n( t!o #&

& "s )o+nt ( on # #& & " sh#-t, is #pp&i ( to th top o- th $'&in( "



h #( #&on5 !ith th 6+#&i=in5 'o% s. Th #& ) $h#nis) #ss )*&' #n(

-+ & in9 $tion no==& on top o- th h #( #" n$&os ( *' A&+)in+) $o "

C,L -ER HEA-+O-EL 362 E * ES

CO 1ERS O TO=0SE OF 1AL1E ROTATORS

DLW h#s int"o(+$ ( V#& 8"ot#to"s to i)p"o th n5in p "-o")#n$

#n(, #i" #n( :h#+st #& &i- . Th s V#& 8"ot#to"s #" no! st#n(#"( on

#&& n ! p"o(+$tion n5in s. V#& 8"ot#to"s p"o i( $i"$+)- " nti#&

)o ) nt o-- th #& s, th+s h &pin5 to p" nt th *+i&( +p o- ( posits on

th #& -#$ s #n( s #ts.

>) L0 E O L P0+P&

It is # positi (isp&#$ ) nt h &i$#& 5 #" p+)p. It is )o+nt ( on th -" n(

o- th *#s #n( is ( "i ( *' (i s & n5in $"#n%sh#-t :t nsion 5 #". Th

p+)p (is$h#"5 into :t "n#& pipin5 th"o+5h # -&#n5 on th p+)p $#sin5.

?) F0EL O L LET&

Th -+ & oi& in& t h #( " s+pp&i s to th in9 $tion p+)ps #n( is &o$#t ( in th

$ont"o& sh#-t $o)p#"t) nt o- th $'&in( " *&o$%. F+ & is ("#!n -"o) th

s+pp&' t#n% *' # -+ & *oost " p+)p -i&t " ( #n( (is$h#"5 ( +n( " p" ss+"

th"o+5h # s $on(#"' -i&t " into th h #( " #t -" n(. F"o) th h #( " th

-+ & is (ist"i*+t ( to th in(i i(+#& FIP s. E:$ ss -+ & ("#ins to th s+pp&'t#n%.

2@) F0EL P0+P CO TROL SHAFT A - CROSSO1ER L KA*E



Th -+ & p+)p $ont"o& sh#-t is &o$#t ( in # $o)p#"t) nt :t n(in5 th -+&&

& n5th o- th $'&in( " *&o$%. >T!o #" " 6+i" ( on V t'p n5in s?. It is

)#( +p o- s $tions o- sh#-tin5 on !hi$h #" )o+nt ( sp"in5 & "s, * #"in5

*"#$% ts #n( s $tion $o+p&in5.Lo$#t ( #t th po! " t#% 8o-- n( o- th sh#-t is #n oi& s #&, oi& s #& " t#in "

!ith # sp $i#& n+t #n( 5o "no" &in% >"i5ht si( sh#-t VEE n5in ?.

Lo$#t ( #t th -" n( o- th sh#-t #" sh#-t th"+st $o&&#"s !ith spi"o& pins to

&o$% th $o&&#"s to th sh#-t #n( # $ont"o& sh#-t $o)p#"t) nt $o " *+shin5

#n( 5#s% t * t! n th $o " #n( $'&in( " *&o$%.

Rot#tion o- th sh#-t $ont"o&s th -+ & p+)p "#$% s ttin5s th"o+5h sp"in5

&o#( ( $ont"o&s & "s )o+nt ( on th sh#-t. In(i i(+#& & "s p ")it #n'

-+ & p+)p to * )#n+#&&' $+t o+t !itho+t #-- $tin5 th $ont"o& o- th

5o "no" o " th " )#inin5 -+ & p+)ps. Th ' #&so p ")it th n5in to *

sh+t (o!n !ith on p+)p "#$% st+$% in th op n position.

C"osso " &in%#5 * t! n th "i5ht #n( & -t si( p+)p $ont"o& sh#-t is

" 6+i" ( on V t'p n5in s.

22) 1AL1E LE1ER +ECHA S+ W THO0T 1AL1E ROTATORS

Th #i" in& t #n( :h#+st #& s #" op "#t ( -"o) th $#)sh#-t *' ) #ns o-

th &i-t ", p+sh"o( #n( #& & " #ss )*&i s.

E#$h $'&in( " +nit h#s # &i-t " #ss )*&' !hi$h $onsists o- t!o p+sh"o( &i-t "s

h# in5 # $o))on sh#-t #s # -+&$"+). Th sh#-t is s+ppo"t ( *' # *"#$% t

!hi$h is #tt#$h ( to th $'&in( " *&o$%. Th &i-t "s h# "o&& "s !hi$h #"-o"$ ( to -o&&o! th p"o-i& s o- th $#)s *' th #& #n( 6+#&i=in5 'o%

sp"in5s.

Th p+sh"o( n(s o- th &i-t " #" -itt ( !ith h#"( n ( st & s #ts into !hi$h

th &o! " n(s o- th #& & "s $#""' h#"( n ( st & #(9+stin5 s$" !s



!hi$h, h# in5 # sph "i$#& h #(, "i( in h#"( n ( s #ts -i: ( in th +pp "

n(s o- th p+sh"o(s. Th s s$" !s #" +s ( to #(9+st #& $& #"#n$ . Th

oth " n( o- th #& & " * #"s #5#inst th 6+#&i=in5 'o% s th"o+5h # *#&&

#n( so$% t 9oint. E#$h 'o% op "#t s t!o #i" o" t!o :h#+st #& s, #$h p#i" o- #& s * in5 op "#t ( -"o) # sin5& $#), p+sh"o( #n( #& & ".

Th 6+#&i=in5 'o% s&i( s +p #n( (o!n on # 5+i( "o(. A #& $& #"#n$

#(9+st) nt is p"o i( ( #t on n( o- th 'o% to $o)p ns#t -o" (i-- " n$ s

in #& st ) & n5ths.

P" ss+" &+*"i$#tion is p"o i( ( -o" th #& & " ) $h#nis). In(i i(+#&

&in s $on(+$t th oi& -"o) # $o))on h #( " to th $'&in( " h #(. Th oi&

th n -&o!s th"o+5h ("i&& ( p#ss#5 s in th $'&in( " h #(s #n( #& & "

*"#$% ts to th #& & " sh#-ts #n( *+shin5s. Th sh#-t #n( *"#$% t #"

( si5n ( to % p th &+* oi& p#ss#5 #&i5n (.

D"i&& ( ho& s th"o+5h th #& & " & #( th oi& -"o) th *+shin5 to th

th"+st *#&& 9oint # ("i&& ( p#ss#5 in th *#&&89oint #n( 'o% &+*"i$#t th

'o% 5+i( #n( #& st )s. In th oth " (i" $tion th oi& p#ss s to th *#&&

s #t o- th #(9+stin5 s$" !. A&& :$ ss oi& -o&&o!s (o!n th p+sh"o(s,

&+*"i$#tin5 th p+sh "o( &i-t " "o&& "s #n( $#)sh#-t &o* s.

23) F LTER< PA EL ATH< E * E A R TAKE

Th p#n & *#th -i&t " )#% s +s o- th #(h si #n( is$o+s p"op "ti s o- oi&

to " )o (i"t p#"ti$& s -"o) n5in int#% #i". B' +sin5 th s p"op "ti s, th p#n & *#th -i&t " ) tho( o- $& #nin5 #i" " (+$ s n5in p#"ts ! #" #n(

&+*"i$#tin5 oi& $ont#)in#tion.

It is #&& ! &( ( $onst"+$tion #n( $onsists o- # p#n & !ith #s #tt#$h ( s+)ps

#n( $o " #ss )*&'.



Th t"#$tion 5 n "#to", ("i n *' th (i s & n5in , -+"nish s po! " to th

&o$o)oti t"#$tion )oto"s.

Th 5 n "#to" -#ns #" ('n#)i$#&&' *#&#n$ ( #n( )#' o" )#' not h#

! i5hts ! &( ( in p&#$ . Un( " no $i"$+)st#n$ s sho+&( ! &( ( ! i5hts *" )o (. F#ns th " o- #pp&i$#*& to #n( int "$h#n5 #*& on #&& 5 n "#to"s.

29) AFTERCOOLER

Th n5in is 6+ipp ( !ith #n #-t " $oo& " to $oo& in& t #i" to th n5in

#-t " it is (is$h#"5 ( -"o) th t+"*o s+p "$h#"5 ". Th $oo& " $onsists o- #

t+* *+n(& )o+nt ( in th #i" int#% p#ss#5 o- th t+"*o s+p "$h#"5 "

s+ppo"t. Th top h #( " $ont#ins th in& t #n( o+t& t $oo& " $onn $tions.

Th t+* *+n(& $onsists o- # s "i s o- -in s t+* s. A !#t " $onn $tion #t th

*#s o- th #-t " $oo& " $# it' #ss+" s $o)p& t ("#inin5 o- th t+* s. A t &&8

t#& pip is p"o i( ( to in(i$#t #-t " $oo& " t+* !#t " & #%s

2>) E * E O1ERSPEE- TR P

Th n5in is 6+ipp ( !ith #n #+to)#ti$ o " sp ( stoppin5 ( i$

$onsistin5 o- # sp"in5 &o#( ( ( i$ !hi$h, (+"in5 no")#& op "#tion, is h &(

!ithin th $#""i ". Ho! ", !h n th $ nt"i-+5#& -o"$ is 5" #t no+5h to

o "$o) th sp"in5 -o"$ >#n o " sp ( $on(ition? th p&+n5 " is inst#nt&'

th"o!n o+t!#"(.

In th o+t!#"( position, th p&+n5 " st"i% s # t"ip & &, " & #sin5 th sp"in5

&o#( ( " s t sh#-t. This sh#-t is (i" $t&' $o+p& ( to th -+ & p+)p $ont"o&sh#-t. As th sp"in5 +n!in(s, it $#+s s "ot#tion o- th -+ & p+)p $ont"o& sh#-t

!hi$h )o s th -+ & p+)p "#$%s to sh+t8o-- position. An o " t"# &

) $h#nis) o-- th 5o "no" n( #&&o!s th o " sp ( ( i$ to " t+"n th

"#$%s to O-- n th"o+5h th 5o "no" )#' " )#in #t -+&& -+ &.



A$$ sso"i s s+$h #s th i*"#tion (#)p " o" -&'!h & )#' * #tt#$h (

* t! n th $#""i " #ss )*&' #n( $#)sh#-t to h &p &i)in#t $#)sh#-t

i*"#tions.

In so) #pp&i$#tions # )i$"o s!it$h is )o+nt ( on # p&#t #tt#$h ( to tho " sp ( t"ip+pp " ho+sin5. This s!it$h is op "#t ( *' # $#) #tt#$h ( to

th " s t sh#-t #n( 5i s ith " #n #+(i*& o" # is+#& in(i$#tion th#t o "

sp ( h#s t"ipp (.

To " s t, p+&& th " s t h#n(& +nti& it &#t$h s. This " !in(s th to"sion sp"in5

#n( " s ts th t"ip & ".

To t"ip )#n+#&&', p+&& th ) "5 n$' sh+t(o!n h#n(& in th (i" $tion o- th

#""o! sho!n on th &o! " ho+sin5 $o ".

2?) E * E ASE

Th n5in *#s is # ! &( ( st & st"+$t+" !hi$h p"o i( s th -o&&o!in57 #

)o+ntin5 s+"-#$ -o" th $'&in( " *&o$%, &+*"i$#tin5 oi& p+)p, !#t " p+)p

#n( -o+" n5in )o+ntin5 p#(s7 in #((ition it #$ts #s # &+*"i$#tin5 oi&

" s " oi".

S$" ns #" -itt ( #$"oss th *#s #t #$h $'&in( " &o$#tion.

Op nin5s on #$h si( o- th *#s 5i #$$ ss to th $onn $tin5 "o(

* #"in5s, $"#n%sh#-t #n( )#in * #"in5s p"o i( s ) #ns -o" insp $tin5 oi&

&in s, piston s%i"ts #n( $'&in( " &in "s. R )o #*& (oo"s n$&os th s

op nin5s. A&so :p&osion (oo"s #" )o+nt ( on th "i5ht #n( & -t si( o- th

*#s #t th po! " t#% 8o-- n(.L+*"i$#tin5 oi& is $#""i ( in th *#s * &o! th *#s s$" ns. A &+*"i$#tin5 oi&

("#in p&+5, *#'on t 5#+5 !ith hi5h #n( &o! & & )#"%in5s #n( # -i&& " pip

#" &o$#t ( in th *#s .

A $"#n%$#s :h#+st " is +s ( to nt th *#s .



3@) CRA KCASE E PLOS O -OOR

In th nt o- # $"#n%$#s :p&osion, # sp"in5 &o#( ( $o " p&#t on th

:p&osion (oo" !i&& *&o! o+t " &i in5 th p" ss+" . With th p" ss+"" (+$ ( th p&#t !i&& sn#p sh+t.

32) S0PPORT< T0R OS0PERCHAR*ER

Th t+"*o s+p "$h#"5 " s+ppo"t o- ! &( ( st & $onst"+$tion n$&os s th

-" n( o- th $'&in( " *&o$% #n( *#s #n( p"o i( s # )o+ntin5 s+"-#$ -o"

th t+"*o s+p "$h#"5 ", #-t " $oo& " #n( oi& $#t$h ".

33) +A EAR * A - CAPS

Th )#in * #"in5s -o" $"#n%sh#-t $onsist o- t!o st &8*#$% (, p" $ision

-itt ( sh &&s !ith ! && *on( ( &inin5s. Th +pp " on -its into # s#((& on th

$'&in( " *&o$% th &o! ", into # -o"5 ( st & * #"in5 $#p. No Shi)s #" +s (.

Th n+)* " o- )#in * #"in5s -o" th 4, 1/ #n( 14 $'&in( " n5in s #" , ,

1< " sp $ti &'. C"#n% n( th"+st is " st"i$t ( ith " *' th +s o- th"+st

$o&& "s inst#&& ( in #$h si( o- th $ nt" )#in * #"in5 s#((& o" *' #n

+pp " th"+st * #"in5 sh && #t th $"#n%sh#-t 9o+"n#& n #" st th po! " t#% 8o--

n( >#&& &o$o)oti n5in s?. In st#tion "' o" )#"in #pp&i$#tions, th"+st

* #"in5 sh && #" +s ( in *oth +pp " #n( &o! " positions.

34.CRA KSHAFT SPL T *EAR

Th $"#n%sh#-t 5 #" -o" th /@1 t'p n5in is )o+nt ( #t th po! " t#% 8o--

n( o- th sh#-t #n( ) sh s !ith $#)sh#-t 5 #"s. It is )#( in t!o h#& s o-

h#"( n ( st & #n( is #$$+"#t &' -itt ( #n( % ' ( to th sh#-t. Th 5 #" is



h &( in p&#$ *' -o+" *o&t #n( h#s &o$#tin5 (o! &s to position th h#& s #s

th ' #" #ss )*& (. D p n(in5 on th st'& +s (, th 5 #" is ith " # 08pit$h

st"#i5ht sp+", o" # 48pit$h h &i$#& t'p .

NOTE: Split gears are statically balanced and the halves are not

interchangeable. They must be replaced in matched pairs.

35) CRA KSHAFT

Th $"#n% sh#-t -o" th 1/ #n( 14 $'&in( " V t'p n5in s is )#( o- on

pi $ o- -o"5 ( st & #&&o', !ith its )#in * #"in5 9o+"n#&s #n( $"#n%pins

)#$hin ( to # hi5h ( 5" o- s)oothn ss. Th sh#-t is s&+n5 +n( " th

$'&in( " *&o$% #n( "ot#t s on th )#in * #"in5s >sh &&s?. It is s+ppo"t ( *'

* #"in5s $#ps th#t #" )o+nt ( to s#((& s in th *&o$% !ith st+( *o&ts #n(

n+ts. Th sh#-t s )#in * #"in5s #n( $"#n%pins #" 9oin ( *' # s "i s o-

$"#n%sh#-t ! *s, to !hi$h $o+nt "*#&#n$ s #" ! &( ( #t int ")itt nt

&o$#tions -o" *#&#n$in5 p+"pos s. T!o "o(s >"i5ht #n( & -t *#n% o- th s#)

$'&in( " n+)* "? #" )o+nt ( si( *' si( on #$h o- th sh#-t s $"#n%pins.

Th sh#-t is ( si5n ( so th#t "' t!o s')) t"i$#&&' opposit pins h# th

s#) "#(i#& th"o! position.

A $"#n%sh#-t 5 #", !hi$h ("i s th & -t #n( "i5ht $#)sh#-t 5 #"s, is #pp&i (

to th po! " t#% 8o-- n( o- th sh#-t. Th -" n( o- th sh#-t p"o i( s th

("i -o" th n5in s $oo&in5 !#t " #n( &+*"i$#tin5 oi& p+)ps.

Th $"#n%sh#-t -o")s #n int 5"#& p#"t o- th n5in s &+*"i$#tin5 s'st ). A$ontin+o+s -&o! o- oi& p#ss s +n( " p" ss+" -"o) th )#in &+*"i$#tin5

h #( " in th n5in s *#s to th * #"in5 $#ps #n( * #"in5s th"o+5h ("i&& (

p#ss#5 s in th sh#-t to th $"#n%pins #n( on th $onn $tin5 "o( * #"in5s.



L+*"i$#tion, o- th *+shin5s is p"o i( ( th"o+5h oi& p#ss#5 s in th n(s o-

th $#)sh#-ts. P#ss#5 s in th * #"in5 ho+sin5s p ")it oi& to ("#in to th

n5in *#s .

39) CRA KSHAFT -R 1E ASSE+ L,'FREE E -Th :t nsion sh#-t #ss )*&' is &o$#t ( #t -" n( o- th n5in $"#n%sh#-t

#n( is +s ( -o" #n #+:i&i#"' po! " t#% 8o--. Its )#9o" $o)pon nts $onsist o-

#n :t nsion sh#-t, #n oi& s #&, # ("i 5 #" #n( # i*"#tion (#)p ".

A. E TE S O SHAFT

Th " #" t!o st'& s o- :t nsion sh#-t. St'& is 1 h#s oi& p#ss n5 " ("i&& ( in

it to s+pp&' oi& to th i*"#tion (#)p " !h " #s st'& / (o s not. Both st'& s

$#n * sho"t n in & n5th, ( p n(in5 +pon th i" po! " t#% 8o-- #pp&i$#tion.

Ho! ", on $ "t#in n5in #pp&i$#tions, th :t nsion sh#-t is not " 6+i" (.

In th s $#s s, th ("i 5 #" #n( i*"#tion (#)p " #" )o+n( ( !ith

th"o+5h $#p s$" !s on $"#n%sh#-t #n( # sp#$ " > o" #(#pt " ? is s+*stit+t (

-o" :t nsion sh#-t. A $o " p&#t is #pp&i ( #t th n(.

. O L SEAL

Th oi& s #& po"tion o- th #ss )*&' $onsists o- # s&in5 " >5"oo s #n(

p #%s?, )#$hin ( into th :t nsion sh#-t, #n( #n oi& $#t$h ", !hi$h -its

$&os &' #"o+n( th sh#-t to $o&& $t th oi& -&o!in5 o+t o- th -" n( o- th

n5in #n( " t+"n it to th $"#n%$#s . In th st'& 1 #ss )*&', th s #& is +s (

to s+pp&' oi& to th i*"#tion (#)p ". Th $"#n%sh#-t oi& ho& is p&+55 ( #n( p" ss+"i= ( oi& -&o!s -"o) #n in& t oi& ho& in th $#t$h ", th"o+5h # -&o#tin5

*+shin5, into oi& p#ss#5 s in th :t nsion sh#-t, #n( into th $'&in( " in th

$ nt" o- th i*"#tion (#)p ". In st'& /, s #& 9+st p "-o")s #n oi& $#t$hin5

-+n$tion.



th spi( "? #" $o " ( !ith oi& !hi$h is $ontin+o+s&' -&o!in5 th"o+5h th

$& #"#n$ #n( s$#pin5 to th $"#n%$#s .

3>) C,L -ER LOCK Th $'&in( " *&o$%, $onst"+$t ( -"o) st & ! &() nts, ho+s s #n( s+ppo"ts

th )#9o" $o)pon nts o- th n5in 7 $"#n%sh#-t #n( )#in * #"in5s,

$#)sh#-t, p+sh"o(s #n( &i-t "s, $onn $tin5 "o(s #n( pistons, $'&in( " &in "s,

$'&in( " h #(s, $"#n%$#s :h#+st ", -+ & p+)p $"ossh #(s #n( & "s #n(

5o "no". It #&so p"o i( s )o+ntin5 s+"-#$ s -o" th t+"*o s+p "$h#"5 "

s+ppo"t, :h#+st )#ni-o&(, #i" int#% &*o!s, !#t " &*o!s, #n( 5 n "#to".

A " p&#$ ) nt &in " s& is -itt ( into th &o! " &in " *o" o- th $'&in( "

*&o$%. It p"o i( s # ! #" s+"-#$ -o" th &o! " -it o- th &in ". On s#& #5 (

*&o$%s, # " p&#$ #*& +pp " &in " s& , !ith #n O "in5 >th s#) t'p

+s ( in th +pp " po"tion o- th $'&in( " &in " its &-?, is #&so -itt ( into th " 8

*o" s +pp " &in " *o" .

Th $"#n%sh#-t )#in &o#(in5 s#((& s, $#)sh#-t * #"in5 s+ppo"ts, #n( th #i"

int#% )#ni-o&( #" int 5"#& p#"ts o- th *&o$%.

Coo&in5 !#t ", $i"$+&#t ( *' th !#t " p+)p, -&o!s th"o+5h th oi& $oo& ",

into # p#ss#5 in th $'&in( " *&o$%. Th " , it $i"$+&#t s #"o+n( th $'&in( "

&in "s. W#t " -"o) th *&o$% is $on(+$t ( to th $'&in( " h #(s *' !#t "

9+)p ".

3?) *O1ER OR -R 1ETh " #" t!o )o( &s o- 5o "no" ("i s +s (. On 5o "no" is s+ppo"t ( *'

th * #"in5 ho+sin5, !hi& th oth " is s+ppo"t ( *' # s p#"#t * #"in5

$#sin5 th#t -its into th * #"in5 ho+sin5. Both )o( &s #" )o+nt ( on th

n5in *&o$% o " th $#)sh#-t 5 #". Th 5o "no" is ("i n *' $#)sh#-t



45) F0EL 7ECT O P0+P

MICO -+ & in9 $tion p+)ps o- sin5& #$tin5, $onst#nt st"o% #n( p&+n5 "

t'p !ith th -- $ti !o"%in5 st"o% , ho! ", * in5 #(9+st#*& . Th p+)p

$onsist o- # ho+sin5, ( &i "' #& #n( sp"in5s, ( &i "' #& ho&( ",& ) nt >p&+n5 " #n( *#"" & #ss )*&'?, p&+n5 " sp"in5, # 5 #" ( $ont"o&

s& #n( $ont"o& "#$% >"o(? #ss )*&'. Th *#"" & #n( # p&+n5 ", !hi$h #"

)#t$h #ss )*& ( to # "' $&os to& "#n$ .

Th -+ & in9 $tion p+)p h#s th" -+n$tions7

• To "#is th -+ & oi& p" ss+" to # #& !hi$h !i&& --i$i nt&' #to)is

th -+ &.• To s+pp&' th $o"" $t 6+#ntit' o- -+ & to th in9 $tion no==&

$o)) ns+"#t !ith th po! " #n( sp ( " 6+i" ) nt o- th n5in .

• To #$$+"#t &' ti) th ( &i "' o- th -+ & -o" --i$i nt #n(

$ono)i$#& op "#tion o- n5in

F+ & oi& nt "s p+)p -"o) oi& h #( " #n( th s+)p s+""o+n(in5 th p&+n5 "

*#"" &. Wh n th p&+n5 " is #t th *otto) o- its st"o% >position 1?, -+ & -&o!s

th"o+5h th *#"" & po"ts, -i&&in5 th sp#$ #*o th p&+n5 " #n( $+t #!#'

#" # o- th h &i:.

As th p&+n5 " )o s +p!#"(, -+ & is p+)p ( *#$% into s+)p +nti& *#"" &

po"ts #" $&os (. F+"th " +p!#"( )o ) nt o- p&+n5 " >position /? "#is s th

p" ss+" o- th t"#pp ( -+ &. Wh n p" ss+" is s+--i$i nt to o " $o) th

-o"$ : "t ( on ( &i "' #& *' #& sp"in5s, ( &i "' #& op ns #n(

-+ & is (is$h#"5 ( into hi5h p" ss+" pip , & #(in5 to in9 $to". F+"th " +p!#"(

)o ) nt o- th p&+n5 " in$" #s s -+ & p" ss+" to n#*& th in9 $tion to

o$$+". D &i "' o- -+ & $ #s s !h n p&+n5 " h &i: op ns th *#"" & po"ts

>position 3?. D+"in5 th " )#inin5 )o ) nt o- th p&+n5 ", -+ & spi&&s into



Th ( &i "' #& #&so #$ts #s # $h % #& to p" nt $o)*+stion 5#s s

-"o) *&o!in5 *#$% into p+)p, i- no==& #& is st+$% in op n position. Th

) t " ( 6+#ntit' o- -+ & -"o) in9 $tion p+)p p#ss s th"o+5h sn+** " #&

#n( hi5h8p" ss+" &in , nt "in5 th no==& ho&( " #t th p" ss+" t+* in& t$onn $tion. D"i&& ( p#ss#5 in th no==& ho&( " $on(+$t -+ & to p" ss+"

$h#)* " #(9#$ nt to th (i-- " nt s $tion o- #& .

Wh n th p" ss+" o- -+ & #$tion on th (i-- " nt s $tion :$ (s th sp"in5

p" ss+" , th no==& #& is -o"$ ( -"o) its s #t. F+ & -&o!s th"o+5h th

no==& sp"#' ho& s +nti& -+ & p+)p $ #s s to ( &i " -+ &. F+ & -&o! is th n

inst#nt#n o+s&' #n( positi &' $+t o--, #s th sp"in5 sn#ps th #& sh+t.

46) S 0 ER 1AL1E

A sn+** " #& #ss )*&' is -itt ( on th -+ & in9 $tion p+)p #t th top o-

th ( &i "' #& ho&( " +sin5 # t+*in5 +nion s& #n( n+t.

It is *#si$#&&' # $h % #& !hi$h " st"i$ts -+ & -&o! in th " s " (i" $tion

th"o+5h # s)#&& o"i-i$ . Its -+n$tion is to (#)p n sho$% !# s t"# &in5

th"o+5h th hi5h p" ss+" &in " s+&tin5 -"o) s+(( n $&os+" o- th ( &i "'

#& #n( th no==& #& .

46) OBBLE HOL-ER

Th -+ & in9 $tion no==& ho&( " $on(+$ts -+ & -"o) p+)p, sn+** " #&

#n( hi5h p" ss+" (is$h#"5 t+*in5 to -+ & in9 $tion no==& #n( p"o i( s #

) #ns o- #(9+stin5 th no==& #& op nin5 p" ss+" . Th no==& #to)i= sth -+ & #n( (i" $ts it, in # ( -init sp"#' p#tt "n into th n5in $o)*+stion

$h#)* ". Th )#9o" $o)pon nts o- th ho&( " *o(', p" ss+" #(9+stin5

sp"in5, shi)s >$o)p ns#tin5 !#sh "s?, 5+i( *+sh, int ") (i#t (is$ #n(

no==& $#p n+t.



4>) 1AL1E< ,'PASS A - REL EF

FILTER BY8PASS VALVE78

Pip ( #"o+n( th &+* oi& -i&t " is # *'8p#ss #& , s t -o" /< psi -o" WDM / ;

3< psi -o" YDM 0 (i-- " nti#& p" ss+" #$"oss th -i&t ". on p+"pos o- this#& is to -+"nish # ( -init #)o+nt o- oi& to th #t #&& ti) s. I- th -i&t "

sho+&( * $o) $&o55 (, this #& !i&& op "#t to *'8p#ss #&& th oi& #"o+n(

th -i&t ".

RELIEF VALVES

T!o " &i - #& s #" +s ( in th &+* oi& s'st ) >" - " to &+* oi& s'st )

s$h )#ti$ -o" +s ?. Th t'p o- #& +s ( is sho!n.

On is &o$#t ( in th oi& p+)p (is$h#"5 &in #n( is s t to " &i #t 1<@811<

PSI -o" WDM/ ; 1/@813< PSI o- YDM0. Th s $on( is &o$#t ( on th

(is$h#"5 si( o- th $oo& " #n( is s t -o" /< psi (i-- " nti#& p" ss+" #$"oss

th -i&t "s.

4?) REL EF A - RE*0LAT * 1AL1E

Th p+"pos o- p" ss+" " &i - #n( p" ss+" " 5+&#tin5 #& s is to p"ot $t

#"io+s $o)pon nts #n( " 5+&#t oi& p" ss+" !ithin th &+*"i$#tin5 oi&

s'st ).

On )#n' +nits, th p" ss+" " &i - #& #n( th p" ss+" " 5+&#tin5 #& s

#" th s#) t'p o- th #& *+t !ith (i-- " nt *o(i s #n( o" p" ss+"

t stin5.

OPERATION

Th inn " #& is #n in "t ( $+p !hi$h s&i( s o " # st#tion#"' piston.Li-tin5 o- inn " #& is oppos ( *' # &on5 sp"in5 !hi$h is ( si5n ( to 5i

# $onst#nt " 5+&#tin5 o " -+&& $#p#$it' "#n5 #s possi*& . In& t p" ss+" is

t"#ns)itt ( to th +n( "si( o- th $+p (is$ th"o+5h # s)#&& ho& in th

$ nt " o- th piston.



!#t " is -&o!in5. B#--& s #" p"o i( ( insi( th sh && to $h#nn & th oi& -&o!

in th )ost --i$i nt )#nn ".

53) S,STE+< L0 R CAT * O L'*E ERAL -ATAA&& &o$o)oti !ith th )o( & /@1(i s & n5in h# # s "io+s s'st ) !ith

-i&t " *'8p#ss p"ot $tion.

Th s'st ) $onsists o- -o&&o!in57 $i"$+&#tin5 p+)p, " 5+&#tin5 #& s, -i&t "

#ss )*&', h #t :$h#n5 " >$oo& "?, st"#in " #n( #sso$i#t ( pipin5.

Th &+*"i$#tin5 oi& p+)p, )o+nt ( on th -" n( o- th n5in , ("#!s th

&+*"i$#tin5 oi& -"o) th n5in s+)p #n( (is$h#"5 s it into th s'st ). A

" &i - #& #t th (is$h#"5 si( o- th p+)p p"ot $ts th p+)p -"o) hi5h

p" ss+" #n( $ont"o&s th (is$h#"5 p" ss+" #t 1<@811< psi *'8p#ssin5 #

po"tion o- th oi& *#$% to th s+)p. Th " )in( " o- th oi& -&o!s th"o+5h

th -i&t ", !hi$h is 6+ipp ( !ith # (i-- " nti#& p" ss+" *'8p#ss #& to

ho&( # " &#ti &' $onst#nt p" ss+" #$"oss th -i&t ". F"o) th -i&t " th oi&

-&o!s on th"o+5h th $oo& ", o" h #t :$h#n5 " n :t, th"o+5h th &+*"i$#tin5

oi& st"#in " #n( th n into th )#in &+*"i$#tin5 oi& h #( " o- th n5in to

p"o i( p" ss+" &+*"i$#tion to th * #"in5 s+"-#$ s. A p" ss+" " 5+&#tin5

#& , &o$#t ( #t th $oo& " (is$h#"5 #n( s t #t @@84< psi, " 5+&#t s th oi&

-&o! th"o+5h th $oo& " #n( th &+* oi& p" ss+" in th s'st ).

L+*"i$#tin5 oi& is ( &i " ( to th )#in &+*"i$#tin5 oi& h #( " in th n5in #t

p" ss+" "#n5in5 -"o) 0< psi to 4< psi. th ( &i "' p" ss+" is # -+n$tion o-

th &+* oi& t )p "#t+" , n5in "p) #n( s ttin5 o- th " 5+&#tin5 #& s.Th no")#& op "#tin5 p" ss+" #t -+&& n5in o+t p+t !i&& * #pp"o:i)#t &'

@@84< psi. Th &+* oi& is (ist"i*+t ( -"o) th )#in h #( " to th )#in

h #"in5s. T!o *"#n$h &in s & #(in5 -"o) th )#in h #( " s+pp&' &+*"i$#tin5

oi& to th t+"*o s+p "$h#"5 " #n( $#)sh#-t * #"in5s. T!o s $on(#"' h #( "s



P"i)#"' #n( s $on(#"' -i&t "s *#si$#&&' o- s#) $onst"+$tion :$ pt in si=

#n( -ittin5 #n( -i&t "in5 & ) nt.

Th p"i)#"' -i&t " is &o$#t ( * t! n -+ & oi& t#n% #n( s+$tion si( o-

*oost " p+)p. Th s $on(#"' -i&t " is &o$#t ( * t! n n5in #n( (is$h#"5 ssi( o- *oost " p+)p.

Wh n th " is 5"#(+#& ("op in -+ & oi& p" ss+" , $h $% *oth p"i)#"' #n(

s $on(#"' -i&t "s. R p&#$ th & ) nt in th -+ & -i&t ".

56) *O1ER OR O L

S " o p"i) @

Di s & n5in $"#n%$#s in #" #s !ith s+&-+" in -+ & +pto <.@ .

S " o PR 0<2. C'&in( " piston, s " o 5 )8 3 >#$$o"(in5 to IOC

sp $i-i$#tion?

58) F0EL O L S,STE+&

F+ & +s ( is hi5h sp ( (i s & o- IS104<81 0 sp $i-i$#tion. C t#n n+)* "

is 6+#& to 0/. Tot#& s+&ph+" p "$ nt#5 *' )#ss )#:i)+) is 6+#& to 1 .

Lo! #t)osph "i$ p" ss+" #n( n5in s op "#tin5 #t hi5h #&tit+( s )#'

" 6+i" th +s o- -+ &s !ith hi5h " C t#n n+)* "

A&& &o$o)oti +nits h# in(i i(+#& -+ & oi& s'st ). E#$h &o$o)oti h#s #

-+ & s+pp&' t#n% &o$#t ( * n #th th +n( " -"#) * t! n th t"+$%s.

A -+ & oi& *oost " p+)p ("#!s -+ & -"o) th t#n% #n( th n (ist"i*+t s it

th"o+5ho+t th s'st ).

Th s+$tion si( is * t! n th t#n% #n( th *oost " p+)p. A&& oi& ("#!n

-"o) th t#n% )+st p#ss th"o+5h p"i)#"' -i&t " +s (.



Th p" ss+" si( is * t! n th *oost " p+)p #n( th p" ss+" " 5+&#tin5

#& . As th oi& -&o!s th"o+5h th s'st ), it -i"st p#ss s *' # p" ss+" " &i -

#& s t -o" @ psi, th p+"pos o- !hi$h is to p"ot $t th *oost " p+)p,

)oto" #n( s'st ) -"o) o "&o#(. Oi& th n p#ss s th"o+5h th p"i)#"' #n(s $on(#"' -i&t "s into th "i5ht *#n% -+ & h #( " !hi$h - ( th -+ & in9 $tion

p+)ps on th "i5ht si( o- th n5in . F+ & $"oss s o " #t th 5 n "#to" n(

into th & -t *#n% h #( " !hi$h - ( th & -t *#$% -+ & in9 $tion p+)ps. Th

3@ psi p" ss+" " 5+&#tin5 #& , &o$#t ( #t th (is$h#"5 n( o- th & -t *#n%

h #( ", $ont"o&s th -+ & oi& p" ss+" in *oth h #( "s. N #" this #& is th

&in $onn $tin5 to th -+ & oi& p" ss+" 5#+5 .

59) *A0*E< L 0 - LE1EL D*LOW'RO-

Th &i6+i( & " G&o8Ro( 5#+5 +s s th p"in$ip& o- pipin5 &i5ht

>s+pp&i ( *' -&#sh&i5ht? th"o+5h th "ti$#& op nin5 in th *o(' o- th 5#+5

in !hi$h th &i6+i( is s n, *' ) #ns o- # t"#ns&+$ nt p&#sti$ "o(. At th

&o! " n( o- th 5#+5 is # $i"$+&#" $on$# it', o" T#"5 t , th"o+5h !hi$h

th &o! " n( o- th p&#sti$ "o( is * nt -o"!#"( to " $ i -&#sh&i5ht

i&&+)in#tion !h n n $ ss#"'.

P&#$in5 # -&#sh&i5ht #5#inst this t#"5 t t"#ns)its &i5ht +p!#"(, th"o+5h th

"o( #n( &i6+i(, to #pp #" #s (ots * &o! th s+"-#$ o- th &i6+i( *+t #s

ho"i=ont#& *#"s #*o th s+"-#$ o- th &i6+i(. Th+s th +s+#& &i5ht &oss s

(+ to " -& $tion *' th 5#+5 !in(o! #" &i)in#t (, #n( " #(in5s #" "#pi(

#n( #$$+"#t .

5>) SW TCH< LOW WATER LE1EL

In #((ition to # hot n5in #&#") s!it$h # &o! !#t " & & s!it$h )#' *

+s (. Th -&o#t s!it$h is )o+nt ( in th :p#nsion t#n% #n( !h n th !#t "



("ops to # p" ( t ")in ( & &, th #&#") !i&& so+n( #n( th n5in !i&& sh+t

(o!n.

H # ' (+t' s'&phon * &&o!s &i)in#t s #&& p#$%in5. D si5n ( #s # *#&#n$ (,

$ nt" 8pi ot ( +nti&, th #$tion o- th -&o#t is t"#ns)itt ( th"o+5h %ni- 8 (5st#in& ss st & * #"in5s.

5?) RA- ATORS

R#(i#to"s p#n &s #" "ti$#&&' )o+nt ( on #$h si( o- th " #" o- th

&o$o)oti s. E#$h o- th s p#n &s $onsists o- t!o o" )o" $o" s. Th $o" s

#" *o&t ( to5 th " th"o+5h -&#n5 s #t th n(s. No -i&& " pi $ s o" $ nt"

t#n%s #" +s ( on th t!o $o" "#(i#to"s.

6@) S,STE+< COOL *WATER *E ERAL -ATA

Th n5in in #$h &o$o)oti +nit h#s #n in(i i(+#& $oo&in5 !#t " s'st ).

In !hi$h th !#t " is $i"$+&#t ( *' # $ nt"i-+5#& p+)p, 5 #" ("i n -"o) th

$"#n%sh#-t. W#t " -&o!s -"o) th p+)p -"o) h #( "s into th "i5ht #n( & -t8

*#n%s o- th n5in *&o$% !h " th !#t " $i"$+&#t s #"o+n( th $'&in( "

&in "s. W#t " #&so -&o!s -"o) th p+)p to th t+"*o s+p " $h#"5 " #n( th

#-t " $oo& ".

Coo&in5 !#t " -"o) th n5in *&o$% "is s into th $'&in( "s h #(s #n( -&o!s

o+t th"o+5h "is "s !hi$h #" $onn $t ( to t!o !#t " o+t& ts h #( "s "+nnin5

#&on5 th top o- th n5in . W#t " th n -&o!s to th "#(i#to"s, #n( :p#nsion

t#n%. Coo& ( !#t " -"o) th "#(i#to"s -&o!s th"o+5h th oi& $oo& " #n(-in#&&' " t+"ns to th !#t " p+)p. Th $oo&in5 s'st ) is # $&os ( on !ith

th :p#nsion t#n% nt ( to #t)osph " th"o+5h #n o "-&o! pip . To "i(

th s'st ) o- #i" #n( 5#s s on #&& &o$o)oti s +nits nt pip s #" $onn $t (



to #i" $o&& $tin5 (o) s #n( & #( to th :p#nsion t#n%. Th "#(i#to"s #&so

nt (.

Th !#t " t )p "#t+" into th n5in is )#int#in ( * t! n 10@ < 81@@< F *'

s!it$h $ont"o&&in5 >E((' $+"" nt $&+t$h?.Th n5in is p"ot $t ( #5#inst hi5h !#t " t )p "#t+" *' # s!it$h !hi$h

so+n(s #n #&#") #n( on so) &o$o)oti s " t+"ns th n5in to i(& !h n

th !#t " o+t& t t )p "#t+" " #$h s 12@ <F.

62) *O1ER OR&

Go "no" +s ( #" GE E& $t"o8M $h#ni$#& o" Woo(!#"( ) $h#ni$#&

5o "no". Th " #" t!o $oi&s, sp ( $oi& ; st#*i&i=in5. Th st#*i&i=in5 $oi&

h#s 0 @ )A $onst#nt $+"" nt s+pp&i ( to it. Sp ( $oi& 5 ts its - (in5

$+"" nt -"o) T $hno 5 n "#to". D p n(in5 +pon th in$" #s o" ( $" #s in

th sp ( th piston )o s +p o" (o!n +n( " th #"'in5 )#5n ti$ -- $t o-

$oi&. Th #& s'st ) )o s th s&# piston +p o" (o!n. This is -+"th "

) shin5 !ith piston !hi$h is -+"th " $onn $t ( to # & " o- th $ont"o&

sh#-t. Th+s th $ont"o& sh#-t $ont"o& th FIP "#$% #n( h n$ th -+ & in& t.

63 T0R O S0PER CHAR*ER

Th $h#"5 " is # s &-8$ont#in ( +nit, $o)pos ( o- # 5#s t+"*in #n( #

$ nt"i-+5#& *&o! " )o+nt ( on # $o))on sh#-t !ith th n $ ss#"'

s+""o+n(in5 $#sin5. Th :h#+st 5#s -"o) th $'&in( "s o- th (i s & n5in

is $on ' ( th"o+5h th :h#+st )#ni-o&( to th t+"*in , !hi$h +ti&i= (so) o- th &o$it' n "5' in th :h#+st 5#s, oth "!is !#st (. This

n "5' in th 5#s is +s ( to ("i th *&o! ", !hi$h -+"nish s #&& th #i"

" 6+i" ( *' th n5in , th"o+5h th #i" int#% )#ni-o&( #t # p" ss+" #*o

#t)osph "i$.



Th t+"*o$h#"5 " +nit is +s ( in $on9+n$tion !ith # )+&tip& pip o" # sin5&

pip :h#+st )#ni-o&(. In this s'st ) th $o)p" ss ( #i" ( &i " *' th

t+"*o$h#"5 " #$$o)p&ish s t!o n(s7 -i"st, it s$# n5 s th hot " si(+#&

5#s s oth "!is & -t in th $'&in( " #t th n( o- th :h#+st st"o% , #n(" p&#$ !ith $oo& " -" sh #i" s $on(, it -i&&s th $'&in( " !ith #n #i" $h#"5 "

o- hi5h " ( nsit' (+"in5 th s+$tion st"o% . Th p"o ision o- # 5" #t "

#)o+nt o- -+ & #n( $ons 6+ nt&' # hi5h " o+tp+t -"o) # t+"*o$h#"5 " n5in

th#n -"o) on not so 6+ipp (.

Th #& ti)in5 o- #n n5in #""#n5 ( -o" p" ss+" $h#"5in5 (i-- "s

p"i)#"i&' -"o) th#t o- th s#) n5in no")#&&' #spi" ( in th#t th :h#+st

#& o- th p" ss+" $h#"5 ( n5in $&os &#t " #n( th in& t #& s op n

#"&i ". Th+s, th #& o "&#p o" p "io( !h n *oth #& #" op n

si)+&t#n o+s&' is $onsi( "#*&' 5" #t ", p ")ittin5 -- $ti s$# n5in5 o-

th $'&in( ". Ti)in5 o- th #& s #n( (i) nsions o- th :h#+st )#ni-o&(

#" ( t ")in ( so th#t ti) ( p" ss+" -&+$t+#tions #" p"op#5#t ( in th

:h#+st )#ni-o&(. Both #& s #" op n !h n th -&+$t+#tin5 p" ss+" in th

:h#+st )#ni-o&( is #t # )ini)+), th+s p ")ittin5 s$# n5in5 !ith &o! "

*&o! " p" ss+" th#n !o+&( oth "!is * possi*& .

S$# n5in5 th $o)*+stion sp#$ !ith $oo& #i" -- $ts # $onsi( "#*& ( 5"

o- $oo&in5 o- th $'&in( " h #(s, $'&in( " !#&&s, #& #n( pistons. Fo" this

" #son, # 5" #t " #)o+nt o- -+ & $#n * *+"n ( #n( 5" #t " po! " ( &op *'

# t+"*o$h#"5 ( n5in !itho+t h#")-+& -- $ts to th n5in p#"ts (+ to

:$ ssi h #t. No $ont"o& o " th t+"*o$h#"5 " is n $ ss#"' #s th $o"" &#t ( #$tion o- th

t+"*in #n( *&o! " is nti" &' #+to)#ti$. Th sp ( #n( o+tp+t o- th

t+"*o$h#"5 " #"' #+to)#ti$#&&' #n( "#pi(&' !ith #"i#tions in n5in &o#(

#n( o" sp (.



-ETA LS OF CO STR0CT O OF T0R OCHAR*ER&

It $onsists o- # sin5& st#5 t+"*in !h & #n( # sin5& st#5 $ nt"i-+5#&

*&o! " i)p && " on # $o))on sh#-t !ith n $ ss#"' s+""o+n(in5 $#stin5s.Th t+"*o$h#"5 " "oto" is nti" &' in( p n( nt o- "ot#tin5 n5in p#"ts.

En5in :h#+st 5#s s #" $on(+$t ( to th 5#s in& t $#sin5 *' th :h#+st

)#ni-o&(. Th t+"*in no==& "in5 is #tt#$h ( to th $ nt " o- th 5#s in& t

$#sin5 th ins o- th no==& "in5 (i" $tin5 th :h#+st 5#s s to th "oto"

(is% *&#( s #t th p"op " #n5& .