TM-5-2010-205-14 Propelling Unit Outboard NSN <a href="http://boatpropulsion.tpub.com/26/01-251-2227.htm">2010-01-251-2227</a> Manual

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TM-5-2010-205-14

OPERATOR, UNIT DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
WARNING
TABLE OF CONTENTS
TABLE OF CONTENTS-cont.
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL-cont.
HOW TO USE THIS MANUAL-cont.
Propelling Unit, Outboard
CHAPTER 1 INTRODUCTION
WARRANTY
Section II. EQUIPMENT DESCRIPTION AND DATA
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued.
Table 1-1. Equipment Data
Table 1-1. Equipment Data-cont.
SAFETY, CARE, AND HANDLING
Section III. PRINCIPLES OF OPERATION
TURBOCHARGER
AIR INLET AND EXHAUST SYSTEM
COOLING SYSTEM
CONTROL PANEL AND CONTROLS
CHAPTER 2 OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS-cont.
Figure 2-2. Hydraulic Oil Level Gauge.
Figure 2-3. Engine Oil Level Dipstick.
Figure 2-6. Expansion Tank.
SECTION II. OPERATOR/CREW PREVENTIVE MAINTENANCE CHECKS AND SERVICES
PMCS Columnar Entries
Table 2-1. Operator/Crew Preventive Maintenance Check and Services
Table 2-1. Operator/Crew Preventive Maintenance Check and Services
Table 2-1. Operator/Crew Preventive Maintenance Check and Services
Table 2-1. Operator/Crew Preventive Maintenance Check and Services
Table 2-1. Operator/Crew Preventive Maintenance Check and Services
Section III. OPERATION UNDER USUAL CONDITIONS
RUNNING
Section IV. OPERATION UNDER UNUSUAL CONDITIONS
CHAPTER 3 OPERATOR MAINTENANCE
Section II. TROUBLESHOOTING PROCEDURES
Table 3-1. Operator Troubleshooting - Continued
Table 3-1. Operator Troubleshooting - Continued
CHAPTER 4 UNIT MAINTENANCE
Section II. SERVICE UPON RECEIPT
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Leakage Definitions for Unit PMCS
Table 4-1. Unit Preventive Maintenance Checks and Services Semiannual Schedule
Table 4-1. Unit Preventive Maintenance Checks and Services Semiannual Schedule-cont.
Section IV. UNIT TROUBLESHOOTING PROCEDURE
ENGINE
ENGINE-cont.
Above Normal Coolant Temperature
Excessive Crankcase Pressure
Low Oil Pressure
Section V. UNIT MAINTENANCE PROCEDURES
Figure 4-1. Propelling Unit
REPAIR ENGINE ASSEMBLY
Figure 4-2. Engine Assembly
REPLACE COOLER ASSEMBLY (OIL)
REPLACEMENT
OIL PUMP ASSEMBLY
Figure 4-4. Turbocharger Assembly
Figure 4-5. Manifold Assembly
REPAIR/REPLACE EXPANSION TANK ASSEMBLY
Figure 4-6. Expansion Tank Assembly
REPLACEMENT
REPLACE FUEL PRIME PUMP ASSEMBLY
Figure 4-7. Fuel Prime Pump Assembly
Figure 4-8. Oil Pan Assembly
REPLACE OIL LEVEL GAUGE ASSEMBLY
Figure 4-9. Oil Level Gauge Assembly.
Figure 4-10. Governor Control Assembly
Figure 4-11. Flywheel Housing Assembly
REPLACE FUEL FILTER ASSEMBLY
Figure 4-12. Fuel Filter Assembly
REPLACE SEAWATER EXCHANGER ASSEMBLY
REPLACE WATER LINES
Figure 4-13. Water Lines
PAIR/REPLACE CONNECTION ASSEMBLY
Figure 4-14. Connection Assembly
REPAIR/REPLACE AUXILIARY LINES
Figure 4-15. Auxiliary Lines
Figure 4-16. Governor Pump Assembly
REPLACE FUEL INJECTION LINES ASSEMBLY
Figure 4-17. Fuel Injection Lines Assembly
REPLACEMENT
REPLACE MECHANICAL COVER ASSEMBLY
Figure 4-18. Mechanical Cover Assembly.
REPLACE AIR LINES ASSEMBLY
Figure 4-19. Air Lines Assembly
REPAIR/REPLACE OIL FILTER ASSEMBLY
Figure 4-20. Oil Filter Assembly
REPAIR/REPLACE PCV LINES ASSEMBLY
REPLACEMENT
Figure 4-21. PCV lines Assembly
Figure 4-22. PCV Lines Assembly
Figure 4-22. Lifting Assembly
REPAIR/REPLACE TURBOCHARGER LINES ASSEMBLY
Figure 4-23. Turbocharger Lines Assembly
REPLACE ENGINE OIL LINES ASSEMBLY
Figure 4-24. Engine Oil Lines Assembly
Figure 4-25. Fastener Assembly
Figure 4-26. Cylinder Head Assembly
Figure 4-27. Valve Mechanism Assembly
REPLACE MANIFOLD ASSEMBLY
REPLACEMENT
Figure 4-28. Manifold Assembly
REPAIR/REPLACE WATER PUMP ASSEMBLY
Figure 4-29. Water Pump Assembly
Figure 4-30. Water Pump Assembly
REPLACEMENT
ENGINE SUPPORT ASSEMBLY
Figure 4-31. Engine Support Assembly.
REPLACE PULLEY AND DAMPER ASSEMBLY
Figure 4-32. Pulley and Damper Assembly
REPLACE STARTER MOTOR ASSEMBLY
Figure 4-33. Starter Motor Assembly
REPLACE WIRING ASSEMBLY
Figure 4-34. Wiring Assembly
REPLACE ALTERNATOR ASSEMBLY
Figure 4-35. Alternator Assembly
REPLACE AUXILIARY PUMP ASSEMBLY
Figure 4-36. Auxiliary Pump Assembly
REPLACE GUARD ASSEMBLY
Figure 4-37. Guard Assembly
REPIACE AIR INTAKE FILTER ASSEMBLY
Figure 4-38. Air Intake Filter Assembly
REPLACE MUFFLER AND PIPE ASSEMBLY
Figure 4-39. Muffler and Pipe Assembly
REPLACEMENT
HYDRAULIC PUMP ASSEMBLY
Figure 4-40. Hydraulic Pump Assembly
Figure 4-41. Control Panel Assembly
REPLACE HEAT EXCHANGER ASSEMBLY (HYDRAULIC OIL)
Figure 4-42. Heat Exchanger Assembly
REPLACEMENT
Figure 4-43. Electrical Wiring Assembly
REPLACE HYDRAULIC HOSE AND VALVE ASSEMBLY
Figure 4-44. Hydraulic Hose and Valve Assembly
REPAIR/REPLACE HYDRAULIC RESERVOIR ASSEMBLY
Figure 4-45. Hydraulic Reservoir Assembly
REPLACEMENT
REPAIR/REPLACE SEAWATER COOLING ASSEMBLY
Figure 4-46. Seawater Cooling Assembly
REPLACEMENT
Figure 4-47. Seawater Cooling Assembly
REMOVE/REPLACE
REMOVE/REPLACE-cont.
REMOVE/REPLACE-cont.
REPLACE BATTERY ASSEMBLY
igure 4-48. Battery Assembly
REPLACEMENT
REPAIR/REPLACE SQUIRREL CAGE FAN ASSEMBLY
Figure 4-49. Squirrel Cage Fan Assembly
REPLACE HAND DRIVEN PUMP ASSEMBLY
Figure 4-60. Hand Driven Pump Assembly
Figure 4-61. Outdrive Housing Assembly
REPLACE STEERING MOTOR ASSEMBLY
Figure 4-62. Steering Motor Assembly
REPAIR/REPLACE DIRECTION INDICATOR ASSEMBLY
Figure 4-63. Direction Indicator Assembly
REPLACEMENT
Figure 4-64. Lower Unit Assembly
Figure 4-15. Lift Cylinder Assembly
REPLACE ELECTRICAL ASSEMBLY
Figure 4-66. Connecting Electrical Assembly
REPLACE CONNECTING HYDRAULIC HOSE ASSEMBLY
REPLACEMENT
Figure 4-67. Connecting Hydraulic Hose Assembly
Section VI. PREPARATION FOR STORAGE OR SHIPMENT
GENERAL
Inspection
CHAPTER 5 DIRECT SUPPORT MAINTENANCE
Section II. DIRECT SUPPORT MAINTENANCE PROCEDURES
Figure 5-1. Propelling Unit
REPAIR/REPLACE FRAMEWORK ASSEMBLY
REPLACEMENT
Figure 5-2. Framework Assembly
REPAIR/REPLACE ENGINE ASSEMBLY
REPLACEMENT
Figure 5-3. Engine and Framework Assembly
REPAIR COOLER ASSEMBLY
Figure 5-4. Cooler Assembly
REPAIR OIL PUMP ASSEMBLY
Figure 5-5. Oil Pump Assembly
REPAIR
REPAIR/REPLACE TURBOCHARGER ASSEMBLY
REPLACEMENT
FIGURE 5-6. Turbocharger Assembly
REPAIR/REPLACE MANIFOLD ASSEMBLY
Figure 5-7 (1 of 2) Manifold Assembly
REPLACEMENT
Figure 5-7 (2 of 2). Manifold Assembly
EXPANSION TANK ASSEMBLY
Figure 5-8. Expansion Tank Assembly
REPAIR/REPLACE OIL PAN ASSEMBLY
Figure 5-9. Oil Pan Assembly
Figure 5-10. Governor Control Assembly
REPLACE FLYWHEEL HOUSING ASSEMBLY
Figure 5-11. Flywheel Housing Assembly
REPAIR SEAWATER EXCHANGER ASSEMBLY
REPLACE GOVERNOR PUMP ASSEMBLY
Figure 5-12. Governor Pump Assembly
REPLACEMENT
REPLACE FLYWHEEL ASSEMBLY
Figure 5-13. Flywheel Assembly
Figure 5-14. Front Housing Assembly
Figure 5-15. Fastener Assembly
REPAIR/REPLACE CYLINDER HEAD ASSEMBLY
REPLACEMENT
Figure 5-16 (1 of 2). Cylinder Head Assembly
Figure 5-16 (2 of 2). Cylinder Head Assembly
Figure 5-17. Head Bolt Locations
REPAIR/REPLACE VALVE MECHANISM ASSEMBLY
Figure 5-18. Valve Mechanism Assembly.
REPLACEMENT
ADJUST
REPLACE ENGINE SUPPORT ASSEMBLY
Figure 5-19. Engine Support Assembly.
CYLINDER BLOCK ASSEMBLY
Figure 5-20. Cylinder Block Assembly.
REPAIR STARTER MOTOR ASSEMBLY
Figure 5-21. Starter Motor Assembly
REPAIR
REPAIR/REPLACE HYDRAULIC PUMP ASSEMBLY
REPLACEMENT
Figure 5-22. Hydraulic Pump Assembly
REPAIR CONTROL PANEL ASSEMBLY
Materials/Parts Required
REPAIR
REPAIR-cont.
Figure 5-23. Control Panel Assembly
REPAIR HEAT EXCHANGER ASSEMBLY (HYDRAULIC OIL)
Figure 5-24. Heat Exchanger Assembly
REPAIR/REPLACE ELECTRICAL WIRING ASSEMBLY
Figure 5-25. Electrical Wiring Assembly
REPAIR/REPLACE HYDRAULIC HOSE AND VALVE ASSEMBLY
MATERIAL/PARTS REQUIRED
REPLACEMENT
Figure 5-26. Hydraulic Hose and Valve Assembly
REPAIR/REPLACE UPPER OUTDRIVE HOUSING ASSEMBLY
REPLACEMENT
Figure 5-27 (1 of 3). Upper Outdrive Housing Assembly
REPLACEMENT
Figure 5-27. (2 of 3). Upper Outdrive Housing Assembly
Figure 5-27 (3 of 3). Upper Outdrive Housing Assembly
REPLACEMENT
REPAIR/REPLACE LOWER UNIT ASSEMBLY
MATERIAL/PARTS REQUIRED
REPLACEMENT
Figure 5-28 (1 of 3). Lower Unit Assembly
Figure 5-28 (2 of 3). Lower Unit Assembly
Figure 5-28 (2 of 3). Lower Unit Assembly
REPLACEMENT
Figure 5-29. Lift Assembly
REPLACEMENT
Figure 5-30. Lift Cylinder Assembly
REPLACEMENT
Section III. PREPARATION FOR SHIPMENT OR STORAGE
CHAPTER 6 GENERAL SUPPORT MINTENANCE
Section II. MAINTENANCE OF ENGINE AND PROPELLING UNIT.
REPAIR ENGINE ASSEMBLY
REPAIR TURBOCHARGER ASSEMBLY
REPAIR
Figure 6-1. Turbocharger Assembly
REPAIR/REPLACE FRONT HOUSING ASSEMBLY
REPAIR
Figure 6-2. Front Housing Assembly
REPAIR-cont.
REPAIR/REPLACE GOVERNOR DRIVE ASSEMBLY
Figure 6-3. Governor Drive Assembly
REPLACE CRANKSHAFT SEAL ASSEMBLY
INSPECT
Figure 6-4. Crankshaft Seal Assembly
REPLACE CAMSHAFT ASSEMBLY
Materials/Parts Required
Materials/Parts Required-cont.
MATERIALS/PARTS REQUIRED
INSPECT (Figure 6-5)
Figure 6-5. Camshaft Lobe
Figure 6-6. Camshaft and Gear Assembly
Figure 6-7. Camshaft Gears
INSTALL CAMSHAFT GEAR AND CAMSHAFT
REPLACE CRANKSHAFT ASSEMBLY
INSPECT
REPLACEMENT
Figure 6-8. Crankshaft Main Bearings
Figure 6-9. Crankshaft Assembly
REPAIR/REPLACE CYLINDER BLOCK ASSEMBLY
Equipment Conditions
REPAIR/REPLACE PISTON AND ROD ASSEMBLY
Figure 6 - 10. Piston and Rod
INSPECT (Figure 6-10)
REPLACEMENT
Figure 6-11. Piston and Rod Assembly
REPLACEMENT-cont.
REPLACEMENT-cont.
REPAIR LIFT CYLINDER ASSEMBLY
REPAIR (Figure 6-12.)
Figure 6-12 (1 of 2). Lift Assembly.
Figure 6-12 (2 of 2). Lift Assembly
Section III. PREPARATION FOR SHIPMENT OR STORAGE
APPENDIX A REFERENCES
APPENDIX B MAINTENANCE ALLOCATION CHART
GENERAL
GENERAL-cont.
Section II. MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART
Section II. MAINTENANCE ALLOCATION CHART
Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS FOR PROPULSION UNIT, OUTBOARD
Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS FOR PROPULSION UNIT, OUTBOARD
APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST
Section III. BASIC ISSUE ITEMS
APPENDIX D ADDITIONAL AUTHORIZATION LIST
APPENDIX E EXPENDABLE/DURABLE SUPPLIES AND MATERIAL LIST
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIAL LIST
APPENDIX F TORQUE TABLE
ALPHABETICAL INDEX
ALPHABETICAL INDEX-cont.
ALPHABETICAL INDEX-cont.
ALPHABETICAL INDEX-cont.
ALPHABETICAL INDEX-cont.
ALPHABETICAL INDEX-cont.
The Metric System and Equivalents
TM-5-2010-205-14
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DISTRIBUTION
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