TM-55-1905-223-24-1 Main Propulsion Engine for Landing Craft Utility (LCU) NSN <a href="http://combatboats.tpub.com/01-154-1191.htm">1905-01-154-1191</a> Manual

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TM-55-1905-223-24-1

TECHNICAL MANUAL
Unit, Intermediate Direct Support and Intermediate General Support Maintenance Instructions
Unit, Intermediate Direct Support and Intermediate General Support Maintenance Instructions
Unit, Intermediate Direct Support and Intermediate General Support Maintenance Instructions
Unit, Intermediate Direct Support and Intermediate General Support Maintenance Instructions
DISTRIBUTION
WARNING
TABLE OF CONTENTS
TABLE OF CONTENTS - continued
Chapter 1. INTRODUCTION
SECTION II. EQUIPMENT DESCRIPTION AND DATA
FIGURE 1-1. Location of Major Components.
Location and Description of Major Components
Location and Description of Major Components - continued
Equipment Data
Table 1-1. Equipment Data
FIGURE 1-2. Diesel Engine.
Cooling System
Chapter 2. UNIT MAINTENANCE INSTRUCTIONS
Preliminary Servicing, Adjustment and Operation of Newly Installed Equipment.
FIGURE 2-2. Oil Level Sight Glass.
Preliminary Servicing, Adjustment and Operation of Newly Installed Equipment.
Starting the Engine
Starting the Engine - continued
SECTION III. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 2-1. Preventive Maintenance Checks and Services
Table 2-1. Preventive Maintenance Checks and Services - continued
Table 2-1. Preventive Maintenance Checks and Services - continued
Table 2-1. Preventive Maintenance Checks and Services - continued
Table 2-1. Preventive Maintenance Checks and Services - continued
Table 2-1. Preventive Maintenance Checks and Services - continued
Table 2-1. Preventive Maintenance Checks and Services - continued
Table 2-1. Preventive Maintenance Checks and Services - continued
Table 2-1. Preventive Maintenance Checks and Services - continued
Table 2-1. Preventive Maintenance Checks and Services - continued
Table 2-1. Preventive Maintenance Checks and Services - continued
SECTION IV. UNIT MAINTENANCE TROUBLESHOOTING
General Symptoms.
Troubleshooting
SYMPTOM INDEX
Table 2-2. Troubleshooting
Table 2-2. Troubleshooting - continued
Table 2-2. Troubleshooting - continued
Table 2-2. Troubleshooting - continued
Table 2-2. Troubleshooting - continued
Table 2-2. Troubleshooting - continued
Table 2-2. Troubleshooting - continued
Table 2-2. Troubleshooting - continued
Table 2-2. Troubleshooting - continued
Table 2-2. Troubleshooting - continued
Table 2-2. Troubleshooting - continued
Table 2-2. Troubleshooting - continued
SECTION V. UNIT MAINTENANCE PROCEDURES
ADJUST
Replace Engine Air Starter
FIGURE 2-8. Engine Air Starter Detail.
REPLACEMENT
Replace/Repair Instrument Panel
FIGURE 2-9. Instrument Panel Group.
REMOVAL
REPAIR
REPLACEMENT
REPLACEMENT - continued
Replace/Repair Water Filter Group
FIGURE 2-10. Water Filter Group.
REMOVAL
REPLACEMENT
Replace/Repair Thermostat Housing/Water Transfer Tube Group.
FIGURE 2-11. Thermostat Housing/Water Transfer Coupling
REMOVAL
FIGURE 2-12. Thermostat Housing Support/Water Transfer Tube Group.
FIGURE 2-13. Water Transfer Tube Positioning for Removal
INSPECTION
REPLACEMENT
REPLACEMENT - continued
REPLACEMENT - continued
FIGURE 2-14. Thermostat Seal Replacement.
Replace/Repair Air Cleaner
FIGURE 2-15. Air Cleaner Group.
REMOVAL
REPLACEMENT
Replace Turbocharger Group
FIGURE 2-16. Turbocharger Group.
REMOVAL
REPLACEMENT
REPLACEMENT - continued
Replace/Repair Fuel Filter Group
FIGURE 2-17. Fuel Filter Group and Assembly.
REPLACEMENT
Repair Fuel Filter Assembly
FIGURE 2-18. Fuel Filter Assembly.
REPAIR
Replace/Repair Sump Pump Group
FIGURE 2-19. Sump Pump Group.
REPLACEMENT
Replace/Repair Water Pump Group
FIGURE 2-20. Water Pump Group.
REPAIR
REPLACEMENT
Replace Lube Oil Filter Assembly
REPAIR
REPLACEMENT
REPLACEMENT - continued
Replace/Repair Lube Oil Bypass Filter Group
FIGURE 2-22. Lube Oil Bypass Filter Group.
REPLACEMENT
Replace/Repair Lube Oil Bypass Fluid Filter Head
REPLACEMENT
Replace/Repair Cold Starting Aid Group
FIGURE 2-24. Cold Starting Aid Group.
REPLACEMENT
Replace supply and return lines.
Replace/Repair Shutdown Valve Group
REPLACEMENT
Replace/Repair Fuel Pump Group.
FIGURE 2-27. Fuel Pump External Throttle Components.
REPLACEMENT
Replace/Repair Rocker Lever Housing Group/Cover Group.
FIGURE 2-28. Rocker Lever Housing Group/Rocker Housing Cover.
REMOVAL
FIGURE 2-30. Water Transfer Tube Positioning for Removal.
REPAIR
FIGURE 2-31. Crack Inspection Areas on Rocker Levers.
REPLACEMENT
REPLACEMENT - continued
FIGURE 2-35. Intake and Exhaust Valve Location.
FIGURE 2-36. Flywheel/Adjustment Marks (Barring Device-Right Bank).
FIGURE 2-38. Firing Order.
FIGURE 2-40. Adjusting Screws.
Valve and Injector Adjustment Chart
FIGURE 2-43. Adjusting Screw Tightening.
FIGURE 2-45. Adjusting Kit Installation.
FIGURE 2-47. Confirming "O" Setting.
Adjust the injector - continued
Repair Injector Group
FIGURE 2-50. Injector Removal Tool.
INSPECTION
FIGURE 2-51. Injector Inspection.
Replace/Repair Air Intake Manifold Group
FIGURE 2-52. Air Intake Manifold Group.
FIGURE 2-53. Crankcase Breather.
Remove aftercooler.
REPLACEMENT
Install air intake manifold.
Install air intake manifold - continued
FIGURE 2-54. Capscrew Tightening Sequence.
Replace/Repair Exhaust Manifold Group
FIGURE 2-55. Exhaust Manifold Group.
REPLACEMENT
Replace/Repair Cylinder Head Group.
FIGURE 2-56. Cylinder Head Group, Cylinder Head Diesel Engine.
REPLACEMENT
FIGURE 2-58. Cylinder Head Tightening Sequence.
Replace/Repair Handhole Cover Group
FIGURE 2-59. Handhole Cover Group.
REPLACEMENT
REPLACEMENT - continued
Repair Oil Pan and Adapter Group.
REPLACEMENT
FIGURE 2-61. Oil Pan and Adapter Group Capscrew Torque Sequence.
Replace/Repair Expansion Tank Group
FIGURE 2-62. Expansion Tank Group.
REPLACEMENT
SECTION VI. PREPARATION FOR STORAGE, RESHIPMENT, AND RETURN TO SERVICE
Preparing a Stored Engine for Service
Inspection.
Chapter 3. INTERMEDIATE DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
Initial Setup Procedure
SECTION IV. INTERMEDIATE DIRECT SUPPORT TROUBLESHOOTING
Table 3-1. Troubleshooting
Table 3-1. Troubleshooting - continued
Table 3-1. Troubleshooting - continued
SECTION V. INTERMEDIATE DIRECT SUPPORT MAINTENANCE PROCEDURES
Solvent/Acid Cleaning.
Solvent/Acid Cleaning - continued
Replace Main Propulsion Engine.
Disconnect electrical wiring
REPLACEMENT
Connect cooling system.
Repair Engine Cooling System Pump.
FIGURE 3-2. Shaft Removal From Pump.
FIGURE 3-3. Shaft Removal.
REPAIR
ASSEMBLY
FIGURE 3-4. Shaft Beveled Edge Position.
Table 3-2. Water Pump Specifications - Inch (mm)
Replace/Repair Engine Accessory Bracket..
FIGURE 3-5. Engine Accessory Bracket.
FIGURE 3-6. Straight Shaft Measurement Locations.
REPLACEMENT
REPLACEMENT - continued
Repair Lube Oil Filter Assembly.
FIGURE 3-7. Lube Oil Filter Assembly.
DISASSEMBLY
ASSEMBLY
ASSEMBLY - continued
ASSEMBLY - continued
Repair Shutdown Valve Assembly
ASSEMBLY
ASSEMBLY - continued
Replace/Repair Lubricating Oil Cooler Group
FIGURE 3-9. Lubricating Oil Cooler Group
REPAIR
REPLACEMENT
Repair Exhaust Manifold Group
FIGURE 3-10. Exhaust Manifold Group.
REPAIR
ASSEMBLY
Remove/Repair Fuel Manifold Group
FIGURE 3-11. Fuel Manifold Group.
Remove fuel blocks assembly.
REPAIR
Install fuel blocks assembly.
Install fuel blocks.
Replace/Repair Engine Support Group
FIGURE 3-12. Engine Support Group.
Replace Pulley Shield and Front Gear Housing Group.
FIGURE 3-13. Pulley Shields and Front Gear Housing Group.
REMOVAL
REPLACEMENT
FIGURE 3-14. Front Gear Cover Torquing Sequence.
Replace access covers
Replace damper guard
Repair Oil Pan and Adapter Group
FIGURE 3-15. Oil Pan and Adapter Group.
REPAIR
Assemble oil pan
Replace/Repair Lubricating Oil Pump Group
Remove transfer tube
Remove oil pump
Perform pre-disassembly checks to oil pump
REPAIR
REPAIR - continued
ASSEMBLY
ASSEMBLY - continued
ASSEMBLY - continued
Install oil pressure relief valve
Replace oil pan and adapter group
Replace/Repair Camshaft and Gear Group.
FIGURE 3-17. Camshaft Gear Group.
Remove camshaft
REPLACEMENT
FIGURE 3-19. Camshaft Pilots.
FIGURE 3-20. Idler Gear Timing Marks.
FIGURE 3-21. Front Gear Train Backlash Measurement.
Replace/Repair Connecting Rod and Piston Group.
FIGURE 3-22. Connecting Rod and Piston Assembly Removal.
Remove piston from connecting rod.
FIGURE 3-23. Removal of Piston from Connecting Rod.
Replace connecting rod and piston.
Replace connecting rod and piston - continued
FIGURE 3-24. Crankshaft Rod Journal.
Table 3-5. Connecting Rod Bolt Tightening
FIGURE 3-26. Piston and Connecting Rod Installation.
Measure connecting rod bolt stretch.
FIGURE 3-28. Connecting Rod Side Clearance Measurement.
Replace/Repair Flywheel Housing Group.
FIGURE 3-29. Flywheel Housing Group.
FIGURE 3-30. Flywheel Housing Bolt Tightening Sequence.
FIGURE 3-29. Flywheel Housing Group.
Housing Bore Check.
FIGURE 3-32. Flywheel Housing Alignment Measurement.
FIGURE 3-33. Flywheel Removal/Replacement.
FIGURE 3-34. Flywheel Bolt Tightening Sequence.
Repair Engine Air Starter
FIGURE 3-35. Engine Air Starter.
DISASSEMBLY
ASSEMBLY
Repair Fuel Pump
FIGURE 3-36. Fuel Pump.
SECTION VI. PREPARATION FOR STORAGE OR SHIPMENT
Chapter 4. INTERMEDIATE GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Initial Setup Procedure
SECTION IV. INTERMEDIATE GENERAL SUPPORT TROUBLESHOOTING
Table 4-1. Troubleshooting
Table 4-1. Troubleshooting - continued
SECTION V. INTERMEDIATE GENERAL SUPPORT MAINTENANCE PROCEDURES
REPAIR
Rebuild cylinder head.
FIGURE 4-4. Cup Plug Removal.
FIGURE 4-6. Valve Stem Inspection.
FIGURE 4-8. Valve Head Height Measurement.
Magnetic crack detector.
FIGURE 4-9. Head Gasket Surface Measurement.
FIGURE 4-11. Valve Magnetic Crack Check.
FIGURE 4-12. Valve Acceptance Criteria.
FIGURE 4-14. Valve Seat Concentricity Measurement.
FIGURE 4-16. Dummy Injector.
FIGURE 4-18. Injector Protrusion Measurement.
FIGURE 4-20. Hydrostatic Tester.
FIGURE 4-21. Valve Depth Measurement.
FIGURE 4-22. Vacuum Test.
FIGURE 4-23. Valve Lapping.
Replace cylinder head valve guide
FIGURE 4-25. Valve Seat Insert Removal.
FIGURE 4-27. Valve Seat Insert Bore Measurement.
FIGURE 4-28. Air Deflector Replacement.
FIGURE 4-31. Valve Seat Angle and Width
FIGURE 4-34. Valve Grinding Angle.
FIGURE 4-35. Crosshead Disassembly/Assembly.
Replace/Repair Cam Follower and Housing Group.
FIGURE 4-38. Cam Follower Removal/Installation.
FIGURE 4-39. Cam Followers. Cover and Push Rods/Tube.
FIGURE 4-40. Cam Roller Pin Removal Socket.
FIGURE 4-41. Cup Plug Installation in Cam Follower Shaft.
ASSEMBLY
REPLACEMENT
Replace/Repair Vibration Damper.
REPAIR
FIGURE 4-43. Vibration Damper Mounting Components.
FIGURE 4-44. Tightening Sequence for Crankshaft Adapter.
FIGURE 4-45. Vibration Damper Eccentricity Measurement.
FIGURE 4-46. Vibration Damper Wobble Measurement.
Repair Crankshaft Assembly and Sleeve Bearings.
FIGURE 4-47. Main Bearing Side Bolt Removal.
FIGURE 4-49. Main Bearing Cap Removal
FIGURE 4-51. Crankshaft Gear Removal.
FIGURE 4-52. Crankshaft Thrust Flange Measurement
FIGURE 4-54. Markings on the Crankshaft for Undersize Main and Connecting Rod Journals.
Table 4-4. Crankshaft Specifications Inch (mm)
REPLACEMENT
FIGURE 4-57. Crankshaft Thrust Bearing Removal/Installation.
REPLACEMENT
REPLACEMENT - continued
FIGURE 4-59. Main Bearing Capscrew Torquing.
FIGURE 4-61. Crankshaft End Clearance Check.
Repair Pulley Shield Front Gear Housing Group.
REPAIR
FIGURE 4-62. Installation Tool and Repair Sleeve.
Table 4-7. Fuel and Water Pump Bore Bushing Specifications - Inch (mm)
Repair Crankshaft and Gear Group.
Check for possible cracks using magnaglo tester.
FIGURE 4-62b. Camshaft Coil Shot Check.
FIGURE 4-63. Camshaft Inspection Areas.
FIGURE 4-64. Camshaft Gear Removal.
Demagnetize and clean the camshaft - continued
FIGURE 4-65a. Camshaft Gear Head Shot Check.
Check gear for cracks.
Check gear for cracks - continued
Repair Connecting Rod and Piston Group
FIGURE 4-66. Connecting Rod Disassembly.
FIGURE 4-68. Connecting Rod Bore Measurement.
FIGURE 4-68a. Connecting Rod Magnetic Check.
FIGURE 4-69. Connecting Rod Inspection.
FIGURE 4-70. Piston Measurement.
FIGURE 4-71. Oil Ring Expander.
Repair Flywheel Housing
FIGURE 4-72. Flywheel Housing/Flywheel and Ring Gear Assembly.
REPAIR
'Unknown' by LOGSA - Page 1 of 412
FIGURE 4-74. Barring Mechanism Shaft Removal.
Assembly barring mechanism
Flywheel housing
Flywheel housing - continued
Replace/Repair Cylinder Block
REMOVAL
FIGURE 4-75. Cylinder Block Assembly.
FIGURE 4-76. Water Pump Shaft Alignment.
FIGURE 4-77. Cylinder Liner Puller.
FIGURE 4-79. Dowel Removal.
FIGURE 4-80. Camshaft Bushing Removal.
FIGURE 4-81. Counterbord Depth Measurement.
FIGURE 4-82. Counterbore Ledge Angle Measurement.
FIGURE 4-85. Packing Ring Bore Measurement.
Clean and inspect cylinder liners.
Measure cylinder liner.
Table 4-8. Engine Measurements
Repair piston cooling valve
Inspect idler shafts
FIGURE 4-88. Single Bushing Installation.
Install cylinder liner
FIGURE 4-90. Liner Sealant.
Install cylinder liner
FIGURE 4-91. Liner Protrusion Measurement.
Install idler gear shafts.
Install idler gear shafts - continued
SECTION VI. PREPARATION FOR STORAGE OR SHIPMENT
Appendix A. REFERENCES
Appendix B. MAINTENANCE ALLOCATION CHART
Explanation of Columns in the MAC, Section II.
Explanation of Columns in Tool and Test Equipment Requirements, Section III.
Explanation of Columns in Remarks, Section IV.
SECTION II. MAINTENANCE ALLOCATION CHART
SECTION II. MAINTENANCE ALLOCATION CHART - continued
SECTION II. MAINTENANCE ALLOCATION CHART - continued
SECTION II. MAINTENANCE ALLOCATION CHART - continued
SECTION II. MAINTENANCE ALLOCATION CHART - continued
SECTION II. MAINTENANCE ALLOCATION CHART - continued
SECTION III. MAINTENANCE ALLOCATION CHART FOR BASIC CRAFT
SECTION III. MAINTENANCE ALLOCATION CHART FOR BASIC CRAFT - continued
SECTION III. MAINTENANCE ALLOCATION CHART FOR BASIC CRAFT - continued
SECTION III. MAINTENANCE ALLOCATION CHART FOR BASIC CRAFT - continued
SECTION III. MAINTENANCE ALLOCATION CHART FOR BASIC CRAFT - continued
SECTION III. MAINTENANCE ALLOCATION CHART FOR BASIC CRAFT - continued
SECTION IV. REMARKS
SECTION IV. REMARKS - continued
Section IV. REMARKS
Appendix C. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST - continued
Appendix D. TORQUE VALUE
APPENDIX D
GENERAL CONVERSION TABLE
TAP DRILL SIZES
GLOSSARY
ALPHABETICAL INDEX
ALPHABETICAL INDEX - continued
ALPHABETICAL INDEX - continued
The Metric System and Equivalents
TM-55-1905-223-24-1
DISTRIBUTION
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