TM-55-1905-223-24-3 Ship s Service Generator 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-55-1905-223-24-3

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
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
Difference Between Models
FIGURE 1-4. Fuel Pump Dataplate.
Equipment Data
Table 1-1. Equipment Data
Table 1-1. Equipment Data - continued
SECTION III. PRINCIPLES OF OPERATION
Fuel System
Lubricating System
FIGURE 1-7. Coolant Flow Path.
Air System
Electric Fuel Control Governor
Chapter 2. UNIT MAINTENANCE INSTRUCTIONS
Deprocessing Unpacked Equipment.
Oil Dipstick Gauge
Starting the Engine
FIGURE 2-1. Instrument Panel Arrangement.
Governor Speed Check and Adjustment
Generator Startup
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
White Smoke-General Information
SYMPTOM INDEX
SYMPTOM INDEX - continued
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
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
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
FIGURE 2-3. Voltage Regulator Panel.
Replace Engine Air Starter
FIGURE 2-4. Engine Air Starter.
REPLACEMENT
REPLACEMENT - continued
Replace/Repair Electric Starting Motor/Magnetic Switch Group
FIGURE 2-5. Electric Starting Motor/Magnetic Switch.
Replace/Repair Instrument Panel Assembly
FIGURE 2-6. Instrument Panel Assembly.
REMOVAL
FIGURE 2-7. Terminal Board.
REPLACEMENT
Replace/Repair Water Filter Assembly
FIGURE 2-8. Water Filter Assembly.
INSPECTION
REPAIR
Replace/Repair Thermostat Housing Group. (Figure 2.-9)
FIGURE 2-9. Thermostat Housing Group.
REPAIR
REPLACEMENT
Replace/Repair Air Cleaner Group
FIGURE 2-10. Air Cleaner Group.
REPAIR
Replace/Repair Turbocharger and Exhaust Group
FIGURE 2-11. Turbocharger and Exhaust Group.
REPLACEMENT
REPLACEMENT - continued
Replace/Repair Fuel Filter Group
FIGURE 2-12. Fuel Filter Group.
REPLACEMENT
Replace/Repair Sump Pump Group
FIGURE 2-13. Sump Pump Group.
REPLACEMENT
Replace/Repair Water Pump and Idler Group.
FIGURE 2-14. Water Pump and Idler Group.
ADJUSTMENT
REMOVAL
REPAIR
FIGURE 2-16. Water Pump Torque Sequence.
Replace/Repair Lubricating Oil Cooler/Filter Group
FIGURE 2-17. Lubricating Oil Cooler/Filter Group.
REPLACEMENT
Replace/Repair Lube Oil Bypass Filter Group
FIGURE 2-18. Lube Oil Bypass Filter Group.
REPLACEMENT
Replace/Repair Coolant Heater Group.
FIGURE 2-19. Coolant Heater Group.
Figure 2-20. Location of Electrical Boxes.
REPLACEMENT
REPLACEMENT - continued
REPLACE PUMP, FUEL, METERING AND DISTRIBUTING ASSEMBLY
FIGURE 2-21. Pump, Fuel, Metering and Distributing Assembly.
REPLACEMENT
REPLACE/REPAIR FUEL TUBING GROUP
FIGURE 2-22. Fuel Line Check Valves.
REPLACEMENT
REPLACE/REPAIR ROCKER LEVER HOUSING COVER GROUP.
FIGURE 2-23. Rocker Lever Housing Group.
DISASSEMBLY
REPAIR
FIGURE 2-24. Set Screw and Oil Passage Holes.
FIGURE 2-25. Installing the Arms and Levers on Shaft.
FIGURE 2-26. Rocker Housing Gaskets and Guide Studs.
FIGURE 2-28. Rocker Housing Torque Sequence.
FIGURE 2-29. Rotating Accessory Drive.
FIGURE 2-30. Identifying Rocker Levers.
FIGURE 2-31. Aligning Pulley and Gear Pointer.
FIGURE 2-32. Installing Dial Indicator and Support.
FIGURE 2-33. Rocker Lever Actuator.
FIGURE 2-34. Torque Methods.
FIGURE 2-35. Injector Adjusting Screw.
FIGURE 2-36. Loosening Injector Adjusting Screw.
Crosshead Adjustment.
FIGURE 2-37. Checking Valve Lash (Feeler Method).
FIGURE 2-38. Tightening Adjusting Screw.
FIGURE 2-39. Cover Manufactured Bow Areas.
FIGURE 2-41. Crankcase Breather and Tube.
Inspect/Replace/Repair Injector Group
FIGURE 2-42. Injector Group.
FIGURE 2-43. Using Rocker Lever Actuator.
REPLACEMENT
REPLACEMENT
Replace/Repair Aftercooler Group.
FIGURE 2-46. Aftercooler Group.
DISASSEMBLY
ASSEMBLY
FIGURE 2-47. Housing to Core Capscrew Torque Sequence.
REPLACEMENT
REPLACEMENT - continued
Replace/Repair Exhaust Manifold Group.
FIGURE 2-50. Exhaust Manifold Group.
REPLACEMENT
REPLACEMENT - continued
Replace/Repair Cylinder Head Group.
FIGURE 2-52. Push Rod Replacement.
FIGURE 2-53. Cylinder Head Group.
REPLACEMENT
FIGURE 2-54. Positioning Head Gaskets.
FIGURE 2-55. Cylinder Head Torque Sequence.
FIGURE 2-56. Crosshead Clearance.
SECTION VI. PREPARATION FOR STORAGE, RESHIPMENT, AND RETURN TO SERVICE
Long Term Storage
Painting the Generator Set.
Inspecting the Generator Set.
Starting the Engine.
Chapter 3. INTERMEDIATE DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
SECTION III . INTERMEDIATE DIRECT SUPPORT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
SYMPTOM INDEX
Table 3-1. Troubleshooting
Table 3-1. Troubleshooting - continued
Table 3-1. Troubleshooting - continued
Table 3-1. Troubleshooting - continued
Section V. INTERMEDIATE DIRECT SUPPORT MAINTENANCE PROCEDURES
REMOVAL
REMOVAL - continued
FIGURE 3-1. Lifting Eyes and Mounts.
REPAIR
REPLACEMENT
REPLACEMENT - continued
Replace/Repair Generator Assembly.
FIGURE 3-3. Generator Assembly.
FIGURE 3-4. Separately Exciting the Generator.
FIGURE 3-5. Voltage Regulator Connections and Wiring.
TEST
FIGURE 3-6. Rectifier Assembly.
Table 3-2. Winding Resistance (Ohms)
Test the permanent magnet exciter
Electronic Control System.
Replacement of semiconductors.
FIGURE 3-7. Generator Terminal Box.
FIGURE 3-8. Generator Coupling and Housing.
FIGURE 3-9. Generator Housing Torque Sequence.
FIGURE 3-10. Coupling Torque Sequence.
REPLACEMENT
Repair Diesel Engine, Air and Electrical Start.
Disconnect starter motor.
REPAIR
REPLACEMENT
Repair Engine Air Starter.
Repair Lubricating Oil Cooler/Filter Group.
FIGURE 3-11. Oil Cooler/Filter - Filter Element Removed.
FIGURE 3-12. Oil Cooler Pressure Regulator.
REPAIR
FIGURE 3-14. Aligning Index Marks.
ASSEMBLY
ASSEMBLY
Repair Fuel Metering and Distributing Pump Assembly.
FIGURE 3-16. Fuel Pump.
FIGURE 3-17. Shutoff Valve Assembly.
FIGURE 3-19. Fuel Pump Gear Assembly.
FIGURE 3-20. Fuel Pump Electric Governor Actuator and Fluid Filter Element Assembly.
REPAIR
ASSEMBLY
ASSEMBLY
Repair Rocker Lever Housing/Cover Group.
REPAIR
REPAIR - continued
Replace/Repair Cam Follower Housing Group.
FIGURE 3-22. Cam Follower Housing Group.
FIGURE 3-23. Cam Follower Housing Torque Sequence.
FIGURE 3-24. Injection Timing.
FIGURE 3-26. Cam Follower Action.
FIGURE 3-27. Injection Timing Tool.
Measuring Injector Timing.
FIGURE 3-28. Timing Tool Travel.
Correcting Injector Timing.
Table 3-3. Injection Timing Codes and Push Rod Travel
Table 3-4. Change in Push Rod Travel Due to Gasket Thickness
FIGURE 3-29. Gasket Stack-Up Thickness.
REPLACE/REPAIR ACCESSORY DRIVE AND PULLEY GROUP.
REMOVAL
FIGURE 3-32. Inspection Hole Plug.
FIGURE 3-33. Gear Alignment.
FIGURE 3-34. Accessory Drive Dowel Pin.
Disassemble pulley
REPAIR
ASSEMBLY
REPLACEMENT
REPLACEMENT - continued
REPLACE/REPAIR GEAR COVER AND SUPPORT GROUP
FIGURE 3-37. Dowel Pin Installation.
FIGURE 3-38. Gear Cover and Support Group.
FIGURE 3-40. Releasing Oil Pan Gasket.
FIGURE 3-41. Removing Gear Cover.
REPLACEMENT
FIGURE 3-42. Support Bearing Clearance.
REPLACEMENT
REPLACEMENT - continued
FIGURE 3-43. Oil Pan Torque Sequence.
REPLACE/REPAIR OIL PAN GROUP.
FIGURE 3-44. Oil Pan Group.
REPAIR
FIGURE 3-45. Flywheel Housing Buttresses.
FIGURE 3-46. Middle Oil Pan Capscrews.
REPLACEMENT
REPLACE/REPAIR ENGINE LUBRICATING OIL PUMP ASSEMBLY.
FIGURE 3-47. Lubricating Oil Pump Group.
FIGURE 3-48. Drive Shaft End Clearance.
REPAIR
FIGURE 3-49. Install the Guide Bushing into the Gear Pocket.
FIGURE 3-50. Install the Boring Tool.
ASSEMBLY
Table 3-6. Oil Pump Shaft Limits - Inch (mm)
REPLACEMENT
Replace Camshaft and Gear Group.
FIGURE 3-52. Camshaft Installation Pilots.
FIGURE 3-54. Gear Alignment.
FIGURE 3-55. Camshaft Gear Backlash Measurement.
Replace Connecting Rod and Piston Group.
FIGURE 3-57. Connecting Rod and Piston Group.
REPLACEMENT
FIGURE 3-58. Ring Gap Positions.
FIGURE 3-59. Guide Pins and Ring Compressor.
FIGURE 3-60. Matching Caps and Rods.
REPLACEMENT
Replace/Repair Flywheel and Flywheel Housing Group.
FIGURE 3-61. Guide Studs and T-Handles.
FIGURE 3-62. Flywheel and Flywheel Housing Group.
FIGURE 3-63. Removing Flywheel.
FIGURE 3-65. Crankshaft Flange Cover.
FIGURE 3-67. Flywheel Housing Guide Studs.
REPLACEMENT
FIGURE 3-69. Flywheel Housing Torque Sequence.
FIGURE 3-70. Measure Bore Alignment.
FIGURE 3-72. Housing Bore Diameter
FIGURE 3-73. Dial Indicator.
REPLACEMENT
FIGURE 3-74. Seal Driver.
FIGURE 3-75. Checking Rear Cover and Oil Pan Flange.
FIGURE 3-77. Installing Seal With Driver.
FIGURE 3-78. Oil Pan Torque Sequence.
FIGURE 3-79. Measuring Flywheel Runout.
Measure the flywheel face runout
Install the magnetic pickup
REPLACEMENT - continued
REPAIR CRANKSHAFT GROUP.
FIGURE 3-82. Measuring Dampener Wobble.
FIGURE 3-83. Dampener and Pulley Removal.
REPAIR
REPAIR CYLINDER BLOCK GROUP.
ASSEMBLY
ASSEMBLY - continued
REMOVE/REPAIR SUBBASE GROUP.
FIGURE 3-84. Subbase Group.
SECTION VI. PREPARATION FOR STORAGE OR SHIPMENT
Chapter 4. INTERMEDIATE GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
SECTION III. INTERMEDIATE GENERAL SUPPORT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
SECTION V. INTERMEDIATE GENERAL SUPPORT MAINTENANCE PROCEDURES
DISASSEMBLY
FIGURE 4-1. Exciter Removal/Installation.
DISASSEMBLY - continued
FIGURE 4-2. Main Rotor Removal/Installation.
Remove the generator bearing
FIGURE 4-3. Bearing Removal.
REPAIR
REPAIR - continued
REPAIR - continued
REPAIR - continued
REPAIR - continued
REPAIR - continued
REPAIR - continued
REPAIR - continued
REPAIR - continued
Automatic voltage regulator adjustments
FIGURE 4-5. AVR Auxiliary Board.
ASSEMBLY
ASSEMBLY - continued
FIGURE 4-6. Bearing Installation.
Install the end bracket
Install the generator assembly
Check and correct the angular position of the permanent magnet stator housing.
REPAIR CYLINDER HEAD GROUP.
REPAIR CYLINDER HEAD GROUP - continued
FIGURE 4-7. Removing and Marking Valves.
FIGURE 4-8. Cylinder Head Group.
REPAIR
FIGURE 4-9. Injector Sleeve Holding Tool.
Water pressure test the cylinder head.
Valve Seat Inserts
Valve Seat Inserts - continued
Valve Guides
Valves. Inspection, grinding and replacement.
FIGURE 4-11. Rim Measurements and Grinding Marks.
Valve Springs. Inspection and replacement.
Table 4-1. Valve Spring Data-inch (mm) lb (N)
FIGURE 4-12. Crosshead Inspection Areas.
FIGURE 4-13. Adjusting Counterbore Cutter.
Fuel injector nozzle cooling sleeves
FIGURE 4-14. Injector Sleeve Puller/Driver.
Installing new sleeves.
FIGURE 4-16. Using Gauge Block.
FIGURE 4-17. Injector Sleeve Measurements.
Specifications
Table 4-2. Specifications for Cylinder Head, Valves, Crosshead Pins, and Injector Sleeves - inch (mm)
Table 4-3. Oversize Valve Seat Insert Specifications - inch (mm)
Table 4-5. Pipe Plug Torque - ft-lb (N )
FIGURE 4-19. Valve and Spring Installation Order.
Test the valve seats.
Install the cylinder head
Replace/Repair Cam Follower Housing Group
FIGURE 4-20. Cam Follower Lockscrews and Plugs.
FIGURE 4-22. Cam Follower Housing Group (Push Rods Removed) with Callouts for Table 4-6 References.
Table 4-6. Cam Follower Group Specifications - inch (mm)
FIGURE 4-23. Inspecting Levers for Cracks.
REPAIR
REPAIR - continued
REPLACEMENT
Repair Camshaft and Gear Group
FIGURE 4-24. Measuring Gear and Shoulder Clearance.
FIGURE 4-25. Removing Camshaft Gear.
Table 4-7. Camshaft Gear Bore I.D.
Table 4-8. Camshaft Gear Bore O.D.
Table 4-9. Camshaft Key Data
Install the camshaft
Repair Connecting Rod and Piston Group.
FIGURE 4-28. Connecting Rod and Piston Group.
FIGURE 4-29. Removing Piston Rings.
FIGURE 4-30. Counterweight Markings for Bearing Sizes.
Clean and inspect the connecting rods
Table 4-10. Connecting Rod Torque Specifications
DISASSEMBLY
FIGURE 4-32. Fillet Radius.
Clean and inspect the pistons
Piston Ring Gap
REPAIR
Install the piston pin bushing
Cut the bore in the piston pin bushing
Piston rings.
FIGURE 4-36. Oil Control Ring.
Rod bearings
REPAIR FLYWHEEL AND FLYWHEEL HOUSING GROUP
FIGURE 4-38. Flywheel and Housing Group.
Inspect the flywheel housing
REMOVE/REPAIR CRANKSHAFT GROUP.
FIGURE 4-39. Crankshaft Group.
FIGURE 4-40. Removing Main Bearing Cap.
FIGURE 4-41. Remove Dowel Ring.
REPLACEMENT
FIGURE 4-42. Bearing Shell Identification.
FIGURE 4-43. Positioning Bearing Grooves.
FIGURE 4-44. Installing the Bearing Shell.
FIGURE 4-45. Bearing Cap Location Marks.
REPLACEMENT
REPAIR CYLINDER BLOCK GROUP.
REPAIR
FIGURE 4-47. Cylinder Block Group.
FIGURE 4-48. Extended Foot Type Puller.
REPAIR
FIGURE 4-50. Liner Press Fit Area.
REPAIR - continued
FIGURE 4-52. Applying Sealant to Liner.
FIGURE 4-53. Measuring Liner Protrusion.
FIGURE 4-55. Checking Liner Bore.
REPAIR - continued
FIGURE 4-57. Camshaft Bushing/Bearing Removal Sequence.
REPAIR - continued
FIGURE 4-58. Bushing Driver Identification.
REPAIR - 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 FOR SHIP' SERVICE GENERATOR
SECTION II: MAINTENANCE ALLOCATION CHART FOR SHIP' SERVICE GENERATOR - continued
SECTION II: MAINTENANCE ALLOCATION CHART FOR SHIP' SERVICE GENERATOR - continued
SECTION II: MAINTENANCE ALLOCATION CHART FOR SHIP' SERVICE GENERATOR - continued
SECTION II: MAINTENANCE ALLOCATION CHART FOR SHIP' SERVICE GENERATOR - continued
SECTION II: MAINTENANCE ALLOCATION CHART FOR SHIP' SERVICE GENERATOR - continued
SECTION II: MAINTENANCE ALLOCATION CHART FOR SHIP' SERVICE GENERATOR - continued
SECTION II: MAINTENANCE ALLOCATION CHART FOR SHIP' SERVICE GENERATOR - continued
SECTION III: TOOL AND TEST EQUIPMENT REQUIREMENTS FOR SHIP' SERVICE GENERATOR
SECTION III: TOOL AND TEST EQUIPMENT REQUIREMENTS FOR SHIP' SERVICE GENERATOR - continued
SECTION III: TOOL AND TEST EQUIPMENT REQUIREMENTS FOR SHIP' SERVICE GENERATOR - continued
SECTION III: TOOL AND TEST EQUIPMENT REQUIREMENTS FOR SHIP' SERVICE GENERATOR - continued
SECTION III: TOOL AND TEST EQUIPMENT REQUIREMENTS FOR SHIP' SERVICE GENERATOR - continued
SECTION III: TOOL AND TEST EQUIPMENT REQUIREMENTS FOR SHIP' SERVICE GENERATOR - continued
SECTION III: TOOL AND TEST EQUIPMENT REQUIREMENTS FOR SHIP' SERVICE GENERATOR - continued
SECTION IV. REMARKS
Appendix C. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
SECTION II. EXPENDABLE / DURABLE SUPPLIES AND MATERIAL LIST
SECTION II. EXPENDABLE / DURABLE SUPPLIES AND MATERIAL LIST - continued
SECTION II. EXPENDABLE / DURABLE SUPPLIES AND MATERIAL LIST - continued
Appendix D. TORQUE VALUES
Table D-2. Torque Values for Tapered Pipe Plugs
Table D-4. Fuel Pump Torque Specifications
ABBREVIATIONS
GLOSSARY - continued
GLOSSARY - continued
GLOSSARY - continued
GLOSSARY - continued
GLOSSARY - continued
ALPHABETICAL INDEX
ALPHABETICAL INDEX - continued
ALPHABETICAL INDEX - continued
The Metric System and Equivalents
TM-55-1905-223-24-3
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