TM-55-1905-223-24-5 Bowthruster 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-55-1905-223-24-5

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
WARNING
TABLE OF CONTENTS
TABLE OF CONTENTS - Continued
CHAPTER 1 INTRODUCTION
SECTION II. EQUIPMENT DESCRIPTION AND DATA
FIGURE 1-1. Location of Major Components
SECTION II. EQUIPMENT DESCRIPTION AND DATA-cont.
FIGURE 1-2. Engine Dataplate Location.
Table 1-1. Equipment Data
EXHAUST SYSTEM
SECTION III. PRINCIPLES OF OPERATION
FIGURE 1-5. Diesel Engine Cycles.
Lubricating System
FIGURE 1-6. Coolant Flow Path.
Coolant Heating
CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS
SECTION II. SERVICE UPON RECEIPT
Checking and Deprocessing Unpacked Equipment
Starting the Engine
Engine Run-In
SECTION III. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
Table 2-1. Preventive Maintenance Checks and Services (PMCS)
SECTION IV. UNIT MAINTENANCE TROUBLESHOOTING
White Smoke-General Information
Symptom Index
How to Use the Troubleshooting Table
Table 2-2. Troubleshooting
Table 2-2. Troubleshooting
Table 2-2. Troubleshooting
Table 2-2. Troubleshooting
FIGURE 2-1. Oil Cooler Bypass Valve
FIGURE 2-2. Oil Cooler Bypass Valve Temperature Check
FIGURE 2-3. Oil Filter/Cooler
FIGURE 24. Oil Temperature Gauge
Excessive lubricating oil loss
FIGURE 2-5. Blowby Check
Excessive lubricating oil sludge in the crankcase
Fuel in lubricating oil
FIGURE 2-6. Injector Adapter Check
FIGURE 2-8. Mercury Manometer Installation
Low power or excessive smoke (low intake manifold pressure)
Engine cranks but will not start (no smoke from exhaust).
Engine cranks but will not start (no smoke from exhaust)-cont.
Figure 2-9. Priming Plug
Engine hard to start or will not start (exhaust smoke present)
Warm engine runs rough or misfires in operating range.
Rough idle
Engine will not reach rated speed when loaded
oFIGURE 2-10 Plug Removal
Exhaust smoke excessive under load
Engine will not shut off
Engine surges at high idle
Excessive engine vibration
Main bearing noise
SECTION V. UNIT MAINTENANCE PROCEDURES
Replace/Repair Electric Starter Motor and Magnetic Switch Group. (FIGURE 2-11)
FIGURE 2-11. Electric Starter and Magnetic Switch
INSPECTION
REPAIR
FIGURE 2-12. Instrument Panel Group
REPLACEMENT
Replace/Repair Water Filter Group. (FIGURE 2-13)
FIGURE 2-13. Water Filter Group.
REMOVAL
REPLACEMENT
Replace/Repair Thermostat Housing Group. (FIGURE 2-14)
FIGURE 2-14. Thermostat Housing Group
INSPECTION
REPLACEMENT
REPLACEMENT-cont.
Replace/Repair Air Cleaner Group. (FIGURE 2-15)
FIGURE 2-15. Air Cleaner Group
REMOVAL
Replace/Repair Turbocharger Group. (FIGURE 2-16)
FIGURE 2-16. Turbocharger Group
REPAIR
FIGURE 2-17. Turbocharger Repair
FIGURE 2-18. Anti-Seize Application
REPAIR-cont.
Replace/Repair Fuel Filter Group. (FIGURE 2-19)
FIGURE 2-19. Fuel Filter Group
REPLACEMENT
Replace/Repair Sump Pump Group. (FIGURE 2-20)
FIGURE 2-20. Sump Pump Group
REPLACEMENT
Replace/Repair of Water Pump and Idler/Belt Guard Group.
FIGURE 2-21. Water Pump and Idler (Sheet 1 of 3).
ADJUSTMENT
FIGURE 2-21. Water Pump and Idler (Sheet 2 of 3).
FIGURE 2-21. Water Pump and Idler (Sheet 3 of 3).
REPAIR
REPLACEMENT
FIGURE 2-22. Bolt-Tightening Sequence
Replace/Repair Lubricating Oil Cooler/Filter Group.
FIGURE 2-23. Lube Oil Cooler/Filter Group
REPAIR
REPLACEMENT
Replace/Repair Lubricating Oil By-Pass Filter Group.
FIGURE 2-24. Lubricating Oil Bypass Filter Group
Replace/Repair Coolant Heater Group
REPAIR
FIGURE 2-25. Coolant Heater Group
FIGURE 2-26. Location of Electrical Boxes on Coolant Heater
REPLACEMENT
Replace/Repair Fuel Tubing, Shutdown Valve and Fuel Pump Group
FIGURE 2-27. Fuel Pump
REPAIR
FIGURE 2-29. Fuel Line Check Valves
REPLACEMENT
Replace Rocker Lever Housing/Cover Group
FIGURE 2-30. Rocker Lever Housing/Cover Group
FIGURE 2-31. Rocker Lever Housing Gaskets
FIGURE 2-32. Rocker Lever Adjusting Screw
FIGURE 2-33. Rocker Lever Housing Torque Sequence
FIGURE 2-35. Rocker Cover Torque Sequence
Replace/Repair Injector Group
FIGURE 2-36. Rocker Lever Covers
FIGURE 2-37. Removing Injector
INSPECTION
FIGURE 2-38. Identifying Rocker Levels
Table 2-3. Injector and Valve Adjustment Sequence
FIGURE 2-40. Installing Dial Indicator and Support
FIGURE 2-41. Holding the Adjusting Screw
FIGURE 2-42. Aligning Pulley and Gear Pointer
FIGURE 2-43. Injector Adjusting Screw
FIGURE 2-44. Crosshead
Valve Adjustment
FIGURE 2-45. Manufactured Bow Areas in Rocker Covers
FIGURE 2-46. Engine Poppet Cover Torque Sequence
Replace/Repair Expansion Tank Group. (FIGURE 2-47)
FIGURE 2-47. Expansion Tank Group
INSPECTION
Replace/Repair Seawater Pump/Belt Guard Group. (FIGURE 2-48)
FIGURE 2-48. Seawater Pump Group
REMOVAL
REPLACEMENT
Replace/Repair Heat Exchanger and Heat Exchanger Group. (FIGURE 2-49)
FIGURE 2-49. Heat Exchanger Group
REMOVAL
REMOVAL-cont.
Replace/Repair Air Intake Manifold Group. (FIGURE 2-50)
FIGURE 2-50. Air Intake Manifold Group
REPAIR
Replace/Repair Exhaust Manifold Group. (FIGURE 2-51)
FIGURE 2-51. Exhaust Manifold
REPLACEMENT
Replace/Repair Cylinder Head Group. (FIGURE 2-53)
FIGURE 2-53. Cylinder Head Group
FIGURE 2-54. Cylinder Head Torque Sequence
REPLACEMENT
Replace/Repair Power Take-Off Assembly. (FIGURE 2-55)
FIGURE 2-55. Power Take-Off Assembly Repair
INSPECTION
INSPECTION-cont.
FIGURE 2-56. Bearing End Clearance
Replace Friction Clutch Assembly
FIGURE 2-57. Friction Clutch Assembly Repair (Sheet 1 of 2).
FIGURE 2-57. Friction Clutch Assembly Repair (Sheet 2 of 2).
INSPECTION
REPLACEMENT
FIGURE 2-58. Bearing End Clearance
Repair Oil Pan Group. (FIGURE 2-59)
FIGURE 2-59. Oil Pan Group
INSPECTION/REPAIR
FIGURE 2-61. Oil Pan Capscrews Torque Sequence
SECTION VI. PREPARATION FOR STORAGE OR SHIPMENT
SECTION VI. PREPARATION FOR STORAGE OR SHIPMENT-cont.
Preparing an Engine From Storage to Service
Inspecting 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
Low power
Piston noise
SECTION V. INTERMEDIATE DIRECT SUPPORT MAINTENANCE PROCEDURES
FIGURE 3-1. Bowthruster Engine
FIGURE 3-2. Lifting Fixture P/N ST-125
Repair Lubricating Oil Cooler/Filter Group
REPAIR
FIGURE 3-3. Oil Cooler Pressure Regulator
REPAIR-cont.
FIGURE 3-5. Tube Bundle Tester
FIGURE 3-6. Aligning Index Marks
REPLACEMENT
Repair Fuel Tubing, Shut-Down Valve, and Fuel Pump Group
FIGURE 3-8. Fuel Pump.
FIGURE 3-10. Fuel Pump Fluid Pressure Dampener
DISASSEMBLY
FIGURE 3-12. Fuel Pump Electric Governor Actuator and Fluid Filter Element Assembly
REPAIR
ASSEMBLY
ASSEMBLY-cont.
Replace/Repair Rocker Lever Housing/Cover Group
FIGURE 3-13. Rocker Lever Housing Group
REMOVAL
REPAIR
FIGURE 3-15. Installing the Arms and Levers on Shaft
REPLACEMENT
FIGURE 3-17. Rocker Lever Adjusting Screw
FIGURE 3-18. Rocker Housing Torque Sequence
FIGURE 3-19. Rotating Accessory Drive
Table 2-4. Injector and Valve Adjustment Sequence
FIGURE 3-21. Aligning Pulley and Gear Pointer
FIGURE 3-22. Installing Dial Indicator and Support
FIGURE 3-22. Installing Dial Indicator and Support
FIGURE 3-24. Torque Methods
FIGURE 3-25. Injector Adjusting Screw
FIGURE 3-26. Loosening Injector Adjusting Screw
Crosshead Adjustment
FIGURE 3-27. Checking Valve Lash (Feeler Method )
FIGURE 3-29. Cover Manufactured Bow Areas
FIGURE 3-30. Rocker Arm Cover Torque Sequence
FIGURE 3-31. Crankcase Breather and Tube
Repair Heat Exchanger Group. (FIGURE 3-32)
FIGURE 3-32. Heat Exchanger Group .
REPLACEMENT
Replace/Repair Cam Follower Housing Group.
FIGURE 3-33. Cam Follower Housing Group
REPLACEMENT
FIGURE 3,-35. Advanced and Retarded Timing
FIGURE 3-36. Timing Changes
FIGURE 3-37. Injection Timing Tool
Figure 3-38. Crankshaft Rotation for Timing
Check the injection timing
Table 3-3. Injection Timing Codes and Push Rod Travel
Table 3-3. Injection Timing Codes and Push Rod Travel - CONT
Table 3-4. Change in Push Rod Travel Due to Gasket Thickness
Table 3-4. Change in Push Rod Travel Due to Gasket Thickness-cont.
Replace/Repair Accessory Drive and Pulley Group
FIGURE 3-40. Power Take Off, Accessory Drive and Pulley Group
FIGURE 3-42. Inspection Hole
FIGURE 3-43. Gear Alignment
FIGURE 3-45. Removing Accessory Drive
FIGURE 3-46. Relieving Press Fit
REPLACEMENT
REPLACEMENT-cont.
Replace/Repair Gear Cover Group
FIGURE 3-47. PTO Housing and Mounts
FIGURE 3-48. Bearing Support
FIGURE 3-50. Gear Housing (Cover )
REPLACEMENT
FIGURE 3-51. Dial Indicating Crankshaft Face
Shim Thickness
REPLACEMENT-cont.
FIGURE 3-53. Oil Pan Capscrew Torque Sequence
Replace/Repair Power Takeoff Assembly
FIGURE 3-54. Power Takeoff Assembly (SL-111 HP2 )
FIGURE 3-55. Power Takeoff Assembly (SL-111 HP2 )
DISASSEMBLY
REPAIR
FIGURE 3-56. Adjusting Roller Bearings
FIGURE 3-57. Adjusting Retainer Nut
ASSEMBLY
ASSEMBLY-cont.
FIGURE 3-58. Pilot Bearing (PTO/SL-111)
REPLACEMENT
Replace/Repair Friction Clutch Assembly
FIGURE 3-59. Friction Clutch Assembly (SP-214-P1)
REPAIR
FIGURE 3-60. Friction Clutch Assembly Repair (Sheet 1 of 2)
FIGURE 3-60. Friction Clutch Assembly Repair (Sheet 2 of 2).
REPAIR-cont.
FIGURE 3-61. Adjusting Roller Bearings.
FIGURE 3-62. Adjusting Retainer Nut
REPAIR-cont.
FIGURE 3-63. Bearing End Clearance.
REPLACEMENT
Replace/Repair Lubricating Oil Pump Group
FIGURE 3-64. Lubricating Oil Pump Group.
FIGURE 3-65. Drive Shaft End Clearance
REPAIR
FIGURE 3-66. Install the Guide Bushing into the Gear Pocket
DISASSEMBLY
ASSEMBLY (Refer to FIGURE 3-64)
Table 3-5. Oil Pump Shaft Limits - Inch (mm)
REPLACEMENT
Replace Camshaft Group
FIGURE 3-69. Holding Camshaft Pilots in Place
REPLACEMENT
FIGURE 3-72. Checking Gear Backlash
Replace/Repair Connecting Rod and Piston Group
FIGURE 3-73. Rotating Crankshaft to Bottom Dead Center (BDC)
REPLACEMENT
REPLACEMENT-cont.
FIGURE 3-75. Positioning Ring Gaps
FIGURE 3-77. Using Piston Ring Compressor
FIGURE 3-78. Matching Rod Cap Numbers
Replace/Repair Flywheel and Flywheel Housing Assembly
FIGURE 3-79. Guide Studs and T-Handles
FIGURE 3-80. Flywheel and Flywheel Housing Group
FIGURE 3-81. Removing Flywheel
FIGURE 3-82. Rear Cover Capscrews
FIGURE 3-84. Crankshaft Flange Cover
REPAIR
FIGURE 3-86. Flywheel Housing Guide Studs
FIGURE 3-88. Flywheel Housing Torque Sequence.
FIGURE 3-89. Attaching Dial Indicator to Crankshaft.
FIGURE 3-91. Housing Bore Diameter
Table 3-10. Allowable Total Indicator Reading Flywheel Housing Bore and Face
Table 3-10. Allowable Total Indicator Reading Flywheel Housing Bore and Face-c0nt.
FIGURE 3-93. Using Seal Driver
Checking Rear Cover and Oil Pan Flange
FIGURE 3-96. Installing Seal With Driver
FIGURE 3-98. Install Pilot Bearing
Install the flywheel
FIGURE 3-100. Checking Flywheel Face Runout
Install the flywheel.-cont.
Install the flywheel.-cont.
Replace Cylinder Block Group
REPLACEMENT
Replace Bowthruster Sub-Base Assembly
FIGURE 3-101. Bowthruster Sub-Base Assembly
SECTION VI. PREPARATION FOR STORAGE OR SHIPMENT
CHAPTER 4 INTERMEDIATE GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
SECTION II. SERVICE UPON RECEIPT
Table 4-1. Troubleshooting
Lubricating oil in the coolant
SECTION V. INTERMEDIATE GENERAL SUPPORT MAINTENANCE PROCEDURES
Repair Cylinder Head Group
FIGURE 4-1. Cylinder Head Assembly - Exploded View
REPAIR
FIGURE 4-3. Cylinder Head (Table 4-3 Reference)
FIGURE 4-4. Injector Sleeve Holding Tool.
FIGURE 4-5. Hydrostatic Tester and Plate.
Cylinder head pressure test procedures
FIGURE 4-6. Removing the Arbor
Remove test equipment.
FIGURE 4-8. Using Staking Tool Driver and Staking
Valve Guides. Inspection and replacement procedures
Valves. Inspection, grinding and replacement
Valve grinding
Valve Springs. Inspection and replacement
FIGURE 4-10. Crosshead Inspection Areas
Cylinder head water holes. Inspection and repair
FIGURE 4-11. Adjusting Counterbore Cutter
Injector sleeves
FIGURE 4-12. Installing Injector Sleeve O-Ring
FIGURE 4-13. Using Gauge Block
FIGURE 4-14. Injector Sleeve Measurements
Table 4-3. Specifications for Cylinder Head, Valves, Crosshead Guides, and Injector Sleeves-inch (mm)
Table 4-4. Oversize Valve Seat Insert Specifications-inch (mm)
ASSEMBLY
FIGURE 4-15. Expansion (Cup) Plug Specifications
ASSEMBLY
Test the valve seats
Repair Cam Follower Housing Group
FIGURE 4-17. Cam Follower Lockscrews
REPAIR
Table 4-7. Cam Follower Group Specifications-inch (mm)
FIGURE 4-20. Inspecting Levers for Cracks
Inspect the rollers
ASSEMBLY
ASSEMBLY-cont.
Repair Power-Takeoff (PTO) Assembly. (SL111 HP2/with non-adjusting clutch.)
FIGURE 4-21. Power Takeoff Assembly (SL-111)
DISASSEMBLY
REPAIR
ASSEMBLY
FIGURE 4-22. Adjusting Roller Bearings
FIGURE 4-23. Adjusting Retainer Nut
Dial indicate the end play
FIGURE 4-24. Pilot Bearing (PTO/SL-111)
Dial indicate the end play-cont.
Repair Friction Clutch Power-Takeoff Assembly. (SP 214 Pl/with a djustable clutch.)
DISASSEMBLY
FIGURE 4-25.FRICTION CLUTCH (POWER TAKE OFF ) ASSEMBLY .(SP-214).
DISASSEMBLY-CONT
REPAIR
ASSEMBLY
FIGURE 4-26. Pilot Bearing (PTO/SP-214)
ASSEMBLY-CONT.
Repair Camshaft Group
FIGURE 4-27. Removing Camshaft Gear
FIGURE 4-28. Measuring Gear Bore
FIGURE 4-29. Measuring Camshaft Nose
ASSEMBLY
FIGURE 4-30. Seating the Gear and Checking Clearance.
Repair Connecting Rod and Piston Group
FIGURE 4-31. Connecting Rod and Piston Group
FIGURE 4-32. Removing Piston Rings
FIGURE 4-33. Counterweight Markings for Bearing Sizes
FIGURE 4-34. Connecting Rod Torque Sequence
Table 4-8. Connecting Rod Torque Specifications
Table 4-8. Connecting Rod Torque Specifications-CONT.
FIGURE 4-35. Fillet Radius
Clean and inspect the pistons
FIGURE 4-36. Ring Gap
REPAIR
FIGURE 4-37. Installing Piston Pin Bushing
ASSEMBLY
FIGURE 4-38. Installing Rings
FIGURE 4-39. Oil Control Ring
Rod bearings
Repair Flywheel and Flywheel Housing Group
FIGURE 4-41. Flywheel and Housing Group
REPAIR
Replace/Repair Crankshaft Group
FIGURE 4-42. Crankshaft Group
FIGURE 4-44. Removing Dowel Ring
REPLACE/REPAIR
FIGURE 4-46. Measuring Crankshaft Bore
FIGURE 4-47. Front Counterweight Markings
FIGURE 4-48. Rear Counterweight Markings
REPLACEMENT
FIGURE 4-49. Bearing Shell Identification
FIGURE 4-50. Positioning Bearing Grooves
FIGURE 4-51. Installing the Bearing Shell
FIGURE 4-52. Bearing Cap Location Marks.
Align the bearing shell with the dowel ring
FIGURE 4-54. Example of Oversize Thrust Bearing Marks
Repair Cylinder Block Group
DISASSEMBLY
FIGURE 4-55. Cylinder Block Group
FIGURE 4-56. Extended Foot Type Puller
FIGURE 4-57. Liner Press Fit Area.
Measuring Counterbore
FIGURE 4-59. Applying Sealant to Liner
FIGURE 4-60. Measuring Liner Protrusion.
FIGURE 4-61. Liner and Lower Liner Bore Clearance
FIGURE 4-62. Checking Liner Bore
FIGURE 4-63. Piston Coolin2 Nozzles.
FIGURE 4-64. Camshaft Bushing/Bearing Removal Sequence.
FIGURE 4-65. Bushing Driver Identification
Camshaft Bushing Guide
ASSEMBLY
SECTION VI. PREPARATION FOR STORAGE OR SHIPMENT
APPENDIX A REFERENCES
APPENDIX B MAINTENANCE ALLOCATION CHART
Maintenance Functions
Explanation of Columns in Tool and Test Equipment Requirements, Section III.
Explanation of Columns in Remarks, Section IV.
SECTION II. MAINTENANCE ALLOCATION CHART FOR BOWTHRUSTER ENGINE
SECTION II. MAINTENANCE ALLOCATION CHART FOR BOWTHRUSTER ENGINE
SECTION II. MAINTENANCE ALLOCATION CHART FOR BOWTHRUSTER ENGINE
SECTION II. MAINTENANCE ALLOCATION CHART FOR BOWTHRUSTER ENGINE
SECTION II. MAINTENANCE ALLOCATION CHART FOR BOWTHRUSTER ENGINE
SECTION II. MAINTENANCE ALLOCATION CHART FOR BOWTHRUSTER ENGINE
SECTION II. MAINTENANCE ALLOCATION CHART FOR BOWTHRUSTER ENGINE
SECTION III. TOOL AND TEST REQUIREMENTS FOR BOWTHRUSTER ENGINE
SECTION III. TOOL AND TEST REQUIREMENTS FOR BOWTHRUSTER ENGINE
SECTION III. TOOL AND TEST REQUIREMENTS FOR BOWTHRUSTER ENGINE
SECTION III. TOOL AND TEST REQUIREMENTS FOR BOWTHRUSTER ENGINE
SECTION III. TOOL AND TEST REQUIREMENTS FOR BOWTHRUSTER ENGINE
SECTION III. TOOL AND TEST REQUIREMENTS FOR BOWTHRUSTER ENGINE
SECTION III. TOOL AND TEST REQUIREMENTS FOR BOWTHRUSTER ENGINE
SECTION IV. REMARKS BOWTHRUSTER ENGINE
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
SECTION II. EXPENDABLE / DURABLE SUPPLIES AND MATERIAL LIST
SECTION II. EXPENDABLE / DURABLE SUPPLIES AND MATERIAL LIST
APPENDIX D TORQUE VALUES
Table D-1. Capscrew Markings and Torque Values-CONT
Table D-4. Fuel Pump Torque Specifications
GLOSSARY
GLOSSARY - CONT
GLOSSARY - CONT
GLOSSARY - CONT
GLOSSARY - CONT
GLOSSARY - CONT
INDEX
INDEX - CONT
INDEX - CONT
THE METRIC SYSTEM AND EQUIVALENT
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