Enclosure 64 - TM-55-1905-223-24-1 - Main Propulsion Engine (MPE).pdf

TM 55-1905-223-24-1

TECHNICAL MANUAL

UNIT, INTERMEDIATE DIRECT INTRODUCTION 1-1

SUPPORT

AND INTERMEDIATE GENERAL SUPPORT UNIT MAINTENANCE 2-1

MAINTENANCE INSTRUCTIONS INSTRUCTIONS

MAIN PROPULSION ENGINE INTERMEDIATE GENERAL

FOR MAINTENANCE INSTRUCTIONS 3-1

LANDING CRAFT UTILITY (LCU)

NSN 1905-01-154-1191 INTERMEDIATE GENERAL SUPPORT

MAINTENANCE INSTRUCTIONS 4-1

APPENDIXES A-1

ALPHABETICAL INDEX-1

INDEX

STARBOARD (RIGHT SIDE) PORT (LEFT SIDE)

HEADQUARTERS, DEPARTMENT OF THE ARMY

JANUARY 1989

DISTRIBUTION STATEMENT A: Approved for public release, distribution is unlimited.

WARNING

MODIFICATION HAZARD

Unauthorized modifications, alterations or installations of or to this equipment are prohibited and are in violation of AR 750-10. Any such unauthorized modifications, alterations or installations could result in death, injury or damage to the equipment.

HIGH PRESSURE

HYDRAULIC SYSTEM HAZARDS

Hydraulic systems can cause serious injuries if high pressure lines or equipment fail.

Never work on hydraulic systems or equipment unless there is another person nearby who is familiar with the operation and hazards of the equipment, and who can give first aid. A second person should stand by controls to turn off hydraulic pumps in an emergency. When the technicians are aided by the operators, the operators must be warned about dangerous areas.

MOVING MACHINERY HAZARDS

Be very careful when operating or working near moving machinery.

Running engines, rotating shafts, and other moving machinery parts could cause personal injury or death.

ELECTRICAL HAZARDS

Whenever possible, the power supply to the equipment must be shut off before beginning work on the equipment. Do not be misled by the term "low voltage." Potentials as low as 50 volts may cause death under adverse conditions.

Be careful not to contact 115-Vac input connections when installing or operating this equipment.

Whenever the nature of the operation permits, keep one hand away from the equipment to reduce the hazard of current flowing through the body.

For Artificial Respiration, refer to FM 21-11.

(b blank) a

C 5

CHANGE HEADQUARTERS

DEPARTMENT OF THE ARMY

NO. 5 WASHINGTON, D.C., 01 July 2009

UNIT, INTERMEDIATE DIRECT SUPPORT AND

INTERMEDIATE GENERAL SUPPORT

MAINTENANCE INSTRUCTIONS

MAIN PROPULSION ENGINE

FOR

LANDING CRAFT UTILITY (LCU)

NSN 1905-01-154-1191

DISTRIBUTION STATEMENT A: Approved for public release, distribution is unlimited.

TM 55-1905-223-24-1, 17 January 1989, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages

Insert pages

A and B i and ii i and ii 1-1 through 1-4 1-1 through 1-4 1-7 and 1-8 1-7 and 1-8 2-1 and 2-2 2-1 and 2-2 2-11 through 2-14 2-11 through 2-14 . . . . 2-14.1 and 2-14.2 . . . . 2-18.1/(2-18.2 blank) 2-21 and 2-22 2-21 and 2-22 2-25 through 2-34 2-25 through 2-34 . . . . 2-34.1 through 2-34.4 2-37 through 2-40 2-37 through 2-40 . . . . 2-40.1 through 2-40.6 2-69 through 2-74 2-69 through 2-74 . . . . 2-74.1 through 2-74.6 3-99 through 3-104 3-99 through 3-102 . . . . 3-102.1 through 3-102.4 . . . . 3-103 and 3-104 B-5 and B-6 B-5 and B-6 B-17 and B-18 B-17 and B-18 B-19/(B-20 blank) Index 1 through Index 3/(Index 4 blank) Index 1 through Index 3/(Index 4 blank) 2028's 2028's

TECHNICAL MANUAL

C 5

2. Retain this sheet in front of manual for reference purposes.

DISTRIBUTION:

To be distributed in accordance with initial distribution number (IDN) 253659, requirements

By Order of the Secretary of the Army:

GEORGE W. CASEY, JR.

General, United States Army

Chief of StaffOfficial:

0819301

JOYCE E. MORROW

Administrative Assistant to the

Secretary of the Army for TM 55-1905-223-24-1.

C4

CHANGE HEADQUARTERS

DEPARTMENT OF THE ARMY

NO. 4 WASHINGTON, D.C., 28 February 1994

Unit, Intermediate Direct Support and Intermediate General Support Maintenance Instructions

MAIN PROPULSION ENGINE

for

LANDING CRAFT UTILITY (LCU)

NSN 1905-01-154-1191

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited

TM 55-1905-223-24-1, 17 January 1989, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages i and ii i and ii 2-117 and 2-118 2-117 and 2-118 B-17 and B-18 B-17 and B-18

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVAN

General, United States Army

Chief of Staff

Official:

MILTON H. HAMILTON

Administrative Assistant to the

Secretary of the Army 06473

DISTRIBUTION:

To be distributed in accordance with DA Form 12-25-E, block no. 3659, requirements for TM 55-1905-223-

24-1.

C3

CHANGE HEADQUARTERS

DEPARTMENT OF THE ARMY

NO. 3 WASHINGTON, D. C., 09 NOVEMBER 1992

Unit, Intermediate Direct Support and Intermediate General Support Maintenance Instructions

MAIN PROPULSION ENGINE

FOR LANDING CRAFT UTILITY (LCU)

(NSN 1905-01-154-1191)

Approved for public release; Distribution is unlimited

TM 55-1905-223-24-1, 17 January 1989 is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

2-143 and 2-144 2-143 and 2-144 B-9 and B-10 B-9 and B-10 B-17 and B-18 B-17 and B-18

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVAN

General, United States Army'

Chief of Staff

MILTON H. HAMILTON

Administrative Assistant to the

Secretary of the Army 03011

DISTRIBUTION:

To be distributed in accordance with DA Form 12-25-E, block no. 3659, requirements for TM 55-1905-223-

24-1.

C2

CHANGE HEADQUARTERS

DEPARTMENT OF THE ARMY

NO. 2 WASHINGTON, D. C., 27 APRIL 1992

UNIT, INTERMEDIATE DIRECT SUPPORT AND INTERMEDIATE

GENERAL SUPPORT MAINTENANCE INSTRUCTIONS

MAIN PROPULSION ENGINE

FOR LANDING CRAFT UTILITY (LCU)

(NSN 1905-01-154-1191)

Approved for public release; distribution is unlimited

TM 55-1905-223-24-1, dated 17 January 1989 is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

2-17 and 2-18 2-17 and 2-18 3-25 through 3-30 3-25 through 3-30

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

GORDON R. SULLIVAN

General, United States Army

Chief of Staff Official:

MILTON H. HAMILTON

Administrative Assistant to the

Secretary of the Army 01072

DISTRIBUTION:

To be distributed in accordance with DA Form 12-25E, (qty rqr bl no. 3659).

C1

CHANGE HEADQUARTERS

DEPARTMENT OF THE ARMY

NO. 1 WASHINGTON, D. C., 10 July 1990

Unit, Intermediate Direct Support and Intermediate General Support

Maintenance Instructions

MAIN PROPULSION ENGINE

for

LANDING CRAFT UTILITY

(NSN 1905-01-154-1191)

Approved for public release; distribution is unlimited

TM 55-1905-223-24-1, 17 January 1989, is changed as follows:

1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the margin. An illustration change is indicated by a miniature pointing hand.

Remove pages Insert pages

2-29 and 2-30 2-29 and 2-30 2-35 through 2-38 2-35 through 2-38 2-45 and 2-46 2-45 and 2-46 2-49 and 2-50 2-49 and 2-50 2-121 and 2-122 2-121 and 2-122 2-129 through 2-132 2-129 through 2-132 2-139 and 2-140 2-139 and 2-140 3-9 and 3-10 3-9 and 3-10 3-21 and 3-22 3-21 and 3-22 3-25 and 3-26 3-25 and 3-26 3-51 and 3-52 3-51 and 3-52 3-61 and 3-62 3-61 and 3-62 3-73 and 3-74 3-73 and 3-74 3-91 and 3-92 3-91 and 3-92 3-99 and 3-100 3-99 and 3-100 4-5 through 4-8 4-5 through 4-8 4-29 and 4-30 4-29 and 4-30 4-37 and 4-38 4-37 and 4-38 4-43 and 4-44 4-43 and 4-44 4-59 and 4-60 4-59 and 4-60 4-69 and 4-70 4-69 and 4-70 4-75 and 4-76 4-75 and 4-76 4-83 and 4-84 4-83 and 4-84 B-5 through B-18 B-5 through B-18

2. Retain this sheet in front of manual for reference purposes.

C1

By Order of the Secretary of the Army:

CARL E. VUONO

General, United States Army

Chief of Staff Official:

WILLIAM J. MEEHAN, II

Brigadier General. United States Army

The Adjutant General

DISTRIBUTION:

To be distributed in accordance with DA Form 12-25E, Unit, Intermediate Direct Support and Intermediate

General Support Maintenance requirements for Landing Craft, Utility, LUC-1466, Type III

* Zero in this column indicates an original page.

Change 5 A

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED DATA.

LIST OF EFFECTIVE PAGES

NOTE: The portion of text affected by the changes is indicated by a vertical line in the outer margins of the page.

Changes to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original 0 17 January 1989 Change 1 10 July 1990 Change 2 27 April 1992

Change 3 09 November 1992 Change 4 28 February 1994 Change 5 01 July 2009

TOTAL NUMBER OF PAGES IS 432 CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Cover a/(b blank) i ii 1-1 1-2 1-3 and 1-4 1-5 and 1-6 1-7 and 1-8 1-9/(1-10 blank) 2-1 2-2 2-3 through 2-11 2-12 through 2-14 2-14.1 and 2-14.2 2-15 through 2-18 2-18.1/(2-18.2 blank) 2-19 and 2-20 2-21 and 2-22 2-23 and 2-24 2-25 through 2-34 2-34.1 through 2-34.4 2-35 2-36 2-37 2-38 2-39 and 2-40 2-40.1 through 2-40.6 2-41 through 2-45 2-46 2-47 through 2-49 2-50 2-51 through 2-68 2-69 2-70 and 2-71 2-72 2-73 2-74 2-74.1 through 2-74.6

2-75 through 2-116 2-117 2-118 through 2-120 2-121 2-122 through 2-128 2-129 2-130 and 2-131 2-132 2-133 through 2-139 2-140 2-141 and 2-142 2-143 and 2-144 2-145 through 2-148 3-1 through 3-9 3-10 3-11 through 3-20 3-21 3-22 through 3-25 3-26 3-27 3-28 and 3-29 3-30 through 3-50 3-51 3-52 through 3-61 3-62 3-63 through 3-72 3-73 3-74 through 3-90 3-91 3-92/(3-93 blank) 3-94 through 3-99 3-100 through 3-102 3-102.1 through 3-102.4 3-103 3-104 through 3-106 4-1 through 4-5 4-6 and 4-7 4-8 through 4-29 4-30

* Zero in this column indicates an original page.

B Change 5

Page *Change Page *Change No. No. No. No.

4-31 through 4-36 4-37 4-38 through 4-42 4-43 4-44 through 4-59 4-60 4-61 through 4-68 4-69 4-70 through 4-75 4-76 4-77 through 4-83 4-84 4-85 through 4-106

A-1/(A-2 blank) B-1 through B-4 B-5 and B-6 B-7 and B-8 B-9 B-10 B-11 through B-16 B-17 B-18 C-1 through C-3/(C-4 blank) D-1 through D-4 Glossary 1/(Glossary 2 blank) Index 1 through Index 3/(Index 4 blank)

Change 5 i

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY

No. 55-1905-223-24-1 WASHINGTON, D.C. 17 January 1989

UNIT, INTERMEDIATE DIRECT SUPPORT

AND INTERMEDIATE GENERAL SUPPORT

MAINTENANCE INSTRUCTIONS

MAIN PROPULSION ENGINE

FOR

LANDING CRAFT, UTILITY (LCU)

NSN 1905-01-154-1191

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TABLE OF CONTENTS

PAGE

CHAPTER 1 INTRODUCTION......................................................................................................1-1

Section I General Information .................................................................................................1-1 Section II Equipment Description and Data .............................................................................1-2 Section III Principles of Operation.............................................................................................1-7

CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS..................................................................2-1

Section I Repair Parts, Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Support Equipment ..........................................................2-1 Section II Service Upon Receipt ..............................................................................................2-1 Section III Unit Preventive Maintenance Checks and Services (PMCS) .................................2-7 Section IV Unit Maintenance Troubleshooting ........................................................................2-19 Section V Unit Maintenance Procedures................................................................................2-35 Section VI Preparation for Storage, Reshipment, and Return to Service .............................2-146

CHAPTER 3 INTERMEDIATE DIRECT SUPPORT MAINTENANCE INSTRUCTION.................3-1

Section I Repair Parts, Special Tools; Test, Measurement and Diagnostic Equipment (TMDE); and Support Equipment ..........................................................3-1 Section II Service Upon Receipt .............................................................................................3-1 Section III Intermediate Direct Support Preventive Maintenance Checks and Services (PMCS)..................................................................................3-2

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil.

The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LC-LMPP / TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726.

ii

TABLE OF CONTENTS - cont

PAGE

Section IV Intermediate Direct Support Troubleshooting...............................................................3-3 Section V Intermediate Direct Support Maintenance Procedures.................................................3-7 Section VI Preparation for Storage or Shipment ........................................................................3-106

CHAPTER 4 INTERMEDIATE GENERAL SUPPORT MAINTENANCE

INSTRUCTIONS...........................................................................................................4-1

Section I Repair Parts, Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Support Equipment ...............................................................4-1 Section II Service Upon Receipt ..................................................................................................4-1 Section III Intermediate General Support Preventive Maintenance Checks and Services (PMCS) .....................................................................................4-2 Section IV Intermediate General Support Troubleshooting ...........................................................4-3 Section V Intermediate General Support Maintenance Procedures .............................................4-6 Section VI Preparation for Storage or Shipment ........................................................................4-106

APPENDIX A REFERENCES ............................................................................................................ A-1

APPENDIX B MAINTENANCE ALLOCATION CHART ..................................................................... B-1

APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST ................................. C-1

APPENDIX D TORQUE VALUES ...................................................................................................... D-1

GLOSSARY ABBREVIATIONS AND DEFINITIONS ............................................................Glossary 1

ALPHABETICAL INDEX ..................................................................................................................... Index 1

Change 5 1-1

CHAPTER 1

INTRODUCTION

Page

Section I. General Information....................................................................................................1-1

Section II. Equipment Description and Data ................................................................................1-2

Section III. Principles of Operation ...............................................................................................1-7

SECTION I. GENERAL INFORMATION

1-1. Scope. The scope of this manual is as follows:

a. Type of Manual. Unit, Intermediate Direct Support and Intermediate General Support Maintenance manual.

b. Model Number and Equipment Name. Main Propulsion Engine, Model KTA50-M.

c. Purpose of Equipment. Provides drive power to the marine gear to propel the craft.

1-2. Maintenance Forms, Records, and Reports. Department of the Army forms and procedures used for equipment maintenance are prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

1-3. Destruction of Army Materiel. Refer to TM 750-244-3 for instructions covering the destruction of Army materiel to prevent enemy use.

1-4. Reporting Equipment Improvement Recommendations (EIR). If your Engine needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment.

Let us know why you don't like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/aepspublic.cfm (scroll down and choose the “Submit Quality Deficiency Report” bar). The Internet form lets you choose to submit an Equipment Improvement Recommendation (EIR), a Product Quality Deficiency Report (PQDR) or a Warranty Claim Action (WCA). You may also submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 via e-mail, regular mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply.

1-5. Preparation for Storage or Shipment. Administrative storage of equipment issued to and used by Army activities will have preventive maintenance performed in accordance with the Preventive Maintenance Checks and Services (PMCS) charts before storing. When removing the equipment from administrative storage, the PMCS should be performed to assure operational readiness. Repacking of equipment for shipment or short term storage is covered in paragraph 2-38.

1-2

Section II. EQUIPMENT DESCRIPTION AND DATA

1-6. General Description. The KTA50-M is a 1250 hp, 16 cylinder, water-cooled diesel engine designed for marine use. The main propulsion engines furnish drive power to the marine gear. The main propulsion engines are equipped with remote and local control stations.

1-7. Characteristics, Capabilities, and Features. A very broad view of the main propulsion engines is as follows:

a. Characteristics.

(1) Turbocharger allows more horsepower to be developed.

(2) Fuel injectors deliver atomized fuel into combustion chambers for ignition by heat of compressed air.

(3) Four stroke cycle, in order, is: intake stroke, compression stroke, power stroke, and exhaust stroke.

(4) Cooling as follows:

(a) Engine operating heat is controlled by coolant.

(b) Lube oil is controlled by lube oil cooler.

(c) Air is cooled or heated as necessary by an aftercooler.

b. Capabilities and Features.

(1) Furnishes 1,250 hp to drive the marine propellers.

(2) Can put out 2,100 rpm (maximum).

(3) Engine idle speed is 725-775 rpm.

(4) Has both remote and local controls.

1-8. Location and Description of Major Components. FIGURE 1-1 shows views of each side of the engine with the locations of major components indicated. Refer to FIGURE 1-1 and the reference number key below for the description of these components.

a. Turbocharger Group (1). Two turbine wheels, one located on the exhaust manifold on each side of the engine.

b. Air Cleaner Group (2). Two filter canister and cover assemblies, located on the top of the engine.

c. Air Intake Manifold Group (3). Intake air distribution piping, located on both sides of the engine.

d. Thermostat Housing/Water Transfer Tube Group (4). Thermostat and water distribution piping, located on the front of the engine behind the water filters.

Change 5 1-3

FIGURE 1-1. Location of Major Components.

1-4 Change 5

e. Water Filter Group (5). Four spin-on filters and head assembly, located on the front of the engine.

f. Cylinder Block assembly (6). The engine block, which supports the assemblies necessary for engine operation.

f.1. Fuel Filter/Water Separator (6A). Applies only to vessels with MWO 55-1905-223-55-7 installed.

Two 30 micron filters, located on the front of the engine.

g. Water Pump Group (7). Centrifugal water pump, located on the right side near the front of the engine.

g.1. Coalescer Filter (7A). Filters compressed air for air start system, located on the right side of the engine.

g.2. Lubricator (7B). Provides atomized lubricant to compressed air for air start system, located on the right side of the engine.

h. Cold Starting Aid Group (8). Two thermostatically controlled coolant heaters, located on the deck on either side of the engine.

i. Lubricating Oil Pump Group (9). Gear driven lube oil pump, located in the cylinder block directed below the crankshaft.

j. Lube Oil Bypass Filter Group (10). Two spin-on filters and head assembly, located on the lower right rear corner of the engine.

k. Engine Air Starter (11). Turbine driven starter, located on the right side near the rear of the engine.

l. Lubricating Oil Cooler Group (12). Plate type heat exchangers, located in the main water passage in the center of the "V" of the cylinder block.

m. Sump Pump Group (13). Manually operated lube oil pump, located at the right rear of the engine.

n. Fuel Manifold Group (14). Fuel distribution piping assembly, located on the rocker lever housing on both sides of the engine.

o. Rocker Housing Cover, Rocker Lever Housing Group (15). Sixteen rocker lever assemblies, located on the top of the cylinder heads.

p. Cylinder Head Group (16). Sixteen cylinder head assemblies, located on the top of the cylinder block.

q. Instrument Panel Group (17). Electrical panel, located at the top rear of the engine, that contains gauges and switches for local control of the engine.

r. Exhaust Manifold Group (18). Exhaust air assembly, located on the top of both sides of the engine.

s. Fuel Filter Group (19). Applies only to vessels without MWO 55-1905-223-55-7 installed. Two filter canister assemblies, located on the rear of the engine near the top.

t. Connecting Rod and Piston Group (Internal. 20). Sixteen sets of pistons and connecting rods, located in the cylinder block.

u. Flywheel Housing Group (21). The flywheel, ring gear, and barring mechanism assemblies, located at the lower rear of the engine.

v. Handhole Cover Group (22). Eight access covers, located on each side of the cylinder block.

w. Lube Oil Filter Assembly (23). Five spin-on filters and head assembly, located on left side of engine near the rear.

x. Oil Pan and Adapter Group (24). Lube oil pan, located under the engine.

y. Fuel Pump Group (25). Gear-driven pump and throttle assembly, located on the left side near the front of the engine.

z. Engine Support Group (26). Engine mounting support assembly, located below the front and rear of the engine.

aa. Camshaft and Gear Group (27). Two camshafts and gears, located in the cylinder block.

ab. Vibration Damper/Bearings/Crankshaft Group (28). Vibration damper and crankshaft, located in the cylinder block.

ac. Pulley Shield/Front Gear Housing Group (29). Housing assembly, located on the front of the engine.

ad. Shutdown Valve Group (30). Solenoid-operated shutdown valve assembly,

ae. Cam Follower and Housing Group (31). Sixteen cam follower assemblies located in the cylinder block.

af. Injector Group (32). Sixteen fuel injectors, one in each cylinder head.

1-5

1-9. Equipment Data. Characteristics and reference data are provided in Table 1-1. Also see the equipment data given in the operator's manual, TM 55-1905-223-10.

Table 1-1. Equipment Data Characteristics Reference Data

GENERAL ENGINE DATA

Horsepower 1250 hp Engine Speed @ Maximum Output 2100 rpm Bore and Stroke 6.25 in (159 mm) x 6.25 in (159 mm) Displacement 3067 in3 (50.3 litres) Compression Ratio 14.5:1 to 15.5:1 Firing Order 1R-1L-3R-3L-7R-7L-5R-5L-8R-8L-6R-6L-

2R-2L-4R-4L Engine Weight Dry Weight 11,000 lb (4950 kg) Wet Weight 12,000 lb (5400 kg) Dimensions (overall) Length 98.8 in (251.0 cm) Width 55.3 in (105.5 cm) Height 91.0 in (231.0 cm)

AIR INDUCTION SYSTEM

Maximum allowable turbocharged intake restriction 25 in H20 (63.5 cm H20)

LUBRICATION SYSTEM

Oil pressure at idle 20 psi (138 kPa) minimum idle 45 psi (310 kPa) minimum rated rpm 70 psi (483 kPa) maximum rated rpm

Oil capacity of engine:

Bypass filter 0.75 U.S. gl (2.8 litres) Full flow filter 0.93 U.S. gl (3.5 litres) Oil pan capacity (low-high) 32 to 55 U.S. gl (121-208.5 litres) Maximum oil temperature 250°F (120°C)

COOLING SYSTEM

Coolant capacity (engine only) 40.5 U.S. gallons (153 litres) Standard thermostat modulating range 175-195°F (80°-90°C) Maximum allowable top tank temperature 203°F (95°C) Minimum recommended top rank temperature 160°F (70°C) Minimum recommended pressure cap 7 psi (48 kPa)

1-6

Change 5 1-7

Table 1-1. Equipment Data-CONT

Characteristics Reference Data

EXHAUST SYSTEM

Maximum allowable back pressure imposed by piping and silencer 3 in Hg (75 mm Hg) Exhaust pipe size (normally acceptable inside diameter)

6 in (152 mm)

FUEL SYSTEM

Engine idle speed 725 to 775 rpm Engine Speed 725 to 2100 rpm

NOTE

Applies only to vessels without MWO 55-1905-223-55-7 installed.

Maximum allowable restriction to pump:

With clean filter 4 in Hg (100 mm Hg) With dirty filter 8 in Hg (200 mm Hg) Maximum allowable fuel return line restriction 2.5 in Hg (63 mm Hg)

Applies only to vessels with MWO 55-1905-223-55-7 installed.

Engine idle speed 725 to 775 rpm Engine Speed 725 to 2100 rpm Maximum allowable restriction to pump:

With clean filter 2 in Hg With dirty filter 10 in Hg Maximum allowable fuel return line restriction 2.5 in Hg (63 mm Hg) Fuel Filter/Water Separator Maximum Operating Pressure 15 psi Maximum Flow Rate 360 gph

1-10. Safety, Care, and Handling. Safety precautions must be observed at all times while performing maintenance. General WARNINGS and first-aid data appear in the front of this manual. Review all safety information before starting any task. Carefully read through an entire maintenance procedure before performing any maintenance function. Make sure the task can be done safely. All WARNINGS, CAUTIONS, and NOTES are of great importance to your safety and the safety of the equipment.

SECTION III. PRINCIPLES OF OPERATION

1-11. Diesel Engine Operation. Diesel engine operation is different from spark-ignited engine operation.

Compression ratios are higher and the charge taken into the combustion chamber during the intake stroke consists of air only, with no fuel mixture. Injectors receive low-pressure fuel from the fuel system and deliver it into individual combustion chambers at the proper time, and in the right quantity and atomized condition for burning.

Ignition of fuel is caused by heat of compressed air in the combustion chamber.

1-8 Change 5

a. Diesel Engine Cycles. The diesel engine four stroke combustion cycle consists of four piston strokes. The four strokes happen in this order: intake stroke, compression stroke, power stroke, and exhaust stroke (FIGURE 1-2). In order for the four strokes to function properly, valves and injectors must act in direct relation to each of the four strokes of the piston. The intake valves, exhaust valves, and injectors are camshaft actuated, linked by tappets or cam followers, push rods, rocker levers, and valve crossheads. The camshaft is driven by the crankshaft gear, and that means rotation of the crankshaft drives the camshaft, which then controls the opening and closing sequence of the valves and injection timing (fuel delivery).

FIGURE 1-2. Diesel Engine.

(1) Intake Stroke. During the intake stroke, the piston travels downward, the intake valve is open, and the exhaust valve is closed. The downward travel of the piston allows air from the intake manifold to enter the cylinder. The intake manifold is pressurized with air from the turbocharger.

(2) Compression Stroke. At the end of the intake stroke, the intake valve closes and the piston starts upward on compression stroke (exhaust valve remains closed). At end of compression stroke, air in combustion chamber is compressed into a small space, causing the air temperature to rise to a point high enough for ignition of fuel. During the last part of compression stroke and early part of power stroke, a small metered charge of fuel is injected into combustion chamber. The fuel is then ignited by the hot compressed air.

(3) Power Stroke. During the beginning of the power stroke, the piston is pushed downward by the burning and expanding gases (intake and exhaust valves are still closed). As more fuel is added and burns, gases get hotter and expand to further force the piston downward to deliver driving force to crankshaft rotation.

(4) Exhaust Stroke. During the exhaust stroke, the intake valve is closed, exhaust valve is open, and the piston is on the upstroke. Upward travel of the piston forces burned gases out of combustion chamber through the open exhaust valve port and into the exhaust manifold.

b. Cooling System. The coolant system removes heat created during engine operation. Coolant is circulated by a centrifugal water pump with mounted thermostats to control engine operating temperature.

Coolant temperature is reduced in a keel cooler (heat exchanger), and circulated through a water filter which passes a small amount of coolant from the system through a filtering and treating element. The engine is also equipped with two (one on each side of the block) coolant heaters which are thermostatically controlled to aid in cold weather operation. The system is treated with antifreeze to afford protection.

c. Lubrication System. The engine is pressure lubricated by a gear-type lube oil pump mounted to the block directly below the crankshaft and driven from the rear crankshaft gear. An external electric motor driven pump provides prelube pressure for starting.

(1) Filtering. Lube oil is filtered by five spin-on lube filters mounted to a common filter he ad. In the event of filter blockage, a bypass valve on the filter head routes the lube oil directly to the main oil galleries providing uninterrupted lube oil flow until the main filters are changed.

(2) Cooling. Lube oil is routed from the lube oil pump to lube oil cooler elements located in the block "V" between the cylinder banks and under the aftercooler. The coolers are finned heat exchangers which give off heat to the engine coolant which is circulated around them.

(3) Turbocharger Lubrication. Lube oil is routed from block drillings to the turbocharger supply line. The return line runs from the turbocharger to a block drilling where it is then routed back to the oil pan.

d. Air System. For the engine to operate efficiently, intake and exhaust systems must not be restricted. Intake air is routed through an air cleaner directly to the turbocharger and then to the aftercooler.

(1) Aftercooler. The aftercooler reduces or increases intake air temperature. It consists of a housing which is part of the engine intake air manifold, with an internal core made of tubes through which coolant circulates. Air is cooled or heated by passing over the core prior to entry into the engine combustion chambers, thereby improving combustion through better control of intake air temperature.

(2) Turbocharger. The turbocharger forces additional air into combustion chambers so the engine can burn more fuel and develop more horsepower than if it were naturally aspirated. The turbocharger consists of a turbine wheel and a centrifugal blower (compressor wheel), separately encased but mounted on and rotating with a common shaft. Power to drive the turbine wheel, which in turn drives the compressor, is obtained from the energy of engine exhaust gases. Rotating speed of the turbine changes as the energy level of exhaust gas changes, providing the engine with additional air to meet increased load requirements.

e. Fuel System. Filtered diesel fuel is supplied to the injectors via the fuel filters, fuel manifold and cylinder head drillings, from a fuel pump that is driven by the front camshaft (geared to the crankshaft).

(1-10 blank)/1-9

2-1

CHAPTER 2

UNIT MAINTENANCE INSTRUCTIONS

Page Section I. Repair Parts, Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Support Equipment....................................................2-1

Section II. Service Upon Receipt..........................................................................................................2-1

Section III. Unit Preventive Maintenance Checks and Services (PMCS)..............................................2-7

Section IV. Unit Maintenance Troubleshooting ...................................................................................2-19

Section V. Unit Maintenance Procedures...........................................................................................2-35

Section VI. Preparation for Storage, Reshipment, and Return To Service........................................2-146

SECTION I. REPAIR PARTS, SPECIAL TOOLS; TEST, MEASUREMENT,

AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT

2-1. Common Tools and Equipment . For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE) applicable to your organization.

2-2. Special Tools, TMDE, and Support Equipment . Special tools; test, measurement, and diagnostic equipment; and support equipment requirements are listed and illustrated in the Repair Parts and Special Tools List (RPSTL), TM 55-1905-223-24P. These items are also listed in the Maintenance Allocation Chart (MAC), Appendix B of this manual.

2-3. Repair Parts. Repair parts are listed and illustrated in the Repair Parts and Special Tools List (RPSTL), TM 55-1905-223-24P.

SECTION II. SERVICE UPON RECEIPT

2-4. Checking Unpacked Equipment.

a. Inspect the equipment for damage incurred during shipment. If the equipment has been damaged, report the damage in accordance with the instructions of DA Pam 738-750.

b. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies in accordance with the instructions of DA Pam 738-750.

c. Check to see whether the equipment has been modified.

d. Remove protective caps, plugs, inserts, wrappings, and tape when inspection/inventory is completed.

Inspect piping openings for damage. Wipe off dirt, grease, or protective films at time of installation.

2-2 Change 5

e. Remove chocks from resilient mounted components.

2-5. Preliminary Servicing, Adjustment and Operation of Newly Installed Equipment.

a. New and Rebuilt Engine Break-In. The way a new engine is operated during the first 100 hours of service will have an important effect on the life of the engine and its parts. Even though all engines are run on a dynamometer for several hours before they leave the factory, an additional period of careful operation is required.

(1) Perform pre-starting procedures (paragraph 2-5(b)).

(2) Avoid operation for long periods at engine idle speeds, or at maximum horsepower levels in excess of 5 minutes.

(3) Develop the habit of watching engine instruments closely during operation and reduce speed if oil temperature reaches 250°F (121°C) or coolant temperature exceeds 190°F (88°C).

(4) Check oil level each 10 hours during break-in period.

b. Pre-Starting Procedures. Follow these procedures when starting a new or rebuilt engine for the first time:

(1) Prime the Fuel System.

(a) Ensure there is an adequate supply of diesel fuel in the day tanks.

(b) Vessels without MWO 55-1905-223-55-7 installed; fill fuel filter canisters with clean diesel fuel oil.

(c) Vessels with MWO 55-1905-223-55-7 installed; fill fuel filter/water separator with clean diesel fuel oil. Check fuel filter/water separator for water/sediment in see-thru bowl.

Bleed air from housing.

(d) Remove suction line from fuel pump and prelubricate gear pump with 2 to 3 oz (50 to 60 cc) of clean lubricating oil.

CAUTION

Do not attempt to prime engine lubricating system from bypass filter.

(2) Priming the Lubricating System. The engine is primed automatically by an external electrically driven pump. However, in the event of problems in the self priming system, the following procedures should be performed before starting the engine:

(a) Remove oil inlet line from the turbocharger and prelubricate bearing with 2 to 3 oz (50 to 60 cc) of clean lubricating oil. Reconnect oil supply line.

(b) Fill crankcase until oil on dipstick (2, FIG. 2-1) or in liquid level gauge (FIG. 2-2) reaches the "H" (High) mark.

(c) Remove plug (1, FIG. 2-1) from lubricating oil filter head and use this opening as the priming point.

(d) Connect a hand or motor-driven priming pump hose from source of clean lubricating'oil to priming point.

(e) Prime until a 30 psi (207 kPa) pressure is obtained.

FIGURE 2-1. Lube Oil Priming Point and Oil FIGURE 2-2. Oil Level Sight Glass.

Fill/Dipstick Arrangement.

2-3

(f) Crank engine at least 15 seconds (with fuel shutoff valve closed or disconnected to prevent starting), while maintaining external oil pressure at a minimum of 15 psi (103 kPa).

(g) Remove priming hose and replace the plug removed in step (c).

(3) Lubricating Oil Dipstick Gauge Marking. All marine engines are shipped with unmarked lubricating oil dipstick gauges. The reason for this is the engine mounting angle which is determined at installation. Even though a given amount of oil is required, the dipstick must be marked so the oil level is correct at the engine mounting angle. If marking has not been previously accomplished or the dipstick is lost, the following procedures apply:

(a) With engine in the installed position and the boat in the water, use the sump pump to completely drain the engine.

CAUTION

Any oil left in oil pan will cause error in marking. Oil sometimes accu mulates as the oil drains from upper portions and oil passages within the engine; therefore, it is necessary to wait 15 minutes after the sump pump has emptied the oil pan initially to pump out the remaining oil, ensuring complete evacuation of oil from the engine.

(b) A tag is attached to new engines indicating high and low capacities of the oil pan. The capacity of the KTA50-M engine is 32 gallons (low) to 55 gallons (high).

NOTE

The above figures do not include amount required to fill oil lines and oil purifier.

(c) Fill engine with amount of oil listed as low-level oil pan capacity (32 gallons).

(d) Allow 5 minutes or more for oil to drain to the oil pan. If engine and/or oil temperature is below 40°F (4°C), a longer period may be required.

(e) Insert dipstick (2, FIG. 2-1) into gauge tube until fully seated; hold for 5 to 10 seconds, then ` withdraw slowly.

(f) Mark oil level indicated on dipstick with an electric etch. Depth of mark must not exceed 0.010 inch (0.24 mm). Etch "L" above mark.

(g) Add enough additional oil to fill engine to listed high-level capacity (55 gallons).

(h) Repeat steps (d), (e), and (f). Etch letter "H" directly above the second or "high" level mark.

2-4

(i) Start engine (TM 55-1905-223-10) and operate at idle for 3 minutes. Stop engine and fill to high mark. Additional oil may be required to fill oil filters and lines.

NOTE

The above procedure determines dipstick gauge marking for oil pan capacity only. Do not confuse with complete oil system capacity which also includes drilled passages, lines, and filters.

(4) Check Air Connections. Check for loose clamps or connections; cracks, punctures, or tears in hoses or tubing; collapsing hose; or other damage. Tighten clamps or replace parts as necessary to ensure an airtight air intake system. Make sure that all air goes through the air cleaner.

(5) Check Engine Coolant.

(a) Observe the sight level gauge on the expansion tank located on top of EOS to check engine coolant supply.

CAUTION

Do not, under any circumstances, add a large amount of cold water to a hot engine suddenly.

The rapid cooling may crack the cylinder liner and head or seize the piston.

(b) If coolant level is low, check for evidence of coolant leakage around tubing, hose connections, etc.; correct as necessary. Inspect water pump bleed hole for leakage; leakage indicates a worn or damaged seal. Fill the expansion tank to the proper level as indicated in the sight glass on the coolant expansion/fill tank.

(6) Check Fuel Supply and Connections. Visually check for evidence of external fuel leakage at fuel connections and tighten as necessary. Inspect hoses and tubing for damage and replace as necessary.

c. Starting the Engine. After the above actions are taken, the engine is ready to start.

WARNING

Ensure that all personnel are clear of the engine, the marine gear is disengaged, and appropriate operations personnel are notified before starting the engine.

CAUTION

Protect the engine and engine components during start-up by idling until normal idle oil pressure (20 psi minimum) is obtained.

Do not prolong idling unnecessarily. Operation at low temperatures can result in serious damage.

2-5

(1) Place marine gear in neutral.

(2) Place engine ON/OFF switch to the ON position. This activates the fuel solenoid.

NOTE

A manual override knob provided on the forward end of the electric shutdown valve allows the valve to be opened in case of electric power failure. To use, open by turning fully in a clockwise direction.

CAUTION

To prevent permanent starter motor damage, do not crank engine for more than 30 seconds continuously. If engine does not start within first 30 seconds, wait 1 to 2 minutes before recranking. Damage to starter motor will occur if pushbutton is pressed before starter motor stops rotation.

(3) Press starter button and hold till the engine starts.

(4) After engine has run for a few minutes, shut down and wait 5 minutes for oil to drain back into pan.

Check engine oil level again; add oil as necessary to bring oil level to "H" mark on dipstick. The drop in oil level is due to absorption by the oil filter and filling of the oil cooler.

CAUTION

Never operate the engine with oil level below the low level mark (L), or above the high level mark (H).

(5) Check for evidence of external oil leakage. Secure capscrews, fittings, connections, or replace gaskets, and O-rings as necessary to correct. Check oil dipstick and filler tube caps to see that they are secure.

2-6. Normal Startup. Refer to the operator's manual, TM 55-1905-223-10.

2-7. Shutdown Procedure (Usual or Unusual). Refer to the operator's manual, TM 55-1905-223-10.

2-6

SECTION III. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

2-8. Explanation of PMCS Table . PMCS is designed to keep the equipment in good working condition.

This is accomplished by performing certain tests, inspections, and services. Table 2-1 lists items to be serviced and the procedures needed to accomplish the PMCS. The "Interval" column tells you when to perform a check or service. If needed, PMCS may be performed more frequently than the indicated interval. The "Procedures" column tells you how to perform the required checks and services. If your equipment does not perform as required, see Table 2-2, Troubleshooting. Report any malfunctions or failures on DA Form 2404. In the "TM" Number column on DA Form 2404, record the appropriate Item Number from the PMCS table.

CAUTION

Never operate the engine with oil level below the low level mark or above the high level mark.

2-7

Table 2-1. Preventive Maintenance Checks and Services

D-Daily Q-Quarterly A-Annually B-Biennially Item Intervals Items To Be No. D Q A B Inspected/Serviced Procedures

1 * Lube Oil Level Check oil level at the sight level gauge (FIG. 2-2) or with the dipstick (2, FIG. 2-1). For accurate readings, oil level should not be checked until oil has settled into the pan after engine shutdown (approximately 15 minutes). Keep oil level as near the "H" mark as possible.

CAUTION

Do not, under any circumstances, add a large amount of cold water to a hot engine suddenly. The rapid cooling may crack the cylinder liners and heads or seize the pistons.

2 * Coolant Level Keep cooling system filled to operating level on the expansion tank sight gauge. Investigate for causes of coolant loss. Check coolant level when system is cool. Whenever coolant is added, check the corrosion inhibitor and antifreeze concentration by using DCA coolant checking kit, Item 14, Appendix C.

3 * Intake Air System Check air connections for loose clamps or connections, cracks, punctures, or tears in hose or tubing, collapsing hose, or other damage. Secure clamps or replace parts as necessary to make sure that the air intake is airtight. Make sure that all air goes through the air cleaner.

4 * Throttle Linkage Look for evidence of binding, loose fittings, obstructions, etc., that affect the smooth operation of the throttle throughout its range.

5 * Engine Give the engine a thorough visual inspection. Look for anything that appears to be damaged, leaking, broken, torn, missing, or out of the ordinary. Be sure that exhaust system and hoses are checked as follows:

2-8

D-Daily Q-Quarterly A-Annually B-Biennially Item Intervals Items To Be No. D Q A B Inspected/Serviced Procedures

5 * Exhaust System Check exhaust manifold for exhaust leaks, water leaks, and corrosion. Check insulation blankets (turbocharger also) to make sure that all hot surfaces are properly covered to prevent any possibility of oil spraying on the hot surfaces.

* Fuel, Lube and Make sure there are no signs of abrasion. Make sure all hoses are properly connected.

Coolant Hoses Make sure there is no seepage or leaks of hoses or fittings. Make sure clamps are tightened properly.

NOTE

Inspect under operating conditions with engine running. No twisting or bending force should be applied during inspection, since flexible hose may "take a set" after being in service.

* Fuel Pump Check for misadjustment, evidence of tampering, and leakage.

6 * Lube Oil (or at Change lube oil. The engine is provided with a manually operated sump pump located every 250 at the right rear of the engine, mounted to the flywheel housing. The output side of the operating hours) pump is connected to the "Dirty Lube Oil" tank. To change oil, proceed as follows.

Bring engine to operating temperature (175 ° to 195°), then shut down. Wait 15 minutes, then open the valve between the engine sump and sump pump. Be sure the valve to the marine gear is closed. Turn the handle until all oil has been pumped from the oil pan. Close valve when all oil has been removed. Fill the crankcase to the "H" mark on the dipstick or on the sight gauge. Start engine and check for leaks. Shut down engine; allow 15 minutes for oil to drain back into pan; recheck oil level. Add oil as required.

I

2-9

D-Daily Q-Quarterly A-Annually B-Biennially Item Intervals Items To Be No. D Q A B Inspected/Serviced Procedures

7 * Lube Oil Filters Change lube oil filters. Unscrew all filter elements (3, FIG. 2-3).

CAUTION

Only one valve at a time should be in OFF position. All other valves should be in ON position.

NOTE

If necessary, as dictated by mission requirements, main oil filters may be changed (one at a time) while the engine is running by turning the valve for each filter to the OFF position. Be sure to turn the valve ON before proceeding to the next filter.

FIGURE 2-3. Lube Oil Filter Change

2-10

2-11

T M

55-1905-223-24-1

Table 2-1. Preventive Maintenance Checks and Services

D – Daily Q – Quarterly A – Annually B - Biennially

Intervals Item No. D Q A B

Items To Be Inspected/Serviced

Procedures

7 * Lube Oil Filters – continued

Bypass filters are changed in the same manner as main filters.

Fill replacement filters with lube oil

Mechanical tightening may distort threads or damage filter element seal.

Position oil filter element (3, FIGURE 2-3) to filter head. Secure by hand until seal touches filter head. Make additional one-half to three-fourths turn. Run engine, check for leaks, recheck oil level; add oil as necessary to bring oil level to "H" mark on dipstick or sight gauge.

Always allow oil to drain back to oil pan before checking level.

This may require 15 minutes.

2-12 C hange 5

T M

55-1905-223-24-1

Table 2-1. Preventive Maintenance Checks and Services

D – Daily Q – Quarterly A – Annually B - Biennially

Intervals Item No. D Q A B

Items To Be Inspected/Serviced

Item No. 8 is only applicable to vessels without MWO 55-1905-223- 55-7 installed.

8 * Fuel Filters ________

Remove the fuel filters slowly and very carefully. Allow as much of the fuel to run out into the canister case as soon as possible before removing. Have a bucket available to place the filters in when removed. Wipe up all spills immediately.

Make sure the fuel supply is turned off. Remove canister tops and remove old filters. (FIGURE 2-4)

LEGEND

1. FUEL OUTPUT 4. MOUNTING BOLTS

2. FUEL IN 5. FUEL INPUT CUTOFF VALVES

3. CANNISTER TOPS 6. FUEL OUTPUT CUTOFF VALVES

FIGURE 2-4. Fuel Filter.

hange 5

2-13

T M

55-1905-223-24-1

Table 2-1. Preventive Maintenance Checks and Services

D – Daily Q – Quarterly A – Annually B - Biennially

Intervals Item No. D Q A B

Items To Be

8 * Fuel Filters - continued Clean and inspect sealing ring. Replace if necessary. Clean out the canister cases thoroughly with a clean rag. Install new fuel filters. Fill canisters with clean fuel oil. Replace canister tops. Tighten the hold-down bolt to 20 to 25 ft-lb (27 to 34 N·m) torque. Turn the fuel supply on and check for leaks.

Item No. 8.1 is only applicable to vessels with MWO 55-1905-223-

8.1 * Fuel Filter/Water Separator Perform service quarterly or when compound pressure-vacuum gauge…