Attachment_0002_DMWR_247_A2_Engine.pdf

DMWR 9--2815--247

US Army Tank--Automotive and Armaments Command, Warren, MI 01 June 2006

DEPOT MAINTENANCE WORK REQUIREMENT

FOR

ENGINE WITH CONTAINER: TURBOSUPERCHARGED:

DIESEL, FUEL INJECTION, 90-- DEGREE “V” TYPE,

AIR--COOLED, 12--CYLINDER, ASSEMBLY

MODEL AVDS--1790--8CR (2815--01--414--6821)

AVAILABILITY STATEMENT: This publication is not available through the AG publications center. This publication is available through US Tank--Automotive and Armaments Command, Rock Island, IL 61299--7630.

NOTICE: Reproduction for non--military use of the information or illustrations contained in this publication is not permitted without specific approval of the US Tank--Automotive and Armaments Command, Rock Island, IL 61299--7630.

DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government Agencies and their Contractors. Other request for this document must be referred to Commander: US Tank--Automotive and Armaments Command, Rock Island, IL 61299--7630.

DESTRUCTION NOTICE: If required, destroy by any method that will prevent disclosure of contents or reconstruction of this document.

US Army Tank--Automotive and Armaments Command, Warren, MI 19 September 2004

LIST OF EFFECTIVE PAGES/WORK PACKAGES

*Zero in this column indicates an original page

Date of issue for the original is:

Original 01 JUNE 2006

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 24. TOTAL NUMBER OF WORK

PACKAGES IS 59 CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Cover 0. . . . . . . . . . . . . . . . . . . . . WP 0036 00 (6 pages) 0 Blank 0. . . . . . . . . . . . . . . . . . . . . WP 0037 00 (4 pages) 0 i -- iii 0. . . . . . . . . . . . . . . . . . . . . . WP 0038 00 (8 pages) 0 blank 0. . . . . . . . . . . . . . . . . . . . . WP 0039 00 (16 pages) 0 WP 0001 00 (4 pages) 0. . . . . . WP 0040 00 (16 pages) 0 Chapter 1 Title Page 0. . . . . . . . WP 0041 00 (10 pages) 0 WP 0002 00 (6 pages) 0. . . . . . WP 0042 00 (10 pages) 0 WP 0003 00 (2 pages) 0. . . . . . WP 0043 00 (12 pages) 0 Chapter 2 Title Page 0. . . . . . . . WP 0044 00 (2 pages) 0 WP 0004 00 (12 pages) 0. . . . . WP 0045 00 (6 pages) 0 WP 0005 00 (2 pages) 0. . . . . . WP 0046 00 (6 pages) 0 WP 0006 00 (6 pages) 0. . . . . . WP 0047 00 (6 pages) 0 WP 0007 00 (20 pages) 0. . . . . WP 0048 00 (2 pages) 0 WP 0008 00 (16 pages) 0. . . . . WP 0049 00 (4 pages) 0 WP 0009 00 (12 pages) 0. . . . . WP 0050 00 (2 pages) 0 WP 0010 00 (6 pages) 0. . . . . . WP 0051 00 (2 pages) 0 WP 0011 00 (10 pages) 0. . . . . WP 0052 00 (2 pages) 0 WP 0012 00 (14 pages) 0. . . . . WP 0053 00 (8 pages) 0 WP 0013 00 (8 pages) 0. . . . . . Chapter 3 Title Page 0 WP 0014 00 (6 pages) 0. . . . . . WP 0054 00 (6 pages) 0 WP 0015 00 (8 pages) 0. . . . . . WP 0055 00 (4 pages) 0 WP 0016 00 (30 pages) 0. . . . . WP 0056 00 (4 pages) 0 WP 0017 00 (10 pages) 0. . . . . WP 0057 00 (10 pages) 0 WP 0018 00 (6 pages) 0. . . . . . WP 0058 00 (16 pages) 0 WP 0019 00 (8 pages) 0. . . . . . WP 0059 00 (2 pages) 0 WP 0020 00 (8 pages) 0. . . . . . Index--1 -- Index 3 0 WP 0021 00 (8 pages) 0. . . . . . Blank 0 WP 0022 00 (6 pages) 0. . . . . . Authentication Page 0 WP 0023 00 (10 pages) 0. . . . . Blank 0 WP 0024 00 (6 pages) 0. . . . . . DA Form 2028 Sample (Pt1) 0. .

WP 0025 00 (8 pages) 0. . . . . . DA Form 2028 Sample (Pt2) 0. .

WP 0026 00 (10 pages) 0. . . . . DA Form 2028 (Pt1) 0 WP 0027 00 (4 pages) 0. . . . . . DA Form 2028 (Pt2) 0 WP 0028 00 (14 pages) 0. . . . . DA Form 2028 (Pt1) 0 WP 0029 00 (6 pages) 0. . . . . . DA Form 2028 (Pt2) 0 WP 0030 00 (4 pages) 0. . . . . . Conversion Table 0 WP 0031 00 (12 pages) 0. . . . . Blank 0 WP 0032 00 (4 pages) 0. . . . . . Measurement Page 0 WP 0033 00 (6 pages) 0. . . . . . Blank 0 WP 0034 00 (6 pages) 0 WP 0035 00 (2 pages) 0

A/B blank i

DEPOT MAINTENANCE WORK REQUIREMENT

FOR

ENGINE WITH CONTAINER: TURBOSUPERCHARGED:

DIESEL, FUEL INJECTION, 90--DEGREE “V” TYPE,

AIR--COOLED, 12--CYLINDER, ASSEMBLY

MODEL AVDS--1790--8CR (2815--01--414--6821)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. 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 http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS REQUEST FORM.” The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. 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, fax, or E--mail your letter or DA Form 2028 direct to AMSTA--LC--CI Tech Pubs, TACOM--RI, 1 Rock Island Arse-nal, Rock Island, IL 61299--7630. The email address is TACOM--TECH--PUBS@ria.army.mil. The fax number is DSN 793--0726 or Commercial (309)782--0726. A reply will be furnished to you.

AVAILABILITY STATEMENT – This publication is not available through the AG publications center.

This publication is available through US Tank--Automotive and Armaments Command, Rock Island, IL 61299--7630.

NOTICE – Reproduction for non--military use of the information or illustrations contained in this publi-cation is not permitted without specific approval of the US Tank--Automotive and Armaments Com-mand, Rock Island, IL 61299--7630.

DISTRIBUTION STATEMENT C – Distribution authorized to U. S. Government Agencies and their Contractors. Other requests for this document must be referred to Commander: US Tank--Automo-tive and Armaments Command, Rock Island, IL 61299--7630.

DESTRUCTION NOTICE – If required, destroy by any method that will prevent disclosure of contents or reconstruction of this document.

ii

TABLE OF CONTENTS

WP Sequence No.

GENERAL INFORMATION 0001 00--1

CHAPTER 1 – EQUIPMENT DESCRIPTION AND DATA

LOCATION AND DESCRIPTION 0002 00--1

EQUIPMENT DATA 0003 00--1

CHAPTER 2 – DEPOT MAINTENANCE INSTRUCTIONS

GENERAL MAINTENANCE INSTRUCTIONS 0004 00--1

REMOVAL OF ENGINE FROM CONTAINER 0005 00--1

TRANSMISSION ADAPTER 0006 00--1

CRANKCASE, FLYWHEEL AND ASSOCIATED PARTS 0007 00--1

CYLINDER HEAD ASSEMBLY 0008 00--1

CRANKSHAFT AND ASSOCIATED PARTS 0009 00--1

PISTON AND CONNECTING ROD ASSEMBLY 0010 00--1

CRANKSHAFT DAMPER AND OIL FILTER HOUSING 0011 00--1

CAMSHAFT AND DRIVE GEARS, RIGHT OR LEFT BANK 0012 00--1

OIL LEVEL GAUGE ROD, UPPER AND LOWER OIL FILLER TUBES,

OIL DRAIN HOSE AND ASSOCIATED PARTS

(NEW CONFIGURATION) 0013 00--1

OIL PAN ASSEMBLY 0014 00--1

OIL PUMP ASSEMBLY 0015 00--1

CYLINDER HEAD OIL DRAIN TUBES 0016 00--1

BREATHER TUBES, OIL SUPPLY HOSES, OIL COOLER VENT HOSES

AND ASSOCIATED PARTS 0017 00--1

OIL COOLER FRAMES, SHROUDS, AND ASSOCIATED PARTS 0018 00--1

OIL COOLERS, OIL COOLER SCREENS AND ASSOCIATED PARTS 0019 00--1

EXHAUST MANIFOLD AND ASSOCIATED PARTS (LEFT AND RIGHT BANK) 0020 00--1

INTAKE MANIFOLD AND ASSOCIATED PARTS (LEFT AND RIGHT BANK) 0021 00--1

AFTERCOOLERS AND BYPASS VALVE SYSTEM AND ASSOCIATED PARTS 0022 00--1

GENERATOR DRIVE ASSEMBLY, IDLER GEARS AND SHAFTS 0023 00--1

STARTER DRIVE ASSEMBLY, IDLER GEARS AND SHAFTS 0024 00--1

ACCESSORY DRIVE HOUSING AND ASSOCIATED PARTS 0025 00--1

POWER TAKE--OFF DRIVE ASSEMBLY AND FUEL PUMP DRIVE 0026 00--1

AUTOMATIC INJECTION ADVANCE ASSEMBLY 0027 00--1

FUEL INJECTOR NOZZLE AND HOLDER ASSEMBLY 0028 00--1

FUEL METERING PUMP BASE, DRIVE COUPLING AND ASSOCIATED PARTS 0029 00--1

FUEL INJECTOR TUBES, NOZZLE, FUEL RETURN TUBES, BRACKETS

AND ASSOCIATED PARTS 0030 00--1

FUEL BACKFLOW VALVE AND ASSOCIATED PARTS 0031 00--1

iii

TABLE OF CONTENTS -- CONTINUED

WP Sequence No.

SMOKE GENERATING SYSTEM 0032 00--1

TURBOSUPERCHARGER TIE ROD, BASE AND ASSOCIATED PARTS 0033 00--1

DUST DETECTOR AND ASSOCIATED PARTS 0034 00--1

WATER SEPARATOR, PRIMARY AND MANIFOLD HEATER FUEL FILTERS

AND ASSOCIATED PARTS 0035 00--1

PRIMARY/WATER SEPARATOR FUEL FILTER ASSEMBLIES 0036 00--1

MANIFOLD HEATER ASSEMBLIES (LEFT AND RIGHT BANK), SOLENOID VALVE

AND HEATER PUMP, LINES AND ASSOCIATED PARTS 0037 00--1

THROTTLE CONTROL, SOLENOID ASSEMBLY, METERING PUMP THROTTLE

LINKAGE AND ASSOCIATED PARTS 0038 00--1

ENGINE SHROUDS, AIR DEFLECTORS, AND COOLING FANS, VANES,

AND HOUSINGS 0039 00--1

REAR FAN DRIVE ASSEMBLY 0040 00--1

FRONT FAN DRIVE ASSEMBLY 0041 00--1

FAN DRIVE CLUTCH ASSEMBLY 0042 00--1

ENGINE STARTER CRADLE, ENGINE CRADLE SUPPORT AND

ASSOCIATED PARTS 0043 00--1

ENGINE GENERATOR CRADLE, GENERATOR BRACKET OIL HOSES AND

ASSOCIATED PARTS 0044 00--1

ENGINE ELECTRICAL COMPONENTS 0045 00--1

ENGINE WIRING HARNESSES, BRACKETS, STRAPS AND ASSOCIATED PARTS 0046 00--1. . .

IDENTIFICATION PLATES, OVERHAUL/REPAIR PLATES AND

ASSOCIATED PARTS 0047 00--1

ENGINE SHIPPING AND STORAGE CONTAINER 0048 00--1

FIRE EXTINGUISHER TUBE AND ASSOCIATED PARTS 0049 00--1

FINAL INSPECTION 0050 00--1

DEPOT MOBILIZATION 0051 00--1

QUALITY ASSURANCE 0052 00--1

CHAPTER 3 – SUPPORTING INFORMATION

REFERENCES 0053 00--1

EXPENDABLE AND DURABLE ITEMS LIST 0054 00--1

TOOL IDENTIFICATION LIST 0055 00--1

MANDATORY REPLACEMENT PARTS LIST 0056 00--1

MANUFACTURED ITEMS LIST 0057 00--1

TORQUE LIMITS 0058 00--1

ENGINE DYNAMOMETER TEST 0059 00--1

OVERHAUL AND VISUAL INSPECTION PROCEDURES 0060 00--1

INDEX INDEX--1

DA FORM 2028

AUTHENTICATION PAGE

BACK COVER

iii/iv blank iv

0001 00--1

GENERAL INFORMATION 0001 00

SCOPE

This depot maintenance work requirement (DMWR) contains the information required to overhaul the AVDS--1790--8CR Diesel Engine.

Because of the voluminous content of this DMWR, and to assure high quality processes during overhaul, the depot/ contractor must prepare specific instructions, i.e., build sheets, work station instructions, design sheets, standard operating procedures, integrated maintenance quality plans, etc., for all work stations. Information will be extracted from this DMWR and all reference technical publications. Other information, if/when required, will be provided by the procuring activity/commodity manager (PA/CM). Depots refer to DESCOM--R 702--1, Depot Quality System.

These DMWR instructions are for use by depot/contractor personnel. They apply to the AVDS--1790--8CR Diesel Engine and, in case of conflict between instructions in this DMWR and other instructions, follow this order of prece-dence:

Current authorized waivers.

Contract or work directive.

Depot Maintenance Work Requirement.

Item Overhaul Specification; Department of the Army or US Army Tank--automotive and Armaments Command Purchase Descriptions; and functional performance requirements referenced on drawings.

Engineer drawings.

Technical Manuals and Technical Bulletins.

All AVDS 1790--8CR engine carriers must be worked to the most current TDP.

Condition of overhauled engine carriers will be that utility and performance are equal to that of a condition code A as defined in AR 725--50, Requisition, Receipt, and Issue System. These instructions apply to:

Major assembly/Major component Part number (Cage Code) NSN

Engine Diesel AVDS--1790--8CR 12366412 (06085) 2815--01--414--6821

FORMS, RECORDS, AND REPORTS

Department of the Army forms, records, and procedures used for equipment maintenance by depot/contractor per-sonnel will be those specified in DA PAM 738--750, Functional Users Manual for The Army Maintenance Manage-ment System (TAMMS), work directive/contract, and other reporting forms listed in DARCOM--R (AMC--R) 702--7, Logistics Product Assurance, and DESCOM--R 702--1. A list of the forms referenced in this DMWR is included in

WP 0053 00.

0001 00--2

GENERAL INFORMATION -- CONTINUED 0001 00

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If you know of any improvements that could be made to the AVDS--1790--8CR Diesel Engine pertaining to design, methods, or processes, you may submit them as an EIR. All EIRs are considered. Results and status of EIRs submitted to TACOM are published quarterly in TB 43--0001--39, Equipment Improvement Report and Maintenance Digest.

EIRs will be prepared using SF Form 368 (Product Quality Deficiency Report). Instructions for preparing QDRs are provided in DA PAM 738--750. Mail them to: Commander, US Army Tank--automotive and Armaments Command, ATTN: AMSTA--TR--E/MPA/267, Warren, Michigan 48397--5000. A reply will be furnished directly to you.

PREPARATION FOR STORAGE OR SHIPMENT

See WP 0048 00 for information about administrative storage or shipment of the AVDS--1790--8CR Diesel Engine and components.

QUALITY OF SUPPLIES

Material used for replacement, repair, or modification must meet the requirements of this manual. If quality of ma-terial requirements are not stated in this manual, the material must meet the requirements of the drawings, stan-dards, specifications, or approved engineering change proposals applicable to the subject equipment.

DEVIATIONS AND EXCEPTIONS

Request for deviations or exceptions to this Depot Maintenance Work Requirement (DMWR) will be processed in accordance with current standards, or equivalent.

MOBILIZATION REQUIREMENTS

All requirements of this DMWR will be exempted or revised in the event of mobilization. Only those procedures necessary to return the AVDS--1790--8CR Diesel Engine to a serviceable condition will be performed.

COMMON TOOLS AND EQUIPMENT

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE), CTA 69--970, or CTA 8--100, as applicable to your unit.

For required tools, see WP 0055 00.

SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

See TM 9--2815--247--34P for lists and illustrations of special tools needed to rebuild the engine.

See WP 0057 00 in this manual for an illustrated list of manufactured items needed to rebuild the engine.

REPAIR PARTS

See WP 0056 00 in this manual for a list of mandatory replacement parts needed to rebuild the engine.

0001 00--3

GENERAL INFORMATION -- CONTINUED 0001 00

COPYRIGHT CREDIT LINE

Copyright @ 2004 by United Defense, L.P. All rights reserved under the copyright laws.

This material may be reproduced for U. S. Government purposes only, pursuant to the copyright license under clause at (DFARS 52.227--7013) 1994.

END OF WORK PACKAGE

0001 00--3/4 blank

0001 00--4

CHAPTER 1

EQUIPMENT DESCRIPTION AND DATA

0002 00--1

LOCATION AND DESCRIPTION 0002 00

THIS WORK PACKAGE COVERS:

Location and Description

LOCATION OF ENGINE COMPONENTS

In this manual, the terms defined below will be used to identify the location of parts and assemblies on the engine.

The ends of the engine will be called the “damper end” or “front” and the “flywheel end” or “rear.”

As viewed from the front end toward the rear, the side to the right will be called the “right side” and the side to the left will be called the “left side.” Beginning at the front, the right bank of cylinders is numbered 1R through 6R and the left bank of cylinders is numbered 1L through 6L.

Starting from the front, the main bearings are numbered 1 through 7.

The cylinders, pistons, connecting rods, and connecting rod bearings are numbered with their respective cylinder number locations.

GENERAL DESCRIPTION

The engine (Figures 1--1 through 1--5) is a 12--cylinder, 90--degree, “V”--type, 4--cycle, air--cooled turbosuper-charged diesel. The cylinder assemblies are individually replaceable units with overhead valves and valve rocker assemblies in the head. The cylinders are arranged in two banks of six cylinders each. Each bank of cylinders has an overhead camshaft arrangement to actuate the valves of each cylinder.

The engine features a fuel injection system and a turbosupercharged air induction system which obtains optimum engine performance. The fuel injection system has a fuel metering pump which supplies metered fuel to individual cylinders through fuel injector nozzles. The fuel supply pump assembly (Figure 1--1), located at the front of the en-gine, draws fuel through the primary and secondary fuel systems from the vehicle fuel tanks and delivers it to the metering pump. A turbosupercharger assembly (Figure 1--4) is located on each side of the engine at the rear. The turbosuperchargers are exhaust--gas driven and increase the air flow pressure entering the air intake manifolds (Figure 1--1).

The engine is equipped with a 28--volt, oil--cooled, direct--current generator (Figure 1--1) capable of 650 ampere output over the engine operating range. The generator produces an alternating current which is rectified within the unit to give a direct current to the output terminals.

The engine has a 24--volt solenoid--operated starter (Figure 1--3). A low voltage sensing module prevents starter activation with improperly charged batteries.

The engine is lubricated by a forced--feed system. The system consists of four circuits: the scavenge circuit, the main or pressure oil circuit, the leveling circuit, and the make up circuit. These circuits are operated independently by one oil pump which consists of four separate sections.

The engine is equipped with two intake manifold heaters (Figure 1--3) which are installed in the air intake systems between the aftercooler bypass and the turbosuperchargers. The heaters, when operated, preheat the air entering the cylinders to facilitate cold weather starting and cold weather idle operation.

The engine is equipped with an aftercooler and an aftercooler bypass. The bypass uses a valve system that oper-ates as follows: an unrestricted airflow path exists during initial transient response. At steady state, full load condi-tions where engine thermal loading is at its maximum, the valve directs all induction air through the aftercooler, pro-viding maximum aftercooler effectiveness and minimum manifold temperature.

The engine crankcase is vented by an enclosed crankcase breather system which is vented through the crankcase breather tube (Figure 1--3) at the left turbosupercharger exhaust pipe.

The engine fuel/water separator--type secondary and primary fuel filters (Figures 1--1 and 1--2) both have top mounted bleeder valves to assist in the removal of air from the fuel system. Water is removed automatically by a constant bleed orifice in the primary fuel filter and an automatic water drain in the fuel/water separator filter.

0002 00--2

LOCATION AND DESCRIPTION -- CONTINUED 0002 00

GENERAL DESCRIPTION -- CONTINUED

FRONT LIFTING

EYES

TACHOMETER DRIVE

ADAPTER

FUEL PUMP

ASSEMBLY

PRIMARY FUEL

FILTER

TRANSMISSION OIL

COOLER

THERMOSTATIC

BYPASS VALVE

TRANSMISSION OIL

COOLER

GENERATOR

ENGINE OIL

COOLER

INTAKE

MANIFOLDOIL PAN

CRANKCASE

FUEL BACKFLOW

VALVE

OIL PRESSURE

REGULATOR VALVE

OIL FILTER

BYPASS VALVE

TIME TOTALIZING

METER

ENGINE OIL COOLER

THERMOSTATIC

BYPASS VALVE

01i270m

Figure 1--1. AVDS--1790--8CR Engine Assembly -- Right Front View.

0002 00--3

LOCATION AND DESCRIPTION -- CONTINUED 0002 00

GENERAL DESCRIPTION -- CONTINUED

SMOKE GENERATING

FUEL SOLENOID

VALVE

FIRE EXTINGUISHER

TUBE

SPEED GOVERNING

SOLENOID

OIL COOLER

VENT LINE

OIL COOLER

VENT BOLT

MANUAL FUEL

SHUT--OFF

OIL COOLER

VENT LINE

OIL PRESSURE

WARNING SWITCH

POWER TAKE--OFF

DRIVE HOUSING

CYLINDER HEAD OIL

DRAIN TUBE

MANIFOLD HEATER

FUEL FILTER

OIL COOLER

BYPASS VALVE

OIL FILTER

COVER

FUEL/WATER

SEPARATOR

FILTER

FRONT

CRANKCASE

BREATHER

TUBE

SMOKE GENERATOR

MANUAL FUEL

SHUT--OFF VALVE

OIL SAMPLING

VALVE

(DRAIN COCK)

OIL PRESSURE

GAUGE TRANSMITTER

DAMPER HOUSING

OIL DRAIN VALVE

01i271m

Figure 1--2. AVDS--1790--8CR Engine Assembly -- Front View.

0002 00--4

LOCATION AND DESCRIPTION -- CONTINUED 0002 00

GENERAL DESCRIPTION -- CONTINUED

OIL FILLER

TUBE

OIL FILLER

TUBE CAP

REAR CRANKCASE

BREATHER TUBE DUST

DETECTOR

DUST DETECTOR

INDICATOR/RESET

SWITCH

REAR LIFTING

EYE

FLYWHEEL

TRANSMISSION

ADAPTER (PLATE)

STARTER

INTAKE

MANIFOLD

HEATER

TRANSMISSION

ADAPTER

(HOUSING)

01i273m

Figure 1--3. AVDS--1790--8CR Engine Assembly -- Left Rear View.

LEFT TURBO--

SUPERCHARGER

EXHAUST MANIFOLD

PIPE

RIGHT TURBO--

SUPERCHARGER

TURBOSUPERCHARGER

OIL INLET HOSES

MANIFOLD HEATER

FUEL RETURN

SOLENOID

01i274m

Figure 1--4. AVDS--1790--8CR Engine Assembly -- Rear View.

0002 00--5

LOCATION AND DESCRIPTION -- CONTINUED 0002 00

GENERAL DESCRIPTION -- CONTINUED

REAR ENGINE

COOLING FAN

HOUSING

REAR ENGINE

COOLING FAN

VANE HOUSING

FRONT ENGINE

COOLING FAN

VANE HOUSING

ENGINE OIL

LEVEL CHECK

SMOKE GENERATING

SYSTEM FUEL

SUPPLY TUBE

FRONT ENGINE

COOLING FAN

HOUSING

01i276m

Figure 1--5. AVDS--1790--8CR Engine Assembly -- Top View.

0002 00--5/6 blank

0002 00--6

0003 00--1

EQUIPMENT DATA 0003 00

THIS WORK PACKAGE COVERS:

Equipment Data

GENERAL

Refer to pertinent organizational maintenance manual for the tabulated data pertaining to general characteristics and performance of the engine.

ENGINE

Make GDLS Type Diesel, air--cooled, V--12 Model AVDS--1790--8CR Dimensions, including shroud:

Length (transmission adapter to guide bars) 71.84 in. (1824.7 mm) Width (overall, shrouds installed) 67.75 in. (1720.8 mm) Height 43.70 in. (1110 mm)

Displacement 1790 cu. in. (29,333 cc) Weight, wet (without flywheel) 5155 lbs. (2340 kg) Speed:

Governed, full load 2400 rpm Governed, no load 2660 rpm (max.)

Idle 825--875 rpm

Horsepower, gross 1050 to 1080 bhp at 2400 rpm Horsepower, net 893 to 923 bhp at 2400 rpm Torque, gross 2420 to 2510 lb--ft (3281.5--3403.5 N•m) at 1800 rpm Torque, net 2226 to 2313 lb--ft (3018.5--3136.5 N•m) at 1800 rpm Cylinders:

Number 12 Arrangement 90_ upright “V” Numbering (from front):

Left side 1L, 2L, 3L, 4L, 5L, 6L Right side 1R, 2R, 3R, 4R, 5R, 6R Firing order 1R, 2L, 5R, 4L, 3R, 1L, 6R, 5L, 2R, 3L, 4R, 6L Bore 5.750 in. (146.05 mm) Pistons:

Stroke 5.750 in. (146.05 mm) Compression ratio 14.5:1 Displacement 149:1 cu in. per cylinder

Cooling:

Type Air--cooled by two engine--driven fans Air flow 30,000 cfm at 2400 rpm

Drive (from crankshaft) Direct Crankshaft rotation (viewed from front) Clockwise Camshafts:

Number 2 Rotation (viewed from front) Counterclockwise

Ignition Compression Fuel System:

Induction Supercharged Air flow (at rated power and speed) 2400 cfm (18,878 ccm)

Fuel:

Type Turbine fuel Grade JP--8 Specification MIL--DTL--83133 Supply pressure (at injection pump inlet) 75--90 psi (517.1--620.5 kpa) Consumption at 1050 hp and 2400 rpm 0.417 lbs per hr (0.189 kg per hr)

0003 00--2

EQUIPMENT DATA -- CONTINUED 0003 00

ENGINE -- CONTINUED

Valve timing:

Intake opens 30_ before top center (BTC) Intake closes 40_ after bottom center (ABC) Intake remains open 250_ Exhaust opens 63_ before bottom center (BBC) Exhaust closes 37_ after top center (ATC) Exhaust remains open 280_

Valves:

Lift 0.460 in. (11.68 mm) Clearance (cold engine):

Exhaust 0.025 in. (0.635 mm) Intake 0.010 in. (0.254 mm)

Fuel metering pump timing:

Static setting with advance in fuel retarded position 26_ BTC

Lubrication:

Oil specifications 0_F (--17.8_C) and above OE/HDO 15/40, MIL--PRF--2104 +15 to + 90_F (--9.4 to 32.2_C) OE/HDO--30, MIL--PRF--2104 --15 to + 40_F (--26 to 4.4_C) OE/HDO--10, MIL--PRF--2104 --65 to + 40_F (--53.9 to 4.4_C) OEA, MIL--L--46176 Normal oil temperature 180_F (82_C) at 60_F (15.5_C) ambient Maximum oil temperature (out of cooler) 250_F (121_C)

Oil pressure (crankcase main oil gallery):

850 rpm 20 psi (137.9 kpa) (15W--40 oil at 180_F(82_C)) 2400 rpm 40 to 70 psi (275.8--482.6 kpa) (15W--40 oil at 180_F(82_C))

Oil pump output (SAE 30 oil at 180_F (82_C) at 3600 rpm of pump):

Pressure pump 97 gpm (367.14 lpm) Scavenge pump 121 gpm (458 lpm)

Oil capacity (approximate):

Dry engine 24.0 gallons (90.8 liters) Oil and filter change 21.0 gallons (79.5 liters)

Manifold heater (cold weather starting and idle operation in cold weather):

Type Flame type, spark ignition Spark plug (ignition) gap 0.094 in. to 0.114 in. (2.388 to 2.896 mm) Pump 90 psi (620.5 kpa) Spray nozzle flow 1.5 to 2.2 lbs/hr (0.68--1 kg/hr) Fuel (type) same as engine fuel

DRIVE RATIOS AND ROTATION (FROM FRONT)

Camshafts 0.500:1 counterclockwise Cooling fans 2.270:1 clockwise Generator 3.200:1 clockwise Starter 11.846:1 clockwise Fuel injection metering pump 1.000:1 clockwise Fuel supply pump 0.500:1 clockwise Oil pump 0.500:1 clockwise Tachometer drive 1 counterclockwise

CHAPTER 2

DEPOT MAINTENANCE INSTRUCTIONS

0004 00--1

GENERAL MAINTENANCE INSTRUCTIONS 0004 00

THIS WORK PACKAGE COVERS:

General Maintenance Instructions

GENERAL

The procedures for cleaning, inspection, repair, and assembly of many parts and components which make up the engine subassemblies are similar. Therefore, to avoid repetition, procedures detailed in this work package will be referenced throughout this DMWR.

CLEANING

The importance of cleaning must be thoroughly understood by maintenance personnel. Great care and conscien-tious effort are required in all cleaning operations. The presence of dirt or foreign material is a constant threat to satisfactory engine operation and maintenance. A dirty operation can result in cylinder scuffing or scratching, high oil consumption, bearing destruction, and a variety of component failures directly attributed to the entrance of dirt.

Maintain rigid cleaning standards during all phases of the cleaning operation. The following general instructions apply to all cleaning operations.

Clean all parts before inspection, after repair, and before assembly.

Hands should be kept free of any accumulation of grease, which can collect dust and grit.

After cleaning, all parts should be covered or wrapped to protect them from dirt and dust accumulation.

Castings

Remove sludge and gum deposits using a stiff brush.

WARNING

Clean all surfaces with dry--cleaning solvent (item 5, WP 0054 00). Repeat operation if surface is not free of scale or adhering material which might be dislodged later.

WARNING

Blow out all tapped holes with compressed air.

After cleaning, dry casting with compressed air.

0004 00--2

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

CLEANING -- CONTINUED

Oil Passages

Particular attention must be given to all oil passages in machined parts. All oil passages must be free of obstruc-tions.

CAUTION

Use care not to force probes into passageways. Failure to comply could result in equipment damage.

Clean passages with probes fabricated from 0--12 inch (3.1 mm) brass welding rods to break up all sludge or gum deposits.

WARNING

Wash passages by flushing with dry--cleaning solvent (item 5, WP 0054 00). Be sure passages are free from ob-structions and remove any particles which might later become dislodged and contaminate the oil system.

WARNING

After cleaning, dry passages with compressed air.

Electrical Cables and Flexible Hoses

CAUTION

Do not use dry--cleaning solvent or mineral spirits paint thinner on rubber components and flexible hoses. Con-tact with these cleaners causes leather, rubber, and syn-thetic materials to dry rot and lose pliability, making them unserviceable.

Clean cables and flexible hoses with soap and water.

Ball and Needle Bearings

Bearings require special attention in cleaning and oiling. After removing the surface dirt, oil, or grease, the bear-ings, except the sealed, permanently lubricated type, should be placed in hot oil (about 150_F (65_C)) to loosen congealed oil and grease. After cleaning, the bearings should be wrapped tightly in oiled or waxed paper until in-spection and assembly.

0004 00--3

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

CLEANING -- CONTINUED

Ball and Needle Bearings -- Continued

WARNING

CAUTION

Do not immerse sealed type ball bearings in dry--cleaning sol-vent (MIL--PRF--680, Type II), or hot oil. Entrance of cleaning agent will destroy lubricants sealed in bearing at time of manufacture. Loss of lubricant will result in premature failure of bearing and possible severe damage to the engine.

Clean sealed ball bearings by wiping the exterior surfaces with a clean cloth moistened in dry--cleaning solvent (item 5, WP 0054 00). Compressed air must never be used in cleaning or drying of ball or needle bearings. Dam-age to bearings will result from spinning of bearing by air blast.

Refer to TM 9--214 for information on inspection, care, and maintenance of bearings.

Painted Parts

The reconditioning of painted parts should be a matter of good judgment. Parts that appear to be in good condition after cleaning need not be stripped and repainted in their entirety, but should be cleaned and designated for touch--up only. Parts that are rusted or otherwise devoid of paint must be stripped to bare metal. Rubber composition shroud seals must be removed and discarded before the parts can be stripped of paint.

INSPECTION

The engine is precision--built with tolerances fixed at extremely close limits. Key letters are used in the overhaul inspection procedures (OIPs) to locate points of measurement for overhaul limits. Each section following this work package includes OIPs for critical parts or components covered in this work package. OIP references for such parts or components are included in the wear limits, fits, and tolerance tables. Where an OIP is referenced in more than one section (e.g., the same part is used on several subassemblies), the OIP is included only in the section where first referenced. To locate such OIPs, refer to the list of overhaul inspection procedures.

Extreme care must be exercised in all phases in inspection.

Inspect finish of all parts. Mark all parts that require refinishing. When dye penetrant inspection procedures are required, ZYGLO can be used.

Wear Limits, Fits, and Tolerances

Each OIP table will provide wear limits, fits, and tolerances that contain the maximum, minimum, and key dimen-sions of new or repair parts. The clearances will automatically be achieved if the mating parts are within the dimen-sion tolerances listed in the tables. In some cases, a part that is out of tolerance may be used provided the mating part is carefully selected, and when mated, is within the maximum clearance specified in the wear limits column.

The wear limit indicates the point to which a part may be worn before replacement is required. In order to assure maximum service, all parts which have not worn beyond dimensions shown in the wear limits column, or are not damaged, will normally be approved for service.

0004 00--4

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

INSPECTION -- CONTINUED

Symbols

Symbols employed in the wear limits, fits, and tolerance tables are identified as follows:

An asterisk “*” in the wear limits column indicates that the part must be replaced when worn beyond the limits given in the sizes and fits of new parts column.

The letter “L” following the tolerance dimensions given in the sizes and fits of new parts column and the wear limits column indicates a loose fit (clearance).

The letter “T” following the tolerance dimensions given in the sizes and fits of new parts column indicates a tight fit (interference).

Castings

Inspect all ferrous (cast iron, steel, etc.) castings for cracks. Inspect all nonferrous (aluminum) castings for cracks.

Suspected cracks in the nonferrous casting can be checked with a magnifying glass (five power magnification mini-mum) and a strong light. Check particularly the areas adjacent to studs, pipe plugs, or threaded inserts and in sharp corners and fillets.

Inspect machined surfaces of castings for nicks, burrs, or raised metal. Mark damaged areas for repair.

Check all mating flanges and mounting pads with a straight edge or surface plate for warpage. Inspect mating flanges and mounting pads for discoloration which may indicate persistent oil leakage.

Inspect all tapped openings for stripped or damaged threads.

Check all castings for conformance to the applicable overhaul inspection procedures.

Ball and Needle Bearings

Refer to TM 9--214 for inspection of anti--friction bearings. Check all bearings for conformance to the applicable wear limits, fits, and tolerances tables.

Studs

Inspect all studs for damaged or stripped threads, bent or loose condition, or for any signs of stretching.

Dowel Pins

Inspect dowel pins for looseness or damage. Mark loose pins for repair.

Gears and Shafts

NOTE

There are no established wear limits for gear teeth and splines. Good judgment is required to determine need for replacement.

Inspect all gears and shafts for cracks using a magnetic particle method.

Inspect all gear teeth and splines for wear, sharp fins, burrs, and galled or pitted surfaces.

Inspect shaft and gear hub splines for damage, wear, and fit with splines on mating parts. Mating splines must match without binding or looseness.

Check all gears and shafts for conformance to the applicable overhaul inspection procedures.

0004 00--5

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

INSPECTION -- CONTINUED

Oil Seals

Generally, metal--encased oil seals are mandatory replacement parts and must be replaced during repair.

Helical--Coil and Screw Thread Inserts

To permit higher stresses on studs and bolts which are set in aluminum castings, it is common practice to install inserts of a stronger metal into which the studs or bolts are threaded. Helical--coil and screw thread inserts are des-ignated to perform this function. The inserts are spiral steel coils having a right hand thread--shaped form on the inside and outside diameter of the coils. A bar or tang at the bottom end of the coil, which is engaged by an insert-ing tool, is used for threading the insert into the casting. Some inserts have a serrated tooth section at the top end of the coil to stake them in place in the castings. Other inserts have turns at the center of the coil in the form of a hexagon. This provides a locking effect when the stud or bolt is threaded into the insert.

Inspect all screw thread inserts for a secure fit in the casting and for galled or stripped threads.

Sheet Metal Parts

Straighten parts as necessary and check for broken welds or loose rivets or weld nuts. If parts are cracked or torn, they must be repaired or replaced. Check shroud seals for hardness, tears, or other damage. Mark damaged seals for replacement if the part is otherwise serviceable.

Bushings, Liners, and Bushing--type Bearings

Check all bushings, liners, and bushing--type bearings for secure fit in their respective casting or mating part, and for evidence of heating, which may be indicated by discoloration of bushing or bearing surface.

Inspect for wear, burrs, nicks, or out--of--round condition.

Check for dirt in lubrication holes or grooves. Holes and grooves must be clean and free from damage to ensure proper lubrication.

Inspect thrust faces of bushing--type bearings for wear by temporarily assembling mating parts and checking end play with a feeler gage inserted between the thrust faces.

Check for conformance to the applicable overhaul inspection procedures.

Mounting Hardware

Bolts, nuts, washers, and other mounting hardware not specified as mandatory replacement items must be inspected for wear, cracks, or thread damage before being reused. Items found unserviceable must be replaced.

0004 00--6

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

GENERAL REPAIR

Most engine parts and components may be repaired as outlined below. Any repair procedures that are peculiar to a specific part or component is covered in this work package. After repair, clean all parts thoroughly to prevent metal chips from repair operations, or abrasive used in repair operations, from entering working parts of engine.

Repair of Castings

Replace all castings when cracks have penetrated high stress areas such as fillets or webbing.

Replace all castings which do not conform to tolerances specified in the appropriate overhaul inspection procedures.

WARNING

Replace all castings on which machined surfaces are burred or nicked to the point of impairing subsequent assem-bly or operation. Repair minor damage to machined surfaces with a fine mill file or crocus cloth (item 4, WP 0054 00) dipped in dry--cleaning solvent (item 5, WP 0054 00).

Replace all castings having flanges that are severely warped and cannot be repaired to provide a proper seating surface with its mating part. Repair minor warpage of mounting flanges and mounting pads by working surface across a sheet of crocus cloth (item 4, WP 0054 00) held tightly on a surface plate or similar flat surface.

CAUTION

Pipe plug threads in castings must be in good condition to prevent oil leakage.

Repair damaged screw thread inserts in tapped holes with a used tap.

Ball and Needle Bearings

Replace all galled, pitted, or damaged bearings.

Replace all bearings which do not conform to tolerances specified in the appropriate wear limits, fits, and tolerances table.

Refer to TM 9--214 for information on inspection, care, and maintenance of anti--friction bearings.

Studs

Replace all bent or loose studs or studs showing evidence of stretching. Repair minor damage with a thread chas-

er. Replace all studs having stripped or damaged threads. Remove and replace studs as outlined below.

Stud identification

Stud identification tables appear in the repair sections of TM 9--2815--247--34. Each table contains the appropriate information regarding stud setting heights, number required, and reference figures of stud identification and loca-tion.

Removal

Using a stud extractor, back studs out slowly to avoid heating and possible seizure. When studs are broken off too short to use extractor, drill stud and extract with a suitable remover. Short studs may also be removed by welding a piece of bar stock or a nut to stud and removing with a wrench.

0004 00--7

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

GENERAL REPAIR -- CONTINUED

Studs -- Continued

Replacement

Repair minor thread damage in tapped holes with a used tap.

When threads are stripped or damaged, or when stud is removed from an aluminum casting for loose fit, always replace stud with next larger oversize, or in cases of complete thread pullout, drill out threaded holes, tap hole for thread insert, install insert and standard stud for repair. Markings and color code indicates whether stud is standard or oversize. Check marking and color as shown in illustration to be sure replacement is the proper size.

STUD

MARK

COLOR CODE

STANDARD

0.003

OVERSIZE

0.007

OVERSIZE

NONE RED BLUE

CAUTION

When the threads on each end of the stud are a different size, the coarse thread end must enter the aluminum casting.

Studs available for replacement, as shown in illustration, are marked on the coarse thread end of stud.

Apply a small amount of lubricant (item 12, WP 0054 00) to threads before installing stud.

Drive stud into tapped hole slowly to prevent heating. Drive stud to setting height given in appropriate table in

TM 9--2815--247--34.

When tapped holes in castings cannot be fitted with oversize studs, the holes in the castings can be fitted with screw thread inserts (TM 9--2815--247--34) and studs of the original size can then be installed.

Replace loose dowel pins. If original dowel pin was only slightly loose, install new pin using sealing compound (item 2, WP 0054 00). In cases where the dowel pin hole is grossly out--of--round, it will be necessary to drill the hole oversize, fashion a bushing, and install a new dowel pin in the bushing.

Painted Parts

Retouch or paint parts as necessary to produce an acceptable part. Retouch or re--paint parts in their original color in accordance with procedures contained in TM 43--0139.

Gears and Shafts

Replace all cracked gears and shafts, and shafts that are bent or twisted.

Replace all gears and shafts which do not conform to tolerances specified in the overhaul inspection procedures.

0004 00--8

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

GENERAL REPAIR -- CONTINUED

Gears and Shafts -- Continued

WARNING

Replace all gears and shafts having worn, galled, nicked, burred, or pitted teeth and splines. Remove any sharp fins and burrs from splines with crocus cloth (item 4, WP 0054 00) dipped in dry--cleaning solvent (item 5, WP 0054 00).

Replace all splined gears and shafts that are damaged to the point of impairing assembly or operation. Replace all gears and shafts having splines which do not match properly with mating splines.

Bushings, Liners, and Bushing--type Bearings When bushings, liners, and bushing--type bearings are damaged or worn beyond specified limits, generally the as-sociated parts with which they are used must be replaced.

Removal

Drill out bearing retaining pins used to secure bearings in castings or retaining cages, when applicable.

Installation

Align bushing, liner, or bushing--type bearing in casting or retaining cage. Press into place with a suitable pressing arbor.

Select proper drill size for installation of bearing retaining pins. Drill through bearing and into casting or retaining cage to the proper depth so that the pin will be flush with the bearing surface after installation. Drive retaining pin through bearing and into casting or retaining cage. Cut off any portion of the pin that extends above bearing.

Ream or burnish bushing, liner, or bushing--type bearing to size specified in appropriate wear limits, fits, and toler-ances table.

Clean repaired parts thoroughly before assembly or installation.

Oil Seals Replace all oil seals at engine repair.

Removal

Press or pry oil seal from casting or adapter.

WARNING

Repair

When oil seal bore in casting or adapter is burred or damaged to a point where an oil--tight seal is impossible, repair or replace casting or adapter. Remove slight nicks, burrs, and scratches from oil seal bore in casting or adapter with crocus cloth (item 4, WP 0054 00) dipped in dry--cleaning solvent (item 5, WP 0054 00).

Installation

Install new oil seal in bore of casting or adapter.

0004 00--9

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

GENERAL REPAIR -- CONTINUED

Helical--coil and Threaded Inserts

Replace all helical--coil and screw thread inserts which do not fit securely in the casting or when casting threads have become galled or stripped.

Replacement

Replace all unserviceable helical--coil and screw thread inserts in the same manner as outlined in the following in-structions. For instructional purposes, helical--coil inserts in the cylinder assembly will be replaced.

Removal

Use a diamond--shaped punch to remove the staked, serrated--tooth type section of insert (1) from the thread in cylinder casting.

Install screw thread insert extractor (2) (item 103 or 104, WP 0055 00) into insert. Remove insert by applying constant pressure while turning extractor counterclockwise until insert is removed.

Installation

NOTE

The special coil screw lock inserter tools (items 98 through 102, WP 0055 00) must be used when installing the self--locking thread type inserts. These special insert-ers are further identified by painted areas marked either with a red handle or a red stripe around the body.

Thread new insert (1) into the threaded guide of inserter (3) by slowly turning the pilot (4) until insert is flush with the end of the tool. Insert the pilot of the screw thread inserter (3) into the threaded hole in cylinder with face of the in-serter resting solidly against the casting as shown.

Slowly turn handle (5) of pilot clockwise until no further resistance is felt. The insert will then be flush with cylinder casting. Remove inserter and break off insert tang.

2 3

0004 00--10

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

WELDING

NOTE

The information presented below is based on the applica-ble paragraphs in AWS D17.1 and outline the require-ments, equipment, and welding process used for repair of aluminum alloy castings.

Operator welding shall be performed by welding operators who have successfully meet the requirements of AWS D17.1, for Material Group IV (Aluminum Alloys). Operational: TC 9--237 (May 1993). The base material covered in this procedure is Type 355--T71 ASTM B 26/B 26M.

Equipment

An alternating current arc welding machine shall be used for heli arc welding. Class R4043, conforming to AWS A5.10/A5.10M welding rod, is compatible with base material and shall be used for all welding repairs in this material group. All equipment shall be consistent with good standard welding practices, and be acceptable to the Govern-ment inspector.

Processes

The MIG (Metal Inert Gas) process is recommended when welding aluminum plate greater than 1/8 inch thickness.

TIG (Tungsten Inert Gas) process is recommended when welding aluminum plate 1/8 inch thick and under.

Casting Preparation

Cleaning All foreign material must be removed from the area to be welded prior to repair operations. The area shall be cleaned using a stainless steel wire brush, drill, burring tool, or approved chemical process, whichever is applicable.

Cracks Determine flow of cracks by using dye check method. Drill stop holes at crack ends with 1/4 inch drill and mill out cracks to provide a V aperture.

Fractures Check area around the fracture for cracks using dye check. Drill stop holes at the ends of detected cracks with a 1/4 inch drill and mill out crack to provide a V aperture.

Missing Metal If the size of the damaged area permits, mill out and chamfer that area to 30 degrees to provide a 60 degree included angle. The insert piece required for this area must be identical in composition and may be cut from scrapped castings or suitable sheet stock. Fit insert piece into milled area, so that 1/6 to 1/8--inch is main-tained between insert and casting wall.

Preparation for Welding

Precisely measure castings at appropriate locations to detect dimensional changes caused by welding repair. Re-cord dimensions for checking after repair has been made to be sure that critical dimensions have been held.

0004 00--11

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

WELDING -- CONTINUED

Preheat Prior to Welding

Preheat castings as outlined in AWS D17.1. Preheat slowly in an oven or other suitable method for two hours to approximately 350° + 35° F. Control heat process to avoid incipient melting, excessive grain growth, or other unde-sirable structural changes that might reduce the mechanical properties.

CAUTION

Oven preheating is required when welding large sections of a casting. A welding torch should be used to preheat small sections (approximately 1 sq. in. area). Preheat should not exceed 350_ F.

Welding Cracks

The inert gas shielded arc welding process shall be used when making repairs on aluminum alloy. After casting has reached the prescribed preheat temperature, position the casting into the most advantageous welding position.

Cover casting with thermal blankets, except for area to be welded. Weld the outside milled groove with a good root weld. Apply fillet welds until groove is closed. Rotate casting and weld inside groove in the same manner if double V is used. Remove thermal blankets and allow castings to cool progressively to room temperature.

Follow these steps to fill in any fractured or missing metal along the crack, using the specifications in the paragraphs CASTING PREPARATION, PREPARATION FOR WELDING, and PREHEAT PRIOR TO WELDING:

Place “insert” piece in opening.

Align and secure with clamps or tack weld in three or four places with one inch welds.

Place a good root weld in groove and apply fillet welds until groove is closed.

Rotate casting and weld inside groove in the same manner.

NOTE

The temperature of the casting surrounding the welded area should not exceed 295_ F. If necessary, stop weld-ing, cover casting with thermal blanket and allow to cool to a satisfactory temperature, then resume welding.

Final Inspection and Cleanup

Repaired cracks and areas where metal has been replaced must be radiographically inspected and be equal to, or better than, reference standard 3, TACOM STD 113, (available from USTACOM DRSTA). All other areas shall be inspected by dye penetrant. Defects must be re--welded in accordance with above methods. Measure casting and compare dimensions taken before repair. Dimensional change will not exceed that as specified on applicable engi-neering drawing, except as noted. Check machined surfaces for warpage or other dimensional changes. Clean seams with a wire brush and remove weld beads and all sharp edges. X--ray entire repaired area. Remove excess flux with suitable material, rinse with clean water, dry, and anodize. Pressure test oil passages that have been re-paired to 90 psi air; use soap solution to detect any leak.

0004 00--12

GENERAL MAINTENANCE INSTRUCTIONS -- CONTINUED 0004 00

ASSEMBLY

Extreme care must be exercised in all assembly operations to insure satisfactory engine performance. General rules for assembly are outlined below. Procedures for assembling the various components are covered in the work package relating to the specific component.

Precautionary Rules

Cleanliness is essential in all assembly operations. Dirt and dust, even in minute quantities, are abrasive. Parts must be cleaned as specified and kept clean. Wrap or cover parts and components when assembly procedures are not immediately completed.

Coat all bearings, shafts, and all contact surfaces with lubricant (item 14, WP 0054 00) to ensure lubrication of parts during initial engine starting.

Always use new gaskets and preformed packings when assembling engine.

Use flat washers under all lockwashers, nuts, and bolts to protect aluminum surfaces.

Most bolts, cap screws, and nuts must be secured with lockwashers, tab washers, locking wire, or cotter pins, de-pending on method of locking specified.

Whenever a locking method is not specified for bolts and cap screws, the mid--grip helical--coil threaded inserts into which the bolts or screws are threaded serve as the locking device.

It is also important that all hardware be tightened to the specified torque. Refer to TORQUE SPECIFICATIONS in this work package.

TORQUE SPECIFICATIONS

Standard Torques for Nuts and Bolts

Apply a light film of lubricant (item 12, WP 0054 00) to bolts, cap screw threads, contact face of nuts, bolt heads, and cap screws. Avoid excessive amounts of lubricant in blind tapped holes. Refer to WP 0058 00 unless other-wise noted.

Special Torques for Studs and Bolts

Apply a light film of lubricant (item 12, WP 0054 00) to studs, bolts, cap screw threads, contact face of nuts, bolt heads, and cap screws (except as noted). Avoid excessive amounts of lubricant in blind tapped holes. Special torques are listed in each task where applicable.

NOTE

On assemblies subjected to wire or cotter pin hole align-ment, set torque wrench to low limit and torque nut. To facilitate alignment it is permissible to tighten nut to first hole beyond torque setting.

Standard Pipe Plug Torques

Apply pipe thread compound to all pipe thread connections prior to installation. Pipe thread compounds are speci-fied in initial setups of work packages in TM 9--2815--247--34. Refer to WP 0058 00 for torque specifications.

0005 00--1

REMOVAL OF ENGINE FROM…