TM T.O. 38G

Size: px

Start display at page:

Download "TM T.O. 38G"

Clement Garrison
5 years ago
Views:

1 T.O. 38G TECHNICAL MANUAL VOLUME 2 OF 2 PART 1 OF 2 MAINTENANCE DIRECT SUPPORT AND GENERAL SUPPORT LEVEL ENGINE ASSEMBLY, DIESEL (MULTIFUEL): NATURALLY ASPIRATED OR TURBOCHARGED, FUEL-INJECTED, WATER-COOLED, 6-CYLINDER MODELS: LD-465-1, NSN ; LD-465-1C, NSN ; LDT-465-1C, NSN ; LDS-465-1, NSN ; LDS-465-1A, NSN ; AND LDS-465-2, NSN AND CLUTCHES DEPARTMENTS OF THE ARMY AND THE AIR FORCE APRIL 1981

2 TECHNICAL MANUAL NO TECHNICAL ORDER NO. 38G * TM T.O. 38G TECHNICAL MANUAL VOLUME 2 OF 2 PART 1 OF 2 MAINTENANCE DIRECT SUPPORT AND GENERAL SUPPORT LEVEL DEPARTMENTS OF THE ARMY AND THE AIR FORCE Washington DC, 3 April 1981 ENGINE ASSEMBLY, DIESEL (MULTIFUEL): NATURALLY ASPIRATED OR TURBOCHARGED, FUEL-INJECTED, WATER-COOLED, 6-CYLINDER MODELS: LD-465-1, NSN ; LD-465-1C, NSN ; LDT-465-1C, NSN ; LDS-465-1, NSN ; LDS-465-1A, NSN ; AND LDS-465-2, NSN AND CLUTCHES REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedure, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms).or DA Form located in the back of this manual direct to: Commander, US Army Tank-Automotive Command. ATTN: DRSTA-MB, Warren, Michigan A reply will be furnished to you. TABLE OF CONTENTS Paragraph CHAPTER 1. GENERAL MAINTENANCE INFORMATION Scope General Maintenance Cleaning * This manual, together with TM , 3 April 1981, and TM , 3 April 1981, supersedes TM , 16 June i

3 TABLE OF CONTENTS-CONT Paragraph Painting Torque Values Special Tools and Equipment Safety Inspection and Testing of Lifting Devices Forms and Records Equipment Improvement Report and Maintenance Digest (EIR MD) and Equipment Improvement Report and Maintenance Summary (EIR MS) Reporting Improvement Recommendations Metric System Destruction to Prevent Enemy Use Administrative Storage Calibration Description Type Fuel Requirements Model Differences Location of Engine Components Engine Ends Engine Sides Cylinder Numbering Main Bearing Numbering Connecting Rod Numbering Crankshaft and Camshaft Rotation Fuel Filters Oil Filters Cylinder Heads Water Outlet Manifolds Rocker Arms, Shafts and Supports Differences Between Models Tabulated Data General Engine Identification Data Application Authorized Fuels General Primary Fuels Alternate I Fuels Alternate II Fuels Emergency Fuels, Alternate Fuel Correction Procedures o a 1-15b 1-15c 1-16 l-16a 1-16b 1-16c 1-16d 1-16e 1-16f 1-16g 1-16h 1-16i 1-16j 1-16k a 1-18b 1-18c a 1-19b 1-19c 1-19d 1-19e o 1-1o 1-1o ii

4 TABLE OF CONTENTS-CONT Paragraph CHAPTER 2. PRELIMINARY PROCEDURES FOR ENGINE MAINTENANCE Section I. Scope Equipment Items Covered Equipment Items Not Covered Section II. Preparation of Engine for Repair Removal of Engine from Shipping And Storage Container Draining of Engine Coolant, Oil, and Fuel Draining Engine Coolant Draining Engine Oil Draining Fuel Mounting Engine on Transport Stand CHAPTER 3. ENGINE DISASSEMBLY Section I. Scope Equipment Items Covered Equipment Items Not Covered Section II. Removal of Engine Accessories Starter Assembly Engines LD-465-1, LD-465-1C, and LDT-465-1C Engines LDS-465-1, LDS-465-1A, and LDS Generator Assembly Engines LD-465-1C and LDT-465-1C Engines LD-465-1, LDS-465-1, and LDS-465-1A Engine LDS Turbocharger Assembly Engine LDT-465-1C Engine LDS Engines LDS-465-1A and LDS Crankcase Breather Tube (Engines LD and LD-465-1C) Disconnection of Fuel Injection Pump Fuel Line and Oil Hoses Engines LD-465-1, LD-465-1C, and LDT-465-1C Engine LDS-465-A Engine LDS Engine LDS a 2-4b 2-4c a 3-3b a 3-4b 3-4c a 3-5b 3-5c a 3-7b 3-7c 3-7d o o 3-1o iii

5 TABLE OF CONTENTS-CONT Fuel Injector Tubes Tube Clamps Fuel Injector Tubes Fuel Injection Pump Drive Gear Access Cover or Hydraulic Pump Assembly Engines LD-465-1, LD-465-1C, and LDT-465-1C Engines LDS-465-1, LDS-465-1A, and LDS Fuel Injection Pump Assembly Oil Filter Elements Air Compressor Assembly All Engines Except LDS Engine LDS Hydraulic Pump Oil Reservoir (Engine LDS-465-2) Fuel Filter Assembly, Fuel Tubes, and Oil Hose Preliminary Procedure Engines LD-465-1, LD-465-1C, and LDT-465-1C Engine LDS-465-1A Engine LDS Engine LDS Oil Cooler and Filter Housing Oil Cooler Oil Cooler and Filter Housing Tappet Chamber Cover Engine LDS Engines LD-465-1, LD-465-1C, LDT C, and LDS-465-1A Engine LDS Air Compressor Support and Fuel Injection Pump Adapter Air Compressor Support Fuel Injection Pump Adapter Fuel Injector Nozzle and Holder Assemblies Crankcase Breather Adapter All Engines Except LDS Engine LDS Paragraph a 3-8b a 3-9b a 3-12b a 3-14b 3-14c 3-14d 3-14e a 3-15b a 3-16b 3-16c a 3-17b a 3-19b iv

6 TABLE OF CONTENTS-CONT Paragraph Intake Manifold Flame Heater and Elbow Engines LD and LD-465-1C Engines LDS-465-1A and LDS Engine LDS Flame Heater Ignition Unit and Flame Heater Fuel Pump Preliminary Procedure System Identification Top Mounted-Covered Flame Heater Ignition Unit and Fuel Pump Top Mounted-Uncovered Flame Heater Ignition Unit and Fuel Pump Side Mounted Flame Heater Fuel Pump Air Pressurization Tube Assemblies (Engine LDS-465-2) Generator Mounting Bracket Oil Pressure Regulator Valve Housing Assembly Oil Gage Support Engines LD-465-1, LD-465-1C, and LDT-465-1C Engines LDS-465-1, LDS-465-1A, and LDS Oil Pressure Transmitter and Coolant Drain Cock Engine Cooling Fan, Thermostat, and Water Pump Assembly Engines LD-465-1, LD-465-1C, LDT-465-1C, LDS-465-1, and LDS-465-1A Engine LDS Cylinder Head Cover All Engines Except LDS Engine LDS Cylinder Head Water Outlet Manifold Intake and Exhaust Manifolds Preliminary Procedure Removal Section III. Disassembly of Engine Assembly Mounting Engine on Maintenance Stand..... Preliminary Procedures Mounting a 3-20b 3-20c a 3-21b c d e a b a 3-27b a 3-28b a 3-30b a 3-31b v

7 TABLE OF CONTENTS-CONT Engine Front and Rear Lifting Brackets Rocker Arms, Rocker Arm Push Rods, and Valve Tappets Cylinder Head Assemblies Clutch Assembly (All Engines Except LDS-465-2) Engines LD-465-1, LD-465-1C, and LDT-465-1C Engines LDS and LDS-465-1A Flywheel Engines LD-465-1, LD-465-1C, and LDT-465-1C Engines LDS and LDS-465-1A Engine LDS Flywheel Housing Crankshaft Rear Oil Seal and Housing Oil Pan Engines LD-465-1, LD-465-1A and LDT-465-1C Engine LDS Engine LDS-465-1A Engine LDS Oil Pump Tubes Engines LD-465-1, LD-465-1C, and LDT-465-1C Engines LDS-465-1, LD-465-1A, and LDS Oil Pump Assembly Oil Pump Gear Backlash Check Removal Piston and Connecting Rod Assemblies Crankshaft Damper and Pulley Assembly Tachometer Drive Adapter AU Engines Except LDS Engine LDS Timing Gear Cover Assembly Camshaft Gear and Crankshaft Gear Oil Pump Idler Gear Assembly Main Bearing Caps, Crankshaft Assembly and Main Bearings Engine Front Plate Piston Cooling Nozzles Camshaft Assembly Removing Cylinder Block from Overhaul Stand Paragraph a 3-35b a 3-36b 3-36c a 3-39b 3-39c 3-39d a 3-40b a 3-41b a 3-44b vi

8 TABLE OF CONTENTS-CONT Part 2 of 2 (TM ) Paragraph CHAPTER 4. Section I. Section II. Section III. CHAPTER 5. Section I. Section II. CHAPTER 6. Section I. Section II. Figure CLEANING, INSPECTION AND REPAIR Scope General Cleaning, Inspection, and Repair Procedures Cleaning, Inspection, and Repair of Engine Components and Accessories FINAL ASSEMBLY Scope Assembly of Engine Assembly DYNAMOMETER TESTS AND RUN-IN PROCEDURES Scope Run-In, Tests, and Adjustments LIST OF ILLUSTRATIONS Title Model LDS Engine Assembly, Left Front View Model LDS Engine Assembly, Right Rear View Model LDS-465-1A Engine Assembly, Right Front View Model LDS-465-1A Engine Assembly, Left Rear View Model LD Engine Assembly, Left Front View Model LD Engine Assembly, Right Rear View Model LD-465-1C Engine Assembly, Right Rear View Models LD-465-1C and LDT-465-1C Engine Assemblies, Left Front View Model LDT-465-1C Engine Assembly, Right Rear View Model LDS Engine Assembly, Right Front View Model LDS Engine Assembly, Left Rear View Fuel Injection Pump Gear Hub Holding Wrench Fabrication Instructions Nozzle and Holder Remover Fabrication Instructions Pilot Stud Fabrication Instructions vii

9 Figure Number LIST OF ILLUSTRATIONS - CONT Title Rear Oil Seal Housing Drain Hole Machine Shop Instructions Typical Oil Pump Test Setup Pressure Relief Valve Shims Cylinder Head Sealing Plate Fabrication Instructions Valve Seats and Valves Machining Specifications.... Valve Grinding Specifications Damper Pulley Locator Fabrication Instruction..... Oil Pressure Regulator Valve Adapter Fabrication Instructions Guide Bolt Fabrication Instructions Flywheel Adapter Fabrication Instructions Flywheel Rear Mounting Plate Fabrication Instructions LIST OF TABLES Title Standard Torque Specifications Special Tools and Equipment Differences Between Models Data Application Oil Pump Idler Gear Shaft Wear Limits Crankshaft Bushing Type Pilot Bearing Wear Limits Crankshaft Pilot Bearing and Bore Wear Limits..... Standard Size Crankshaft Main Bearing Journals Wear Limits Inch Undersize Crankshaft Main Bearing Journals Wear Limits Inch Undersize Crankshaft Main Bearing Journals Wear Limits Standard Size Crankshaft Connecting Rod Journals Wear Limits Inch Undersize Crankshaft Connecting Rod Journals Wear Limits Inch Undersize Crankshaft Connecting Rod Journals Wear Limits Crankshaft Thrust Bearing Journal, Crankshaft Pulley End, Crankshaft Gear, and Crankshaft Damper and Pulley Wear Limits viii

10 LIST OF TABLES - CONT Number Title Main Thrust Bearing Half Wear Limits Main Thrust Bearing Half and Saddle Wear Limits Crankshaft Main Thrust Bearings and Journal Wear Limits Standard Size Crankshaft Main Bearing Half Wear Limits Inch Undersize Crankshaft Main Bearing Half Wear Limits Inch Undersize Crankshaft Main Bearing Half Wear Limits Standard Size Crankshaft Main Bearings and Oil Clearance Wear Limits Inch Undersize Crankshaft Main Bearings and Oil Clearance Wear Limits Inch Undersize Crankshaft Main Bearings and Oil Clearance Wear Limits Camshaft Thrust Plate Wear Limits Camshaft Gear Wear Limits Camshaft Journals Wear Limits Camshaft Bearing Wear Limits Camshaft Bearing Bore Wear Limits Rear Camshaft Journals and Camshaft Bearings Wear Limits Front Camshaft Journals and Camshaft Bearings Wear Limits Valve Tappet Bores and Valve Tappets Wear Limits.... Cylinder Bore Wear Limits Cylinder Sleeve Wear Limits Early Model Oil Pump Pressure Relief Valve Wear Limits Late Model Oil Pump Pressure Relief Valve Wear Limits... Oil Pump Impeller Shaft and Bushing Type Bearings Wear Limits Oil Pump Impeller Drive Shaft and Bushing Wear Limits Oil Pump Driven Impeller, Impeller Bore, Impeller Shaft, and Impeller Bushing Wear Limits Oil Pump Drive Impeller and Impeller Bore Wear Limits Scavenge Oil Pump Impellers and Impeller Bores Wear Limits Engine LDS Oil Pump Pressure Relief Valve Wear Limits ix

11 LIST OF TABLES - CONT Number Title Engine LDS Oil Pump Impeller Drive Shaft and Bushings Wear Limits Engine LDS Oil Pump Driven Impeller Shaft Wear Limits Engine LDS Pressure Pump Driven Impeller and Driven Impeller Bore Wear Limits Engine LDS Pressure Pump Drive Impeller and Drive Impeller Bore Wear Limits Engine LDS Scavenge Pump Driven Impeller and Impeller Bore Wear Limits Engine LDS Scavenge Pump Drive Impeller and Impeller Bore Wear Limits Early Model Oil Pressure Regulator Valve Plunger Spring Wear Limits Late Model Oil Pressure Regulator Valve Plunger Spring Wear Limits Oil Pressure Regulator Valve Housing Wear Limits Valve Guides and Valve Guide Bores Wear Limits Intake Valve Seat Inserts and Counterbores Wear Limits Exhaust Valve Seat Inserts and Counterbores Wear Limits Intake and Exhaust Valve Length Wear Limits Intake Valves and Guides Wear Limits Exhaust Valves and Guides Wear Limits Early Model Cylinder Head Intake Valves and Guides Wear Limits Early Model Cylinder Head Exhaust Valves and Guides Wear Limits Inner Valve Springs Wear Limits Outer Valve Springs Wear Limits Valve Rocker Arm Bearings and Shafts Wear Limits... Valve Rocker Arm Thrust Spring Wear Limits Oil Cooler and Filter Housing Assembly Wear Limits... Oil Cooler and Filter Bypass Valve Springs Wear Limits Fuel Filter Pressure Relief Valve Wear Limits Air Compressor Pulley Pins, Hub, and Sleeve- Type Bearings (Engine LDS-465-2) Wear Limits Air Compressor Bearing Sleeve and Pulley Spring (Engine LDS-465-2) Wear Limits Fan Idler Pulley and Arm Assembly Wear Limits Fan Idler Pulley and Arm Assembly Fits and Wear Limits Run-In Schedule-Long (Models LD and LD-465-1C) Run-In Schedule-Long (Model LDT-465-1C) x

12 Number LIST OF TABLES - CONT Title Run-In Schedule-Long (Model LDS-465-1) Run-In Schedule-Long (Model LDS-465-1A) Run-In Schedule-Long (Model LDS-465-2) Run-In Schedule-Short (Models LD and LD-465-1C) Run-In Schedule-Short (Model LDT-465-1C) Run-In Schedule-Short (Model LDS-465-1) Run-In Schedule-Short (Model LDS-465-1A) Run-In Schedule-Short (Model LDS-465-2) xi/(xii blank)

13 CHAPTER 1 GENERAL MAINTENANCE INFORMATION 1-1. SCOPE. a. This manual gives instructions for direct support and general support maintenance of multifuel engine models LD-465-1, LD-465-1C, LDT-465-1C, LDS-465-1, LDS-465-1A, and LDS b. Engine models LD and LDT-465-1C are used in the M44A2 series 2 1/2- ton trucks. Engine models LDS and LDS-465-1A are used in the M39A2 series 5-ton trucks. The LDS and LD-465-1C engines are used in the M656, M757, and M791 series 5-ton trucks. c. This manual has procedures for disassembly, cleaning, inspection, repair, test, adjustment, and overhaul as authorized by the maintenance allocation chart. d. Refer to TM P for a listing of repair parts and special tools for the maintenance of multifuel engines covered in this manual. e. Figures 1-1 to 1-11 show the multifuel engines covered in this manual GENERAL MAINTENANCE. General maintenance tasks relating to inspection, care and maintenance of antifriction bearings are given in TM Welding procedures that apply to this type of equipment are given in TM For lubrication, refer to LO /1 and LO CLEANING. Refer to TM for general cleaning materials for this type of equipment. Special cleaning procedures are given in chapter PAINTING. For painting instructions for field use of the equipment covered in this manual, refer to TM

Model LDS-465-1 engine assembly, right rear view Figure 1-3.

14 Figure 1-1. Model LDS engine assembly, left front view Figure 1-2. Model LDS engine assembly, right rear view Figure 1-3. Model LDS-465-1A engine assembly, right front view Figure 1-4. Model LDS-465-1A engine assembly, left rear view 1-2

TM P Supersedes copy dated May 1974 TECHNICAL MANUAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS

TM P Supersedes copy dated May 1974 TECHNICAL MANUAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS Supersedes copy dated May 1974 TECHNICAL MANUAL REPAIR PARTS AND SPECIAL TOOLS LISTS FOR ENGINE, DIESEL (MULTIFUEL): TURBOCHARGED, FUEL INJECTED, WATER COOLED, 6-CYLINDER ASSEMBLY (MILITARY MODELS LDT-465-1D,