TM-5-4310-387-14 Compressor Unit Diesel Engine Driven 20 CFM 3200 PSI Model K-20-D Manual

CHAPTER 1 INTRODUCTION - TM-5-4310-387-14_14
Section II. EQUIPMENT DESCRIPTION - TM-5-4310-387-14_15
1-10.  Equipment Data.
Figure 1-2. Air Compressor Major Components.
1-11.   Safety, Care, and Handling.
Section III. PRINCIPLES OF OPERATION - TM-5-4310-387-14_19
Figure 1-3. Compressor Air Flow Diagram.
1-14.  Detailed Principles of Operation for Engine Assembly.
f. Exhaust System.
CHAPTER 2 OPERATING INSTRUCTIONS - TM-5-4310-387-14_23
Figure 2-1. Air Compressor Assembly, Controls and Indicators.
Function or Use
Figure 2-2. Engine Assembly, Controls and Indicators.
Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-5-4310-387-14_27
2-6. Explanation of Columns
e. Leakage Definitions.
Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS). - TM-5-4310-387-14_30
Operator Preventive Maintenance Checks and Services (PMCS) (Cont). - TM-5-4310-387-14_31
Section III. OPERATION UNDER USUAL CONDITIONS - TM-5-4310-387-14_32
Figure 2-3. Compressor Orientation.
Figure 2-4. Starting Procedures
Figure 2-5. Hand Position.
c. Servicing SCUBA Cylinders
Figure 2-6. Servicing SCUBA cylinders
Table 2-2. SCUBA Cylinder Charging Capacities
Figure 2-7. Shutdown Procedures.
Section IV. OPERATION UNDER UNUSUAL CONDITIONS - TM-5-4310-387-14_40
2-18. Operation In Cold
CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS - TM-5-4310-387-14_42
Section II. OPERATOR TROUBLESHOOTING PROCEDURES - TM-5-4310-387-14_43
Table 3-2. Operator Troubleshooting Procedures.
5. ENGINE EXHAUST EXCESSIVELY BLACK
9. ENGINE EXCESSIVELY NOISY.
12. COMPRESSOR OUTPUT TOO LOW.
CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS - TM-5-4310-387-14_48
4-5. Checking Unpacked Equipment.
Section III. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 4-1. Unit Preventive Maintenance Checks and Services (PMCS) (Cont). - TM-5-4310-387-14_51
Section IV. UNIT TROUBLESHOOTING PROCEDURES - TM-5-4310-387-14_52
Table 4-2. Unit Troubleshooting Procedures. - TM-5-4310-387-14_53
5. ENGINE RUNS HOT. - TM-5-4310-387-14_54
9. COMPRESSOR OUTPUT VOLUME TOO LOW.
Section V. UNIT MAINTENANCE PROCEDURES - TM-5-4310-387-14_56
4-13. Drivebelt Guard.
Figure 4-1. Drivebelt Guard, Replace.
4-14. Compressor Drivebelt.
Figure 4-2. Compressor Drivebelt, Replace.
4-15. Storage Tray.
Figure 4-3. Storage Tray, Replace.
4-16. Air Compressor.
Figure 4-4. Air Compressor Assembly, Service.
4-17. Inlet Filter and Adapter Assembly.
Figure 4-5. Inlet Filter and Adapter Assembly, Service
b. Replace. - TM-5-4310-387-14_67
Figure 4-6. Inlet Filter and Adapter Assembly, Replace.
Figure 4-7. Inlet Filter and Adapter Assembly, Repair.
4-18. Pre-Filter and Hose Assembly.
b. Repair. - TM-5-4310-387-14_71
Figure 4-9. Pre-Filter and Hose Assembly, Repair.
4-19. Oil Filler.
Figure 4-10. Oil Filler, Replace.
4-20. Dipstick.
Figure 4-11. Dipstick, Replace
4-21. Drain Tube.
Figure 4-12. Drain Tube, Replace
4-22. Crankcase Breather Assembly.
Figure 4-13. Crankcase Breather Assembly, Service.
b. Replace. - TM-5-4310-387-14_81
Figure 4-14. Crankcase Breather Assembly, Replace.
4-23. Engine Assembly.
Figure 4-15. Engine Assembly, Service.
b. Replace. - TM-5-4310-387-14_85
Figure 4-16. Engine Assembly, Replace.
4-24. Fuel Lines and Filter.
Figure 4-17. Fuel Supply Line and Filter, Replace
(2)     High pressure fuel line.
Figure 4-18. High Pressure Fuel Line, Replace
(3) Injector overflow line.
Figure 4-19. Injector Overflow Line, Replace
(4) Injector pump overflow line.
Figure 4-20. Injector Pump Overflow Line, Replace.
(5) Fuel tank filter.
Figure 4-21. Fuel Tank Filter, Replace.
4-25. Fuel Tank.
Figure 4-22. Fuel Tank, Replace.
4-26. Engine Air Cleaner Assembly.
Figure 4-23. Air Cleaner, Service.
b. Replace. - TM-5-4310-387-14_101
Figure 4-24. Air Filter, Replace.
4-27. Engine Muffler.
Figure 4-25. Muffler, Replace
4-28. Engine Valve Cover
Figure 4-26. Engine Valve Cover, Replace.
4-29. Governor Assembly.
Figure 4-27. Governor Assembly, Adjust.
4-30. Gear Cover Assembly
Figure 4-28. Crank Handle Guide, Replace
Figure 4-29. Cover Plate, Replace.
Figure 4-30. Filler Cap, Replace
4-31. Oil Filter Screen
Figure 4-31. Oil Filter Screen, Service.
b. Replace - TM-5-4310-387-14_115
Figure 4-32. Oil Screen, Replace.
4-32. Cold Start Assembly.
Figure 4-33. Cold Start Assembly, Replace.
4-33. Frame.
Figure 4-35. Plug, Replace
4-34. Shock Mounts
Figure 4-36. Shock Mounts, Replace.
4-35. Support Brackets.
Figure 4-37. Support Bracket, Replace.
Section VI. UNIT LEVEL CLEANING PROCEDURE FOR DIVING LIFE SUPPORT AIR SYSTEMS - TM-5-4310-387-14_125
b. Installation or Reinstallation
4-41.   Cleaning Method Non-Ionic Detergent .
4-42. Cleaning Method - Trisodium Phosphate (TSP) .
Table 4-3. TSP Cleaning Solution Volume. - TM-5-4310-387-14_129
Table 4-4. Cleaning Solution Flow Rate.
Table 4-5. Cleaning Agents Comparable with Soft Goods. - TM-5-4310-387-14_131
4-44. Hydrocarbon Inspection and Analysis.
4-45. Documentation and Record Keeping.
Section VII. PREPARATION FOR STORAGE OR SHIPMENT
4-48.   Long Term Storage
4-49. Preparation for Shipment.
Figure 4-38. Compressor Unit Sling and Tie Down Arrangement
CHAPTER 5 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS - TM-5-4310-387-14_138
Table 5-1. Direct Support Troubleshooting Procedures.
2. ENGINE RUNS UNEVENLY: LOW OUTPUT
5. ENGINE RUNS HOT. - TM-5-4310-387-14_141
9. COMPRESSOR PRESSURE LOW. - TM-5-4310-387-14_142
10. COMPRESSOR OUTPUT VOLUME LOW (CONT)
Section III. DIRECT SUPPORT MAINTENANCE PROCEDURES - TM-5-4310-387-14_144
5-7. Gages.
Figure 5-1. Pressure Gages, Replace.
5-8. Gage Panel.
Figure 5-2. Gage Panel, Replace.
5-9. Purifier Assembly.
Figure 5-3. Purifier Assembly, Service.
b. Replace. - TM-5-4310-387-14_151
Figure 5-4. Purifier Assembly, Replace.
c. Repair. - TM-5-4310-387-14_153
Figure 5-5. Purifier Assembly, Repair.
5-10. Air Compressor.
Figure 5-6. Air Compressor, Replace.
5-11. Fanwheel Assembly.
Figure 5-7. Fanwheel Assembly, Replace.
5-12. Second Stage Separator Assembly.
Figure 5-8. Second Stage Separator Assembly, Replace.
b. Repair. - TM-5-4310-387-14_161
Figure 5-9. Second Stage Separator Assembly, Repair.
5-13. Safety Valve.
(6) Inspect pipe
5-13. Safety Valve
Figure 5-10. Safety Valve, Replace.
5-14. Final Separator Assembly..
Figure 5-11. Final Separator Assembly, Replace.
b. Repair. - TM-5-4310-387-14_169
Figure 5-12. Final Separator, Repair.
5-15. Safety Valve.
Figure 5-13. Safety Valve, Replace.
5-16. First Stage Intercooler Coil.
Figure 5-14. First Stage Intercooler Coil, Replace.
5-17. Second Stage Intercooler Coil.
Figure 5-15. Second Stage Intercooler Coil, Replace.
5-18. Aftercooler.
Figure 5-16. Aftercooler, Replace.
5-19. Lines and Fittings.
Figure 5-17. First Stage Cooler Line, Replace.
b. Replace Second Stage Cooler Line.
Figure 5-18. Second Stage Cooler Line, Replace.
c. Replace Oil Feed Line.
Figure 5-19. Oil Feed Line, Replace.
d. Replace Oil and Filter Line.
Figure 5-20. Oil and Filter Line, Replace.
d. Replace Tube Assembly.
Figure 5-21. Tube Assembly, Replace
Figure 5-22. Intercooler to Separator Line, Replace
Figure 5-23. Third Stage Inlet Line, Replace.
h. Replace Final Separator to Purifier Assembly Line.
Figure 5-24. Final Separator to Purifier Assembly Line, Replace
5-20. Oil Pressure Regulator.
Figure 5-25. Oil Pressure Regulator, Replace.
Figure 5-26. Oil Relief Valve, Replace.
Figure 5-27. Sight Glass, Replace.
5-21. Oil Pump.
Figure 5-28. Oil Pump, Replace.
5-22. First Stage Valve Head and Valve Assembly.
Figure 5-29. Valve Head and Valve Assembly, Replace.
b. Repair. - TM-5-4310-387-14_201
Figure 5-30. Valve Head and Valve Assembly, Repair.
5-23. Second Stage Valve Head Assembly.
Figure 5-31. Second Stage Valve Head Assembly, Replace.
b. Repair. - TM-5-4310-387-14_205
Figure 5-32. Second Stage Valve Head Assembly, Repair.
5-24. Safety Valve (Second Stage Valve Head).
Figure 5-33. Safety Valve, Replace
5-25. Third Stage Valve Head Assembly.
Figure 5-34. Third Stage Valve Head Assembly, Replace.
b. Repair. - TM-5-4310-387-14_211
Figure 5-35. Third Stage Valve Head Assembly, Repair.
(5) Inspect valve plates
5-26. Sheave (Pulley).
Figure 5-36. Sheave (Pulley), Replace.
5-27. Fuel Injector.
Figure 5-37. Fuel Injector, Test.
b. Replace. - TM-5-4310-387-14_218
Figure 5-38. Fuel Injector, Replace.
5-28. Fuel Injection Pump.
Figure 5-39. Fuel Injector Pump, Adjust.
Table 5-2. Fuel Injection Timing-Millimeters BTDC (+2 mm).
Figure 5-40. Fuel Injection Pump, Replace
5-29. Engine Cylinder Head Assembly
Figure 5-41. Valves, Adjust.
b. Replace - TM-5-4310-387-14_226
Figure 5-42. Cylinder Head Assembly, Replace.
c. Repair. - TM-5-4310-387-14_228
Figure 5-43. Cylinder Head Assembly, Repair
(19) Inspect rocker arm shaft
5-30. Speed Control Assembly
Figure 5-44. Speed Control Assembly, Replace.
FOLLOW-ON MAINTENANCE - TM-5-4310-387-14_233
5-31. Compression Release Assembly.
Figure 5-45. Compression Release Assembly, Replace.
5-32. Gear Cover Assembly.
Figure 5-46. Gear Cover Assembly, Replace
5-33. Cylinder
Figure 5-47. Cylinder, Replace.
5-34. Oil Pump Assembly.
Figure 5-48. Oil Pump Assembly, Replace.
5-35. Flywheel.
Figure 5-49. Flywheel, Replace.
5-36. Fanwheel.
Figure 5-50. Fanwheel, Replace
5-37. Pressure Maintaining Valve.
Figure 5-51. Pressure Maintaining Valve, Replace.
(7) Apply tefIon tape
5-38. Air Tank Charging Whip Assembly
Figure 5-52. Air Tank Charging Whip Assembly, Replace.
b. Repair - TM-5-4310-387-14_251
Figure 5-53. Air Tank Charging Whip Assembly, Repair.
5-39. Frame.
Figure 5-54. Frame, Replace.
Figure 5-55. Frame, Repair
CHAPTER 6 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS - TM-5-4310-387-14_256
Table 6-1. General Support Troubleshooting Procedures - TM-5-4310-387-14_257
2. ENGINE RUNS UNEVENLY: LOW OUTPUT.
7. UNUSUAL ENGINE KNOCKS AND NOISES.
9. COMPRESSOR PRESSURE LOW. - TM-5-4310-387-14_260
10. COMPRESSOR OUTPUT VOLUME LOW.
6-7. Gages.
6-8. First Stage Cylinder.
Figure 6-1. First Stage Cylinder, Replace.
(6) Install piston
6-9. First Stage Piston and Connecting Rod Assembly.
Figure 6-2. First Stage Piston and Piston Rod Assembly, Replace.
b. Repair. - TM-5-4310-387-14_268
Figure 6-3. First Stage Piston and Connecting Rod Assembly, Repair.
(3) Clean piston
6-10. Second Stage Cylinder.
Figure 6-4. Second Stage Cylinder, Replace.
(7) Install piston
6-11. Second Stage Piston and Connecting Rod Assembly.
Figure 6-5. Second Stage Piston and Connecting Rod Assembly, Replace
b. Repair. - TM-5-4310-387-14_276
Figure 6-6. Second Stage Piston and Connecting Rod Assembly, Repair.
6-12. Third Stage Cylinder
Figure 6-7. Third Stage Cylinder and Crosshead Guide, Replace.
6-13. Third Stage Crosshead and Rod Assembly
Figure 6-8. Third Stage Crosshead and Connecting Rod Assembly, Replace
b. Repair. - TM-5-4310-387-14_282
Figure 6-9. Third Stage Crosshead and Connecting Rod Assembly, Repair.
(2) Clean piston
6-14. Compressor Crankshaft and Main Bearings
Figure 6-10. Compressor Crankshaft and Main Bearings, Replace
FOLLOW-ON MAINTENANCE - TM-5-4310-387-14_287
6-15. Compressor Crankcase
Figure 6-11. Compressor Crankcase, Replace.
6-16. Fuel Injection Pump
Figure 6-12. Fuel Injection Pump, Repair.
6-17. Governor Assembly
Figure 6-13. Governor Assembly, Replace.
b. Repair. - TM-5-4310-387-14_294
Figure 6-14. Governor Assembly, Repair.
6-18. Gear Cover Assembly
Figure 6-15. Shaft Bushing, Replace.
(2) Replace primer assembly.
Figure 6-16. Primer Assembly, Replace.
6-19. Camshaft Assembly.
Figure 6-17. Camshaft Assembly, Replace.
b. Repair. - TM-5-4310-387-14_302
Figure 6-18. Camshaft Assembly, Repair.
6-20. Piston and Connecting Rod Assemblies.
Figure 6-19. Piston and Connecting Rod Assemblies, Replace
b. Repair. - TM-5-4310-387-14_306
Figure 6-20. Piston and Connecting Rod Assemblies, Repair
6-21. Crankshaft and Mainbearing Support.
Figure 6-21. Crankshaft, Replace.
b. Replace. - TM-5-4310-387-14_310
Figure 6-22. Crankshaft, Repair.
6-22. Engine Crankcase.
Figure 6-23. Crankcase, Replace.
6-23. Air Tank Charging Whip Assembly
Figure 6-24. Air Tank Charging Whip Assembly, Calibrate
APPENDIX A REFERENCES - TM-5-4310-387-14_316
APPENDIX B MAINTENANCE ALLOCATION CHART - TM-5-4310-387-14_317
B-3.    Column Entries.
B-4.    Tool and Test Equipment Requirements
Section II MAINTENANCE ALLOCATION CHART
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-387-14_321
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-387-14_322
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-387-14_323
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-387-14_324
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-387-14_325
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-387-14_326
Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS - TM-5-4310-387-14_327
Section IV. REMARKS - TM-5-4310-387-14_328
APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS - TM-5-4310-387-14_329
Section II. COMPONENTS OF END ITEMS - TM-5-4310-387-14_330
Section III. BASIC ISSUE ITEMS - TM-5-4310-387-14_331
Description Usable On Code
APPENDIX D ADDITIONAL AUTHORIZATION LIST - TM-5-4310-387-14_333
APPENDIX E EXPENDABLE SUPPLIES AND MATERIALS LIST - TM-5-4310-387-14_334
Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST - TM-5-4310-387-14_335
EXPENDABLE SUPPLIES AND MATERIALS LIST (Cont)
APPENDIX F TORQUE LIMITS - TM-5-4310-387-14_337
Table F-2. Self-Locking Nut Breakaway Torque Values

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