TM-5-4310-389-14 Air Compressor 5.1 CFM Diesel Engine Driven Model KA7-DA Manual

CHAPTER 1 INTRODUCTION AND DESCRIPTION
1-5. LIST OF ABBREVIATIONS (Contd).
Section II. EQUIPMENT DESCRIPTION AND DATA
Figure 1-1. K-20, Front View
Figure 1-2. K-20, 3/4 Rear View
Table 1-1. Equipment Data/Characteristics
Equipment Data/Characteristics (Continued)
1-10 SAFETY, CARE, AND HANDLING.
l. The engine and compressor
Section III TECHNICAL PRINCIPLES OF OPERATION
Figure 1-3. Compressor Air Flow Diagram
Figure 1-4. Air System Flow Diagram
CHAPTER 2 OPERATING INSTRUCTIONS - TM-5-4310-389-14_26
2-3 SAFETY DEVICES.
Figure 2-1. Instrument Panel
Figure 2-2. Venting Bore
Section II PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 2-1. Operator Preventive Maintenance Checks and Services (PMCS) - TM-5-4310-389-14_31
Operator Preventive Maintenance Checks and Services (PMCS)(Continued)
Section III. OPERATION UNDER USUAL CONDITIONS - TM-5-4310-389-14_33
Figure 2-4. Intake Hose Extended
2-9 START-UP PROCEDURE (ELECTRIC).
2-10 START-UP PROCEDURE (MANUAL).
Figure 2- 6. Decompression Device
2-11   SHUTDOWN PROCEDURE
2-13 DECAL/INSTRUCTION PLATES
Figure 2-8. Operating Instructions
Figure 2-9. Maintenance Schedule
Figure 2-12. Cylinder Cartridge (058825) Replacement Schedule
Figure 2-14. Throttle Control Knob
Section IV. OPERATING UNDER UNUSUAL CONDITIONS
a. Locate ignition switch.
Figure 2-17. Cold Start Aid
2-15 OPERATION IN EXTREME HEAT
2-18 OPERATION IN SALT WATER AREAS
CHAPTER 3 UNIT MAINTENANCE - TM-5-4310-389-14_49
3-4 FILLING/CHECKING ENGINE OIL LEVEL
Figure 3-4. Intake and Exhaust Manifold Securing Bolts
b. Compressor
Section II. REPAIR PART, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
Section III. SERVICE UPON RECEIPT OF MATERIAL
Section IV. PREVENTIVE MAINTENANCE CHECKS AND SERVICES - TM-5-4310-389-14_55
Table 3-1. Unit PMCS (Continued)
Unit PMCS (Continued) - TM-5-4310-389-14_57
Unit PMCS (Continued) - TM-5-4310-389-14_58
Section V. UNIT TROUBLESHOOTING PROCEDURES
Table 3-2. Unit Troubleshooting Procedures (Continued)
Unit Troubleshooting Procedures (Continued) - TM-5-4310-389-14_61
Unit Troubleshooting Procedures (Continued) - TM-5-4310-389-14_62
Unit Troubleshooting Procedures (Continued) - TM-5-4310-389-14_63
Unit Troubleshooting Procedures (Continued) - TM-5-4310-389-14_64
Unit Troubleshooting Procedures (Continued) - TM-5-4310-389-14_65
Unit Troubleshooting Procedures (Continued) - TM-5-4310-389-14_66
Unit Troubleshooting Procedures (Continued) - TM-5-4310-389-14_67
Section VI. UNIT MAINTENANCE PROCEDURES - TM-5-4310-389-14_68
Figure 3-5. Compressor Block
Figure 3-6. Oil Drain Plug
Figure 3-7. Venting the Oil Pump
Figure 3-8. Belt Guard
Figure 3-10. Oil Pressure Regulating Valve
TEST - TM-5-4310-389-14_74
3-17 LOWER CRANKCASE (COVER).
3-18 TENSION PULLEY ASSEMBLY (OIL PUMP TIMING BELT)
Figure 3-12. Oil Pump Drive Belt Adjustment
3-19 COOLING SYSTEM (COMPRESSOR).
Figure 3-13. Compressor Fan and Cooling Fins
3-20 INTAKE FILTER ASSEMBLY (COMPRESSION)
INSPECT - TM-5-4310-389-14_81
3-21 ENGINE
Figure 3-17. Changing Oil
Figure 3-18. Checking V-Belt Deflection (Belt Guard Removed)
3-22 CYLINDER HEAD SET (VALVE COVERS)
c. Clean gasket mating surface
3-23 TIMING GEARS (VALVE ADJUSTMENT/DECOMPRESSION CHECK)
Figure 3-21. Valve Clearance
3-24 LUBE OIL FILTER (ENGINE)
During trial run following reassembly
3-25 LUBE OIL COOLER (ENGINE)
Figure 3-24. Lube Oil Cooler/Removal
3-26 FUEL FILTER CARTRIDGE (ENGINE).
c Clean sealing surface
3-27 FUEL INJECTION PIPES (ENGINE).
Figure 3-26. Injection Lines
3-28. FUEL FEED PUMP (ENGINE)
Figure 3-27. Feed Pump Strainer
3-29 FUEL HOSE (ENGINE).
REPAIR - TM-5-4310-389-14_100
3-30 FUEL RETURN LINE (ENGINE).
b Filter Return Line.
3-31 OIL BATH AIR CLEANER (ENGINE).
REPLACE REPAIR - TM-5-4310-389-14_104
3-32 INTAKE MANIFOLD (ENGINE).
Figure 3-31. Intake Manifold
3-33 COOLING AIR DUCTING SYSTEM (ENGINE).
Figure 3-32. Cooling System Components
REPAIR - TM-5-4310-389-14_109
3-34 STARTING MOTOR.
Figure 3-35. Starter Motor
3-35 V-BELT GUARD (ENGINE).
REPLACE REPAIR - TM-5-4310-389-14_113
3-36 EXHAUST MANIFOLD ASSEMBLY (ENGINE).
Figure 3-37. Exhaust Manifold
3-37 COLD START AID (ENGINE)
b Remove expended ether cartridge
3-38 ALTERNATOR (ENGINE)
Figure 3-40. Cable Harness Voltage Test
Figure 3-41. Alternator Output Test
Figure 3-42. Alternator
3-39 CLUTCH SYSTEM.
Figure 3-43. Grease Fittings
3-40 HANDLE ASSEMBLY
3-41 PRESSURE MAINTAINING VALVE.
3-42 PURIFIER CHAMBER.
3-43 SEPARATOR BLOCK.
Figure 3-46. Separator Block
3-44 INSTRUMENTS AND CONTROL PANEL ASSEMBLY (GAUGES).
a. Service Line Pressure, Final Pressure, Compressor Oil Pressure.
Figure 3-47. Instrument Panel
3-45 ELECTRICAL SYSTEM.
c. Relay Latch.
i. Compressor Oil Safety Switch.
TEST - TM-5-4310-389-14_135
Figure 3-48. Wiring Diagram
f. Condensate Heater Switch.
k. Condensate Heater Relay.
ADJUST - TM-5-4310-389-14_139
3-46 TUBINGS AND FITTINGS.
CHAPTER 4 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
Table 4-1. Direct Support Troubleshooting Procedures (Continued)
Direct Support Troubleshooting Procedures (Continued) - TM-5-4310-389-14_143
Direct Support Troubleshooting Procedures (Continued) - TM-5-4310-389-14_144
Direct Support Troubleshooting Procedures (Continued) - TM-5-4310-389-14_145
Direct Support Troubleshooting Procedures (Continued) - TM-5-4310-389-14_146
Section II. DIRECT SUPPORT MAINTENANCE
Table 4-3. Fuel Injection System
Table 4-4. Cylinder Head (Continued)
Cylinder Head (Continued) - TM-5-4310-389-14_150
Cylinder Head (Continued) - TM-5-4310-389-14_151
Cylinder Head (Continued) - TM-5-4310-389-14_152
Cylinder Head (Continued) - TM-5-4310-389-14_153
Cylinder Head (Continued) - TM-5-4310-389-14_154
Table 4-7. Compressor Valve Tolerances
Table 4-8. Compressor Tolerances (Continued)
Table 4-9. Clutch Tolerances
4-4    GENERAL NOTES ON ENGINE REPAIR
To avoid fatigue failure
4-6    LOWER CRANKCASE (TIMING BELT).
b.    Reassembly.
4-7    CYLINDER BLOCK ASSEMBLY; ALL STAGES (COMPRESSOR).
REPLACE    REPAIR
INSPECT - TM-5-4310-389-14_164
Figure 4-1. Piston Ring Sets
Figure 4-2. Installing Cylinder Meter
4-8   VALVE HEAD ASSEMBLY (1ST, 2ND, 3RD, AND 4TH STAGES) (COMPRESSOR).
Figure 4-4.   Valve Head, 1st Stage
INSPECT - TM-5-4310-389-14_169
Figure 4-6.    Valve Head, 4th Stage
d. Head Removal (1st Stage).
Figure 4-7.   Valve Head Tightening Sequence
Figure 4-8.   Cooling System Components
2nd Stage Intercooler
3rd Stage Intercooler
b.    Install.
4-9   FLYWHEEL/COOLING FAN (COMPRESSOR).
Figure 4-9.   Flywheel / cooling Fan
4-10 OIL LUBRICATING SYSTEM (COMPRESSOR).
Figure 4-10. Lube Oil Pump
Figure 4-11. Oil Pressure Regulating Valve
4-11 ENGINE.
b. Engine.
Figure 4-13. Stop Lever/Solenoid Speed Control/Throttle
1. Remove throttle linkage
4-12 CYLINDERS (ENGINE)
Figure 4-15. Correct Installation of Cylinder
Figure 4-17. Measuring the Cylinder Bore
4-13 CONNECTING ROD (ENGINE).
Figure 4-19. Connecting Rod Assembly
Figure 4-20. Measuring Piston Pin Bushing Figure 4-21. Checking Connecting Rod Connecting Rod Bearing Bore
Figure 4-22. Checking Connecting Rod for Squareness
4-14 PISTON
INSPECT - TM-5-4310-389-14_194
REPLACE   REPAIR
d. Press the piston pin
4-15 CYLINDER HEAD SET (ENGINE)
Figure 4-28. Checking Piston Crown Clearance
Figure 4-30. Aligning the Intake and Figure 4-31. Assembling Spring onto Exhaust Flanges
Figure 4-32. Fitting Seal Rings to Figure 4-33. Removing Spring Tensioner Push Rod Tube
Figure 4-34. Mounting Rocker Arm Figure 4-35. Upper Cover Plate Shaft Support
Figure 4-36. Rear Vertical Plate
4-16 TIMING GEARS (SET TIMING).
Figure 4-37. Measuring and Marking Figure 4-38. Setting the Adjusting Drive Halfway Points
Figure 4-39. Zeroing Magnetic Protractor
Figure 4-42. Install Camshaft Jacking Bolts
n) Install the hand crank plate
4-17 INJECTORS (ENGINE)
Figure 4-44. Injector Components
4-18. FUEL INJECTION PUMP (ENGINE).
ADJUST - TM-5-4310-389-14_211
Figure 4-47. Securing Graduated Scale to Figure 4-48. Zeroing Magnetic Protractor V-Belt Pulley
Figure 4-49. Setting Gauge Pointer Figure 4-50. Measuring and Making Halfway Points
Figure 4-51. Removing Starting Figure 4-52. Turning Camshaft Using Crank Bearing
Figure 4-53. Deutz Fuel Injection Pump
g. Operational Check.
9. Fuel balancing
4-19. FUEL FEED PUMP (ENGINE).
Figure 4-55. Fuel Feed Pump
4-20. COOLING AIR BLOWER (ENGINE).
Figure 4-56. Cooling Air Blower
Figure 4-57. Checking V-Belt Pulley Alignment
4-21. STARTING MOTOR.
Figure 4-58. No-Load Test Connections
5. When test is complet
Figure 4-59. Locked Rotor Test Connections
c. Starter Motor Repair.
Figure 4-60. Starter Drive Retainer Removal
Figure 4-61. Starter Drive Snap Ring Installation
Figure 4-62. Securing Drive Retainer
4-22. ALTERNATOR (ENGINE).
Figure 4-64. Alternator
Figure 4-65. Stator Winding Test
j. Separate rotor from front housin
Figure 4-66. Removing Slip Ring Assembly
Figure 4-68. Alternator Performance Test
Follow on maintenance
4-23. CLUTCH.
Figure 4-69. Clutch
b. Removal of clutch from shaft.
REPLACE REPAIR
b. Clutch Reassembly
3. Place pressure plate
8 Place clutch release lever
c. Disassembly of Ball Bearing
d. Reassembly Procedure.
f. Install Clutch.
4-24. PRESSURE MAINTAINING VALVE (PMV)
Figure 4-70. Pressure Maintaining Valve (PMV)
c. Reassemble
4-25. PURIFIER CHAMBER.
SERVICE
Figure 4-71. Purifier Chamber
REPLACE         REPAIR
3. Install service line.
4-26. SEPARATOR BLOCK
Figure 4-72. Separator Block (Sheet 1 of 2)
Figure 4-72. Separator Block (Sheet 2 of 2)
c. Inspect and clean separator assembly
8. Reconnect the six tubing fittings
4-27. INSTRUMENTS AND CONTROL PANEL ASSEMBLY (VALVES)
Service Line Check Valve.
d. Install.
4-28. ELECTRICAL SYSTEM
TEST - TM-5-4310-389-14_265
Figure 4-73. Stop Lever/Solenoid Speed Control/Throttle
Table 4-10. Run Solenoid Resistance Values
Table 4-11. Condensate Drain Coil Resistance Values
4-29. TUBINGS AND FITTINGS
CHAPTER 5 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS - TM-5-4310-389-14_270
Table 5-1. General Support Troubleshooting (Continued)
General Support Troubleshooting (Continued) - TM-5-4310-389-14_272
General Support Troubleshooting (Continued) - TM-5-4310-389-14_273
Section II. GENERAL SUPPORT MAINTENANCE PROCEDURES
5-3. UPPER CRANKCASE AND DRIVE GEAR (COMPRESSOR)
Figure 5-1. Connecting Rod Axial Play
REPAIR - TM-5-4310-389-14_277
5-4. LOWER CRANKCASE AND TENSION PULLEY ASSEMBLY (COMPRESSOR)
Figure 5-3. Lower Crankcase
b. Reassembly.
5-5. ENGINE
Figure 5-4. Removing Camshaft Cover
Figure 5-8. Remove Camshaft
Figure 5-12. Removing Front End Shield
Figure 5-16. Oil Galley Plugs
Figure 5-18. Removing/Reinstalling Figure 5-19. Oil Dosing Plug/Installing Crankshaft
Figure 5-20. Installing Bore Sealing Cover
Figure 5-24. Fitting Thrust Ring
Figure 5-26. Inserting Bearing Cap Bolts Figure 5-27. Align End Shield Oil Hole (Engine Upside-down)
Figure 5-30. Pressing in Front End Shield
Figure 5-32. Installing Crankcase Cover Figure 5-33. Installing Camshaft in Bearing (Engine Block Upside-down)
41.    Secure the camshaft gear wheel
Figure 5-36. Mounting Front Cover with Figure 5-37. Assembling Threaded Sleeve Lube Oil Pump
Figure 5-40. Fitting the Piston Pin
Figure 5-42. Positioning Big End Bearing Figure 5-43. Preloading Cylinder Bearing on Crankpin
Figure 5-44. Fitting Screw Plugs into Figure 5-45. Assembling Push Rod Cylinder Head
Figure 5-46. Installing Push Rods/ Figure 5-47. Assembling Front Vertical Mount Rocker Arm Shaft Support
Figure 5-48. Checking Alignment Figure 5-49. Attaching Exhaust Air-Plate of V-Belts
o. Set the decompression device
Figure 5-50. Removing Starter Gear Ring
Figure 5-53. Remove Crankshaft Seal
Figure 5-55. Correct Installation of Radial Seal
Figure 5-58. Remove Pulley Retaining Nut
5-6 CRANKCASE (ENGINE)
Figure 5-60. Measuring Main Bearing Bore
Figure 5-62. Standard and Oversize Wall Figure 5-63. Measuring Width of Locating Thickness
Figure 5-64. Mounting Refacing Device 003-0505
Figure 5-66. Setting the Refacing Tool
5-7. CRANKSHAFT (ENGINE)
Figure 5-68. Measuring Points on Journal
Figure 5-69. Measuring Crankshaft
5-8 CYLINDER HEAD SET (ENGINE).
Figure 5-71. Checking the Cylinder Head Figure 5-72. Intermediate Ring Seating Surface
Figure 5-73. Seating New Valve Ring
Figure 5-74. Driving Out Valve Guide
5-9 CAMSHAFT AND HAND CRANKING ASSEMBLY (ENGINE)
Figure 5-76. Measuring Camshaft Journal from Drive End
Figure 5-79. Removal/Reinstallation of Bearing Bushing
Timing marks
13. The end clearance
5-10 TIMING GEARS (ENGINE)
Figure 5-83. Rocker Arm Bracket Assembly
5-11 LUBE OIL PUMP (ENGINE).
INSPECT - TM-5-4310-389-14_324
5-12 FUEL INJECTION PUMP
Figure 5-85. Assembled Plunger and Figure 5-86. Disassembled Plunger and Metering Sleeve
Figure 5-87. Copper Washer and Barrel Figure 5-88. Barrel Assembly (Flange Removed)
8. Install washers and nuts
5-13 INSTRUMENTS AND CONTROL PANEL.
Section III. PREPARATION FOR STORAGE OR SHIPMENT
5-16    STORAGE LONGER THAN SIX MONTHS.
Figure 5-89. Two-Chamber Fuel Source
5-17 PREVENTIVE MAINTENANCE DURING STORAGE
5-18 REACTIVATING THE COMPRESSOR UNIT.
APPENDIX A REFERENCES - TM-5-4310-389-14_335
APPENDIX B MAINTENANCE ALLOCATION CHART - TM-5-4310-389-14_336
B-3 EXPLANATION OF COLUMNS IN THE MAC
B-4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS
Section II. MAINTENANCE ALLOCATION CHART - TM-5-4310-389-14_339
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-389-14_340
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-389-14_341
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-389-14_342
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-389-14_343
MAINTENANCE ALLOCATION CHART -cont - TM-5-4310-389-14_344
Section III TOOL AND TEST EQUIPMENT REQUIREMENT
TOOL AND TEST EQUIPMENT REQUIREMENT -cont - TM-5-4310-389-14_346
TOOL AND TEST EQUIPMENT REQUIREMENT -cont - TM-5-4310-389-14_347
TOOL AND TEST EQUIPMENT REQUIREMENT -cont - TM-5-4310-389-14_348
Section IV. MAINTENANCE ALLOCATION CHART - TM-5-4310-389-14_349
APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS - TM-5-4310-389-14_350
e. Column (5)
SECTION II. COMPONENTS OF END ITEM LIST
SECTION III. BASIC ISSUE ITEMS - TM-5-4310-389-14_353
APPENDIX D ADDITIONAL AUTHORIZATION LIST - TM-5-4310-389-14_354
APPENDIX E EXPENDABLE SUPPLIES AND MATERIALS LIST - TM-5-4310-389-14_355
SECTION II. EXPENDABLE SUPPLIES AND MATERIALS
EXPENDABLE SUPPLIES AND MATERIALS -cont
APPENDIX F TORQUE LIMITS - TM-5-4310-389-14_358
F-2   TIGHTENING INSTRUCTIONS FOR ENGINE BOLTS AND STUDS
Table F-1. Tightening Table for Bolts and Nuts
Tightening Table for Bolts and Nuts -cont

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