T.O. 34Y1-56-71 TECHNICAL MANUAL OPERATION AND MAINTENANCE INSTRUCTIONS WITH PARTS BREAKDOWN COMPRESSOR, RECIPROCATING, POWER DRIVEN, AIR, DIESEL ENGINE, 15 CFM, 3,500 PSI, TYPE MC-1A, MODEL 2MC-1A PART NUMBER 66960 NSN 4310-01-060-0642 (DAVEY comPRessoR co.) Foge0281c-0108 Fo9s03.94¢.0322 arcemtrn en 3 JUNE 1980 " CHANGE 20 — 9 OCTOBER 19861.0, 3471-56-71 LIST OF EFFECTIVE PAGES A Dates of isu for origina and changed pags are: INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES, NOTE: ‘The portion of the text alfected by the changes is indicated ‘by avretial ne in the outer marina of the Page, Charon 6 iiustrations are indicates by miniature Dototing hands. ‘Changes 10 wing diagrams ae indeatod by shaded aveae Original,...0.... 3Jun 80 Change , 26 May 83 Change. .14 .. .10 Jan 85 LULL @Nov et Change | 4 Aug 83 Change 1115 |. 21 Mar 85 5 dan 82 218 Oct 83 Change © ..116 |. 24 Oct 85 + 11 Mar 82 39 Jan 84 Change | 2217 1) 27 Feb 86 ees oa es Sla2dul 84 Change. ..18 24 Apr 86. Change 11115 2121 7 Oct 82 "a7 Sep o4 Change -. 19 1) 19 dune 86 Ghange | 118... 10 Mar 83 2 a5 Oet 84 Change +...20 9 Oct 86 TOTAL NUMBER OF PAGES IN THISPUBLICATION IS CONSISTING OF THE FOLLOWING. Page ‘Change Page No. No, S51... 13 55200111! tall! BIBRA Added |. 15-16, 5.52 Blank Added...) 158 Ty — 7.8, 553-562. eet olina ie 6 B88... S20 nag? 0 SBE ESB nat ae eRe ae Lerner 0 588598 agar 0 B88. lll thet ye eee 0 BROT! aeiyae 0. S01 See aaO eta : Parermcestecraeacenal yg aeini0n: I WB eters BE Blank, LILI $108 6108 8 leas Hee 0 SNOB ee 3 : Wilissssesssss 5 BAOB—SaI9, 0 0 BAD ee 15 persressss 8 Sapa! ! 138 0 Baa = yg BAB 8 pam —Sise | 440. agit cier a aan) eset eae tegen tae 3 Sabai ees 3 BABB eee esse 3 0 Buse 816o «0+ ae Be. eciveeescesces 5 BAO es ee eee 20 SAISSUL ITI Sled added... «+ 7 Baz. [20 $1642 Blank Added: 0 513. : 51655167... 0 522-5. 531-6, 5.39 5.50 ‘Change 20 O6 ee eee eens O GB eee sees BB. 18 64 Blank, . . | fee O eee mney f 5.168 5.169—5.170 . 5171 5-176 Added, . 61. 62... BBs 64 eee uuee owe euousmious fee 1B DBL ‘Zero inthis oluron indicates an orginal page, 164d 'adaed 21) 7.64.2 Blank Added, ,LIST OF EFFECTIVE PAGES.(Cont.) Page *Change Page No. No. No. POSTE. cece 0 781 16 188 0 749, 10 7-70 Tm. 12. 18. a4 781. 7.82. 7-82A ~ 7.828 Added... 7.83 — 7-87 : re 7.98 7-99— 7-100. 01 7102 7.108 104. 1405 ¢ 7.108 T10T 7108. 7109 2 Haglan, it Td FB THE even Index 3+ Index 4. =Index 722 Index 8 Blank...” *Zero in this column indicates an original page. 7.0, 94V1-56-71 Change Page *Change No. No. No. Change 20 B/(C blank)T.0.4Y15671 INDEX Paresreph, Paragraph, Figure, Table, Figure, Table, Subject Number Subject Number A Adjustment 5-100 Clutch Adjusting Yoke . $15, F511 (Clutch Operating ROd ssrnenewnssnanes S16, PS-12 $183, F22 Engine Tappet Clearance. 5-180 Extra Fuel Device. ‘$179, P22 5.181, F533 $182 5-189, F23. 1. 5-195, F535, F26 5-56, F25 552 5463, F4 557, F24 517, F21 S101, F27 5-183, F22 $189, F23 ‘Ait Pressure Regulator Subassombly .. ‘Ait Receiver Assembly Bleed Valve Assembly .... $-123, P12 Electrical System Wiring Diagram..... Clutch and Housing Group, 5-55, F5-27, F33 Inspection. sssssenrensenne Clutch Assembly., _ 5-237, F33 Operation Instructions enn Condensate Receiver Assembly s.crvuse 5153, P17 Repair or Replacement ....... 5-51, F524, F5-25, F526 ‘Continuous Bleed Valve Subassembly 5-129, F5.31, F13 ‘Theory of Operation .. Control Panel Assembly............, 5-159, F5-34, F17 ‘Troubleshooting ‘Diesel Engine Assembly. .. 5-243, P35 Tubing Diagram... Dehydrator Cylinder Asse 5-105, F9 Dew Point Indicator Subassembly... 5-165, F19 rain Valve Assembly... 5.291, Fas Drain Valve and Usloader Control Box Group 5-53, F42 Engine and Accessories Group 5.54, F34 Engine Air Filter Assembly. 5-81, F5 Filter and Dehydrator Group 5-86, F6 First Stage Head, Cylinder, an . $177, F2i First Stage Trap Assembly .. 5-135, F14 SATA Four Wheel Axle Assembly senses $303, FAG ‘5.173, P21. Fourth Stage Head and Cylinder Group «... 5-225, F31 '-175,F532 Fourth Stage Piston Subassembly . $231, F32 S176 ‘Frame and Axle Group » 5-297, F4S Fuel Filter Subassembly ‘5-267, F39 $101,F27 Fuel injection Pump Subassembly 5-262, F38 rove 5198 Fuel Injector Subsssembly - $273, Fao ‘$197, F27 Fuel Transfer Pump Subassembly. $279, P41 .. 5-199 ‘Hose Reel Assombly .....-.0000+0 5-75, F3T.0.34¥1-56-71 INDEX (Continued Paragraph, Figure, Table, Subject ‘Number Subject Instrument Panel Subsssembly 5.171, F20 Filter and Dehydrator Group. Mechanical Filter Assembly S11, FIO First Stage Head, Cylinder, and Priority Valve Assembly «oon $.93,F7 Piston Group ‘Second Stage Head, Cylinder, First Stage Trap Assembly. and Piston Group 5-213, F29 Second Stage Trap ASSEMBLY eres 5141, PIS Starting Motor Subassembly ... 5-248, F36, Fourth Stage Piston Subassembly 5208 $256, F37 Frame and Axle Group 5294 ‘Ten-Micron Filter Assembly 5.99, FS Fuel Filter Subassembly 5.264 ‘Third Stage Head, Cylinder, and Fuel Injection Pump Subassembly.... 5259 Piston Group... 5-219, F30 Fuel Injector Subsssembiy $270 Third Stage Trap Assembly .... 5-147, F16 Fuel Transfer Pump Subsssembly 5.276 Trap Mounting Group... 5.137, FI Hose Reel Assembly $72 Unloader Control Box Assembly 5-285, P43 Instrument Panel Subassembly 5168 Vale and Air Chuck Assembly 5-66, F2 Mechanical Filter Assembly 5-108 Priority Valve Assembly $90 ‘Automatic Control and Drain System Second Stage Head, Cylinder, and Theory of Operation se 411, FAD Piston Group... Troubleshooting... 153 Second Stage Trap ASsembIY svn. enn ‘Starting Motor Subassembly 8 ‘TemMicron Filter Assembly... Bleed Valve Assembly ‘Third Stage Head, Cylinder, and 5.123, F12 Piston Group... $120 ‘Third Stage Trap Assembly. 5-119, FIZ Trap Mounting Group... wo $121 Unloader Control Box Assembly ce Calibration sa. ssen 5307 ‘Cleaning ‘Air Compressor Assembly $192 Air Compressor Unit .m. 549 Ai Cooler Subassembly .... S174 ‘Air Filter Subassembly -. 5-198 ‘Air Pressure Regulator Subassembly 5180 ‘Air Receiver Assembly eee 5186 Bleed Valve Assembly 5120 (Clutch Assembly $234 Condensate Receiver Assembly «. 5.150 Continuous Bieed Valve Subassembly 5126 Control Panel Assembly 5156 Diesel Engine Assembly 5240 Dehydrator Cylinder Assembly . 5102 Dew Point Indicator Subassembly «. on $162 Drain Valve Assembly nese 5288 Drain Valve and Unloader Control 550 Engine Air Filter Assembly 5.78 Index 2 ‘Valve and Air Chuck Assembly... (Clutch and Housing Group 5.55, FS-27, F33 5-46, F33 $237, F33 5.234 5.233, F33 sees $235 ene 5-236 15:3 Inspection ‘Repair or Replacement 5-153, FI7 $150 5.149, F17 SASL, F532 2. 5152.0.34Y1-56-71 INDEX (Continued) Paragraph, Figure, Table, Subject Continuous Bleed Valve Subassembly 5-129, F5-31, F13 setnne SAI 5-125, F13 Inspection .. _ $127 Repair or Replacement 5128 Conta Panel Ase Assembly. " 5.159, F534, FI8 ‘Cleaning 5.156 BL Disassembiy 15.155, FIS Inspection. 2.22 Repair ox Replacement. -- BH Subassembly, 1/4 Inch Vaive. 21733, F18A Consumable Materials... _ 120,72 D Diesel Engine Assembly Assembly ... 5243, F5.S0, PS.S1, F5.52, F553, F554 F5.55,F5.56, F5.57, F558, F559, 35 Cleaning en sens $240 Disassembly..5-239, F537, F5-38, F5-39, F5-40, P51, F542, F543, F549, F5-45, FS Inspection .. 5.241, 754 Repair or Replacement «... ‘5242 Troubleshooting .--.. TS4 Dehydrator Cylinder Assembly Assembly 5-105, F9 Cleaning ... 5102 Disassembly sess S101, F9 Inspectios 5103 Repair or Replacement S104 Description ‘Air Compressor Group ..... 114, F12 ‘Air Receiver Assembly. - 2113, F12 Clutch and Housing Group... 1:15, F1-2 Compressor Housing Group sane 1-6, FLD, Control Panel Assembly... me FA, Draia Valve and Unloader Control Box Group 1-17, F1-2 Engine and Accessories Group 1-16, FL2 Frame and Axle Group 1-18, FL2 Hose Reel Assembly 15,FL2 Valve and Air Chuck Assembly 1-4, FI2 Dow Point Indicator Subassembly Assembly ... 5.165, F19 Cleaning 5-162 Disassembiy, . 161, F19 Paragraph, Figure, Table, Subject Number Inspection . . : 5-163 Repair or Replacement. S164 ‘Troubleshooting 154 Daagrams ‘Air Compressor Unit Air Service System Flow Diagram ... Fe1 ‘Air Compressor Unit Electrical System Schematic. P63 ‘Air Compressor Unit Electrical System Wiring ..... F64 ‘Ait Compressor Unit Tubing .. F6-2 Disassembly ‘Air Compressor Assembly. 5-191, F26 Air Compressor Group . 5-45, F25, Air Compressor Unit fine 538 ‘Air Compressor Unit Housing Group... . . .5-41, P& ‘Air Compressor Unit Tubing Group ....., . 5-44, F24 ‘Ait Cooler Subassembly .. 5-173, P21 Air Filter Subassembly.. 5-197, 27 ‘Air Pressure Regulator Subassemibiy 5-179, F22 Ait Receiver ASSGMBIY .o.cjeeceesseseis 5185, F23 Bleed Valve Assembly ..... ~ S119, F12 Clutch and Housing Group ... 5-46, F33 Clutch Assembly... 5-233, F33 Condensate Receiver Assembly 5-149, FLT Continuous Bieed Valve Subassembly . . .. . 5-125, F13 Control Panel Assembly ........ +++. 5158, F18 Diesel Engine Assembly. 5-239, F35 Dehydrator Cylinder Assembly ..........5101,F9 ‘Dew Point Indicator Subsssembly « - $161, FID Drain Valve Assembly 5-287, P44 Drain Valve and Unloader Control Box Group .........- 5-48, F42, Engine Air Filter Assembly STFS. Engine and Accessories Group sere SAT, P34 Filter and Dehydrator Group. . .. 5.83, F6 First Stage Head, Cylinder, and Piston Group 5-203, F28 First Stage Trap Assembly... 5-131, FL Four Wheel Axle Assembly. . 5-299, Fa6 Fourth Stage Head and Cylis . 5-221, P31 Fourth Stage Piston Subassembly... . $227, P32 Frame and Axle Group 5-293, Fas, Fuel Filter Subassembly .. 1+ $-263, F39 Fuel Injection Pump Subassembly . $258, F38 Fuel Injector Subassembly 5-269, F40 Fuel Transfer Pump Subassembly . $:275, Fal Hose Reel Assembly... 5-71, F3 Instrument Pane] Subassembly ... 5-167, F20 Mechanical Filter Assembly... » $107, FLO Priority Valve Assembly... . 589, FT Change 3 Index 3T.0.34Y1-56-71 INDEX (Continued) Paragraph, Peare, Table, Sutject ‘Number — Subject ‘Second Stage Head, Cylinder, and Piston Group serivee 5-209, F29 ‘Second Stage Trap Assembly .. vo» 5-137, FIS Repair or Replacement Starting Motor Subassembly .-. 5-245, F36, ‘Ten-Micron Filter Assembly ‘Third Stage Head, Cylinder, and -251-F37 First Stage Trap Assembly ‘$95, FB Piston Group ser «$215, F30 ‘Third Stage Trap Assembly 5-143, FI6 ‘Trap Mounting Group... » $.113,F1 Unloader Control Box Assembly - + 5-281, Fa3 Valve and Air Chuck Assembly . >| | Drain Valve Assembly + 565, F2 Fourth Stage Head end Cylinder Group z Assembly . $225, F31 ‘Drain Valve and Unloader Control Box Group Cleaning...... -- 5222 nn 553,F42 Disassembly, + 5-221, F31 . $223 $224 $-231, F32 Theory of Operation... GEE aye Wiring Diagram i 5-227, F32 Emergency Inspection 5.229 Stopping Procedure Repair or Replacement... $-230 ‘Wiring Diagram oe. Fousth Stage Piston. Subasemby, vai Engine and Accessories Group ‘Assembly. $2314, F324 | Danenbiy -227A, F324 Frame and Axle Group ony ‘ently Cleaning .. ‘Disassembly. . 5-293, Fas ee Inspection 5295 ns ee or! 5296 Repalr or Replacement fare xtra Fuel Device Alignment ......... - 5.21, F514,752 § Fuel Filter Subatsembly ‘Assembly. 5.267, F39 Cleaning .. eens $264 Disassembly 5-263, F39 Inspection snne 5265 Repair or Replacement 5.266 : Fuel Injection Pump Subassembly First Stage Head, Cylinder, and Piston Group ASSEMBYY. cece + 5.261, B38 Assembly ...... ‘Cleaning . weee . a+. S258 l ‘Cleaning Disassembly, os 5.257, F38 Index 4 Change 3T.0.34Y1-56-71 INDEX (Continued) Paragroph, Paragraph, Figure, Toble, Figure, Table, Subject ‘Number Subject ‘Number 5.279, Fat 5.276 215, FAL $277 5.218 ‘Assembly iw $22, F517 F576 ‘High-Low Air Service System ‘Theory of Operation Air Compressor Unit + 550 Air Cooler Subassembly . $175 Air Filter Subassembly . 5199 Air Pressure Regulator Subassembly $181 Air Receiver Assembly . 5187 Bleed Valve Assembly . $121 Clutch Assembly. $235 Condensate Receiver Assembly . S151 Continuous Bleed Valve Subassembly.. 5-127, T5-5, 75-6 nnenrnnesens SAST 1 $241, 15-5, 156 Control Panel Assembly Diesel Engine Assembly Dehydrator Cylinder Assembly Dew Point Indicator Subassembly Drain Valve Assembly . Drain Valve and Unloader Control Box Group . Engine Ais Filter Assembly First Stage Head, Cylinder, and Piston Group... §-205 First Stage Trap Assembly .... 5133 Four Wheel Axle Assembly ..... $301 Fourth Stage Head and Cylinder Group 5.223 Fourth Stage Piston Subastembly .. 5228 Frame and Axle Group.. 5.295 Fuel Filter Subassembly srs 5.265 Fuel Injection Purnp Subsssembly... 5-260 Fuel Injector Subsssembly osc 1, TSS Fuel Transfer Pump Subessembly 5277 Hose Reel Assembly an. 573 Instrument Panel Subassembly $169 Mechanical Filter Assembly Priority Valve Assembly soe 591, TS5, T56 Second Stage Head, Cylinder, and Piston Group .. 5-211 ‘Second Stags Trap Assembly $139 Starting Motor Subsssembly.. 246, 5-254 Ten-Micron Filter Assembly $97 Third Stage Head, Cylinder, and Piston Group... $217 ‘Third Stage Trap Assembly .... Valve and Air Chuck Assembly Inspection and Preventive Maintenance ‘Air Compressor Air Filter 5.6, P53 ‘Air Compressor Crankcaso Filter we 5:19, F514 Air Cooler Subassembly... 517 Ait Service Hose Replacement ....... 5-23, F518, T5-1 Battery 59,751 (Clutch Adjusting Yoke Adjustment Engine Cooling Ribs and Blower 518, F513 Engine Fuel Filter Element «ev-weeer-eers 5-10, F5-6 Engine Tappet Adjustment vensicnnesne 5-24, F519 First, Second, and Third Stage Traps wae 5-13, F5.9 Front End Alignment 5-21, FS-16 Hand Brake Adjustment 5:22, F517 Injector Nozzle Replacement 5.25, F520 Line Strainers 5.14, F510 Sell, BS-7 S12, ESB 5.171, F20 $1687.0.34V1-56-71 INDEX (Continued) Paragraph, Paragraph, Figure, Table, Figure, Table, Subject Number Subject Number Disassembly 5-167,F20_ Priority Valve Inspections eee S169 Repair or Replacement sens $170 L Line Strainers Inspection and Preventive Maintenance ..- 5-14, F510 Lubrication Instructions ‘Axle and Wheel Bearings ‘Clutch Lubrication Compressor Lubricating Oi! + $29,753 ‘Compressor Oil Filter vos $30,753 Engine Lubricating Oil 527,753 : Engine Oil Filer .. $28,153 Air Cooler Subassembly Paiming Air Compresior Oil Pump... 531,F523,753 Air Filter Subastembly, ‘Air Presoure Regulator Si ™ ‘Alt Receiver Assembly Mechanical Filter Assembly Bleed Valve Assembly . Assembly snenee 1 SHML,FIO Catch Asembly sarees Cleaning... sseenenee $108 Disassembly 5-107, F10 Inspection -. $109 Inspection and Preventive Maintenance .....- Sel1, F5-7 Repair or Replacement ‘S110 0 Operation Theory of ne 42, F44, P43 Operation Instructions Air Compressor Unit Operation... 459 Connection Between Air Compressor Unit and Pneumatic System to be Chargedinee 4:56 Emergency Stopping Procedure +... 461 Operating Controls and Indicators 418, F43 Prior to Operation 7 sens ASS Starting Under Extreme Colé Conditions, Below S°F (-15°C) ww 458 Starting Under Normal Conditions, Above $°F (-15°C) Stopping Procedut . Operational Checkout Pressure Switch, Condensate Receiver Assembly ‘Continuous Bleed Valve Subassembiy Control Panel Assembly Diesel Engine Assembly Detydrator Oplinder Assembly Dew Point Indicator Subassembiy Drain Valve Assembly Drain Vaive end Unlosder Contsol Box Engine Air Filter Assembly... Filter and Dehydrator Group First Stage Head, Cylinder, and Piston Group . Firat Stage Trap Assembly «1... Fout Wheel Axle Assembly Fourth Stage Head and Cylinder Group Fourth Stage Piston Subassembly Frame and Axle Group Fuel Filter Subassembly Fuel injection Pump Subassembly ~~ uel Injector Subassembiy Fuel Transfer Pump Subassembly Hose Reel Assembly «-» Instrument Panel Subassembly Mechanical Filter Assembly. Priority Valve Assembly. Second Stage Head, Cylinder, Second Stage Trap Assembly’. Starting Motor Subsssembly . ‘Ten-Micron Filter Assembly .T.0.34Y1-56-71 INDEX (Continued) Paragraph, Paragraph, Figure, Table, Table, Subject ‘Number ‘Number ‘Third Stage Head, Cylinder, and Riston Group 5.216 ‘Thitd Stage Trap Assembly «... ads . $215,730 ‘Trap Mounting Group... $217 Unloader Control Bax Assembly... 5.218 ‘Valve and Air Chuck Assembly .. 8 Second Stage Head, Cylinder, end Piston Group ‘Assembly « oe $213, F29 5-141, FIS vn $138 ve $137, FIS 5.139 5140 Repair or Replacement 5-248, F36, 5-256, F37 - 5-245, $282 5-244, F36, 5-251, F37 5-246, 5-253, ‘Third Stage Head, Cylinder and Piston Gre Assembly... - $219, 30 +» $147, F16 a S144 . $143, F16 Saas 5.146 Assembly $137, FIL Geaning 5.134 Disassembly 5-133, FLL Inspection eae isas Repair or Replacement 5-136 ‘Troubleshooting ‘Air Compressor Assembly. 153 ‘Air Compressor Unit L153 Cutch Assembly Diesel Engine Assembly”. Dew Point Indicator Subassembly. u Unloader Control Box Assembly ‘Valve and Air Chuck Assembly ‘Assembly sssesns a ‘5. GOVERNMENT PRINTINGOFFICE1987 726-007 S3884RECIONNO.« Index 7/(Index 8 Blank)Section/ Para m Vv Figure 1M 12 21 22 ar 42 43 1 32 53 54 53 56 INTRODUCTION AND GENERAL INFORMATION. : LA. Tntroduction 1-2. General Information .... 13, Description ..... 1-20, Consumable Materials... ee 22. Special Tools and Test Equip PREPARATION FOR USE AND SHIPMENT 31. General 3.2. Preparation for Use 33, Preparation for Storage or Shipment OPERATION INSTRUCTIONS 41. General... 42. Theory of Operation 417. Operation Instructions MAINTENANCE INSTRUCTIONS ... 51. General Operational Checkout 5.26. Lubrication Instruetions 5.34. Troubleshooting... Title ‘Type MC-1A Air Compressor, Model 2MC-IA ..., Ait Comptessor Unit Component Loca Engine Special Tool Kit Engine Work Stand ‘SPECIAL TOOLS AND TEST EQUIPMENT. 5-4. Inspection and Preventive Maintenance. High-Low Air Service Sysiom Flow Di ‘Automatic Control and Dain System Flow Diagram ...... Operating Controls and Indicators Pressure Switch Adjustment Dew Point Indicator Air Compressor Air Filter. Engine Air Filter... Dehyérators 7.0.38Y1-56-71 TABLE OF CONTENTS NOTE ‘An alphabetical index is located in the back of this manual Section/ Page Para Page 5-35, Repai 537 se 5304, Table of Limits. 5148 Hd $306. Tet esesesernen 5169 ~ Hd 5-307, Calibration. 5.170 uM 5308. Optional Installation of Large Capacity 1s Battery + S171 $.309. Optional Oil Filler Tube Brace | 5.174 a4 5310 Optional Rework of Oi Dipstick . 5-171 VI DIAGRAMS 61 61. General 61 62. Diagrams . 61 at 63. Symbols 7 61 7 6-4, Reference Designation 61 S. Index of Diagrams s 65. Index of Diagrams... 6 41 VIL ILLUSTRATED PARTS 41 BREAKDOWN soe DL at 7, General a Tel 45 7-2. Maintenance Parts Liste. 1 7 7113, Numerical Index .... rey a 717, Reference Designation os IEE veror cnn 72 52 718, Manufacturer's + 518 Codes 72 5.22 LIST OF ILLUSTRATIONS Page Figure Title Page 5-7 Mechanical Filter 10 58 TenMicron Filter 510 13 $9 First, Second, and Thitd Stage Traps Sl 23° S10 Line Strainers... Sat 24 5.11 Clutch Adjusting Yoke Adjustment 512 42 S12 Clutch Operating Rod Adjustment $13 5-13 Engine Cooling Ribs and Blower 513 44 S14 Air Compressor Crankease Filter S14 46 S15 Engine Crankcase Breather Sieve Slt SS S16 Front End Alignment 516 SS SAT Hand Brake Adjustment. S16. -$6 S18 Air Service Hose Replacement wet SAT 56 S19. Engine Tappet Adjustment 2 SAT 57 $20 Injector Nozzle . 518. $8 5-21 Engine Oil Filter 5.21 Engine Fuel Filter Element Change 6.0.94Y1-56-71 Figure $22 523 5.24 5.25 5:26 $27 527A. 5.28 5.29 5:30 531 $32 5.33 534 3.38 536 537 538 $39 $40 Sat 5.42 543 545 S47 3.48 549 550 SSI $82 5.53 554 335 556 537 538 559 560 561 5.62 5.63 5.64 5.65 LIST OF ILLUSTRATIONS - Continued Page 2 S21 Stee! Tubing and Fitting Assembly. Presetting Tubing Sleeve Rubber Hose Repair ... Clutch Assembly Installation .. MCHA Rain Cap... Swivel Joint Repair... Priority Valve Test Setup ...... - 5-59 Seating Priotity Valve EIBOW sssnnseesenn 5-62 Bleed Valve Port Locations Typical Safety Vaive Test Setup Air Pressure Regulator Test Setup Positioning of Hand Valves, Non Drive End Cover, Oil Pump and Seal Installation, Lentoid Spring Assembly Detail Positioning of Speed Control Lever Diesel Engine Mounted in Work Stand Removing Camshaft Bearing. ‘Attaching Axial Limitation Tool to Crankshaft Removal of Cx Instaling Punches in Canta 2. 5110 Removing Alternator Rotor from Flywheel. 5-111 Removing Pins from Alternator Pug svn. S111 Removing Altemator Stator... SU Fuel Injection Pump Mounting Dimensions. 5-113 Fuel Injection Pump End of Delivery Test Setup 2. S13 Fuel Injection Pump Delivery Volume Test Setup ses a $115 Fuel Injector Spray Patera 5-116 ‘Assembling Bearing Flange to Crankease .. 5-118, Assembly of Governor ve S119 ‘Bumping Clearance Measurement senses S320 ‘Assembling Governor Housing to: Crankease - $121 Flywheel at Top Dead Center (TDC) sare $123 Disassembly of Pressure Valve .... $123 Adjusting Device... 123 ‘Timing Gauge .. S124 Engine Test Setup 1 5124 Extra Fuel Device Adjustment . $125 Removing Retainer from Snap Ring... 5-127 Removing Snap Ring from Armature... 5-127 Grounded Armature Test Setup. 5-128 Field Winding Test Setup vss $129 Testing Commutator Frame a 5129 Snap Ring Expansion Tool 5-130 Assembling Snap Ring to Armature 5.130 Change 15 Figure 5-67 5.68 569 5-70 S71 52 8B 514 5.75 * Drain Valve Assembly... Title Assembling Snap Ring and Retainer... Alignment of Control Rack and Sleeves leaning the Nozzle Tip «... Cleaning the Orifice Holes Cleaning Nozzle and Seat Cleaning Nozzle Valve Inspecting Mating Surfaces .. ‘Checking Freedom of Valve in Nozzle Pressure Switch Test Setup Positioning of Hand Brake Linkage Continuous Bleed Valve Subassembly ‘Compressor Oil Seal Cover Outer Oil Pump Cover Non Drive End Cover... il Pump Rotor ... il Pump Blade .... Oil Pump Inner Cover Drive End Cover ... Flywheel Compressor Connecting Rods ‘Compressor Crankshaft... First Stage Cylinder, Piston and Pin Second Stage Cylinder, Piston and Pin . ‘Third Stage Cylinder, Piston and Pin Fourth Stage Cylinder and Liner. Fourth Stage Piston and Pin Alternate Fourth Stage Piston and Pin Assembly... . Rocker Arms .... Intake and Exhaust Valves Engine Cylinder Head Pistons... Engine Crankshaft and Bearings Engine Connecting Rods. +. Fuel Injection Pump Assembly Adjusting Engine RPM. Manufacture of Battery Box Extension Plate. . Rework of Battery Hold-Down Bracket Rework of Existing Battery Box. Installation of Extension Plate. Manufacture of Optional Oi Filler Tube Brace. . : ‘it Compressor Unit Air Service System Flow Diagram.. Air Compressor Unit Tubing Diagram 63 ‘Air Compressor Unit Electrical System Schematic Diggram .... snc 6 Air Compressor Unit Electrical Stem Wiring Dggram .... 1 6SFigure Number Mu 12 21 SH T.0.34Y156-71 UST OF ILLUSTRATIONS - Continued Tile Page Figure Title Page How to Use the HustratedPartsBreakdown.... 7-5 27 Air Filter Subassembly oe 158 TypeMCIAAirCompressorUnitModel2MCIA.7-6 28 ‘First Stage Head, Cylinder, and Piston Group, 7.59 Valve and Air Chuck Assembly ww» TB 29 Second Stage Head, Cylinder, and Hose Reel ASSEMIY weaeene 19 760 ‘Ait Compressor Unit Housing Group wu... 711 39 Engine Air Filter Assembly ary Filter and Dehydrator Group TAS 31 Fourth Stage Head and Priority Valve Assembly, Th Cylinder Group... Ten-Micron Filter Assembly... 32 Fourth Stage Piston Subassembly Dehydrator Cylinder Assembly, 32A Alternate Fourth Stage Piston Mechanical Filter Assembly, ‘Trap Mounting Group ... 33 Bleed Valve Assembly 34 Engine and Accessories Group Continuous Bleed Vale Subassemibly 35 Diesel Engine Assembly (Sheet 1 of 8) First Stage Trap Assembly 35 Diesel Engine Assembly (Sheet 2 of 8) Second Stage Trap Assembly 35. Diesel Engine Assembly (Sheet 3 of 8) ‘Third Stage Trap Assembly 35. Dietel Engine Assembly (Sheet 4 of 8) Condensate Receiver Assembiy ,.... 35 Diesel Engine Assembly (Sheet 5 of 8) Control Panel Assembly (Shest i of 2) 35 Diesel Engine Assembly (Sheet 6 of 8). Control Panel Assembly (Sheet 2 of 2)... 3s Diesel Engine Assembly (Sheet 7 of 8) .. 1/4 inch Valve Assembly. . 35 Diesel Engine Assembly (Sheet 8 of 8). Dev Point Indicator Subassembly 35A Fuel Line Kit... Instrument Panel Subassembly 36 Starting Motor Subasserably Air Cooler Subassembly.. 7 37 Stasting Motor Subassembly Air Pressure Regulator Subassembly 38 Fuel injection Pump Subassembly Alt Receiver Assembly sso 39 Fuel Filter Subassernbly ‘Air Compressor Unit Tubing Group 40 Fuel Injector Subassembiy (Sheet of 4) sv 41 Fuel Transfer Pump Subassembiy ‘Ait Compressor Unit Tubing Group 42_Drain Valve and Unloader Control (Sheet 20f 4 . 7 Box Group ae ‘Air Compressor Unit Tubing Group 43 Unloader Control Box Assembly. (Sheet 3 OF 4) ores 44° Drain Valve Assembly en ‘Att Compressor Unit Tubing Group 45 Frame and Axle Group... (Sheet 4 0f4) 46 Four Wheel Axle Assembly Air Compressor Group se (Bheet 1 OF 2) seer 197 Air Compressor Assembly (Sheet | of 3) 46. Four Wheel Axle Assembly ‘Air Compressor Assembly (Shest 2 of 3) Gheet 2 of 2) Air Compressor Assembly (Sheet 3 of 3) Tite ‘Table of Leading Particulars Consumable Materials Special Tools and Test Equipment Instrument Panel Meter and Gauge Indication Number Title Page 52 Inspection, Checks, and Services. 53 $3 Lubrication Instructions .. 519 54 Troubleshooting 5.23 55 Table of Limits... 5148 56 Miscellaneous Table .. 5-1687.0.34V1.56-71 LEFT FRONT VIEW RIGHT REAR VIEW Figure 1. Type MGIA Air Compressor, Model 2MCTA7.0.34¥1-56-71 SECTION! INTRODUCTION AND GENERAL INFORMATION 14, INTRODUCTION. This manual contains operation and ‘maintenance instructions with illustrated parts breakdown for the Type MC-1A Ait Compressor, Model 2MC-1A, Part Number 66960, Leading features of Air Compressor, Model 2MC-1A are listed in Table 1-1, Model 2MC-1A air com- pressor is shown in Figure 1-1. Air Compressor, Model OMC-IA, is hereafter referred to as the air compressor unit 1.2. GENERAL INFORMATION. The air compressor unit is a portable, four-wheel trailer mounted, diesel engine Ativen, reciprocating, air compressor. It is designed for con- tinnous operation at arated capacity of 15 scfm (0.43m°/s) at pressures up to 3,500 psig (24,133 KPa). The compressed air having a pressure dew point of minus 65°F(-54°C) or lowe et and filtered to a solid particle size of ten microns. Oper ing temperature range of the air compressor unit is-65° to 125°F (32° to 52°C) at altitudes up to 5,000 feet(1.5 Km). ‘The air compressor unit is used to charge aircraft pneumatic, systems, hydraulic accumulators, oleo struts and tires. Also, for servicing trailers which will in turn service aircraft. Ait pressure ftom 50 to 3,200 pa (345 to 22,064 KPa) is avai able to meet aircraft air servicing requirements. The ait compressor unit is air transportable and is designed to oper ate under extreme climatic conditions. ‘This unit is not to be used for pneumatic hand tools. NOTE ‘The rear of the air compressor unit contains the contro! panel. When the operator is facing the ‘control panel, the right-hand side isto the oper- ator’sright, the left-hand side isto the operator's Jeft, The front is the end to which the tow bar is attached. 4-3. DESCRIPTION. The air compressor unit consists of ten major components: valve and air chuck assembly; hose reel assembly; compressor housing group; control panel as- sembly; air receiver assembly; air compressor group; clutch and housing group; engine and accessories group; drain valve and unloader control box group; and frame and axle group. See Figure 1-2. Table 1-1. Table of Leading Particulars rem PARTICULARS AIR COMPRESSOR UNIT : Specification Military Specification MIL-C-9001 Type Reciprocating Air volume 15 sofm (0.43m?/s) Air pressure (max.) 3,500 psig (24,133 KPa) Power source Diesel engine Operating temperature range -65° to 18°F (32° to 52°C) Mounting 4 wheel trailer with pneumatic tires Brakes Mechanical hand brake Tine size 6:00 x 9, (152.4 x 288.6 mm) 6 ply Tire pressure 30 psig (206.9 KPa) Taming radius 14 feet @ ten mph (170 m @ 16 Km/h) Towing speed - Improved surface Unimproved surface Electrical system Length (OA) - Towbar down Towbar up Width (OA) Height (OA) - Towbar down ‘Towbar up Volume Weight (dry) 2 mph (40 Km/h) 10 mph (16 Km/h) 12 de, neg. gad 119.1/2 in, (3035.3 mn) 84-1/2 in. (2,070.1 mn) 66-3/4 in. (1,695.5 mm) 5-3/8 in, (1,406.5 rn) 60 in, (1,524 mm) 193 ou ft (5.78 m?) 2,100 Ibs (952.6 Ka) Change 4 WW7.0.34¥1-56-71 Table I-1. Table of Leading Partiewlars - Continued TEM PARTICULARS: AIR COMPRESSOR ASSEMBLY Specification Miltary Specification MIL-C-26805 Type 4 stage, radia, reciprocating Number of elinders 4 Cooling Forged air Operating temperature range Re iaste (32.0 52°C) DIESEL ENGINE ASSEMBLY ‘Specification ‘Military Standard MILSTD-1410 Type 4 stroke cyte, reciprocating Namber of eylinders 2 Bore and stroke 3.54 in. (90 mm) x 3:94 i, (100 mm) Displacement ‘77.5 cu in. (1.27 itr) Governed speed 2,000 rpen (2,000 ¢/min) ee 18.46 2,000 rpm, SAE (18.6 © 2,000 r/min, DIN) Combustion method Direct injection Cooling Forced air Compresion rtio 18:1 Operating temperature range CF (18°C) 0 +125°F (52°C) ENGINE ACCESSORIES Starting motor I2vde Alternator 135 amp, 12 de, negativ ground Fuel Military Specification MILJ-5624 or Federal Specification VV-F-800 CLUTCH ASSEMBLY . Ti Dry, single plate, manually operated CAPACITIES Fuel tank 16-3/4 gallons (62 Itr) Engine lubricating of ‘With iter change 43 quarts(4t9 Without filter change 3.2 quarts (3Itr) Compressor lubricating oi! With filter change ‘S quarts (4.7 Itr) Without iter change 4 quarts (38 kt) Air reset 500 cu in. (8.21) 1-4. Valve and Air Chuck Assembly (Figure 1-2). The high- low pressure service hose is fitted with a valve and air chuck assembly (19). The air chuck is « hose fitting designed for ‘adapting the discharge end of the service hose to valvestems, adapters, etc., etc. The valve serves as 2 secondary servicing valve, It permits unrestricted airflow when in the open posi tion. Normally, thisyalve is operated in one of two positions, closed of open. 1-5. Hose Reel Assembly (Figure 1.2). A spring rewind ‘mechanism (18) is used to store the high-Jow pressure service hhose during storage and transportation. 1-6, Compressor Housing Group (Figure 1-2). The housing roof assembly (26), front housing. support assembly (7), 12 side panels (12 and 33), filter and dehydrator group (14), and trap mounting group (35) compris the housing group, 1-7. Housing Roof Assembly (Figure 1-2) Attached to the roof (46) are two side doors (44 and 47) and a rear door (2), These doors protect the air compressor unit components from the elements. The housing roof assembly may be re- ‘moved as a complete assembly. Two side doors (44 and 47) allow access to components within the comprestor. The left hhand side door (44) is equipped with aheater duct (45) for ‘connection ofa heater hose from a Type! Ground Engine and Shelter Heater for cold weather starting, Spring latches ae provided onthe rear door and two side doors for latching ‘the doors inthe closed position,7.0.34¥156-71 DIESEL ENGINE AssaMOLY Exuausr eLoow EXHAUST HOSE ‘CAP ENGINE AIR INTAKE COVER 10. BATTERY 12. RH SIDE REAR PANEL 28, UNCOADER CONTROL BOX ASSY 48, AIR INTAKE HOSE, Figure 1-2. Air Compressor Unit Compurient Location7.0.34Y1-56-71 1.8. Front Housing Support (Figure 1-2). Supporting the front end of the housing root assembly (46) is the front housing support assembly (7). Attached to the outside of the housing support are the engine assembly exhaust rmufller guard (5). An engine air intake in the housing support is equipped with a cover (8) for closing off the air intake, The housing support is attached to the frame and axle group (20). 1.9. Mechanical Filter, Dehydrator, and Ten Micron Filter Group (Figure 1-2). This group consists of a mechanicel filter assembly (16), Type MF-1. The filter conforms to Military Specification, MIL-F-5504. Oil, moisture, and air- borne foreign particles are removed from the pressurized air by the filter prior to the air entering the dehydrator assem- blies (15 and 17). Bach dehydrator conforms to Military Specification, MIL-C-83959, Each dehydrator contains an ‘oxygen purifier cartridge, conforming to Military Specifica- tion, MIL-C-26058 (Type MA-2). The dehydrators remove oil and moisture from the pressurized air. Each dehydrator Is identified as to which is number one and number two by an identification plate. The plate also contains instructions for changing purifier cartridges, A blank space is provided for recording hourmeter elapsed time indications, in pencil Elapsed time indications are used to determine when purifier ‘cartridges should be changed. The ten micron filter assembly ‘contains a replaceable filter element, conforming to Military Specification, MIL-F-5504. This element traps any remaining foreign particles larger than ten microns and traps any ‘condensate remainingin the pressurized alr. 1-10. Trap Mounting Group (Figure 1-2). The trap mounting group (35)is attached to the front housing support assembly (7), control pane! assembly (30), left tide rear panel (33), and the frame and axle group (20). Attached to the inside of the trap mounting group (35) are the frst through the third stage trap assemblies (36, 37, and 38) and the condensate receiver assembly (40). The trap mounting group is attached to the front housing support assembly (7). Also, to the ‘control panel assembly (30), left side rear panel (33), and the frame and axle group (20). 1r11. Control Pane! Assembly (Figure 1-2). The rear end of the housing roof asembly (46) supported by the contol panel assembiy (30). The instrument panel assembly (34) is tached to the control panel. Shock mounts onthe inseu- tment panel protect the guuges and meters from vibration. ‘All operating controls and indicators, with the exception of the secondary service valve, are located on either the control panel or instrument pane. The air cooler subassembly (29) fsattached tothe nsie ofthe contro panel. Two removable sling cooler éoors(31) attached tothe contol panel allow thearea ofthe ar cooler exhaust tobe varied for best opers: tion of the air cooler. Camps on the cooler door allow for 4 stationary positioning of the doors. Both side rear panels (12 and 33) are attached to the control panel (30) and ’ hhousing roof assembly (46). The control panel is alto attached to the frame and axle group (20). 1-12, Ait Cooler Subaisembly (Figure 1-2). The air cooler subassembly (29) removes the heat of compression from the air between stages. Air compressed in the fist stage cylinder passes through the first stage air cooler and moisture separator into the second stage cylinder. Similarly, ait compressed in the second stage cylinder passes through the second stage air cooler and moisture separator into the third stage cylinder. Air compressed in the third stage cylinder passes through the third stage air cooler and moisture sep- arator into the fourth stage cylinder. Air compressed in the fourth stage cylinder passes through the fourth stage air cooler, mechanical filter (16), dehydrators (15 and 17), and Into the ar system. Air pasting through the air coolers lowers the air temperature. This increases compressor efficiency Also, condensed water and oil is removed between stages prior to entering the dehy drators. Cooling is accomplithed by air being drawn through the cooler subassembly by the fan (27.1) mounted on the compressor (27) crankshaft. Hinged doors (31) are provided on the control panel (30). These doors control the amount of sir drawn through the cooler sseembly and biown over the compressor assembly. Each ait ‘cooler stage is equipped with « pressure relief safety valve. 113. Air Receiver Assembly (Figure 1-2), The receiver as. sembly (22) i8 a device that stores the compressed ait until the time that the energy is required. 1.14, Air Compressor Group (Figure 1-2), The air com- pressor assembly (27) is a four cylinder, air-cooled, radial compressor. Compression of air from initial intake to final discharge is accomplished in four distinet stages. Discharge pressure is indicated on the instrument panel (34) pressure zauges, Lubrication of the moving parts is provided by an ‘ilpump located in the non-drive end cover. A ait circulating fan mounted on the non- pressor, To install filter, hand turn the new filter clockwise until the gasket just contacts the mounting bracket. Do not use a strap wrench to install filter Figure 5-22, Compressor Oil Fiter 4. Hand turn the filter an additional half turn clockwise 5:31. Priming Air Compressor Assembly Oil Pump. (Figure 5.23), To prime the air compressor assembly ofl pump, pro: ‘eed as follows: NOTE After changing the ofl filter or potting an compressor unit into service, which has been idle ‘or in storage for a considerable length of time, it may be necessary to prime the compressor oil pump to obtain @ correct air compressor oll pressure indication, 4, Disconnect oil filter-to-otl pump tube assembly (1) at adapter (2) on oil filter mounting bracket (3). b. Raive oil filterto-oit pump tube (1) slightly above adapter (2). ¢. Using a pressure type oiler (4, containing compressor lubricating oll as specified in Table $3, fill ofl ftero-oil pump tube (1) until ol flows from tube. 4. Connect oil fiter-to-il pump tube (1) to adapter (2) ‘on fllter mounting bracket (3). Change 2 521T.O.34Y1-56-71 2, OIL FLTR-TO.ONL PUMP ‘TUBE Assy. 2, STRAIGHT ADAPTER Figure $-23, Priming Air Compressor Assembly Ol! Pump 5.32. Clutch Lubrication. Lubricate the clutch lubrication Fitting located inside access hole in the left-hand sie of the clutch housing. Use « grease gun and lubricant specified in Table 5:3. 5.33. Axles and Wheel Bearings. The two axles and whee! bearings shall be lubricated withthe lubricant listed in Table 5.3. The axles are equipped with lubrication fittings. Apply grease to the fittings with a grease gun until grease being forced through the fitting appears at the joint of the moving parts, Wipe excess grease off joint and fitting, To hibricate the wheel bearings, perform the following procedures: Use jack stands to support the unit, a, Jack the unit up high enough to allow the wheel being serviced to turn freely. . Remove the hub outer cap and the cotter pin holding the nut to the axle. Unscrew the nut and remove the tongue washer. . Pull the wheel off the axe and separate the bearing cones fom the cups. If itis evident that grease has been leaking past giease sel, discard the seal and replace at assembly. 522 Provide adequate ventilation when using dry leaning solvent (Federal Specification P-D-680, ‘Type II). Avoid prolonged breathing of vapors and minimize skin contact. 4d. Wash off the old grease from all parts, including the inside of the wheel hub, with solvent, per Federal Specifi- ation P-D-680, Type Il. Dry parts thoroughly, Inspect Dearing cone and cup for rust, pitts, or chips that will affect serviceability, ¢, Repack each bearing with lubricant specified in Table ‘5-3 making certain grease is forced into the bearing cage and sound rollers, £ Install the inner bearing cone in the wheel hub and press in the inner grease seal, & Place the wheel hub on the axle and install the outer bearing cone on the axle. ‘h, Place the tongue washer on the axle and screw on the ‘mut, Tighten the mut ustil the wheel hub will not turn freely to be aure the bearings are properly sealed. Then, back off the nut far enough for wheel to turn freely. Insert cotter pin through axle. Lock cotter pin in place and install the hub cap. i Repeat for each wheel. 634, TROUBLESHOOTING. A tabulation of trouble- shooting is contained in Table 5-4, This table will id and suide the maintenance personnel by indicating the possible malfunctions that may occur duting operation of the sir compressor unit. The table lists probable causes of and postible remedies for correcting the malfunctions. The ma functions and possible causes are listed in the order in which they are most apt to occur. The remedies for corrective action include servicing, adjusting, or replacing the com- ponent causing the tiouble. The remedy may reference other detailed paragraphs of this manual, Once the mak function has been isolated and corrected, petform OPER- ATIONAL CHECKOUT (Section V) to ensure proper oper- ation of the air compressor unit.Table $4. Troubleshooting 1. Insufficient fuel supply TROUBLE 1. Engine falls to start, or starts then stops 2. Fuel filter logged 3, Wire lead number 15 (Figure 1-5) dis ‘connected from fuel solenoid valve. “4. Throttle control cable retainer screw loose at speed control lever cable stop. 5. Fuel transfer pump malfunctioning Fuel injection pump malfunctioning Fuel injector is malfunctioning. Engine out of time. 7.0.3471.56-71 ‘REMEDY, 1. Refer to Table 6-1 and fll tank with appropriate fuel If fuel tank has sufficient fuel supply, proceed to probable cause 2 7 Refer to FUEL FILTER (Section V) clean and change fuel filter. If fuel filter is not clogged, proceed to probable cause 3. ‘Connect wire lead to solenoid. Irlead is connected to solen probable cause 4 proceed to “4 Tighten screw in cable stop. If screw is tight, refer to probable cause.5. 'S. Refer to INSPECTION (Section V) ‘and perform fuel transfer pump tests. If pump is operating properly proceed to probable cause 6. 6, Refer to REPAIR (Section V) and perform fuel injection pump tests. If ‘pump is operating properly, proceed to probable cause 7. 7. Refer to REPAIR (Seetion V) and perform fuel injector tes. If injector/s ‘are operating properly, proceed to probable cause 8. 8, Refer to REPAIR (Section V ) and time engine. 2. Engine is hard to turn 1. Wrong grade lubricating oil |. Tappet clearance incorrect Engine exhaust restricted, 1. Refer to Table 5-3 and fil with correct ‘il. If engine i stil hard to turn, refer to probable cause 2, 72. Refer to INSPECTION AND PRE ‘VENTIVE MAINTENANCE (Section V), check and adjust tappet clearance. If tappet clearance is correct, refer to probable cause 3. 73. Inspect engine exhaust system. Trew hhaust system is not restricted, proceed to probable cause 4, 523T.0.36V1-56-71 TROUBLE 2. Engine is hard to turn (Continued) Table $4. Troubleshooting - Continued REMEDY, 4, Examine valve/s and valve seat/s If valves are not sticking, proceed to probable cause 5. 5. Refer to REPAIR (Section V)and perform fuel injector leak test. IF injector/sisare not leaking, proceed to probable cause 6. 4, Engine exhaust valve/s stuck closed. ‘S-lnjector/s leaking into eylinder/s causing hydraulic lockup. ‘6 Refer to REPAIR (Section Vand examine pistons and cylinders for ‘evidence of seizing. Replace all de- fective parts 6. Piston/s seizing on cylinder walls. 3. Black smoke coming from exhaust 1. Air filter clogged 1. Refer to INSPECTION AND PRE- \VENTIVE MAINTENANCE (Section ‘V) and service filter. If air filter is not clogged, refer to probable cause 2. 2, Refer to INSPECTION AND PRE \VENTIVE MAINTENANCE (Section V) and replace Fuel injector nozzle/s fnozae(s fare clogged, refer to probable cause 3. 3. Refer to INSPECTION AND PRE- VENTIVE MAINTENANCE (Section V), check and adjust tappet clearance. If tappet clearance is comect, refer to probable cause 4. 4. Refer to Table 5 and check injector retaining nuts torque value. If torque value is correct, proceed to probable cause 5. 3. Tappet clearance incorrect 4 Injectorjs not tightened to proper torque value. 5 ean injectors. If injector/s are clean, proceed to probable cause 6. ‘6, Wom engine intake andor exhaust valves. ‘evidence of wear. Replace all defective parts 4 Engine overheats 524 T. Gean cooling ar inlet, Tt cooling air inlet i clean, refer to probable cause 2. 1. Lack of cooling airTROUBLE 4, Engine overheats (Continued) 7.0.34V1.56-71 Table 5-4. Troubleshooting - Continued 2. Excessive ofl in crankcase, 3, Improper injector nozzles spray “4. Timing of fuel injection pump incorrect. '5. Loote, worn, or damaged engine com ponents causing excessive friction. REMEDY 2, Refer to Table 5-3, drain oil to normal level. If oll level is correct, refer to probable cause 3. 3. Refer to INSPECTION AND PRE- VENTIVE MAINTENANCE (Section V) and replace injector nozzles. If nozzle/s is/are not at fault, refer to probable cause 4, Refer to REPAIR (Section V). Check and reset pump timing if necessary. If pump timing is correct, proceed to probable cause 5. 3 Refer 10 REPAIR (Section V), dias semble engine assembly. Check engine parts against limits specified in Table 5.5. Replace parts which are worn beyond permissible limits. ‘5. Engine looses power. (Engine rpm [r/min] drops under load). T. Lack of combustion air 2, Tappet clearance incorrect. 3. Cylinder head attaching nuts not tightened to correct torque value. Detective cylinder head gasket. ', Valves sticking or not seating comectly, T. Refer to wouble murnber 3, probable causes and remedies 1 and 2. [flack of combustion aris not at fault, pro- cxed to probable cause 2. 2, Refer to trouble number 3, probable cause and remedy 3. If tappet clearance is correct, efer to probable ‘cause 3. | 3. Check and tighten nuts fo conect torque value if necessary. If nuts are correcily tightened, refer to probable cause 4, “E Remove and inspect oylinder head — gasket. Replace a defective gasket. IF gasket is not defective, refer to probable cause 5. 3. Disassemble cylinder head. Check cylinder bead parts against limits specified in Table 5-5. Replace or tepair parts which are not within specified tolerance. Reassemble cylinder head, 525T.0.4¥1-5671 Table 5-4 Troubleshooting - Continued TROUBLE |. Refer to INSPECTION AND PRE- \VENTIVE MAINTENANCE (Section ‘V) and service filter. If air filter is not ‘logged, refer to probable cause 2. 6. Engine stops suddenly. ‘2 Refer to Table 5-3 and fill with appro- eiate fuel, If fuel tank is not empty, refer to probable cause 3. 3. Drain fuel tank, refer to Table 53 and fll tank with appropriate fuel. If fuel supply is correct, refer to probable cane 4. “4. Refer to trouble 3 probable causes and remedies. “4. Fuel system clogged or leaking. 7. Engine becomes overloaded | 1. Compressor cylinders scored; 1. Disassemble, clean, inspect and repair ‘when compressor is driven defective compressor bearing. ‘compressor as necessary. Refer to through clutch REPAIR (Section V). If parts are not defective, refer to probable cause 2. 72, Remove the compressor valves, clean, inspect and replace as necessary. Refer to REPAIR (Section V). If parts are ‘ot defective, refer to probable cause 3 2 Compressor valves broken, stuck, or carbonized. 73. Refer toall above engine troubles, probable cause, and remedies. T. Adjustment clutch. Refer to INSPEC. ‘TION AND PREVENTIVE MAINTE- [NANCE (Section V) and adjust clutch. If clutch is adjusted properly, refer to probable cause 2. 8 Compressor does not operate at proper speed when cluteh is engaged. 7. Refer to all proceeding engine ‘roubles, probable causes, and remedies. If engine is operating prop- ‘rly, refer to probable cause 3. 3. Refer to REPAIR (Section V), di. ausemble air compressor. Check com- rewsot parts against limits specified in ‘Table $-5. Replace parts which are ‘worn beyond permissible limits. 5287.0.34715671 Table 5-4. "Troubleshooting - Continued TROUBLE PROBABLE CAUSE REMEDY 9, COMPRESSOR OIL PRES- | 1: Compressor oil level in erankesse too | 1. Add oil to compressor oil sump to ‘SURE gauge indication too low. full mark on dipstick. If dipstick indi- low. cates correct oil level, proceed to Prime oil ine for compseisor. probable cause 2. Pine air compressor all pump. Rater INSPECTION AND PREVENTIVE MAINTENANCE (Section V) and prime air cotapresior assembly ol pump. foil pump is primed, refer to probable cause 3. 3. Viscosity of oll too low for operating ambient temperature, Change olla comprewor ciankease, Refer to LUBRICATION INSTRUC- TIONS (Section V) and Table 5.3. for ambient temperature. If oll is of cortect viscosity, refer to probable cause 4. 4. Compressor oll pump defective pre- venting proper circulation. 7 Kamove ol pump, Giassomble, eam inspect, and repair as necessary. If puma is not defective, efer to prod- able cause 5. 3. Crankshaft oll seals worn causing leakage resulting in probable cause 1 SURE enuge. T. Defective COMPRESSOR O1L- PRESSURE gauge. 10. COMPRESSOR OIL PRES- SURE gauge indicating too high pressure 2. Compressor ol pressure relief ball stuck, 3. Oil pressure relief spring too Jong or too stiff, ‘30 Replace worn oil seals Refer to REPAIR (Section V), [f oil seals are not defective, refer to probable cause 6 [6 Replace « defective gauge. Referto REPAIR (Section V). If gauge is not defective, refer to probable cause 7 7. Replace broken oll prewsure Fl spring. Refer to REPAIR (Section V). T. Replace # delective gauge, Reler 10 REPAIR (Section V). If gauge is not defective, refer to probable cause 2. ‘BRemove and thoroughly clean on pressure relief ball, spring, and oi passage. Replace any damaged parts Refer to REPAIR (Section V). If ball Is not stuck, refer to probable cause 3 3. Replace oil pressure relief spring with correct replacement spring, Refer to 827T.0.34Y1-56-71 Table 5-4, Troubleshooting - Continued PROBABLE CAUSE TROUBLE 11, ISTSTAGEPRESSURE | 1. Compressor intake air filter clement | 1. Disassemble intake air filter, clean ‘gauge indication less than ‘extremely dirty. clement and bowl, replace ofl and 80 psi (371 KPa) while assemble filter. Refer to [NSPECTION ccompresor is loaded. "AND PREVENTIVE MAINTENANCE (ection V). If element is not dirty, refer to probable cause 2, 2, Air leaking from first stage air cooler ‘connections. , Tighten air cooler connections as necessary, Replace any leaking tube line or fittings not seating properly. If none of the above, refer to probable cause 3. 3. Ar cooler first sage safety valve not operating propery. 4. Air leaking from first stage safety valve, 5. Air leaking from first stage trap. 6, Pressure gauge tube ar saubber re- stricted and not allowing correct air ‘pressure to be indicated. 3. Valve is set to open at 80 psig (551.4 KPa), Remove valve and test. Refer to REPAIR (Section V). If valve assembly is defective, replace. If not, proceed to probable cause 4. Replace a leaking safety valve. If not, refer to probable cause 5. 5. Refer to trouble number 22. If not, refer to probable cause 6, ‘Remove tube and snubber and clean thoroughly. If tube and saubber are loan, refer to probable cause 7. "7. Air leaking past first cylinder head gasket, 7 Replace the cylinder head gasket. Tighten cylinder head cap screws to correct torque value, If gasket is not dofective, refer to probable cause 8, '8, Valve subassembly in the compressor first stage cylinder head not operating properly. '&. Defective valve subassembly. Replace valve subassembly. If vale is not de- fective, refer to probable cause 9. 9. Replace the first stage piston rings. Refer to REPAIR (Section V). 9, Firat stage piston rings worn, 12, 2NDSTAGE PRESSURE ‘gauge indication less than 185] ‘psi (1,240 KPs) while com ‘prestor is loaded. 7, First stage pressure too low. 1. Refer to trouble 11, probable causes, and remedies. If first stage pressure is correc, refer to probable cause 2. 12. Tighten air cooler connections as necessary. Replace any leaking tube line or fittings not seating properly. 528