ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 TECHNICAL MANUAL UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS DIESEL ENGINE MODEL 6059T 6 CYLINDER 5.9 LITER NSN: 2815-01-350-2209 This copy is a reprint which includes current pages from Change 1. HEADQUARTERS, DEPARTMENTS OF THE ARMY, AIR FORCE AND HEADQUARTERS, U.S.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 C3 CHANGE HEADQUARTERS DEPARTMENTS OF THE ARMY, AIR FORCE AND HEADQUARTERS, U.S. MARINE CORPS WASHINGTON, D.C., 30 October 1996 NO. 3 Unit, Direct Support and General Support Maintenance Instructions DIESEL ENGINE MODEL 4059T 6 CYLINDER 5.9 LITER NSN: 2815-01-350-2209 DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited TM 9-2815-256-24/TO 38G1-96-2/TM 2815-24/5, 15 September 1993, is changed as follows: 1.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS-TM 2815-24/5 C2 CHANGE HEADQUARTERS, DEPARTMENTS OF THE ARMY, THE AIR FORCE AND HEADQUARTERS, U.S. MARINE CORPS WASHINGTON, D.C., 31 OCTOBER 1995 NO. 2 Unit, Direct Support and General Support Maintenance Instructions DIESEL ENGINE MODEL 6059T 6 CYLINDER 5.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 C2 By Order of the Secretaries of the Army, Air Force and Navy (including Marine Corps): DENNIS J. REIMER General, United States Army Chief of Staff Official: YVONNE M. HARRISON Administrative Assistant to the Secretary of the Army 01212 RONALD R. FOGELMAN General, USAF Chief of Staff HENRY VICCELLIO, JR. General, USAF Commander, Air Force Materiel Command J. E. BUFFINGTON Rear Admiral, CEC.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 C1 CHANGE HEADQUARTERS DEPARTMENTS OF THE ARMY, AIR FORCE AND HEADQUARTERS U.S. MARINE CORPS WASHINGTON, D.C., 15 DECEMBER 1993 NO. 1 TECHNICAL MANUAL Unit, Direct Support and General Support Maintenance Instructions DIESEL ENGINE MODEL 6059T 6 CYLINDER 5.9 LITER NSN: 2815-01-350-2209 DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1 -96-2 MARINE CORPS TM 2815-24/5 C1 By Order of the Secretaries of the Army, Air Force, and Navy (Including the Marine Corps): GORDON R. SULLIVAN General, United States Army Chief of Staff Official: MILTON H. HAMILTON Administrative Assistant to the Secretary of the Army 05837 MERRILL A. McPEAK General, USAF Chief of Staff Official: RONALD W.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 SAFETY SUMMARY For first aid, refer to FM 21-11. Warning The noise level when operating could cause hearing damage. Ear protection must be worn. Warning Where applicable, prior to performing engine maintenance, ensure batteries are disconnected. Warning If the engine has been operating and coolant is hot, allow engine to cool before you slowly loosen filler cap and relieve pressure from cooling system.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 SAFETY SUMMARY - Continued Warning After operating engine, allow exhaust system to cool before removal of turbocharger. Failure to observe this warning could result in personal injury. Warning Compressed air used for cleaning can create airborne particles that may enter the eyes. Pressure will not exceed 30 psig (207 kPa). Eye protection required.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 SAFETY SUMMARY - Continued Warning Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate. Warning Diesel fuel and cleaning solvent are flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 SAFETY SUMMARY - Continued Warning If injured by escaping fuel, see a doctor immediately. Any fluid injected into skin must be surgically removed within a few hours or gangrene can result. Warning Place a clear, protective shield around fuel nozzle spray zone during testing to avoid possible personal injury from spray.
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 SAFETY SUMMARY - Continued Warning Flywheel is heavy. Provide adequate lifting device to support weight. procedure could result in personal injury. Failure to follow this Warning Oil fumes or oil can ignite above 380° F (193° C) - Use a thermometer and do not exceed 360°F (182°C). Do not allow a flame or heating element to be in direct contact with oil. Heat oil in a well ventilated area. Plan a safe handling procedure to avoid bums.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 TECHNICAL MANUAL HEADQUARTERS DEPARTMENTS OF THE ARMY, AIR FORCE AND HEADQUARTERS, U.S. MARINE CORPS WASHINGTON, D.C., 15 September 1993 NO. 9-2815-256-24 Unit, Direct Support and General Support Maintenance Instructions DIESEL ENGINE MODEL 4059T 6 CYLINDER 5.9 LITER NSN: 2815-01-350-2209 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 TABLE OF CONTENTS - continued PAGE Section II. Section III. Section IV. Section V. Section VI. Section VII. Section VIII. Section IX. Section X. Section XI. Troubleshooting ............................................................................................................ General Maintenance.................................................................................................... Cooling System Maintenance............
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 LIST OF ILLUSTRATIONS FIGURE 1-1. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 3-17. 3-18. 3-19. 3-20. 3-21. 3-22. 3-23. 3-24. 3-25. 3-26. 3-27. 3-28. 3-29. 3-30. 3-31. 3-32. 3-33. 3-34. 3-35. 3-36. 3-37. 3-38. PAGE Engine Components ......................................................................................................................... Connecting Test Gage to Intake Manifold..
ARMY TM 9-2815256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 LIST OF ILLUSTRATIONS - Continued FIGURE 3-39. 3-40. 3-41. 3-42. 3-43. 3-44. 3-45. 3-46. 3-47. 3-48. 3-49. 3-50. 3-51. 3-52. 3-53. 3-54. 3-55. 3-56. 3-57. 3-58. 3-59. 3-60. 3-61. 3-62. 3-63. 3-64. 3-65. 3-66. 3-67. 3-68. 3-69. 3-70. 3-71. 3-72. 3-73. 3-74. 3-75. 3-76. 3-77. PAGE Installing Brushes .............................................................................................................................
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 LIST OF ILLUSTRATIONS - Continued FIGURE 3-78. 3-79. 3-80. 3-81. 3-82. 3-83. 3-84. 3-85. 3-86. 3-87. 3-88. 3-89. 3-90. 3-91. 3-92. 3-93. 3-94. 3-95. 3-96. 3-97. 3-98. 3-99. 3-100. 3-101. 3-102. 3-103. 3-104. 3-105. 3-106. 3-107. 3-108. 3-109. 3-110. 3-111. 3-112. 3-113. 3-114. 3-115. 3-116. PAGE Removing Advance Screw Hole Plug ...............................................................................................
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 LIST OF ILLUSTRATIONS - Continued FIGURE 3-117. 3-118. 3-119. 3-120. 3-121. 3-122. 3-123. 3-124. 3-125. 3-126. 3-127. 3-128. 3-129. 3-130. 3-131. 3-132. 3-133. 3-134. 3-135. 3-136. 3-137. 3-138. 3-139. 3-140. 3-141. 3-142. 3-143. 3-144. 3-145. 3-146. 3-147. 3-148. 3-149. 3-150. 3-151. 3-152. 3-153. 3-154. 3-155. PAGE Installing Timing Pin...................................................................................................
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-962 MARINE CORPS TM 2815-24/5 LIST OF ILLUSTRATIONS - Continued FIGURE 3-156. 3-157. 3-158. 3-159. 3-160. 3-161. 3-162. 3-163. 3-164. 3-165. 3-166. 3-167. 3-168. 3-169. 3-170. 3-171. 3-172. D-1. D-2. D-3. PAGE Inspecting Cylinder Block ................................................................................................................. Measuring Main Bearing Bore Diameter ...................................................................................
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CHAPTER 1 INTRODUCTION Section I. GENERAL INFORMATION 1-1. SCOPE. 1-1.1. Type of Manual. This manual contains unit, direct support, and general support maintenance instructions for the Model 6059T Diesel Engine, hereafter referred to as engine. Also included are descriptions of major systems/components and their functions in relation to other systems/components. 1-1.2. Purpose of Equipment.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE All locations referenced herein are given facing the flywheel end (rear) of the engine. 1-8. DETAILED DESCRIPTION. 1-8.1. Turbocharger. A turbocharger, operated by exhaust gases, compresses intake air and routes it to the combustion chamber. 1-8.2. Camshaft. The camshaft is driven by an intermediate gear in the timing gear train which meshes with the crankshaft gear.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 1-1.
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 281524/5 1-9. EQUIPMENT DATA. 1-9.1. Leading Particulars. For a list of Leading Particulars, refer to TABLE 1-1. TABLE 1-1. Table of Specifications Model ...............................................................................................................John Deere 6059T Type..........................................................................Six cylinder, four cycle, turbocharged diesel Bore .........................................
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CHAPTER 2 OPERATION Section I. PRINCIPLES OF OPERATION 2-1. INTRODUCTION. This section contains functional descriptions of the engine systems and how they are connected to the end item. 2-2. COOLING SYSTEM. The cooling system consists of a radiator, hoses, two thermostat, belt driven fan, water pump, and cooling jackets within the engine.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CHAPTER 3 MAINTENANCE Section I. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 3-1. PMCS PROCEDURES. 3-1.1. General. To ensure that engine is ready for operation at all times, it must be inspected so defects can be discovered and corrected before they result in serious damage or failure. Perform operator's PMCS prior to or in conjunction with performance of engine PMCS. For engine PMCS, refer to TABLE 3-1. Table 3-1.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section II. TROUBLESHOOTING 3-2. TROUBLESHOOTING PROCEDURES. 3-2.1. Purpose of Troubleshooting Table. This section contains troubleshooting information for locating and correcting operating troubles which may develop in the engine. Each malfunction for an individual component, unit, or system is followed by a list of tests or inspections which will help you to determine probable causes and corrective action to take.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 1. ENGINE WILL NOT CRANK. Step 1. Check for defective end item starting system. Troubleshoot per end item maintenance manual. If not defective, do step 2. Step 2. Check for defective starter solenoid. a. Listen for audible clink during attempted start. If click is heard, do step 3. b. Replace defective starter solenoid. Refer to paragraph 3-12. Step 3.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 3. ENGINE HARD TO START OR WILL NOT START. Step 1. Check for fuel being supplied to fuel injection pump. a. Test supply pump capacity. Refer to paragraph 3-25.2. If supply pump not defective, do step 2. b. Repair or replace fuel supply pump. Refer to paragraph 3-25. Step 2. Check for clogged fuel filter/water separator. Replace filter cartridge.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 4. ENGINE HARD TO START OR WILL NOT START IN COLD WEATHER. Step 1. Check for faulty cold start system. a. Refer to end item maintenance manual. If not defective, do step 2. b. Repair cold start system. Refer to end item maintenance manual. Step 2. Refer to Malfunction 3, and perform steps 1 thru 6. 5.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 6. Check for defective fuel injection pump. a. Test fuel injection pump. Refer to paragraph 3-27.7. If not defective, do step 7. b. Replace fuel injection pump. Refer to paragraph 3-27. Step 7. Check for valves properly adjusted. Adjust valves. Refer to paragraph 3-32.1. If properly adjusted, do step 8. Step 8. Check for low engine compression.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2. Check for defective thermostat. a. If thermostat is suspected of being defective, replace thermostat. Refer to paragraph 3-9. b. If engine continues to overheat, do step 3. Step 3. Check for defective water pump. a. Remove and check water pump for damage, refer to paragraphs 3-10.1. and 3-10.2. If not defective, do step 4. b.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 9. LOW OIL PRESSURE. Step 1. Check for improper grade of oil. a. Refer to end item Lubrication Order. If proper grade of oil, do step 2. b. If improper grade of oil, refer to paragraph 3-16. and change oil and filter. Step 2. Check for engine running hot. a. Refer to Malfunction 7. b. If engine not overheating, do step 3. Step 3.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 10. EXCESSIVE FUEL CONSUMPTION. Step 1. Check for leak in fuel system. a. Check fuel system for leaks. If no leaks, do step 2. b. Repair fuel system. Step 2. Check for blocked air intake system. Remove blockage as found. If no blockage is found, do step 3. Step 3. Check for defective fuel injector. a. Remove, clean, and test fuel injectors.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 5. Defective fuel injection pump. a. Test fuel injection pump. Refer to paragraph 3-27.7. If not defective, do step 6. b. Replace fuel injection pump. Refer to paragraph 3-27. Step 6. Check for defective turbocharger. a. Inspect turbocharger for damage. Refer to paragraph 3-13.2. If not defective, do step 7. b. Replace defective turbocharger.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 4. Defective fuel injection pump. a. Remove and test fuel injection pump. Refer to paragraphs 3-27.1. and 3-27.7. b. Repair or replace fuel injection pump. Refer to paragraph 3-27. 12. BLUE EXHAUST SMOKE. Step 1. Check for blocked air intake system. Remove blockage as found. If no blockage is found, do step 2. Step 2.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 1. Check for worn or damaged water pump bearing. a. Check for excessive water pump shaft play at cooling fan. If not excessive, do step 2. b. Replace defective water pump. Refer to paragraph 3-10. Step 2. Defective battery charging alternator. a. Remove and inspect battery charging alternator for damage. Refer to paragraphs 3-11.1. and 311.3.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2. Check for loose fuel injection nozzles. a. Inspect fuel injection nozzles for looseness. If not loose, do step 3. b. If loose, replace washers and tighten fuel injection nozzles. Refer to paragraph 3-29. Step 3. Check for damaged cylinder head gasket. a. Inspect area around cylinder head gasket for evidence for gas leakage. b.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P Table 3-2. Troubleshooting - Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Step 2. Test for defective battery charging alternator. a. Inspect and test battery charging alternator. Refer to paragraph 3-11.1. If alternator not defective, do step 3. b. Repair or replace battery charging alternator. Refer to paragraph 3-11. Step 3. Check for breaks or loose connections in charging circuit.
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section III. GENERAL MAINTENANCE 3-3. GENERAL. This section provides general maintenance not found in other sections of Chapter 3. 3-3.1. General Instructions. Warning Where applicable, prior to performing engine maintenance, ensure batteries are disconnected to prevent serious injury or death. NOTE Refer to end item maintenance manual for removal of any components necessary to gain access to engine. a.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 n. Service tools are designed to aid disassembly and assembly procedures and their use will prevent possible unnecessary damage to components. It is recommended that service tools are always used, some operations cannot be safely carried out without aid of relevant tool. o. When removing/disconnecting fuel and lubrication lines and coolant hoses, cover/cap all openings to prevent entry of foreign material.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 q. Remove crankshaft pulley, refer to paragraph 3-38.1. r. Remove timing gear cover, refer to paragraph 3-39.1. s. Remove oil pump drive gear, oil outlet tube, (and its O-ring in block), and pump body, refer to paragraph 3-21.1. t. Remove oil slinger, timing gears, and camshaft, refer to paragraphs 3-40.1. and 3-41.1. Perform wear checks. u. Remove engine front plate, refer to paragraph 3-42.1. v.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 s. Install injection nozzles (with new seals) and injection lines, refer to paragraph 3-29.4. t. Install fuel filter, fuel supply pump, and fuel lines, refer to paragraphs 3-24.4., 3-25.3. and 3-26.3. u. Install engine standard flow oil cooler, new oil filter, and dipstick, refer to paragraphs 3-16.3 and 3-19.2 (Never clean or reuse a contaminated engine oil cooler. Install a new one.) v.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-7. INTAKE MANIFOLD PRESSURE CHECK. a. Remove plug from intake manifold and connect suitable gage to intake manifold, refer to FIGURE 3-1. FIGURE 3-1. Connecting Test Gage to Intake Manifold b. Run engine to bring up to normal operating temperature.(From a cold start, operate engine 10 to 15 minutes at slow idle.) NOTE Engine speed and load should be stabilized before taking readings on gage. Be sure that gage works properly.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (8) Low compression pressure. (9) Faulty fuel injection nozzles. (10) Carbon build-up in turbocharger. (11) Turbocharger compressor or turbine wheel rubbing housing. (12) Low fuel injection pump fuel delivery. (13) Restricted exhaust. f. Remove test gage and install plug in intake manifold.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section IV. COOLING SYSTEM MAINTENANCE 3-8. GENERAL. This section provides maintenance for cooling system components. Components of cooling system not mentioned in this section can be found in the end item maintenance manual. WARNING If the engine has been operating and coolant is hot, allow engine to cool before you slowly loosen filler cap and relieve pressure from cooling system.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-2.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 g. Remove adapter (9) and plug (7), if replacing housing (8). h. Cover all openings to prevent entry of foreign material. 3-9.2. Inspection. a. Inspect thermostat for excessive wear or damage. b. Inspect housing for cracks, corrosion, or other damage. 3-9.3. Replacement. NOTE If thermostat is suspected of being defective, replace thermostat. a. Replace thermostat if worn or damaged. b. Replace housing if badly corroded or damaged. 3-9.4.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-10. WATER PUMP. 3-10.1. Removal. WARNING Do not drain coolant until coolant temperature is below operating temperature prior to removal. Severe personal injury can occur. a. Drain coolant system if not already drained. Refer to end item maintenance manual. b. Loosen hose clamp and remove inlet hose from water pump inlet. c. Loosen four hose clamps (1, FIGURE 3-3) and disconnect cooler hoses (2) at water pump. d.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 h. Remove capscrew (1, FIGURE 3-4), lockwasher (2), and washer (6) attaching alternator adjusting strap (3); move strap out of the way. Discard lockwasher. NOTE Note location of shorter capscrew (7) for installation purposes. i. Remove capscrew (4), nut (5), and capscrew (7). Using an assistant to support water pump (9), turn socket head screw (8) and remove water pump (9). Remove and discard gasket (10). j.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 c. Position alternator adjusting strap (3) and secure with capscrew (1), washer (6), and new lockwasher (2). Tighten capscrew to 35 ft-lbs (47 Nm). d. Install fan and spacer, refer to end item maintenance manual. e. Install fan drive belts, refer to end item maintenance manual. f. Install by-pass hose on water pump and secure with a hose clamp. g.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section V. ELECTRICAL SYSTEM MAINTENANCE 3-11. BATTERY CHARGING ALTERNATOR. 3-11.1. Battery Charging Alternator Test (Installed). a. Check for battery voltage in alternator between terminals POS and ground, and EXC and ground with the master switch (S1) in the PRIME & RUN POSITION. Note voltage. b. Start and operate generator refer to TM 9-6115-645-10 and recheck voltage on alternator terminal POS and ground for 28 " 2 VDC.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-5. Battery Charging Alternator and Mounting Brackets f. Remove bolts (16), diode-trio (17), strap (14), and rectifier bridge (18) from rear housing (20). CAUTION Do not insert screwdriver blades deeper than 1/16 inch (1.587 mm) to avoid damaging stator winding.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 g. Match mark front and rear housings, and remove through bolts (19). Insert two flat tip screwdrivers in opposite openings between stator (22) and rear housing (20), refer to FIGURE 3-7. h. Pry units apart and remove rear housing (20, FIGURE 3-6) and stator (22) from front housing (30). NOTE To remove nut (23), place rotor assembly in a soft-jawed vise. i.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-6. Battery Charging Alternator Assembly FIGURE 3-7.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 e. Inspect other components for damage such as broken terminals or insulation, discoloration, stripped threads, and other obvious damage. f. Replace damaged components as necessary. 3-11.5. Testing. a. Set multimeter for ohms and check brush assembly (refer to FIGURE 3-8) for continuity between mount A and brush B, and mount C and brush D.
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 c. Set multimeter for ohms and check rectifier bridge assembly (refer to FIGURE 3-10) by noting multimeter indications between point A and each point C, and between point B and each point C. Reverse leads, repeat checks, and note indications. If readings are the same in both directions for any diode, replace entire rectifier bridge assembly. A good diode will have a high indication in one direction and a low indication in the other.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-11. Testing Stator Windings POLE FINGERS FIGURE 3-12. Testing Rotor b. Install front bearing retaining screws (31). Torque screws 25 to 35 in-lbs (2.82 to 3.95 Nm). c. Using arbor press, press front housing (30) over rotor assembly (29) until inner bearing race contacts shoulder on shaft. d. Position pulley spacer (27), woodruff key (28), fan (26), and pulley (25) on rotor assembly (29) shaft. e.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 i. Install through bolts (19) and tighten evenly 50 to 60 in-lbs (5.65 to 6.78 Nm). j. If necessary, remove through bolts (19) and (20) and stator (22) to align housings as match marked on disassembly. Reinstall bolts and torque evenly 50 to 60 in-lbs (5.65 to 6.78 Nm). k. Insert strap (14) of rectifier bridge (18) through slot in diode-trio (17) body. Bend strap (14) over B+ terminal and secure with cone washer (13) and nut (12). I.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-11.7. Installation. a. If removed, install jumper wire (18, FIGURE 3-5) and nuts (20). b. If removed, position mounting brackets (15 and 17) on timing gear cover mounting holes; secure with two capscrews (12), washers (13), spacers (16), and nuts (14). c. If removed, position adjusting strap (11) on water pump mounting hole; secure with capscrew (9), washer (19), and new lockwasher (10). d.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 g. When switch is activated, starter should engage and run. h. If solenoid only chatters, hold-in winding is open-circuited. If nothing happens, either pull-in winding is opencircuited or mechanical parts are sticking. To check for sticking, remove solenoid end cover and push plunger by hand. NOTE The solenoid cannot be repaired. i.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-15.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-16. Disconnecting Lead Wire (Typical) c. Remove two through bolts (7, FIGURE 3-15), lockwashers (8), washers (9), and preformed packings (10), refer to FIGURE 3-17. Discard lockwashers (8) and preformed packings (10). FIGURE 3-17. Removing Through Bolts (Typical) d. Remove two screws (11, FIGURE 3-15) and starter end frame (12). Remove yoke assembly (39), refer to FIGURE 3-18.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-18. Removing Starter End Frame and Yoke Assembly (Typical) e. Lift brush springs and remove brushes from brush holder (13, FIGURE 3-15), refer to FIGURE 3-19. Remove brush holder assembly (13).
ARMY IM 9-281-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-19. Removing Brushes f. Remove armature (14, FIGURE 3-15) from magnetic switch assembly (24), refer to FIGURE 3-20. FIGURE 3-20. Removing Armature g. Remove three screws (15, FIGURE 3-15) from housing (16). assembly (24), refer to FIGURE 3-21.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-21. Removing Housing (Typical) h. Remove overrunning clutch (17, FIGURE 3-15) from housing (16), refer to FIGURE 3-22. FIGURE 3-22. Removing Overrunning Clutch (Typical) i. Remove steel ball (18, FIGURE 3-15) from overrunning clutch (17), refer to FIGURE 3-23.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-23. Removing Steel Ball j. Remove starter pinion (19, FIGURE 3-15), retainer (20), and five rollers (21) from housing (16), refer to FIGURE 3-24. FIGURE 3-24. Removing Pinion, Retainer, and Rollers (Typical) k. Remove washer (22, FIGURE 3-15) and spring (23) from magnetic switch assembly (24), refer FIGURE 3-25.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-25. Removing Washer and Spring I. If necessary, remove screw (25, FIGURE 3-15), nuts (26 and 27), washers (28 thru 31), and lockwashers (31 and 32) from terminal studs on magnetic switch assembly (24). m. Remove screws (40), washers (41), end plate (42), and contact (43) from magnetic switch assembly (24). 3-12.4. Inspect and Measure/Repair. a.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-27. Measuring Commutator OD c. Measure commutator segment mica depth as shown in FIGURE 3-28. If depth is less than 0.0079 inch (0.2 mm), undercut the mica. FIGURE 3-28. Measuring Segment Mica Depth d. Check commutator surface for bum spots. This usually indicates an open circuit. Remove these spots using #400 abrasive paper. e. Inspect bearings (34 and 35, FIGURE 3-15) for wear and damage.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-29. Inspecting and Replacing Bearings f. Check field windings of yoke for wear or damage. Check all connections for clean and tight solder joints. g. Measure brush length, refer to FIGURE 3-30. If less than 0.51 inch (13 mm), replace brush holder and/or yoke assembly. FIGURE 3-30. Measuring Brush Length h. Check brush springs for damage or corrosion. If damaged or corroded, replace brush holder. i.
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 281524/5 FIGURE 3-31. Checking Overrunning Clutch 3-12.5. Test. 3-12.5.1 Testing Starter Motor (Installed). a. Make sure batteries are fully charged and that all battery and starter cables are serviceable and properly installed. b. Set multimeter for DC volts, and connect as shown in FIGURE 3-32, Test A. If voltage is indicated solenoid is defective. c. Momentarily connect a jumper as shown in FIGURE 3-32, Test B.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-33. Growler Test b. Set multimeter for ohms and touch one probe to a commutator segment and other one to armature core, refer to FIGURE 3-34. There should be no continuity. If there is continuity, armature is grounded. Replace armature if grounded. FIGURE 3-34. Testing for Grounded Windings c. Set multimeter for ohms and touch probes to two segments, refer to FIGURE 3-35. There should be continuity at any point.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-36. Checking Brush Holder e. Using a multimeter, touch one probe to field winding end of brush and other one to bare surface of yoke body, refer to FIGURE 3-37. There should be no continuity. If there is continuity, field windings are grounded. Replace the yoke assembly. FIGURE 3-37. Checking Field Coils f. Using a multimeter, touch one probe to lead wire and other one to brush, refer to FIGURE 3-38.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-38. Checking for Open Field Coil 3-12.6. Assembly. a. Install contact (43), end plate (42), washers (41), and screws (40) in magnetic switch assembly (24). b. If removed, install nuts (26 and 27, FIGURE 3-15), washers (28 thru 31), lockwashers (32 and 33), and screw (25). c. Apply general purpose grease (630AA) to retainer (20), rollers (21), overrunning clutch (17), steel ball (18), spring (23), and bearings (34 and 35). d.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-40. Installing Cover On Yoke k. Position yoke assembly (39) on magnetic switch assembly (24) engaging tab on yoke assembly with notch in magnetic switch, refer to FIGURE 3-41. Secure with two through bolts (7, FIGURE 3-15), new lockwashers (8), washers (9), and new preformed packings (10). Tighten through bolts 5.1 to 8.7 ft-lbs (6.9 to 11.8 Nm). FIGURE 3-41. Installing Yoke I.
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section VI. INTAKE AND EXHAUST SYSTEM MAINTENANCE 3-13. TURBOCHARGER. 3-13.1. Removal. Warning After operating engine, allow exhaust system to cool before removal. observe this warning could result in personal injury. Failure to CAUTION When cleaning turbocharger, do not spray directly into compressor cover or turbine housing. If turbocharger inspection is required, do not clean exterior prior to removal.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-42. Turbocharger f. Remove two capscrews (6) and lockwashers (7), securing oil drain line (8) to turbocharger. Remove line (8) and gasket (9); discard lockwashers (7) and gasket (9). g. Remove four capscrews (10) and flatwashers (11), securing turbocharger (12) to exhaust manifold. Remove turbocharger and stainless steel gasket (13); discard gasket (13). h. Cover all openings. 3-13.2. Inspection, 3-13.2.1 General.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 The following inspection procedure is recommended for systematic failure analysis of a suspected turbocharger failure. This procedure will help to identify when a turbocharger has failed, and why it has failed so primary cause of failure can be corrected. Proper diagnosis of a "non-failed" turbocharger is important for two reasons.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 TABLE 3-3.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 b. Mark findings on checklist and continue inspection. NOTE You will need a good light source for this check. c. Check compressor inlet for wheel rub on housing. Look very closely for any score marks on the housing itself and check tips of the compressor wheel blades for damage. 3-13.2.3 Compressor Housing Outlet. a. Check compressor housing outlet. Outlet should be clean and free of dirt or oil. b.
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE There will be some play because bearings inside center housing are free floating. d. Next, check shaft end-play by moving shaft back and forth while rotating. There will be some end-play but not to extent that wheels contact housings. 3-13.3. Test 3-13.3.1 Radial Bearing Clearance Test. a. b. c. d. e. NOTE This test will give an indication of condition of radial bearings within center housing and rotating assembly.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 a. b. c. d. e. f. g. h. i. j. Prime turbocharger lubrication system prior to mounting turbocharger on engine. Fill center housing with new engine lubricating oil (MIL-L-2104) through oil drain hole. Turn rotating assembly by hand to lubricate bearings. Inspect air cleaner-to-turbocharger hose to see that it is in good condition. Replace hose if it is hard, cracked, or shows any signs of deterioration. Remove all covers.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-44. Exhaust Manifold 3-14.2. Inspection. Inspect exhaust manifold for cracks or damage. Inspect machined mounting surfaces for burrs or other defects which might prevent gaskets from sealing properly. Replace as necessary.
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-14.3. Installation. a. Remove all covers. NOTE When using gaskets with one steel-backed side, the non steel-backed side must face towards the cylinder head. b. Using six new gaskets (5, FIGURE 3-44) position exhaust manifold (4) on cylinder head. Coat all twelve capscrews (1 and 3) with antiseize compound (CP-8) and install with washers (2) in locations as noted during removal. Tighten capscrews to 35 ft-lbs (47 Nm). c.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-45.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section VII. LUBRICATION SYSTEM MAINTENANCE 3-16. OIL FILTER AND COOLER. 3-16.1. Removal. WARNING If the engine has been operating and coolant is hot, allow engine to cool before you slowly loosen filler cap and relieve pressure from cooling system. Failure to observe this warning could result in severe personal injury. a. Drain engine lubrication system and coolant system, refer to end item maintenance manual. b.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-46.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 i. If defective, remove screw (18) securing strap (19) to engine; remove strap. j. Remove oil filter nipple (12) from cylinder block with a suitable pilot bearing puller, refer to FIGURE 3-47. k. Cover all openings. FIGURE 3-47. Removing Oil Filter Nipple 3-16.2. Inspection. a. Inspect hoses for cracks, brittleness, or any other defects. Replace as necessary. b. Inspect relief valve for damage. Replace as necessary.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-48. Installing Oil Filter Nipple (2) Using a tubular driver, push oil filter nipple into cylinder block until it is flush with cylinder block, refer to FIGURE 3-48. Figure 3-49. Driving Oil Filter Nipple b. Position new preformed packing (11, FIGURE 3-46) and oil cooler on engine block and secure with nipple (9). Tighten nipple to 27 ft-lbs (37 Nm). c. Install two hoses (5 and 6) and two clamps (4) on oil cooler.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE Apply a light coating of engine lubricating oil (MIL-L-2104) to gasket surface prior to installing new element. j. Install new filter element (1) on oil cooler. k. Service engine lubrication and cooling systems, refer to end item maintenance manual. 3-17. OIL PRESSURE REGULATING VALVE. 3-17.1. Removal. a. Drain engine lubrication system, refer to end item maintenance manual. b. Remove crankshaft pulley, refer to paragraph 3-38.1.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-50. Oil Pressure Regulating Valve and Oil Filler Assembly d. Service engine lubrication system, refer to end item maintenance manual. 3-18. OIL FILTER ASSEMBLY. 3-18.1. Removal. a. Drain engine lubrication system, refer to end item maintenance manual. b. Remove two capscrews (5 and 7, FIGURE 3-50) and washers (6) securing filler neck (8) to engine block. Remove filler neck (8) and gasket (9); discard gasket. c.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 a. b. Inspect filler neck for cracks or other damage. Inspect filler cap (10, FIGURE 3-50) and gasket (11) for damage. Replace as necessary. 3-18.3. Installation. a. Remove covers. b. Position new gasket (9, FIGURE 3-50) and filler neck (8) on engine block and secure with two capscrews (5 and 7) and washers (6). c. Service engine lubrication system, refer to end item maintenance manual. 3-19. OIL DIPSTICK. 3-19.1. Removal. a.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-51. Dipstick 3-19.2. Installation. a. Install jam nut (4, FIGURE 3-51) on tube (3) exposing number of threads above nut as noted during removal. b. Screw tube (3) into engine block and tighten jam nut (4). c. If in doubt of level accuracy, perform following: NOTE Engine should be cold and new filter installed before filling. (1) d.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-20. OIL PAN. 3-20.1. Removal. a. Drain engine lubrication system, refer to end item maintenance manual. NOTE Eight of the 36 bolts are longer than the other bolts. Note their location for use during installation. b. c. Support oil pan and remove two bolts (1, FIGURE 3-52), four bolts (3), two bolts (4), eight lockwashers (2), and twenty-eight flanged head bolts (5), securing oil pan (6) to engine block.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 a. b. Put a bead of sealing compound (FORMAGASKET2) on oil pan rail where flywheel housing, front plate, and timing gear cover attach to cylinder block. Place new gasket (7, FIGURE 3-52) and oil pan (6) on engine block and secure with two bolts (1), four bolts (3), two bolts (4), eight new lockwashers (2), and twenty-eight flanged head bolts (5). Install the eight longer bolts (1, 3 and 4) in locations noted during removal.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-53. Oil Pump Assembly c. Loosen nut (3) and remove tube (4), sleeve (5), and fitting (6). d. Remove two bolts (7) and two flatwashers (8). Remove oil pickup (9). Remove and discard packing (10). e. Using O-ring pick, remove and discard preformed packing (11) from engine. 3-21.2. Inspect and Measure. Warning Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required.
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Warning a. b. c. d. Compressed air used for cleaning can create airborne particles that may enter the eyes. Pressure will not exceed 30 psig (207 kPa). Eye protection required. Clean all oil pump parts in solvent. Dry with compressed air. Visually inspect all oil pump components for excessive wear. Inspect pump intake tube-to-flange weld for cracks. If cracks or other defects are found, replace tube.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 c. d. e. f. g. h. Install fitting (6), sleeve (5), and tube (4). Tighten nut (3). Install pump (12) with oil pump intake tube (9) on front plate and secure with two bolts (7) and two flatwashers (8). Tighten bolts to 35 ft-lbs (47 Nm). Rotate oil pump shaft by hand to ensure it turns freely. Install drive gear (2) and nut (1). Tighten nut to 55 ft-lbs (75 Nm). Stake nut (1) to shaft by applying three center punch marks.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-56. Oil Pressure Test Setup 3-22. OIL BYPASS VALVE ASSEMBLY. 3-22.1. Removal. a. Remove four bolts (4, FIGURE 3-52), two capscrews (3), and six lockwashers (2) from front of oil pan. b. Remove timing gear cover and front plate, refer to paragraphs 3-39.1. and 3-42.1. c. Remove oil bypass valve and spring, refer to FIGURE 3-57. FIGURE 3-57. Oil Bypass Valve Installation 3-22.2. Inspect and Measure. a. b.
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-22.3. Installation. a. Install valve and spring in bore of engine block, refer to FIGURE 3-57. b. Install front plate and timing gear cover, refer to paragraphs 3-42.5. and 3-39.3. CAUTION Do not overtighten oil pan- to-timing gear cover capscrews. c. Install four bolts (4, FIGURE 3-52), two capscrews (3), and six new lockwashers (2) in front oil pan. Tighten oil pan-to-timing cover capscrews to 27 ft-lbs (37 Nm).
ARMY TM 92815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section VIII. FUEL SYSTEM MAINTENANCE Warning Escaping diesel fuel under pressure can have sufficient force to penetrate the skin, causing serious injury. Before disconnecting fuel lines, be sure to relieve pressure. Before applying pressure to the system, be sure all connections are tight and lines, pipes, and hoses are not damaged. Keep hands and body away from pinholes and nozzles which eject fuel under pressure.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 a. Loosen fuel supply line at fuel injection pump. b. Operate primer lever of fuel supply pump until fuel flow is free from air bubbles. Tighten fuel supply line to 22 ftlbs (30 Nm). Continue operating hand primer until pumping action is not felt. Pull hand primer outward (away from block) as far as it will go. 3-23.4. Bleed At Fuel Injection Nozzles. a. Place throttle lever in fast idle position.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-58.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 b. Using two wrenches, loosen fuel line connection at injection nozzle. c. Crank engine over with starter (but do not start engine), until fuel free from bubbles flows out of loosened connection. Tighten connection to 20 ft-lbs (27 Nm). d. Repeat procedure for remaining injection nozzles (if necessary) until engine starts or until air has been removed from fuel system. 3-24. FUEL FILTER/WATER SEPARATOR. 3-24.1.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-24.4. Installation. CAUTION Always use two wrenches when removing/installing fittings and/or fuel lines to avoid damage. a. Position filter head (15, FIGURE 3-58) on engine mounting and secure with two capscrews (13) and washers (14). b. Remove caps and connect fuel line (11) to elbow (12) in outlet of filter head. c. Remove caps and connect fuel line (9) to elbow (10) in inlet of filter head. d.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 a. Remove inlet and outlet fittings. b. Install vacuum/pressure gage to inlet side of pump. c. Move primer lever all the way upward. Release lever and at same time observe gage. (1) Gage needle should move to some value, and then very slowly go back to zero (0). This indicates inlet valve and diaphragm are in good condition. Proceed to step d.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-26. FUEL LINES. 3-26.1. Removal. WARNING Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate. CAUTION Always use two wrenches when removing/installing fittings and/or fuel lines to avoid damage. NOTE Catch fuel in suitable container. a.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 c. Connect tube (7) to fitting (18). Connect other end of tube (7) to No. 1 injector using new bushing (8) and coupling nuts (6). Do not overtighten coupling nuts. d. Connect fuel tank return line to No. 6 injector using new bushing (5) and coupling nut (4). Do not overtighten coupling nut. FIGURE 3-59. Fuel Lines and Injection Pump Installation e.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-27. FUEL INJECTION PUMP. 3-27.1. Removal. WARNING Diesel fuel and cleaning solvent are flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/ prolonged contact. Good general ventilation is normally adequate. CAUTION Always use two wrenches when removing/installing fittings and/or fuel lines to avoid damage.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-60. Flywheel Locking Tool FIGURE 3-61. Checking Timing Marks NOTE If timing marks are as illustrated in FIGURE 3-61, insert timing tool (JDE-81-4) into flywheel, refer to FIGURE 3-60. k. Check alignment of governor weight retainer and cam ring timing marks, refer to FIGURE 3-61. NOTE If timing cover is removed, proceed to step 1. If timing cover is not removed, proceed to step m. I.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 m. The following steps cover injection pump removal with timing cover installed. (1). Remove injection pump cover plate from timing gear cover, refer to FIGURE 3-62, cover shown removed. FIGURE 3-62. Fuel Infection Pump Gear Access (Cover Removed) NOTE Be careful not to drop nut and/or washer inside engine. (2). Remove nut and washer securing fuel injection pump drive gear to shaft. (3).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (7) Remove pump (22) from mounting studs (25). n. Cover all openings in pump and place pump in a clean area. 3-27.2. Disassembly. NOTE Work area must be clean and dirt free prior to disassembly of the fuel injection pump. NOTE Prior to disassembly, ensure a clean pan with diesel fuel or calibrating oil is available. Also, ensure a clean pan is available to store disassembled parts.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 l. Using needle nose pliers, gently lift lever while removing shut-off assembly (30). NOTE To aid in correct reassembly, note position of throttle lever (19) key in relationship to groove of throttle shaft assembly (18).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-64. Fuel Injection Pump Assembly m. Remove throttle lever (19), spacer (20), two rubber seal rings (21), and two washers (22).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 n. If damaged, disassemble shut-off lever shaft assembly as follows, refer to FIGURE 3-65. (1) Remove socket screw (23, FIGURE 3-64), adjustment shut-off screw (24), and two lockwashers (25 and 26) securing adjustment shut-off lever (27) to shaft assembly (30). (2) Remove two shut-off screws (28) and nuts (29) from shaft assembly (30). FIGURE 3-65. Disassembly of Shut-off Lever o.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (4). Remove control rod pin (4), control rod guide (6), and seal washer (9). (5). Remove control rod assembly (5), control spring (7), control spring guide (8), and control spring bushing (10). FIGURE 3-67. Speed Droop Governor NOTE Unless damaged, damper barrel assembly (11), damper piston (12), and damper spring (13) should not be removed from governor arm (14). (6).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-68. Disengaging Governor Linkage (Typical) u. Remove metering valve (45, FIGURE 3-64), shim (49), and spring from housing, refer to FIGURE 3-69. FIGURE 3-69. Removing Metering Valve v. Remove vent wire screw assembly (52, FIGURE 3-64), refer to FIGURE 3-70.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-70. Removing Vent Wire Screw w. Remove transfer pump end cap locking screw (2, FIGURE 3-73), retaining plate (3), and seal (4) from hydraulic head, refer to FIGURE 3-71. FIGURE 3-71. Removing Transfer Pump Screw x. Using end cap socket (20548), remove transfer pump end cap (5, FIGURE 3-73). y. Remove valve plate, element strainer (6) and regulator assembly (8), refer to FIGURE 3-72.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-72.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-73.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 z. Disassemble transfer pump regulator components as follows: (1) Remove end plate adjusting plug (7, FIGURE 3-73), regulator (8), piston (9), and spring (10). (2) Using O-ring pick, remove internal regulating seal (11) from regulator (8). (3) If damaged, remove spring pin (12) from regulator (8). Retain spring for reassembly. Refer to FIGURE 3-74. FIGURE 3-74. Transfer Pump Regulator Components aa.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-76. Removing End Cap Seal ac. Invert pump and holding fixture in vise. ad. Remove head locating screw (54, FIGURE 3-64) and two preformed packings (55), refer to FIGURE 3-77. FIGURE 3-77. Removing Head Locating Screw ae. Remove plug (56, FIGURE 3-64), seal (57), and pin (71), refer to FIGURE 3-78.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-78. Removing Advance Screw Hole Plug af. Remove piston hole plug (58, FIGURE 3-64), advanced adjustment guide (61), spring (59), piston spring (60), power piston (68), piston ring (69), and seal from under piston ring (70), refer to FIGURE 3-79. FIGURE 3-79. Removing Spring Side Advance Plug ag. Remove two preformed packings (62 and 63, FIGURE 3-64) from piston hole plug (58). ah.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 am. Invert hydraulic head assembly (17) and let six weights (18), sleeve (19), and thrust washer (20) fall into your hand. an. Remove preformed packing (21) from hydraulic head, refer to FIGURE 3-80. FIGURE 3-80. Disassembling Governor ao. Place hydraulic head on top of holding fixture (FIGURE D-1, Appendix D). ap. Remove one nut (76, FIGURE 3-64) and seal washer (77), refer to FIGURE 3-81. FIGURE 3-81.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-82. Removing Governor Arm as. If damaged, disconnect spring (47) from governor arm (44) and linkage hook assembly (46). at. If damaged, disassemble linkage hook assembly, by removing screw (79) and washer (80) to separate linkage assembly (81) from linkage hook (46). au. Remove drive shaft (42, FIGURE 3-73) from housing as follows: (1) (2) (3) (4) (5) Remove nut, washer, and key (43).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE Rotation of cam ring is clockwise as viewed from drive side of injection pump. ba. Remove cam ring (24), refer to FIGURE 3-84. FIGURE 3-84. Removing Cam Ring (Typical) NOTE If delivery valve does not slide out freely from bore, use extractor (13383) to remove it, refer to FIGURE 3-85. bb. Remove screw (34, FIGURE 3-73), valve stop (35), spring (36), and delivery valve (37) from rotor. Discard valve stop. FIGURE 3-85.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-86. Removing Leaf Spring (Typical) bd. Remove four rollers (27, FIGURE 3-73) and shoes (28) from rotor, refer to FIGURE 3-87. be. If damaged, remove six fuel connectors (47, FIGURE 3-73) from rotor head. NOTE Handle all parts with clean hands and moisten with calibrating fluid. bf. Using brass pick, push two pumping plungers (29) from their bores, refer to FIGURE 3-88. FIGURE 3-87.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 bg. Lift rotor from head (17, FIGURE 3-73). bh. Supporting rotor (48) in weight retainer, remove screw (34), valve stop (35), spring (36), and delivery valve (37) from rotor (48). bi. If damaged, remove four fuel connectors (47) from head. bj. Using needle nose pliers, pull flexible retaining ring (30) from retainer assembly (33). FIGURE 3-88. Removing Pumping Plungers (Typical) 3-27.3. Cleaning.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-27.4.3 Hydraulic Head. Warning Compressed air used for cleaning can create airborne particles that may enter the eyes and cause serious injury. Pressure will not exceed 30 psig (207 kPa). Eye protection required. NOTE Five vent wire screw assembly (52, FIGURE 3-54) sizes are available. If specific oil return flow is not obtained during test, replace screw with appropriate size.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-27.4.7 Cam Rollers and Shoes. CAUTION Never attempt to press a roller into a shoe from outer edges, as groove width at this point is less than roller outside diameter and shoe breakage may result. Check each roller in its shoe for freedom of movement. Inspect top edge of each shoe, where retained by leaf spring, for chipping or excessive wear. Inspect roller and shoe for abrasive wear patterns. 3-27.4.8 Leaf Spring and Screw.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-27.5.3 Roller Shoes. Roller shoes are available in three sizes and are marked on the end, e.g. -010 (PN 20119), -.005 (PN 20124) and -.015 (PN 20120). All four shoes must bear same mark. 3-27.5.4 Plungers. Two each of two different plungers are used with basic part numbers of 11046 and 20250. Four additional standard sizes and four additional oversizes are available for each type of plunger as listed below.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 c. Place rotor on weight cage and secure in vise. d. Place three cushion retainers (31) on the weight retainer pins. NOTE On some fuel injection pumps, the retainers were secured with six retainer rings. The gasket kit used for reassembly will contain three retaining clips (30). All three retaining clips must be installed in same direction with long slot positioned clockwise relative to hole with short slot.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-89. Delivery Valve Replacement CAUTION Always use a new delivery valve stop (35, FIGURE 3-73). Installation of a used stop can result in leakage and low output at cranking speed. CAUTION Excessive tightening of screw (34) can cause seizure of hydraulic head and rotor assembly. Insufficient torque may cause leaking and hard starting. NOTE Tighten screw (34) 120 to 125 in-lbs. (13.6 to 14.1 Nm). j.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-90. Installing Rollers and Shoes (Typical) NOTE If replacing hydraulic head and rotor, or if replacing leaf springs, do steps n thru s. n. Install two leaf springs (26, FIGURE 3-73) on rotor. Secure with two screws (25). o. Carefully handle rotor, holding rollers, and shoes in their slots, and install rotor assembly in fixture (19969) on air inlet side. Warning Compressed air can be hazardous when not used properly. p.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-91. Measuring Roller-To-Roller Dimension r. Perform a centrality check as follows. Maximum allowable tolerance is 0.004 inch (0.102 mm). (1) After setting roller-to-roller dimension, rotate rotor until one roller is aligned with dial indicator plunger. Slide indicator inward until plunger depresses it at least 0.010 inch (0.25 mm).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CAUTION Use care not to cock blades during installation, as sharp edge on liner (15) can score blade ends. aa. Assemble springs (14) to blades (13) and install blades in their slots in rotor. Blade springs (14) must be fully compressed as they are installed. ab. Assemble transfer pump components as follows: (1) If necessary, install new spring pin (12) in correct hole in regulator (8) for clockwise rotation.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (2) Place pump housing on an arbor press with mounting flange upward. Be sure housing rests flat on arbor , press plate. (3) Position installation tool with seal above pump housing and press seal into reduced diameter at bottom of housing bore. (4) Place oil seal (45, FIGURE 3-73) at opposite end of installation tool with lip of removable collar inside seal case (garter spring side faces tool), refer to FIGURE 3-92. FIGURE 3-92.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-93. Installing Protection Tube aj. Place governor arm (44, FIGURE 3-64) into Position in housing. Insert governor shaft (78) through hole in housing so knife edge mates with groove in governor arm, refer to FIGURE 3-94. NOTE Tighten nuts (76, FIGURE 3-64) successively 10 to 15 in-lbs (1.1 to 1.7 Nm). The nut on technician's right is torqued last. ak.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-95. Installing Weights NOTE The two deep grooves of sleeve (19, FIGURE 3-73) should face upward. Sight across tops of assembled weights. They should be level and collapsed against thrust sleeve. am. Insert governor thrust washer (20, FIGURE 3-73) and sleeve (19) into lower slots of weights (18) by tilting weights outward slightly, refer to FIGURE 3-96. FIGURE 3-96. Installing Thrust Washer and Sleeve an.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P CAUTION Exercise care not to insert head assembly too far into housing. Pushing head in too far will damage seal on hydraulic head and result in leakage. Ensure timing mark on drive corresponds with timing mark on rotor. aq. Grasp hydraulic head firmly in both hands and insert it into housing bore with a slight rotary motion. Do not force. If assembly should jam during insertion, withdraw and start over, refer to FIGURE 3-97.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P FIGURE 3-98. Installing Metering Valve aw. Pull back governor linkage hook (46, FIGURE 3-64), stretching spring (47) just enough to assemble hook correctly to fork on governor arm (44). Position opposite end of hook (46) over pin on arm of metering valve (45), refer to FIGURE 3-99. Check all governor parts for freedom of movement. FIGURE 3-99. Installing Governor Linkage ax.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P bc. bd. be. bf. bg. Insert control rod pin (4, FIGURE 3-67) into hole at end of control rod (5) and insert control rod into control rod guide (6). Install adjusting cap seal (3) into seal groove on adjusting cap (2). Align roll pin slot in adjusting cap (2) with control rod pin (4) at end of control rod and slide control rod into control rod guide (6).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-101. Alignment of Shutoff Arm bi. Install two new washers (22) and rubber seal rings (21) using suitable tool on throttle shaft (18) and shutoff lever shaft (30). Apply a light film of general purpose grease (630AA) to each seal. bj. Install throttle shaft assembly (18) partially through its bore in housing.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P bl. With throttle shaft assembly (18) in low idle position and governor control spring relaxed, forked end of throttle lever (19) should straddle and engage flats on bushing (10, FIGURE 3-67). Adjust low idle screw (39, FIGURE 3-64) until forks of lever make contact with flats on bushing. bm. Turn adjusting cap (2, FIGURE 3-67) counterclockwise (from transfer pump end) to end of adjustment, then turn clockwise 1/16 of a turn.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5P CAUTION Never back out low idle screw (38, FIGURE 3-64) or disengagement of throttle lever (19) from guide bushing could result. NOTE Clearance should be 0. 125 to 0. 145 inch (3. 175 to 3. 683 mm) ce. With throttle lever (19) held in wide open position, use linkage gage (18914) to check clearance between rear of shutoff shaft (30) and vertical tab on linkage hook (46), refer to FIGURE 3-103.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-104. Installing Shutoff Cam cj. Install two insulating tubes (85 and 86, FIGURE 3-64) on solenoid terminals. Position solenoid (16) in cover (6) and secure with two new insulator washers (15), one washer (14), one new lockwasher (13), and two nuts (12). ck. Position washer (11), new lockwasher (10), terminal strap (9), terminal (89), and insulator (90) on solenoid studs. Secure with two self-locking nuts (8).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-105. Installing End Cap NOTE Tighten locking screw (2, FIGURE 3-73) 70 to 80 in-lbs (8 to 9 Nm). co. Install new seal (4, FIGURE 3-73), retaining plate (3), and locking screw (2) in head, refer to FIGURE 3-106. FIGURE 3-106. Installing Retaining Plate NOTE Tighten plug (89, FIGURE 3-64) 110 to 115 in-lbs (12.4 to 13.0 Nm). cp. Install plug (89) and seal (90). cq.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-107. Installing Locking Head Bolts cr. Remove pump from holding fixture. cs. Install pilot tube seal (1, FIGURE 3-73) in mounting flange end of pump, refer to FIGURE 3-108. FIGURE 3-108. Installing Pilot Tube Seal 3-27.7. Testing. NOTE Test bench coupling should be of self aligning, zero backlash type. a. Install drive hub (67-3303). b. Ensure rotation of drive shaft on test stand is clockwise.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CAUTION If incorrect connector is used on the transfer pump inlet, damage to internal threads will occur. c. Install transfer pump inlet connector (67-5116). d. Install transfer pressure gage connector (21900). e. Install a shutoff valve to isolate gage when not in use. f. Remove timing line cover and install advanced indicator (23745) g. Energize electric shutoff device with 24 VDC at lowest speed. h.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 I. Operate pump at 500 pump rpm wide open throttle (WOT) for ten minutes or until temperature reaches 1100 F to 115°F (43.3°C to 46.1 °C). Completely dry pump off using compressed air. Observe for leaks and correct as necessary. CAUTION Never back out low idle screw or disengagement of throttle lever from guide bushing could result. m. Back out high idle screw. n. Close valve in fuel supply line.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 TABLE 3-4.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 TABLE 3-4.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 TABLE 3-4. Fuel Injection Pump Specifications - continued Refer to paragraph 3-27.6. w. Perform the following checks at pump rpm specified in TABLE 3-5. TABLE 3-5. Pump Checks NOTE Throttle position is at full load, wide open position (WOT).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-27.8. Installation. NOTE If engine front plate must be replaced, refer to paragraph 3-42.4. for transferring timing mark. No timing mark will be found on new front plate, a mark must be established and scribed. a. Using center bolt on harmonic balancer, rotate crankshaft until No. 1 piston is at TDC on compression stroke. Insert timing pin (JDE-81-4). b.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 e. If timing gear (6, FIGURE 3-109) was not removed from engine, slide injection pump (3) onto mounting studs while inserting pump shaft into timing gear. If timing gear was removed slide injection pump onto mounting studs. f. Install washers (9), lockwashers (8), and nuts (7) onto pump mounting studs and tighten finger-tight only at this time. NOTE Use the timing mark corresponding to the number of cylinders. g.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 o. Remove tags and connect electrical leads to injection pump. p. Connect negative cable to batteries. 3-28. FUEL INJFCTION PUMP TIMING. 3-28.1. Timing Using Flange Timing Mark. a. Check alignment of mark on pump flange with mark on front plate. NOTE If a timing mark does not exist on the front plate, use timing procedure in paragraph 3-28.2. b.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 j. Connect fuel return line and fuel supply line to pump. k. Connect throttle control system, refer to end item maintenance manual. 3-29. FUEL INJECTION NO7ZLE. 3-29.1. Removal. Warning Compressed air used for cleaning can create airborne particles that may enter the eyes. Pressure will not exceed 30 psig (207 kPa). Eye protection required.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-29.2. Cleaning. Warning Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate. a. Remove carbon stop seal (6, FIGURE 3-112) and upper sealing washer (7), using a needlenose pliers. Discard seal and washer. FIGURE 3-112. Fuel Injection Nozzle b.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-29.3. Testing. 3-29.3.1 General. Warning The nozzle tip should always be directed away from operator. Fuel from spray orifices can penetrate clothing and skin causing serious personal injury. Enclosing nozzle in a transparent cover is recommended. Warning Before applying pressure to nozzle tester, be sure that all connections are tight, and that fittings are not damaged. Fluid escaping from a very small hole can be almost invisible.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 b. Open gage valve and raise pressure to a point where gage needle falls rapidly. This is nozzle opening pressure, and should be a minimum of 3330 psi (23,000 kPa) for a used nozzle and 3650 to 3750 psi (25,100 to 25,800 kPa) for a new nozzle. c. If nozzle opening pressure is not within specified range, replace injector, refer to paragraph 3-29.4. 3-29.3.3 Chatter and Spray Pattern Test. a.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-29.4. Installation. 3-29.4.1 Install Seals On Nozzle. CAUTION Each time an injection nozzle is removed from cylinder head, replace carbon stop seal (6, FIGURE 3-112) with a new one. a. Position protector cap (1, FIGURE 3-113) over nozzle tip. A nozzle protector cap can be found on every new or replacement nozzle. b. Position a new carbon stop seal (2) on protector cap.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 c. Install nozzle (5) in cylinder head using a slight twisting motion as nozzle is seated in bore. d. Install bolt (4). Do not tighten bolt (4) at this time. CAUTION Always use two wrenches when loosening or tightening fuel lines at nozzles to avoid damage to equipment. e. Remove caps and connect fuel pressure line to nozzle. Leave connection slightly loose until air is bled from system. f.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 WARNING Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate. b. Drain all fuel from system, including fuel transfer pump, fuel injection pump, and fuel filter into suitable container. c. Securely plug off end of fuel return line.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section IX. CYLINDER HEAD ASSEMBLY MAINTENANCE 3-31. VALVE COVER. 3-31.1. Removal. a. Remove twelve bolts (1, FIGURE 3-114) securing valve cover (2); remove valve cover (2) and gasket (3). Discard gasket (3). b. Remove preformed packing (4). Discard packing (4). 3-31.2. Installation. NOTE Install gasket (3, FIGURE 3-114 dry (no sealant). a.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 b. Remove plastic plugs in engine timing holes. c. Using center bolt on harmonic balancer, rotate crankshaft clockwise until No. 1 piston is at TDC on compression stroke. NOTE If rocker arms for No. 1 cylinder are loose, engine is at No. 1 TDC compression. d. Valve clearance (rocker arm-to valve tip) is: (1) Intake Valve ...........................0.014 in. (0.35 mm) (2) Exhaust Valve .........................0.018 in. (0.45 mm) e.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-116. Checking Valve Clearance 3-32.2. Measure Valve Lift. Measuring valve lift can give an indication of excess wear on cam lobes, followers, and/or pushrods. CAUTION For a more accurate measurement, it is recommended that valve lift be measured at 0.00 inch (0.00 mm) rocker arm to-valve tip clearance. a. Remove valve cover, refer to paragraph 3-31.1. b.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE Refer to FIGURE 3-115 for engine valve locations. d. Place dial indicator tip on top of valve spring cap or rotator. Preload indicator tip and set dial at 0.00 inch (0.00 mm). e. Remove timing pin from flywheel and manually turn engine in running direction one full revolution (360 degrees). f. Observe dial indicator reading as valve is moved to full open. Record readings and compare with specifications given below. Intake Valves....
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 b. Remove twelve rocker arms (8), four supports (3), and three springs (9) from shaft (7). 3-33.3. Inspect and Measure. a. Inspect rocker arm shaft springs and measure spring tension. compressed height is 4 to 6 pounds (18 to 27 N). Spring tension at 1.81 inches (46 mm) NOTE If rocker arm has been damaged by a valve failure, replace it along with the corresponding pushrod, valve rotator, and keepers. FIGURE 3-118.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 c. Roll rocker arm shaft on a flat surface to check for bends or distortion. Replace shaft as necessary. d. Measure rocker arm shaft OD at each rocker arm location. New rocker arm shaft OD is 0. 787 to 0. 788 inch (19. 99 to 20. 02 mm). If rocker arm shaft OD is smaller than 0. 785 inch (19. 94 mm), install a new shaft. e. Inspect and measure each rocker arm shaft support ID. If ID is more than 0. 794 inch (20.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 a. Install pushrods (4, FIGURE 3-118) in same location from which they were removed. NOTE Valve stem tips are specially hardened, wear caps are not required. b. Position rocker arm assembly on engine. CAUTION Make sure that oil supply hole of rocker arm shaft (7) faces the flywheel end of engine and faces downward when rocker shaft is installed, to avoid engine damage. c.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 n. Remove cylinder head gasket (3), inspect for possible oil, coolant, or combustion chamber leaks. Also, check for evidence of incorrect or defective head gasket being used. CAUTON Do not rotate crankshaft with cylinder head removed unless all cylinder liners are secured with cap screws and large flat washers. o. Remove twelve cam followers from bores in engine block and tag them as to their location for assembly purposes. 3-34.2.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-119.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 b. Intake valve recess should be 0.024 to 0.044 inch (0.61 to 1.11 mm) with a maximum recess limit of 0.064 inch (1.63 mm). Exhaust valve recess should be 0.048 to 0.068 inch (1.22 to 1.72 mm) with a maximum recess limit of 0.089 inch (2.26 mm). c. If measurement exceeds maximum limit, install either new valves or inserts, or both to obtain proper valve recess. Grind valve seat inserts as required, refer to paragraph 3-34.4. 3-34.3.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-34.4. Inspection and Measure. Warning Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate. Warning Compressed air used for cleaning can create airborne particles that may enter the eyes. Pressure will not exceed 30 psig (207 kPa). Eye protection required. a.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CAUTION Any carbon left on the stem will affect alignment in valve refacer if valve needs to be refaced. Do not use a wire wheel on plated portion of valve stem. Polish the valve stems with steel wool or crocus cloth to remove any scratch marks left by wire brush. (4) Inspect valve stem tip for excess wear from rocker arm contact. NOTE Valve stem tips are specially hardened, therefore, wear caps are not required.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (1) Inspect all cylinder head passages for restrictions. Heads with restricted or clogged passages can be cleaned by soaking them in tank of hot caustic solution. (2) Scrape all old gasket material from head. Use a powered wire brush to clean sealing surfaces. (3) If cylinder head is not put in a chemical hot tank for cleaning, clean with solvent and a brush. Dry with compressed air and be sure to blow out all passages. g.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (5) Combustion face surface finish (surface grind only) should be 75AA minimum to 130AA maximum. Maximum wave depth should be 0.0005 inch (0.012 mm). j. Clean and measure valve guides as follows: (1) Use a plastic brush to clean valve guides before inspection or repair. NOTE A few drops of light oil or kerosene will help to fully clean the guide. (2) Using a telescopic gage, measure valve guides for wear.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (1) Select a 0. 3125 inch (7. 9 mm) arbor that will extend approximately 2. 754 inches (6. 9 cm) above the valve seat. Wipe the arbor stem with an oily cloth and insert into the valve stem guide. (2) Select a 30 degree angle, 1. 75 inch (4. 4 cm) grinding stone which is in good condition and install the stone in the hex drive. (3) Carefully lower the stone and hex drive unit on the arbor until the stone almost contacts the seat.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE If valve with an oversize stem is to be used, an oversize valve seat insert must be installed. (1) Use pilot driver (JDG-676) and valve seat insert installing adapter (JDG-675) to install valve seat inserts (10 and 11) in cylinder head (2). (2) Use one end of adapter (JDG-675) to install intake valve seat inserts and the other end to install exhaust valve seat inserts.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Exhaust Valve Seat Insert Bore Specifications: A................................ ........................... 1.6570 to 1.6934 inches (42.087 to 43.013mm) B................................ ................................ ...................0.150 inch (3.82 mm) Reference C................................ ................................ .0.3557 to 0.3962 inch (9.036 to 10.064 mm) D................................ ........................
ARMY TM 9281 5-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 WARNING Compressed air used for cleaning can create airborne particles that may enter the eyes. Pressure will not exceed 30 psig (207 kPa). Eye protection required. (2) Use compressed air to remove all loose foreign material from cylinders and top deck. (3) Remove cam followers from block. Wash in solvent. Lubricate with clean engine lubricating oil (MIL-L-2104) and reinstall in the same bore from which removed.
ARMY TM 9-2815-25624 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-34.7. Installation. a. Perform procedures in paragraph 3-34.6. b. Place new cylinder head gasket (3, FIGURE 3-119) on cylinder block. Do not use sealant; install dry. CAUTION Without guide studs, viton O-ring seal bonded in cylinder head gaskets (at rocker arm lube oil passage) could become damaged if cylinder head requires repositioning on engine block to align capscrew holes. c.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE Retorque of cylinder head cap-screws after engine break-in is not required when using the recommended torque procedure along with specified flanged-head capscrews. i. Install pushrods and rocker arm assembly, refer to paragraph 3-33.5. j. Install valve cover, refer to paragraph 3-31.2. k. Install fuel injectors, refer to paragraph 3-29.4. I. Install fuel injector piping, refer to paragraph 3-26.3. m.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section X. FLYWHEEL AND HOUSING ASSEMBLY MAINTENANCE 3-35. FLYWHEEI. 3-35.1. Removal. a. Remove starter, refer to paragraph 3-12.2. WARNING Flywheel is heavy. Provide adequate lifting device to support weight. Failure to follow this procedure could result in personal injury. b. Remove two capscrews (1, FIGURE 3-125) and washers (2). Replace these with two guide studs. c. Remove other two capscrews (1) and washers (2).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 WARNING Oil fumes or oil can ignite above 380° F (193°C). Use a thermometer and do not exceed 360°F (182°C). Do not allow a flame or heating element to be in direct contact with oil. Heat oil in a well ventilated area. Plan a safe handling procedure to avoid bums. WARNING Wear protective gloves to help prevent burns from handling hot ring gear (4). CAUTION If flame heat is used, be sure gear is heated uniformly around circumference.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-125. Flywheel and Housing Assembly c. Start two capscrews (1) and washers (2) in crankshaft. Do not tighten until guide studs are removed and other two capscrews (1) and washers (2) are started. d. Install timing pin (JDE-81-4) to hold flywheel in place while tightening capscrews. e. Tighten capscrews (1) to 120 ft-lbs (163 Nm). f. Install starter, refer to paragraph 1-12.7. 3-36.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CAUTION Do not gouge flange of crankshaft with chisel. Nicks or burrs should be removed with a medium grit stone or polishing cloth (180 grit or finer). d. Carefully cut wear sleeve off crankshaft flange using a small cold chisel. WARNING Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 a. Remove flywheel, refer to paragraph 3-35.1. b. Remove oil seal/wear sleeve (5, FIGURE 3-125), refer to paragraph 3-36.1. c. Support weight of flywheel housing (8) and remove eight 3/8-inch capscrews (6) and four 5/8-inch capscrews (7) securing housing to engine block; remove housing (8) and gasket (9). Discard gasket (9). 3-37.2. Inspect and Measure. a. Inspect flywheel housing for cracks or other damage. b.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section XI. CRANKSHAFT PULLEY AND TIMING GEAR COVER ASSEMBLY MAINTENANCE 3-38. CRANKSHAFT PULLEY. 3-38.1. Removal. a. Remove fan drive belt, refer to end item maintenance manual. b. Remove fan, refer to end item maintenance manual. c. Remove capscrew (1, FIGURE 3-126) and washer (2) securing crankshaft pulley (3). d. Using suitable puller, remove pulley (3) from crankshaft. Remove key (4). FIGURE 3-126. Crankshaft Pulley 3-38.2.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 c. Remove water pump, refer to paragraph 3-10.1. d. Remove battery charging alternator and alternator mounting bracket, refer to paragraph 3-11.1. e. Remove oil fil ler assembly, refer to paragraph 3-18.1. f. Remove oil cooler hoses and mounting bracket, refer to paragraph 3-16.1. g. Remove crankshaft pulley, refer to paragraph 3-38.1. h. Remove gasket between timing gear cover and oil pan. i.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-127. Timing Gear Cover NOTE Seal case has dry sealant, do not add sealant. c. Support back side of timing gear cover with wood blocks. d. Using a seal installer, install oil seal (5) to bottom of bore with spring loaded lip facing inward while supporting seal bore area from back side of cover. e. Make sure gasket surfaces on cover (6) and front plate are clean.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CAUTION Do not invert crankshaft front oil seal main (inner) lip. Make sure that this seal lip faces inward towards crankcase to prevent oil leakage. Dust lip (outer) faces installer away from crankcase. h. Install timing gear cover (6) on engine. i.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section XII. CAMSHAFT ASSEMBLY MAINTENANCE 3-40. CAMSHAFT. 3-40.1. Removal. NOTE Measuring valve lift can give an indication of wear on cam lobes or cam followers. a. Measure valve lift, refer to paragraph 3-32.2. b. Remove rocker arm assembly and pushrods, refer to paragraph 3-33.1. c. Remove timing gear cover, refer to paragraph 3-39.1. d. Measure camshaft end play, refer to paragraph 3-40.2. e.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-128. Camshaft i. Pull camshaft (3) straight up, out of cylinder block. Remove thrust plate (4). j. If necessary, remove gear (5) from camshaft (3) using an arbor press. Remove key (6). 3-40.2. Inspect and Measure.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 a. Measure camshaft end play as follows: (1) Use a dial indicator and measure camshaft end play, refer to FIGURE 3-109. New camshaft end play is 0.002 to 0.009 inch (0.05 to 0.23 mm). Maximum allowable end play is 0.015 inch (0.38 mm). NOTE If end play is excessive, check thrust plate thickness using a newthrust plate and a feeler gage after camshaft is removed, refer to step c.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 c. Measure camshaft thrust plate clearance as follows: NOTE Thrust plate clearance determines camshaft end play. (1) Check thrust plate clearance using a feeler gage, refer to FIGURE 3-130. (2) New part clearance is 0.003 to 0.009 inch (0.08 to 0.23 mm). Maximum allowable clearance is 0.015 inch (0.38 mm). Replace parts as necessary. FIGURE 3-130. Measuring Thrust Plate Clearance d.
ARMY TM 9-2815-25624 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (2) Intake lobe should be 0.273 to 0.292 inch (6.93 to 7.42 mm), with a minimum acceptable lobe height of 0.263 inch (6.68 mm). (3) Exhaust lobe should be 0.266 to 0.286 inch (6.76 to 7.26 mm), with a minimum acceptable lobe height of 0.256 inch (6.50 mm) FIGURE 3-132. Measuring Camshaft Lobe Sight f. Inspect cam followers in accordance with instructions in paragraph 3-34.4. 3-40.3. Installation. a.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE Use the timing mark corresponding to the number of cylinders. (3) Install upper idler gear (3, FIGURE 3-134) on its shaft without turning camshaft gear (5) or injection pump gear. (4) Install washer (2) so hole and spring pin align. Install capscrew (1). Tighten capscrew (1) to 65 ft-lbs (90 Nm). FIGURE 3-133. Aligning Timing Mark and Camshaft Gear (5) Recheck gear timing to make sure it is still correct. h.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section XIII. IDLER GEARS AND FRONT PLATE ASSEMBLY MAINTENANCE 3-41. IDLER GEARS AND SHAFTS 3-41.1. Removal. a. Remove timing gear cover, refer to paragraph 3-39.1. b. Remove oil pan, refer to paragraph 3-20.1. c. Remove front crankshaft sleeve bearing (8, FIGURE 3-137), preformed packing (9), and dirt deflector (10). d. Measure idler gear end play, refer to paragraph 3-41.2. e.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-134. Idler Gears c. Measure sleeve bearing ID. New part ID is 1.751 to 1.753 inches (44.47 to 44.54 mm). d. Measure shaft OD. New part OD is 1.750 to 1.751 inches (44.44 to 44.47 mm). e. Oil clearance (sleeve bearing ID to shaft OD) should be 0.001 to 0.004 inch (0.02 to 0.10 mm). Maximum wear limit is 0.006 inch (0.15 mm). If oil clearance exceeds limit, replace worn parts. 3-41.3. Installation. a.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-135. Spring Pin Protrusion CAUTION Upper and lower idler gear sleeve bearings (4 and 12, FIGURE 3-134) have the same ID, but are different. Sleeve bearing with spiral oil groove goes in lower idler gear. Sleeve bearing without groove goes in upper idler gear (pressure lubed). Do not intermix sleeve bearings or premature sleeve bearing failure will result. d.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-136. Front Plate 3-42.2. Inspection. WARNING Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate. WARNING Compressed air used for cleaning can create airborne particles that can enter the eyes. Pressure will not exceed 30 psig (207 kPa). Eye protection required.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 a. Remove all old gasket material from front plate and engine block. b. Clean plate with solvent and dry with compressed air. Wipe front face of engine block with a cleaning cloth. Be sure gasket surface on engine block is clean. c. Inspect front plate for wear or damage. Replace if necessary. 3-42.3. Replacement. NOTE New replacement front plates do not have a timing mark for the fuel injection pump.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 e. f. g. h. i. Install idler gears, refer to paragraph 3-41.3. Install oil pump and drive gear, refer to paragraph 3-21.3. Install fuel injection pump and drive gear, refer to paragraph 3-27.8. Install camshaft, refer to paragraph 3-40.3. Install timing gear cover, refer to paragraph 3-39.3.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section XIV. CRANKSHAFT AND MAIN BEARINGS MAINTENANCE 3-43. CRANKSHAFT AND MAIN BEARINGS. 3-43.1. a. b. c. d. e. f. Removal. Check crankshaft end play, refer to paragraph 3-43.2. Remove oil pan, refer to paragraph 3-20.1. Remove oil pump, refer to paragraph 3-21.1. Remove rocker arm assembly, pushrods, and cam followers, refer to paragraph 3-33.1. Remove front plate, refer to paragraph 3-42.1.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 WARNING Crankshaft is very heavy, do not attempt to remove crankshaft by hand. equipment. Use proper lifting NOTE Use of bearing gage will determine wear, but will not determine condition of either bearing or journal. k. Attach a nylon sling (or other suitable lifting sling) to journals of crankshaft (7). NOTE An alternate method of attaching sling is to install a capscrew on both ends of crankshaft and attach sling to screws. I.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-137. Crankshaft and Main Bearings n. If bearings (5 and 6) are to be replaced, remove inserts from engine block. Otherwise, leave bearing inserts in block until assembled ID has been measured. o. Remove sleeve bearing (8), preformed packing (9), and dirt deflector (10) from front end of crankshaft. p. Using an arbor press and gear puller, pull gear (11) from crankshaft (7). Remove key (12) from crankshaft. 3-43.2.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 WARNING Compressed air used for cleaning can create airborne particles that may enter the eyes. Pressure will not exceed 30 psig (207 kPa). Eye protection required. a. Inspect gear for wear or damage. b. Check crankshaft end play as follows: NOTE It is recommended that crankshaft end play be measured prior to removing crankshaft to determine condition of thrust bearings. Crankshaft end play may also be checked at front end of crankshaft.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE When inspecting crankshaft for cracks, a method (such as the Fluorescent Magnetic Particle Method) must be used that is capable of detecting minute cracks that are not visible to the eye. This method magnetizes the crank, employing magnetic particles which are fluorescent and glow under black light. Replace crankshaft if cracks are found. The crankshaft must be demagnetized after the test.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-962 MARINE CORPS TM 2815-24/5 (4) Measure width of thrust bearing using an outside micrometer. FIGURE 3-139. Measuring Main Thrust Journal and Thrust Bearing Width (5) New main thrust bearing width (standard size) is 1.528 to 1.530 inches (38.80 to 38.85 mm) (6) New main thrust bearing clearance (thrust journal width minus thrust bearing width) is 0.002 to 0.008 inch (0.05 to 0.20 mm). (7) Maximum allowable thrust bearing clearance is 0.015 inch (0.38 mm).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CAUTION A piston cooling orifice failure could cause damage to pistons, piston pins, rod pin bushings, and liners. If a piston cooling orifice is left out of block during assembly, low or no oil pressure will result. (3) Install all the orifices and tighten to 84 in-lbs (10 Nm). 3-43.3. Repair. If crankshaft is to be reground, use following recommended guidelines.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 d. Care must be taken to avoid localized heating which often produces grinding cracks. Use coolant generously to cool crankshaft while grinding. Do not crowd grinding wheel into work. e. Polish or lap (counterclockwise) ground surfaces to specified finish. Reground journals will be subject to excessive wear unless polished smooth.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (2) Install key (12) in crankshaft (7) slot, and using driver (JDH-7), drive heated gear (11) onto crankshaft. b. Install main bearing (6) inserts. Make sure that tang on inserts is engaged with slot in engine block and main bearing caps. Also make sure that oil holes line up with oil passages in block. CAUTION If new thrust bearing inserts or thrust bearing washers are installed, they must be installed as a set. c. d. e. f.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 I. m. n. o. p. q. Check crankshaft for specified end play, refer to paragraph 3-43.2. Install flywheel housing, refer to paragraph 3-37.3. Install front plate, refer to paragraph 3-42.5. Install rocker arm assembly, pushrods, and cam followers, refer to paragraph 3-33.5. Install oil pump, refer to paragraph 3-21.3. Install oil pan, refer to paragraph 3-20.3.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-2415 Section XV. PISTONS, CONNECTING RODS, CYLINDER LINERS, AND ENGINE BLOCK MAINTENANCE 3-44. REMOVAL. 3-44.1. Pistons and Connecting Rods. WARNING Compressed air used for cleaning can create airborne particles that may enter the eyes. Pressure will not exceed 30 psig (207 kPa). Eye protection required. a. b. c. d. e. Drain coolant and lubrication system, refer to end item maintenance manual.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-141. Removing Carbon From Cylinder Liner h. Before removing pistons, visually inspect condition of cylinder liners with pistons at bottom dead center (BDC). Liners will require replacement if: (1) The crosshatch honing pattern is not visible immediately below the top ring turn around area. (2) Liners are pitted or contain deep vertical scratches that can be detected by the fingernail.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CAUTION Once piston rings have cleared cylinder liner (9), hold on to piston to prevent piston from dropping. 3-44.2. Cylinder Liner. a. Measure cylinder liner height, refer to paragraph 3-46.3., step d. b. Remove capscrews (1, FIGURE 3-140) and washers (2) securing liners (3) to engine block. c. Number cylinder liners (9, FIGURE 3-143) and pistons (7). Stamp front of liner to assure correct assembly.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-143.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-144. Use of Cylinder Liner Puller e. Remove cylinder liner O-rings (10, FIGURE 3-143) from grooves in engine block. Also remove packing (11) from cylinder liner (9), refer to FIGURE 3-145. Discard O-rings and packing. FIGURE 3-145. Cylinder Liner O-Rings and Packing 3-45. DISASSFMBLY. 3-45.1. Engine Block. If complete disassembly of block is required and the following has not been removed, proceed with the following. a. b. c.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 e. f. g. h. i. j. k. Remove camshaft, refer to paragraph 3-40.1. Remove engine front plate and oil bypass valve, refer to paragraphs 3-42.1. and 3-22.1. Remove crankshaft and main bearings, refer to paragraph 3-43.1. Remove pistons and liners, refer to paragraph 3-44.1. and 3-44.2. Remove piston cooling nozzles (13, FIGURE 3-146). Remove water galley plugs, refer to FIGURE 3-146.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-146. Engine Block CAUTION Do not use gasoline, kerosene, or commercial solvents to clean liners. Solvents will not remove all the abrasives from liner walls. e. f. g. h. i. j. k. Thoroughly clean liner ID with a 50 percent solution of hot water and liquid detergent. Rinse thoroughly and wipe dry with a clean, dry rag. Swab out liner as many times as necessary with clean SAE 10W engine lubricating oil (MIL-L-2104).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-147. Piston Inspection I. If the original machining marks are not visible, or the piston skirt is worn to depth of original machining marks, replace both piston and liner. If any defects are found, replace piston and liner as a matched set. If no defects are found, proceed to next step. m. Check top ring groove using a new piston ring and feeler gage, refer to FIGURE 3-148. Ring groove clearance must not exceed 0.008 inch (0.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-149. Checking Piston Pin Clearance q. Check piston pin and piston bore specifications. If either are not within specification, replace pin and/or piston/liner set. (1) Piston large pin OD should be 1.624 to 1.625 inches (41.27 to 41.28 mm). (2) Piston pin OD wear tolerance is 0.005 inch (0.13 mm). (3) Piston bore for large pin should be 1.625 to 1.626 inches (41.28 to 41.30 mm).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-2415 FIGURE 3-150. Inspecting Cylinder Liner Pitting s. Carefully examine cylinder liner for signs of fatigue, such as fine cracks in flange area (A, FIGURE 3-151) and cracks in the ring travel area (B). If any defects are found, replace the piston and liner. If no defects are found, proceed to next step. If pistons and liners have passed all previous checks, proceed to check both for proper specifications, listed in steps t and u.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE Inspect block for cracks or erosion in O-ring packing area. Replace block if any of these defects are found. t. Measure piston skirt (A, FIGURE 3-152) 90 degrees to piston pin bore and 0.74 inch (19 mm) from bottom of piston (B). Record measurement. OD should be 4.188 to 4.189 inches (106.38 to 106.40 mm) FIGURE 3-152. Measuring Piston Skirt u.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-153. Measuring Piston to Liner Clearance (6) Turn piston 90 degrees in liner. Use a feeler gage to measure clearance between piston skirt and liner 90 degrees to piston pin bore. Record the measured clearance. (7) The difference between the two measurements in steps (5) and (6) is the amount the liner is out of roundat the top of the liner. (8) If liner is out of round more than 0.002 inch (0.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 NOTE Use bearing gage (PLASTIGAGEPR1) as directed by manufacturer. Remember, use of bearing gage will determine bearing to journal clearance, but will not indicate the condition of either surface. (1) Remove connecting rod cap. Place a piece of bearing gage (PLASTIGAGEPR1) in center of bearing. Install cap and initially tighten old capscrews to 41 ft-lbs (56 Nm). Tighten capscrews an additional 90 to 100 degrees, refer to paragraph 3-49.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (c) At 45 degrees right of measurement step (a). (d) Rod bore ID should be 2.900 to 2.901 inches (73.66 to 73.69 mm). (7) Compare measurements. If difference between greatest and least measurement is more than 0.0015 inch (0.038 mm), rod and cap are out of round. Replace both connecting rod and cap. d. Inspect piston pins and bushings as follows: (1) Visually inspect piston pin for general overall condition.
ARMY TM 9-2815-25624 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (5) Using driver (JD286), install bushing (12) in connecting rod (4). If required, hone bushing to obtain piston . pin clearance of 0.0008 to 0.0024 inch (0.02 to 0.06 mm). 3-46.3 Engine Block. Warning Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged contact. Good general ventilation is normally adequate.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-9-2 MARINE CORPS TM 2815-24/5 CAUTION A piston cooling nozzle failure could cause damage to pistons, piston pins, rod pin bushings, and liners. If a piston cooling-nozzle is left out at assembly, low or no oil pressure will result. CAUTION If engine block is cleaned in a hot tank, be sure to remove any aluminum parts (such as nameplates). Aluminum parts can be damaged or destroyed by hot tank solutions.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 (2) Thoroughly clean all corrosion and lime deposits from -ring bore. c. Measure cylinder block as follows: (1) Measure main bearing bore diameter, refer to FIGURE 3-157. Main bearing bore diameter must be 3.325 to 3.326 inches (84.46 to 84.48 mm). (2) Measure engine block main thrust bearing width. Width must be 1.3235 to 1.3275 inches (33.62 to 33.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-9-2 MARINE CORPS TM 2815-24/5 FIGURE 3-159. Measuring Camshaft Bore Diameter (6) Measure cylinder block top deck flatness using precision straightedge, refer to FIGURE 3-160. flatness is 0.003 inch (0.08 mm). If flatness is not as specified, resurface engine block. FIGURE 3-160.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 d. Measure cylinder liner height as follows: NOTE If liner height was not checked when liners were removed, refer to paragraph 3-34.6., step e, or a new liner is being installed in a new or used cylinder block, liner height must be checked. (1) Be sure liner bore in cylinder block is clean. (2) Install liners without -rings and packing. CAUTION Liner should rotate smoothly by hand when installed.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-161. Location of Cylinder Liner Shim (3) Use deglazer, to deglaze liner and obtain a 45 degree cross hatch pattern, refer to FIGURE3-163. FIGURE 3-162. Deglazed 45 Degree Cross Hatch Pattern (a) Chuck deglazer in a 1/2 inch slow speed drill. (b) Apply honing oil (MB-30) into cylinder liner. Insert deglazer into cylinder liner. (c) Move deglazer in an up and down direction 10 to 12 complete strokes per cylinder.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-48. 3-48.1. ASSEMBLY. Piston and Rod. a. Connect piston (7, FIGURE 3-143) to connecting rod (4) as follows: CAUTION If a new piston and liner assembly is to be installed, do not remove piston from liner. Push piston out of liner bottom only far enough to install piston pin. (1) Lubricate piston pin (6) and piston pin bore with clean engine lubricating oil (MIL-L-2104).
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-2415 b. Install new piston rings (8, FIGURE 3-143) as follows: (1) Using piston ring expander, install oil ring expander in bottom ring groove. Position end gap over either end of piston pin. (2) Install oil control ring in bottom ring groove over ring expander. Install with end gap on opposite side of piston from ring expander gap. NOTE A dye stain is added to rectangular and keystone compression rings for added identification.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 3-49. INSTALLATION. 3-49.1. General. NOTE Always install a new (matched set) liner when replacing a piston. Distance from top of piston to top of keystone ring groove is 0.158 inch (4 mm). CAUTION Do not stamp top of high ring piston. Piston can be damaged. NOTE New rings are furnished with the correct end gap; therefore, fitting to the liner is not necessary. 3-49.2. Cylinder Liners.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CAUTION Make sure packing is not twisted, otherwise poor sealing and equipment damage will occur. FIGURE 3-166. Location of Cylinder Liner Square Packing e. Slide packing down firmly against shoulder on liner. f. Coat liner packings (A and B, FIGURE 3-165), sealing area of the cylinder liner and engine block packing (A, FIGURE 3-166) with liner lubricant. g.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 k. Clean cylinder liner bores with waterless hand cleaner after installation. I. Wipe dry with clean towels. m. Apply a thin coat of clean engine lubricating oil (MIL-L-2104) immediately to ID of liners to prevent corrosion. 3-49.3. Pistons and Connecting Rods. a. Ensure piston ring gaps are staggered as described in paragraph 3-48.1., and as shown on FIGURE 3-167. b.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-168. Installing Connecting Rod Bearing f. Install other bearing insert in connecting rod cap with tang (A, FIGURE 3-169) in groove (B). Put clean engine lubricating oil (MIL-L-2104) on insert. FIGURE 3-169. Installing Connecting Rod Cap Bearing g. Install cap on connecting rod with tangs (A, FIGURE 3-170) to same side. FIGURE 3-170.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 CAUTION Never use connecting rod capscrews (1, FIGURE 3-123) more than once for final engine assembly. h. Dip new connecting rod capscrews (1) air clean engine lubricating oil (MIL-L-2104) and install. capscrews alternately to 41 ft-lbs (56 Nm). Tighten i. Torque-tum all capscrews 90 to 1 00 degrees as follows: (1) After tightening capscrews (1) to the values given above, mark connecting rod cap (A, FIGURE 3-171) and socket.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE 3-172. Measuring Piston Protrusion l. Install oil pump and outlet tube, refer to paragraph 3-21.3. m. Install oil pan, refer to paragraph 3-20.3. n. Install cam followers, refer to paragraph 3-34.7. o. Install cylinder head, refer to paragraph 3-34.7. p. If engine was completely disassembled, perform steps r through ad of paragraph 3-34.2.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 APPENDIX A REFERENCES A-1 SCOPE. This appendix lists all forms, field manuals, technical manuals and miscellaneous publications references in this manual. A-2 FORMS. Air Force Reporting of Errors Form ................................ ................................ ................................ .......AFTO Form 22 MarineCorps Reporting of Errors Form ................................ ................................ ..............
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 APPENDIX B MAINTENANCE ALLOCATION CHART Section I. INTRODUCTION B-1 THE ARMY MAINTENANCE SYSTEM MAC . a. This introduction (section I) provides a general explanation of all maintenance and repair functions authorized at various maintenance levels under the standard Army Maintenance System concept. b.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 i. Repair. The application of maintenance services1 including fault location/troubleshooting2, removal/installation, and disassembly/assembly3 procedures, and maintenance actions4 to identify troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), end item, or system. j. Overhaul.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 d. Column 4 Maintenance Level. Column 4 specifies, by the listing of a work time figure in the appropriate subcolumn(s), the level of maintenance authorized to perform the function listed in Column 3. This figure represents the active time required to perform that maintenance function at the indicated level of maintenance.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section II. MAINTENANCE ALLOCATION CHART FOR DIESEL ENGINE MODEL 6059T (1) (2) (3) GROUP NUMBER COMPONENT/ ASSEMBLY MAINTENANCE FUNCTION 00 0100 0101 0102 0200 0201 0202 0300 0301 0302 0400 ENGINE ASSEMBLY 60KW COOLING SYSTEM THERMOSTAT AND HOUSING WATER PUMP (4) MAINTENANCE LEVEL UNIT DS DS DEPOT C O F H D INSPECT SERVICE TEST ADJUST REPAIR R/I REPLACE OVERHAUL .2 .3 INSPECT SERVICE REPAIR .1 .2 REMARKS 2.0 4.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section II. MAINTENANCE ALLOCATION CHART FOR DIESEL ENGINE MODEL 6059T (1) (2) (3) GROUP NUMBER COMPONENT/ ASSEMBLY MAINTENANCE FUNCTION 0401 0402 0403 0404 0405 0406 0500 0501 0502 0503 0504 OIL FILTER COOLER, LUBRICATING 1 INSPECT R/I REPLACE .1 1.0 1.0 1,5 1,5 OIL PAN INSPECT R/I REPLACE FUEL SYSTEM FUEL FILTER FUEL SUPPLY PUMP FUEL LINES FUEL INJECTION PUMP TOOLS AND EQUIP. .1 .
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section II. MAINTENANCE ALLOCATION CHART FOR DIESEL ENGINE MODEL 6059T (1) (2) (3) GROUP NUMBER COMPONENT/ ASSEMBLY MAINTENANCE FUNCTION 0505 0600 0601 0602 0603 0604 0700 0701 0702 0800 0900 FUEL INJECTION NOZZLE ASSEMBLY CYLINDER HEAD ASSEMBLY (4) MAINTENANCE LEVEL UNIT DS DS DEPOT C O F H D INSPECT TEST R/I REPLACE .1 .1 .5 2.0 2.0 (5) TOOLS AND EQUIP.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section II. MAINTENANCE ALLOCATION CHART FOR DIESEL ENGINE MODEL 6059T (1) (2) (3) GROUP NUMBER COMPONENT/ ASSEMBLY MAINTENANCE FUNCTION 0901 1000 1001 (4) MAINTENANCE LEVEL UNIT DS DS DEPOT C O F H D CRANKSHAFT FRONT OIL SEAL INSPECT REPLACE SHORT BLOCK ASSMEBLY INSPECT R/I REPLACE REPAIR .5 10.0 10.0 20.0 INSPECT ADJUST TEST R/I REPLACE REPAIR .2 .5 .5 4.5 4.5 .5 CAMSHAFT ASSEMBLY .1 .5 (5) TOOLS AND EQUIP.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section II. MAINTENANCE ALLOCATION CHART FOR DIESEL ENGINE MODEL 6059T (1) (2) (3) GROUP NUMBER COMPONENT/ ASSEMBLY MAINTENANCE FUNCTION 100503 1006 1007 PISTON PIN CYLINDER LINER CYLINDER BLOCK (4) MAINTENANCE LEVEL UNIT DS DS DEPOT C O F H D (5) TOOLS AND EQUIP. INSPECT TEST R/I REPLACE .2 .5 11.0 11.0 4 1,4 1, 4 INSPECT TEST R/I REPLACE REPAIR .2 .5 12.0 12.0 13.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS FOR DIESEL ENGINE MODEL 6059T TOOL OR TEST EQUIPMENT MAINTENANCE REF CODE LEVEL NOMENCLATURE NATIONAL NATO STOCK NUMBER TOOL NUMBER 1 O SHOP EQUIPMENT, AUTOMOTIVE MAINTENANCE AND REPAIR: ORGANIZATIONAL MAINTENANCE COMMON NO.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS FOR DIESEL ENGINE MODEL 6059T - Continued TOOL OR TEST EQUIPMENT MAINTENANCE REF CODE LEVEL NOMENCLATURE NATIONAL NATO STOCK NUMBER TOOL NUMBER 25 H DRIVER, BUSHING JD-286 26 F ADAPTER, COMPRESSION GAGE JT01679 27 F HOLDING CLAMP, COMPRESSION GAGE ADAPTER JT02017 28 F GEAR PULLER JDG670 29 H CAP SOCKET 30 H DRIVER HUB 67-3303 31 H PRESSURE GAGE CONNECTOR 21900
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST Section I. INTRODUCTION C-1 SCOPE. This appendix lists expendable/durable supplies and materials you will need to operate and maintain the engine: These items are authorized to you by CTA 50-970, Expendable/Durable Items (except medical, class V repair parts, and heraldic items). C-2 EXPLANATION OF COLUMNS. a. Column 1. Item number.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 SECTION II.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 APPENDIX D FABRICATION OF TOOLS FIGURE D-1.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 FIGURE D-2.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 10 inches (254.0 mm) 5 inches (127.0 mm) 1.5 inches (38.1 mm) 16 inches (405.4 mm) 13 inches (330.2 mm) 0.38 inch (9.52 mm) 0.5 inch (12.7 mm) 1.25 inches (31.8 mm) 2.5 inches (63.5 mm) 1.0 inches (25.4 mm) 0.25 inch (6.35 mm) 6.0 inches (152.4 mm) 0.328 inch drill through 5/16 inch - 18 tap 2 used 12.0 inches (304.8 mm) 5/16 inch - 18 tap 2.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Appendix E. MAINTENANCE PROCEDURE AND AUTHORIZED LEVEL OF MAINTENANCE Section I. INTRODUCTION SCOPE. This appendix shall be used when a Commercial Off The Shelf (COTS) manual is used by the Military services. This appendix is divided into three sections. Section I gives a brief description of the sections within this appendix. Section II list the paragraphs to the associated maintenance level.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 Section II. PARAGRAPH TO MAINTENANCE LEVEL - Cont. Paragraph 3-31 3-32 3-33 3-34 3-35 3-36 3-37 3-38 3-39 3-40 3-41 3-42 3-43 3-44 3-45 3-46 3-47 3-48 3-49 Maintenance Level F F F F F F F F F F F H H H H H H H H Section III.
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-2415 INDEX PAGE A After Engine Installation Testing................................ ................................ ................................ ................ 3-137 Allocation Chart, Maintenance................................ ................................ ................................ ................... B-1 Alternator, Battery Charging................................ ................................ ...........................
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 INDEX - Continued PAGE D Description, Detailed................................ ................................ ................................ ................................ . 1-2 Destruction of Army Materiel to Prevent Enemy Use ................................ ................................ ................. 1-1 Detailed Description................................ ................................ ................................
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-2415 INDEX Continued PAGE G Gear Cover, Timing ................................ ................................ ................................ ................................ .. 3-164 Gears and Shafts, Idler ................................ ................................ ................................ ............................. 3-174 General Cooling System Maintenance................................ ................................
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 INDEX - Continued PAGE M Main Bearings, Crankshaft and ................................ ................................ ................................ ................. 3-180 Maintenance Allocation Chart................................ ................................ ................................ .................... B-1 Maintenance Forms, Records, and Reports................................ ................................ ......
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 INDEX - Continued PAGE P- Continued Procedures PMCS ................................ ................................ ................................ ................................ ....................... 3-1 Troubleshooting ................................ ................................ ................................ ................................ ........ 3-2 Pulley, Crankshaft................................ .................
ARMY TM 9-2815-256-24 AIR FORCE TO 38G1-96-2 MARINE CORPS TM 2815-24/5 INDEX - Continued PAGE T Test Engine Compression Pressure................................ ................................ ................................ ........... 3-18 Testing, After Engine Installation................................ ................................ ................................ ............... 3-137 Thermostat and Housing................................ ................................ .........................
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