TM-9-2815-255-24 Diesel Engine Model C-240PW-28 4 Cylinder 2.4 Liter Manual

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TM-9-2815-254-24P Diesel Enigine 2815-01-350-2208 Model DN4M-1 Four Cylinder Four Cycle Fuel Injected Manual

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TM-9-2815-255-24P Diesel Enigine 2815-01-350-2207 Model C-240 PW-28 Four Cylinder Four Cycle Fuel Injected Manual

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Tm-9-2815-255-24

Chapter 1 Introduction
1-8. Detailed Description
Figure 1-1. Engine Components
Table 1-1. Table Of Specifications
Chapter 2 Operation
Chapter 3 Maintenance
Section Ii. Troubleshooting
Table 3-2. Troubleshooting
4. Engine Hard To Start Or Will Not Start In Cold Weather
5. Engine Misfires Or Runs Irregularly Or Stalls Frequently
6. Engine Does Not Develop Full Power
8. Execessive Oil Consumption.
9. Low Oil Pressure -Cont
10. Excessive Fuel Consumption
11. Black Or Gray Smoke
12. Blue Exhaust Smoke
14. Engine Makes Abnormal Noise
15. Engine Makes A Gas Leaking Noise.
17. Battery Charger Ammeter Shows No Charge When Batteries Are Low.
Section Iii. General Maintenance
3-4. Disassembly And Assembly Sequence For Overhaul
3-4.2. Assembly
3-5. Test Engine Compression Pressure.
3-6. Measure Engine Blow-By.
Section Iv. Cooling System Maintenance
C. Remove Two Capscrews
Figure 3-2. Thermostat And Housing
3-9.4. Installation.
310. Water Pump
Figure 3-4. Water Pump Assembly
Section V. Electrical System Maintenance
Figure 3-5. Battery Charging Alternator And Mounting Brackets
3-11.4. Inspection.
Figure 3-6. Battery Charging Alternator Assembly
Figure 3-7. Stator And Rear Housing Separation
Figure 3-9. Testing Diode-Trio
Figure 3-11. Testing Stator Windings
B. Install Front Bearing Retaining Screws
Figure 3-13. Battery Charging Alternator Test Circuit
3-12.2. Removal
Figure 3-14. Starter Bench Test Setup
Figure 3-15. Starter Assembly
Figure 3-16. Removing Brush Holder Assembly
Figure 3-18. Starter Solenoid Test Circuit
Figure 3-19. Testing For Grounded Windings
Figure 3-22. Checking Field Coils
3-12.7. Installation.
Section Vi. Intake And Exhaust System Maintenance
Figure 3-24. Turbocharger
3-13.2. Inspection.
Figure 3-25. Turbocharger Inspection Points
Table 3-3. Turbocharger Inspection Chart
3-13.2.3 Compressor Housing Outlet.
3-13.3. Test
3-14. Exhaust Manifold.
Figure 3-26. Exhaust Manifold
3-15. Intake Manifold.
All Intake Manifold Connections
Figure 3-27. Intake Manifold
Section Vii. Lubrication System Maintenance
Figure 3-28. Oil Filter And Cooler
Figure 3-29. Removing Oil Filter Nipple
Figure 3-30. Installing Oil Filter Nipple
3-17. Oil Pressure Regulating Valve
Figure 3-32. Oil Pressure Regulating Valve And Oil Filler Assembly
3-18. Oil Filler Assembly
Figure 3-33. Dipstick
3-20. Oil Pan.
Figure 3-34. Oil Pan
3-21. Oil Pump Assembly
Figure 3-35. Oil Pump Assembly
Figure 3-36. Measuring Oil Pump Axial Clearance
Figure 3-37. Measuring Oil Pump Radial Clearance
Figure 3-38. Oil Pressure Test Setup
Section Viii. Fuel System Maintenance
3-23.3. Bleed At Fuel Injection Pump.
Figure 3-40. Fuel Filter And Fuel Supply Pump
3-24. Fuel Filter/Water Separator
3-25. Fuel Supply Pump.
3-25.2.2. Leakage Test
3-26. Fuel Lines
B. Install New Bushings
Figure 3-41. Fuel Lines And Injection Pump Installation
3-27. Fuel Injection Pump
Figure 3-42. Flywheel Locking Tool
Figure 3-44. Separating Gear And Shaft
3-27.2.2. Procedure
Figure 3-45. Fuel Injection Pump Assembly
F. Remove Two Nuts
Figure 3-46. Speed Droop Governor
Figure 3-48. Removing Metering Valve (Typical)
Figure 3-50. Removing Transfer Pump Screw (Typical)
Figure 3-52. Fuel Injection Pump Hydraulic Head Assembly
Figure 3-53. Transfer Pump Regulator Components
Figure 3-55. Removing End Cap Seal (Typical)
Figure 3-57. Removing Head Locating Screw (Typical)
Figure 3-59. Removing Advance Screw Hole Plug (Typical)
Figure 3-61. Power Side Advance Piston (Typical)
Figure 3-63. Removing Shaft Retaining Nut
Figure 3-65. Removing Rotor Retainers (Typical)
Figure 3-67. Removing Leaf Spring (Typical)
Figure 3-70. Removing Weight Retainer (Typical)
3-27.4. Inspect And Measure.
3-27.4.4 Rotor.
3-27.4.9 Cam Ring
Figure 3-72. Delivery Valve Replacement
Figure 3-73. Installing Rollers And Shoes (Typical)
Figure 3-74. Measuring Roller-To-Roller Dimension
Preformed Packing
The Plug Contains A Viscosity Compensating Orifice
Figure 3-75. Installing Governor Arm
Figure 3-77. Installing Thrust Washer And Sleeve
Figure 3-79. Vent Wire Screw Assembly
Figure 3-81. Installing Governor Linkage
Figure 3-82. Alignment Of Spacer
Figure 3-84. Installing Throttle Shaft Assembly (Typical)
Figure 3-85. Checking Clearance At Linkage Hook
Figure 3-86. Installing Shutoff Cam
Figure 3-88. Installing Retaining Plate (Typical)
Figure 3-90. Installing Pilot Tube Seal (Typical)
E. Operate Pump
Transfer Pump Pressure Gage
Table 3-4. Fuel Injection Pump Specifications
Fuel Injection Pump Specifications - Continued
Fuel Injection Pump Specifications - Continued
Figure 3-91. Fuel Injection Pump Installation
3-28. Fuel Injection Pump Timing
3-29. Fuel Injection Nozzle
Figure 3-92. Fuel Injection Nozzle
3-29.3. Testing.
3-29.3.2 Opening Pressure Test.
Figure 3-93. Fuel Injection Nozzle Seals
3-30. After Engine Installation Testing
Section Ix. Cylinder Head Assembly Maintenance
Figure 3-94. Valve Cover
Figure 3-95. Adjusting Valve Clearance
Figure 3-97. Installing Timing Pin
3-33. Rocker Arm Assembly.
Figure 3-98. Rocker Arm Assembly
3-33.4. Assembly.
3-34. Cylinder Head Assembly
3-34.2. Inspect And Measure Prior To Disassembly
Figure 3-99. Cylinder Head Assembly
3-34.3. Disassembly.
Cleaning Solvent
Figure 3-100. Valve Face Angle
Figure 3-101. Measuring Cylinder Head Thickness
J. Clean And Measure Valve Guides
M. Using Valve Seat Grinding Set
3-34.5. Assembly.
Figure 3-102. Valve Seat Bore Specifications
Figure 3-103. Measuring Cylinder Liner Height
Figure 3-104. Cylinder Head Capscrew Tightening Sequence
Section X. Flywheel And Housing Assembly Maintenance
3-35.3. Installation.
Figure 3-105. Flywheel And Housing Assembly
3-36. Rear Crankshaft Oil Seal/Wear Sleeve Assembly
3-37. Flywheel Housing.
3-37.3. Installation.
Section Xi. Crankshaft Pulley And Timing Gear Cover Assembly Maintenance
3-39.2. Inspection
Figure 3-107. Timing Gear Cover
Section Xii. Camshaft Assembly Maintenance
F. Remove Fuel Supply Pump
Figure 3-108. Camshaft And Balancer Shafts
Figure 3-109. Measuring Camshaft End Play
Figure 3-110. Measuring Thrust Plate Clearance
Figure 3-111. Measuring Camshaft Journals
Figure 3-113. Aligning Timing Mark And Camshaft Gear
3-41. Balancer Shafts And Bushings
3-41.3. Repair.
Figure 3-114. Balancer Shaft Bushing Line Boring References
Section Xiii. Idler Gears And Front Plate Assembly Maintenance
Figure 3-115. Idler Gears
Figure 3-116. Spring Pin Protrusion
3-43. Front Plate
Figure 3-117. Front Plate
3-43.3. Replacement.
Section Xiv. Crankshaft And Main Bearings Maintenance
An Alternate Method Of Attaching Sling
Figure 3-118. Crankshaft And Main Bearings
3-44.2. Inspect And Measure
Figure 3-119. Critical Areas Of Crankshaft Load Stress
Figure 3-120. Measuring Main Thrust Journal And Thrust Bearing Width
3-44.3. Repair
To Maintain The Correct End Play
3-44.4. Installation
Section Xv. Pistons, Connecting Rods, Cylinder Liners, And Engine Block Maintenance
Figure 3-121. Fastening Cylinder Liners
Figure 3-123. Marking Cylinder Liners
Do Not Over-Tighten Liner Puller
Figure 3-124. Pistons, Connecting Rods, And Cylinder Liners
Figure 3-125. Use Of Cylinder Liner Puller
3-47. Inspect Measure
Figure 3-127. Engine Block
Figure 3-128. Piston Inspection
Figure 3-129. Checking Piston Ring Groove Clearance
Figure 3-131. Inspecting Cylinder Liner Pitting
Figure 3-132. Inspecting Cylinder Liner For Cracks
Figure 3-134. Measuring Piston To Liner Clearance
B. Inspect And Measure Connecting Rod Bearing
Figure 3-135. Checking Piston Pin Bushing
3-47.3. Engine Block.
Figure 3-137. Inspecting Cylinder Block
Figure 3-138. Measuring Main Bearing Bore Diameter
Figure 3-139. Measuring Cam Follower Bore Diameter
Figure 3-141. Measuring Cylinder Block Top Deck Flatness
3-48. Repair.
Figure 3-143. Deglazed 45 Degree Cross Hatch Pattern
Figure 3-144. Assembled Piston, Pin, And Connecting Rod
Figure 3-145. Compression Ring Identification Marks
Figure 3-146. Location Of Cylinder Liner Packings
Figure 3-147. Location Of Cylinder Liner Square Packing
3-50.3. Pistons And Connecting Rods.
Figure 3-149. Installing Connecting Rod Bearing
Figure 3-152. Tightening Connecting Rod Caps
Figure 3-153. Measuring Piston Protrusion
Appendix A References
Appendix B Maintenance Allocation Chart
B-3. Explanation Of Columns In The Mac
B-4. Explanation Of Columns In Tool And Test Equipment Requirements
Section Ii. Maintenance Allocation Chart For Diesel Engine Model 4039t
Maintenance Allocation Chart For Diesel Engine Model 4039t -Cont
Maintenance Allocation Chart For Diesel Engine Model 4039t -Cont
Maintenance Allocation Chart For Diesel Engine Model 4039t -Cont
Maintenance Allocation Chart For Diesel Engine Model 4039t -Cont
Section Iii. Tools And Test Equipment Requirements For Diesel Engine Model 4039t
Tools And Test Equipment Requirements For Diesel Engine Model 4039t - Continued
Appendix C Expendable/Durable Supplies And Materials List
Section Ii. Expendable/Durable Supplies List - Continued
Appendix D Fabrication Of Tools
Figure D-2. Fuel Injection Pump Timing Mark Template
Figure D-3. Cylinder Liner Holding Fixture
Appendix E. Maintenance Procedure And Authorized Level Of Maintenance
Section Ii. Paragraph To Maintenance Level - Cont.
Index
Index - Continued
Index - Continued
Index - Continued
Index - Continued
Index - Continued
The Metric System And Equivalents