Tm-5-2815-241-34p

• Chapter 1 Introduction
• Reporting Equipment Improvement Recommendations (Eir)
• Section Ii. Equipment Description And Data
• Water Manifold
• Cylinder Head
• Air Intake Manifold
• Air Compressor
• Location And Description Of Identification Plates
• Equipment Data
• Equipment Data - Continued
• Chapter 2 Maintenance Instructions
• Equipment Inspection
• Section Ill. General Maintenance Instructions
• Castings
• Bushings And Bushing-Type Bearings
• Repair
• Replacement
• Taping Threads
• Preliminary Starting Procedures
• Section Iv. Engine Disassembly And Assembly
• General
• Turbocharger And Oil Line Removal
• Remarks
• Exhaust Manifold Removal
• Cylinder Head
• Oil Dipstick Tube Removal
• Crankcase Access Cover Removal
• Water Manifold Assembly Removal
• Remarks
• Engine Oil Cooler Removal
• Engine Oil Cooler
• Water Inlet Housing Removal
• Water Header Cover Removal
• Piston Cooling Nozzle Removal
• Aneroid Control Valve Removal
• Intake Manifold Removal
• Rocker Arm Cover Removal
• Engine Compression Brake Housing Removal
• Cylinder Head Fuel Line Removal
• Rocker Arm Housing Removal
• Crosshead Removal
• Remarks
• Push Rod Removal
• Fuel Injector Removal
• Fan Hub Removal
• Cylinder Head Removal
• Water Pump Removal
• Water Pump Removal - Continued
• Compression Release Shaft Removal
• Lubricating Oil Pump Removal
• Air Compressor And Fuel Pump Removal
• Air Compressor And Fuel Pump Removal - Continued
• Accessory Drive Removal
• Oil Pan Removal
• Remarks
• Flywheel Housing Removal
• Cam Follower Housing Removal
• Gear Case Cover Removal
• Crankshaft Removal
• Initial Setup - Continued
• Crankshaft Removal - Continued
• Piston Assembly Removal
• Piston Assembly Removal - Continued
• Crankshaft Installation
• Crankshaft Installation - Continued
• Crankshaft Installation - Continued
• Crankshaft Installation - Continued
• Crankshaft Installation - Continued
• Remarks
• Piston Assembly Installation
• Cylinder Sleeve
• Piston Assembly
• Cylinder Block
• Connecting Rod Nut Torquing Sequence
• Piston Assembly Installation - Continued
• Camshaft Installation
• Remarks
• Cylinder Head Installation
• Cylinder Head
• Cam Follower Housing Installation
• Remarks
• Compression Release Shaft Installation
• Initial Setup
• Injector Timing Adjustment
• Cylinder Block
• Dial Indicator
• Remarks
• Fuel Injector Installation
• Initial Setup
• Crosshead Installation
• Initial Setup-Cont.
• Rocker Arm Housing Installation
• Initial Setup-Cont.
• Accessory Drive Installation
• Cylinder Block
• Air Compressor And Fuel Pump Installation
• Accessory Drive
• Lubricating Oil Pump Installation
• Cylinder Block
• Gearcase Cover Installation
• Remarks
• Remarks
• Camshaft Support
• Vibration Damper
• Vibration Damper
• Oil Pan Installation
• Oil Pump
• Flywheel Housing Installation
• Flywheel Housing
• Flywheel Housing
• Location
• Flex Plate
• Schematics
• Cylinder Head Fuel Line Installation
• Fuel Pump
• Valve And Injector Adjustments
• Adjustment
• Gearcase Cover
• Rocker Arm Housing
• Dial Indicator Method - Continued
• Rocker Arm Housing
• Torque Method
• Adjustment
• Two Injector Rocker Arms
• Valve Clearance
• Engine Compression Brake Housing Installation
• Tightening Sequence
• Rocker Arm Cover Installation
• Intake Manifold Installation
• Piston Cooling Nozzle Installation
• Water Pump Installation
• Water Pump
• Fan Hub Installation.
• Water Inlet Housing Installation
• Water Header Cover Installation
• Crankcase Access Cover Installation
• Engine Oil Cooler Installation
• Engine Oil Cooler
• Engine Oil Cooler
• Water Manifold Assembly Installation
• Remarks
• Aneroid Control Valve Installation
• Oil Dipstick Tube Installation
• Exhaust Manifold Installation
• Exhaust Manifold Installation - Continued
• Turbocharger And Oil Line Installation
• Turbocharger
• Turbocharger Crossover Tube Installation
• Follow-On Maintenance
• Section V. Crankcase And Cylinder Block Maintenance
• Disassembly
• Disassembly - Continued
• Cleaning/Inspection
• Cleaning/Inspection - Continued
• Cylinder Block - Continued
• Cleaning/Inspection - Continued
• Cylinder Block
• Cylinder Block
• Cylinder Block - Continued
• Cleaning/Inspection - Continued
• Cylinder Block
• Cylinder Block
• Repair
• Cylinder Block
• Cylinder Block - Continued
• Cylinder Block
• Adapter Plate
• Cylinder Block
• Cylinder Block
• Cylinder Block
• Cylinder Block
• Cylinder Block
• St-1064 Adapter
• Cylinder Block
• Cylinder Block
• Repair - Continued
• Cylinder Block
• Assembly
• Cylinder Sleeve
• Cylinder Block
• Follow-On Maintenance
• Gearcase Cover
• Gearcase Cover
• Assembly
• Cleaning/Inspection
• Section Vi. Cylinder Head Maintenance
• Disassembly.
• Disassembly - Continued
• Cylinder Head - Continued
• Inspection
• Cylinder Head
• Inspection - Continued
• Cylinder Head - Continued
• Cylinder Head
• Valve Guide
• Cylinder Head
• Cylinder Head - Continued
• Inspection - Continued
• Cylinder Head - Continued
• Inspection - Continued
• Repair/Assembly
• Repair/Assembly - Continued
• Cylinder Head
• Repair/Assembly - Continued
• Valve Seat Insert Specifications
• Repair/Assembly - Continued
• Caution
• Repair/Assembly - Continued
• Cylinder Head - Continued
• Repair/Assembly - Continued
• Cylinder Head
• Repair/Assembly - Continued
• Injector Sleeve
• Cutter Specifications
• Cylinder Head
• Valve Specifications
• Valve Seating Area
• Repair/Assembly - Continued
• Cylinder Head
• Valve Guide
• Cylinder Head
• Repair/Assembly - Continued
• Valve
• Section Vii. Crankshaft Maintenance
• Crankshaft Assembly - Continued
• Inspection - Continued
• Repair
• Assembly
• Vibration Damper
• Section Viii. Piston And Connecting Rod Maintenance
• Piston And Connecting Rod - Continued
• Cleaning/Inspection
• Piston Pin
• Connecting Rod Nuttightening Sequence
• Piston Pin Bushing Bore
• Cleanlng/Lnspectlon - Continued
• Master Connecting Rod
• Piston And Connectlng Rod - Continued
• Piston And Connectlng Rod - Continued
• Cleaning/Inspection - Continued
• Repair
• Repair - Continued
• Repair - Continued
• Connecting Rod
• Connecting Rod
• Assembly
• Bearing Cap
• Section Ix. Camshaft And Timing System Maintenance
• Inspection
• Assembly
• Thrust Bearing
• Rocker Arm Housing And Push Rod
• Rocker Arm Housing And Push Rod - Continued
• Disassembly - Continued
• Inspection
• Inspection - Continued
• Exhaust Rocker Arm
• Inspection - Continued
• Rocker Arm Shaft
• Inspection - Continued
• Assembly
• Assembly - Continued
• Rocker Arm Shaft
• Cam Follower Assembly
• Two Lockscrews
• Inspection
• Injector Cam Follower Roller
• Inspection - Continued
• Cam Follower Socket
• Assembly
• Cam Follower Assembly - Continued
• Assembly - Continued
• Two New Cup Plugs
• Section X. Engine Lubrication System Maintenance
• Disassembly
• Disassembly - Continued
• Inspection/Repair
• Inspection/Repair - Continued
• Drive Shaft
• Assembly
• Remarks
• Section Xl. Manifold Maintenance
• Remarks
• Intake Manifold
• Assembly
• Section Xii. Accessory Drive Maintenance
• Inspection/Repair
• Inspection/Repair - Continued
• Accessory Drive - Continued
• Accessory Drive Pulley
• Inspectlon/Repair
• Section Xiii. Engine Compression Brake Maintenance
• Remarks
• Engine Compression Brake Housing - Continued
• Remarks
• Assembly
• Engine Compression Brake Housing - Continued
• Assembly - Continued
• Section Xiv. Fuel System Maintenance
• Initial Setup
• Disassembly
• Disassembly - Continued
• Remarks
• Filter Screen Inspection
• Gear Pump Repair
• Gear Pump Repair - Continued
• Remarks
• Gear Pump Repair - Continued
• Gear Pump Housing
• Gear Pump Repair - Continued
• Pulsation Damper Repair
• Pulsation Damper Repair - Continued
• Pulsation Damper Assembly
• Shutdown Valve Repair
• Fuel Pump - Continued
• Shutdown Valve Repair - Continued
• New O-Ring
• Front Cover Assembly Repair
• Front Cover
• Front Cover Assembly Repair - Continued
• Front Cover
• Front Cover Assembly Repair - Continued
• Weight Carrier
• Front Cover Assembly Repair - Continued
• Drive Shaft
• Front Cover Assembly Repair - Continued
• Tachometer Drive Shaft
• Front Cover Assembly Repair - Continued
• Remarks
• Front Cover Assembly Repair - Continued
• Remarks
• Fuel Pump Housing Repair
• Remarks
• Fuel Pump Housing Repair - Continued
• Governor Plunger Repair
• Governor Plunger
• Remarks
• Governor Spring Pack Repair
• Throttle Shaft Repair
• Fuel Pump Assembly
• Remarks
• Fuel Pump Assembly - Continued
• Fuel Pump Calibration
• Mounting Pump To Test Stand
• Remarks
• Mounting Pump To Test Stand - Continued
• Remarks
• Fuel Pump Run-In
• Remarks
• Pump Seal Testing
• Fuel Pump
• Throttle Testing And Adjusting
• Fuel Pump Calibration - Continued
• Idle Speed Testing And Adjusting
• Throttle Lever Travel Checking And Adjusting
• Pump Main Pressure Testing And Adjusting
• Governor Fuel Pressure Testing And Adjusting
• Governor Weight Setting Checking And Adjusting
• Removing Pump From Test Stand
• Removing Pump From Test Stand - Continued
• Fuel Pump Calibration - Continued
• Fuel Injector
• Fuel Injector - Continued
• Disassembly - Continued
• Cup Retainer
• Cleaning
• Plunger
• Inspection - Continued
• Cup Contact Area Of Barrel
• Inspection - Continued
• Remarks
• Inspection - Continued
• Injector Spring Data
• Assembly - Continued
• Special Screw
• Assembly - Continued
• Injector Grooves
• Testing
• Injector
• Testing - Continued
• Remarks
• Testing - Continued
• Injector Data Markings On Injector Adapter
• Testing - Continued
• Injector
• Testing - Continued
• Burnishing Tool
• Testing - Continued
• Injector
• Injector Orifice Plugs
• Remarks
• Remarks
• Remarks
• Turbocharger
• Disassembly
• Disassembly - Continued
• Remarks
• Remarks
• Inspection
• Inspection - Continued
• Floating Bearing
• Inspection - Continued
• Assembly
• Assembly - Continued
• Remarks
• Assembly - Continued
• Final Inspection
• Aneroid Control Valve
• Disassembly
• Cleaning
• Inspection - Continued
• Assembly
• Aneroid Control Valve Body
• Section Xv. Cooling System Maintenance
• Idler Pulley
• Inspection
• Water Pump
• Water Pump
• Inspection
• Assembly
• Shaft
• Water Pump Body
• Pulley
• Section Xvi. Final Testing, Adjustments, And Troubleshooting On Engine Test Stand
• Procedures Before Starting
• Procedures Before Starting - Continued
• Remarks
• Starting
• Engine Testing
• Engine Testing - Continued
• Remarks
• Engine Testing - Continued
• Engine Coolant
• Troubleshooting On Engine Test Stand
• Malfunction Test Or Inspection Corrective Action
• Coolant Temperature Low
• Engine Hard To Start (Cranking System Working)
• Engine Misses At Idle.
• Excessive Black Smoke Under Load
• Excessive Crankcase Pressure
• Excessive Smoke Under Acceleration
• Fuel Knocks (Combustion Noise)
• Mechanical Knocks
• Section Xvii. Engine Specifications
• Section V, Crankcase And Cylinder Block Continued
• Section Vi, Cylinder Head And Valves
• Section Vii, Crankshaft
• Section Viii, Pistons And Connecting Rods
• Torque Limits Ft Lb (NM)
• Section Ix, Camshaft And Timing System Continued
• Section X, Engine Lubrication System
• Section Xii, Accessory Drive
• Section Xiv, Fuel System
• Section Xv, Cooling System
• Appendix A References
• Appendix A References
• Appendix B Expendable/Durable Supplies And Materials List
• Section Ii. Expendable/Durable Supplies And Materials List
• Section Ii. Expendable/Durable Supplies And Materials List-Continued
• Appendix C Repair Parts And Special Tools Lists
• Source Code
• Application/Explanation
• Explanation Of Columns (Sections Ii And Ill) -Continued
• Explanation Of Columns (Section Iv)
• Special Information
• Abbreviations
• Figure 1. Engine Mounting Brackets.
• Description Usable On Code
• Description Usable On Code
• Figure 3. Cylinder Head
• Description Usable On Code
• Figure 4. Crankshaft, Gears And Bearings
• Description Usable On Code
• Figure 5. Flywheel Housing And Flexplate
• Description Usable On Code
• Figure 6. Piston And Connecting Rod.
• Description Usable On Code
• Figure 7. Camshaft
• Description Usable On Code
• Figure 8. Gearcase Cover
• Description Usable On Code
• Figure 9. Valves, Springs And Guides
• Description Usable On Code
• Figure 10. Push Rods And Cam Followers
• Description Usable On Code
• Description Usable On Code
• Figure 11. Rocker Housing Cover And Breather
• Description Usable On Code
• Figure 12. Rocker Arms And Housing
• Description Usable On Code
• Description Usable On Code
• Figure 13. Oil Pan And Dipstick.
• Description Usable On Code
• Figure 14. Engine Breather Assembly.
• Description Usable On Code
• Figure 15. Engine Breather Hose
• Description Usable On Code
• Figure 16. Engine Oil Filter Cooler
• Description Usable On Code
• Description Usable On Code
• Figure 17. Lubricating Oil Pump
• Description Usable On Code
• Description Usable On Code
• Figure 18. Intake Manifold.
• Description Usable On Code
• Figure 19. Exhaust Manifold
• Description Usable On Code
• Figure 20. Accessory Drive
• Description Usable On Code
• Figure 21. Engine Compression Brake.
• Description Usable On Code
• Figure 22. Fuel Injectors.
• Description Usable On Code
• Figure 23. Fuel Pump Housing.
• Description Usable On Code
• Description Usable On Code
• Figure 24. Mainshaft Cover.
• Description Usable On Code
• Figure 25. Gear Pump
• Description Usable On Code
• Figure 26. Damper
• Description Usable On Code
• Figure 27. Spring Pack
• Description Usable On Code
• Figure 28. Aneroid Control
• Description Usable On Code
• Description Usable On Code
• Figure 29. Turbocharger
• Description Usable On Code
• Description Usable On Code
• Figure 30. Shut Down Valve
• Description Usable On Code
• Figure 31. Fuel Pump Filter.
• Description Usable On Code
• Figure 32. Glow Plug And Preheater.
• Description Usable On Code
• Figure 33. Throttle Shaft.
• Description Usable On Code
• Figure 34. Thermostat Housing
• Description Usable On Code
• Figure 35. Water Manifold.
• Description Usable On Code
• Figure 36. Water Pump.
• Description Usable On Code
• Description Usable On Code
• Description Usable On Code
• Figure 37. Fan Hub.
• Description Usable On Code
• Figure 38. Name Plates.
• Description Usable On Code
• Description Usable On Code
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• National Stock Number And Part Number Index
• Description And Usable On Codes
• Figure 2. Cylinder Block.
• Description And Usable On Codes
• Description And Usable On Codes
• Figure 3. Cylinder Head.
• Description And Usable On Codes
• Figure 4. Crankshaft, Gears, And Bearings.
• Description And Usable On Codes
• Figure 5. Flywheel Housing And Flexplate.
• Description And Usable On Codes
• Figure 6. Piston And Connecting Rod.
• Description And Usable On Codes
• Figure 7. Camshaft.
• Descriptlon And Usable On Codes
• Figure 8. Gearcase Cover.
• Description And Usable On Codes
• Figure 9. Valves, Springs, And Guides.
• Description And Usable On Codes
• Figure 10. Pushrods And Cam Followers.
• Description And Usable On Codes
• Figure 11. Rocker Housing Cover And Breather
• Description And Usable On Codes
• Figure 12. Rocker Arms And Housing.
• Description And Usable On Codes
• Figure 13. Oil Pan And Dipstick.
• Description And Usable On Codes
• Figure 14. Engine Breather Assembly
• Description And Usable On Codes
• Figure 15. Engine Breather Hose
• Description And Usable On Codes
• Figure 16. Engine Oil Filter Cooler
• Description And Usable On Codes
• Description And Usable On Codes
• Figure 17. Lubricating Oil Pump.
• Description And Usable On Codes
• Figure 18. Intake Manifold.
• Description And Usable On Codes
• Figure 19. Exhaust Manifold.
• Description And Usable On Codes
• Figure 20. Accessory Drive.
• Description And Usable On Codes
• Figure 21. Engine Compression Brake
• Description And Usable On Codes
• Figure 22. Fuel Injector.
• Description And Usable On Codes
• Figure 23. Fuel Pump Housing
• Description And Usable On Codes
• Figure 24. Mainshaft Cover
• Description And Usable On Codes
• Figure 25. Gear Pump
• Descrlption And Usable On Codes
• Figure 26. Damper
• Description And Usable On Codes
• Figure 27. Spring Pack
• Description And Usable On Codes
• Figure 28. Aneroid Control
• Description And Usable On Codes
• Figure 29. Turbocharger.
• Description And Usable On Codes
• Figure 30. Shutdown Valve.
• Description And Usable On Codes
• Figure 31. Fuel Pump Filter.
• Description And Usable On Codes
• Figure 32. Glow Plug And Preheater.
• Description And Usable On Codes
• Figure 33. Throttle Shaft.
• Description And Usable On Codes
• Figure 34. Thermostat Housing.
• Description And Usable On Codes
• Figure 35. Water Manifold
• Description And Usable On Codes
• Figure 36. Water Pump.
• Description And Usable On Codes
• Figure 37. Fan Hub
• Description And Usable On Codes
• Figure 38. Engine Data Plates.
• Description And Usable On Codes
• Descrlption And Usable On Codes
• Description And Usable On Codes
• Description And Usable On Codes
• Cross-Rfference Indexes
• Cross-Reference Indexes
• National Stock Number Index
• National Stock Number Index
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cress-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes

• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Cross-Reference Indexes
• Appendix D Illustrated List Of Manufactured Items
• Appendix E Torque Limits
• Torque Values - Continued
• Index
• Index - Continued
• Index - Continued
• Index - Continued
• Index - Continued
• Index - Continued
• Index - Continued
• Index - Continued
• Index - Continued
• Index - Continued
• Index - Continued
• Index - Continued
• The Metric System And Equivalents