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Tm-9-2815-254-24

• Chapter 1 Introduction
• Destruction Of Army Material To Prevent Use
• Section Ii. Equipment Description And Data
• Figure 1-1. Engine Components
• Equlpment Data.
• Lnspectlng And Servlcing Engine
• Chapter 2 Operation
• Electrical System.
• Section Ii. Operating Instructions
• Chapter 3 Maintenance Section I. Preventive Maintenance Checks And Services (Pmcs)
• Table 3-1. Preventive Maintenance Checks And Services (Pmcs) - Continued
• Section Ii. Troubleshootlng
• Table 3-2 Troubleshooting
• Table 3-2. Troubleshooting - Continued
• Table 3-2. Troubleshooting - Continued
• Table 3-2. Troubleshooting - Continued
• Table 3-2. Troubleshooting - Continued
• Table 3-2 Troubleshooting - Continued
• Table 3-2. Troubleshooting - Continued
• Table 3-2. Troubleshooting - Continued
• Section Iii. General Maintenance
• Disassembly.
• Assembly
• Assembly-Cont.
• Section Iv. Cooling System Maintenance
• Replacement
• Water Pump
• Installation.
• Figure 3-2. Water Pump
• Section V. Fuel System Maintenance
• Disassembly
• Figure 3-3. Fuel Filter Assembly
• Fuel Lnjectors And Piping
• Disassembly (Fuel Injector)
• Figure 3-4. Fuel Lnjectors And Piping
• Fuel Injector.
• Cleaning.
• Assembly (Fuel Injector).
• Figure 3-5. Fuel Injector Spray Pattern
• Fuel Injection Pump
• Figure 3-6. Lop Dead Center
• Disassembly
• Figure 3-7. Fuel Feed Pump And Timer Assembly
• Figure 3-8. Fuel Injection Pump Assembly
• Figure 3-9. Attaching Coupling (Typical)
• Figure 3-11. Removing Screw Plug (Typical)
• Figure 3-13. Removing Tappet Holder (Typical)
• Figure 3-14. Removing Tappet (Typical)
• Figure 3-15. Removing Delivery Valve
• Feed Pump
• Timer Assembly.
• Injection Pump
• Figure 3-18. Checking Plunger And Barrel Movement
• Figure 3-20. Checking Plunger And Barrel For Damage
• Figure 3-22. Lower Spring Seat
• Feed Pump.
• Tuner Assembly.
• Feed Pump
• Njection Pump.
• Figure 3-28. Checking Sleeve Pinion Movement
• Figure 3-30. Inserting Tappet
• Attach Coupling
• Testing.
• Figure 3-31. Measuring Device Installed (Typical)
• Table 3-1. Fuel Pump Test Specifications
• Do Not Move Flywheel Pointer After It Has Been Placed In This Position.
• Scribe A Mark To Identify Starting Point
• Figure 3-32. Feed Pump Test
• Figure 3-33. Priming Pump Test
• Figure 3-34. Capacity Lest
• Figure 3-35. Feed Pump Pressure Test
• Installation
• Figure 3-37. Removal Of Mechanical Governor
• Bleeding And Priming Fuel System
• Bleeding And Priming Fuel System
• Adjustment Procedure
• Tighten Priming Pump Cap.
• Section Vi. Lubrication System
• Oil Pressure Relief Valve
• Oil Piping
• Figure 3-39. Oil Piping
• Installation
• Installation.
• Removal / Disassembly
• Lnspect And Measure,
• Figure 3-42. Oil Pump Inspections
• Figure 3-43. Oil Pressure Test Setup
• Section Vii. Intake And Exhaust System Maintenance
• Figure 3-44. Pcv Assembly
• Installation.
• Ntake And Exhaust Manifolds
• Figure 3-45. Intake And Exhaust Manifolds
• Figure 3-45. Intake And Exhaust Manifolds-Cont.
• Section Viii. Electrical System
• Figure 3-46. Glow Plugs Assembly
• Disassembly.
• Testing Starter (Installed).
• Figure 3-48. Starter Solenoid Test Circuit
• Cleaning And Inspection
• Cleaning And Inspection
• Assembly
• Alternator.
• Disassembly,
• Inspection/Testing
• Figure 3-49. Alternator Assembly
• Assembly.
• Installation
• Sectlon Ix. Engine Block Maintenance
• Figure 3-50. Front Gear Cover
• Installation.
• Rocker Cover And Arms
• Figure 3-52. Rocker Covet And Arms
• Inspect And Measure
• Figure 3-55. Rocker Arm Shaft Outside Diameter
• Figure 3-56. Rocker Arm Oil Ports
• Figure 3-57. Rocker Arm Correction
• Installation
• Adjustment.
• Cylinder Head Assembly.
• Figure 3-60. Cylinder Head Assembly
• Figure 3-61. Cylinder Head Bolt Loosening Sequence
• Figure 3-62. Hot Plug Removal
• Inspect And Measure.
• Figure 3-64. Cylinder Head Height (Reference)
• Figure 3-65. Hot Plug Depression
• Figure 3-66. Valve Stem And Guide Clearance
• Figure 3-68. Checking Valve Thickness
• Figure 3-70. Checking Valve Contact Width
• Figure 3-71. Valve Spring Free! Height
• Figure 3-73. Push Rod Curvature
• Flgure 3-74. Valve Seat Correction
• Figure 3-75. Valve Seat Insert Installation
• Repair.-Cont.
• Installation
• Figure 3-76. Cylinder Head Bolt Tightening Sequence
• Pistons, Connecting Rods, And Crankshaft
• Removal.-Cont.
• Figure 3-77. Pistons, Connecting Rods, And Crankshaft
• Figure 3-78. Crankshaft End Play
• Nspect And Measure
• Flgure 3-80. Piston Ring And Groove Clearance
• Figure 3-82. Measuring Piston Ring Gap
• Figure 3-83. Connecting Rod Side Face Clearance
• Figure 3-84. Basic Dimension Measurements
• Figure 2-85. Crankshaft Run-Out
• Figure 3-87. Crankshaft Journal And Crankpin Diameter
• Figure 3-88. Crankshaft Journal And Bearing Clearance
• Figure 3-90. Crankshaft Joumal And Bearing Clearance
• Flgure 3-91. Comparing Bearing Gage
• Figure 3-92. Crankshaft Gear Installation
• Assembly-Cont.
• Figure 3-93. Piston Ring Installation
• Flgure 3-94. Crankshaft Bearing Location
• Figure 8-95. Crankshaft Bearing Cap Bolts Tightening Sequence
• Figure 3-96. Crankshaft Rear Oil Seal And Spacer
• Figure 3-97. Piston Ring Gap Setting
• Crankcase.
• Figure 3-98. Crankcase
• Camshaft And Idlelr Gear Assemblies
• Figure 3-100. Measuring Timing Gear Backlash
• Figure 3-101. Camshaft And Idler Gear Assemblies
• Disassembly Of Camshaft.
• Figure 3-103. Idler Gear Shaft Outside Diameter
• Figure 3-105. Cam Height
• Figure 3-106. Camshaft Runout
•  Installation
• Flywhell And Housing
• Figure 3-107. Flywheel And Housing
• Figure 3-108. Flywheel Bolt Loosening Sequence
• Lnstallation.
• Cyclinder Block Assembly.
• Disassembly.
• Figure 3-111. Cylinder Block Assembly
• Remove Dowel Pins And Fittings Only If Necessary. 3-32.2. Lnspection/Repair. Note Letters And Numbers Are Stamped On Top Face Of Block At Each Cylinder Bore. Letters (A Or C) Represent Grade Of Piston Installed During Production. Numbers (1, 2, 3, Or 4) Represent Grade Of Cylinder Liner Installed During Production. However. When Ordering A New Cylinder Liner For Service Repair Either A No. 2 Or No. 3 Grade Cylinder Liner Will Be Supplied. Either One May Be Used To Replace Whatever Grade Liner Was Used In Production. A. Check Cylinder Block Upper Face Warpage As Follows. (1) (2) (3) (4) If Not Removed, Remove Dowel Pin. Remove Cylinder Liner, Refer To Paragraph 3-32.1 Step H. Using A Straight Edge And A Feeler Gage, Measure The Four Sides And Two Diagonals Of Cylinder Block Upper Face, Refer To Figure 3-112. Standard Warpage Is 0.002 In. (0.05 Mm) Or Less. If Measured Value Exceeds 0.008 In. (0.2 Mm) But Is Less Than 0.016 In. (0.4 Mm), Regrind The Cylinder Block. If Measured Value Is Greater Than 0.006 In. (0.14 Mm), Replace Cylinder Block. Change 2 3-165
• Remove Dowel Pins And Fittings Only If Necessary
• Measure Cylinder Liner Bore As Follows
• Figure 3-114. Cylinder Liner Bore Measurement
• Assembly
• Figure 3-115. Cylinder Liner Installation
• Figure 3-116. Pressing Cylinder Liner
• Appendix A References
• Appendix A References - Continued
• Appendix B Maintenance Allocatlon Chart
• Explanation Of Columns In The Mac, Section Ii
• Explanation Of Columns In Tool And Test Equipment Requirements, Section Iii
• Explanation Of Columns In Remarks, Section Iv
• Sectlon Ii. Maintenance Allocation Chart For Diesel Engine Model C-240pw-28
• Section Ii. Malntenance Allocationchart - Continued
• Section Ii. Maintenance Allocation Chart - Continued
• Sectlon Ill. Tool And Test Equipment Requirements
• Sectlon Iv. Remarks
• Appendix C Expendable/Durable Supplies And Materials List
• A P P E N D I X C Expendable/Durable Supplies And Materials List - Continued
• Figure D-1. Fuel Injection Pump Tappet Holder
• Appendix E. Maintenance Procedure And Authorized Level Of Maintenance
• Section 111. Maintenance Leveltd Paragraphs
• Index
• Index-Continued
• Index - Continued
• The Metric System And Equivalents