TM-9-2815-256-24 Diesel Engine Model 3.9 Liter 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-9-2815-256-24P Diesel Enigine 2815-01-350-2208 Model 4039TF002 Four Cylinder Four Cycle Turbocharged Manual

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Tm-9-2815-256-24

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
3. Engine Hard To Start Or Will Not Start.
4. Engine Hard To Start Or Will Not Start In Cold Weather
6. Engine Does Not Develop Full Power
8. Excessive Oil Consumption
9. Low Oil Pressure
10. Excessive Fuel Consumption
11. Black Or Gray Smoke.
12. Blue Exhaust Smoke
15. Engine Makes A Gas Leaking Noise
16. Detonation Or Preignition.
18. Battery Charge Ammeter Shows Excessive Charging After Prolonged Period
Section Iii. General Maintenance
3-4. Disassembly And Assembly Sequence For Overhaul
3-4.2. Assembly
3-5. Test Engine Compression Pressure
3-7. Intake Manifold Pressure Check
F. Remove Test Gage And Install Plug
Section Iv. Cooling System Maintenance
Figure 3-2. Thermostat And Housing
3-9.2. Inspection
3-10. Water Pump.
Figure 3-4. Water Pump Assembly
Air Must Be Expelled
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 3-8. Testing Brush Assembly
Figure 3-10. Testing Rectifier Bridge
Figure 3-11. Testing Stator Windings
Figure 3-13. Battery Charging Alternator Test Circuit
3-12. Starter.
Figure 3-14. Starter Bench Test Setup
Figure 3-15. Starter Assembly
Figure 3-16. Disconnecting Lead Wire (Typical)
Figure 3-18. Removing Starter End Frame And Yoke Assembly (Typical)
Figure 3-19. Removing Brushes
Figure 3-21. Removing Housing (Typical)
Figure 3-23. Removing Steel Ball
Figure 3-25. Removing Washer And Spring
Figure 3-27. Measuring Commutator Od
Figure 3-29. Inspecting And Replacing Bearings
Figure 3-31. Checking Overrunning Clutch
Figure 3-33. Growler Test
Figure 3-36. Checking Brush Holder
Figure 3-38. Checking For Open Field Coil
Figure 3-40. Installing Cover On Yoke
Section Vi. Intake And Exhaust System Maintenance
Figure 3-42. Turbocharger
Figure 3-43. 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 3-44. Exhaust Manifold
3-15. Intakf Manifold.
Figure 3-45. Intake Manifold
Section Vii. Lubrication System Maintenance
Figure 3-46. Oil Filter And Cooler
Figure 3-47. Removing Oil Filter Nipple
Figure 3-48. Installing Oil Filter Nipple
3-17. Oil Pressure Regulating Valve
Figure 3-50. Oil Pressure Regulating Valve And Oil Filler Assembly
3-19. Oil Dipstick
Figure 3-51. Dipstick
Figure 3-52. Oil Pan
3-21. Oil Pump Assembly.
Figure 3-53. Oil Pump Assembly
Figure 3-54. Measuring Oil Pump Axial Clearance
3-21.4. Test
Figure 3-56. Oil Pressure Test Setup
3-22.3. Installation
3-23. Bleeding Fuel System.
3-23.4. Bleed At Fuel Injection Nozzles.
Figure 3-58. 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
Figure 3-59. Fuel Lines And Injection Pump Installation
3-27. Fuel Injection Pump
Figure 3-61. Checking Timing Marks
Figure 3-62. Fuel Infection Pump Gear Access (Cover Removed)
3-27.2. Disassembly.
L. Using Needle Nose Pliers
Figure 3-64. Fuel Injection Pump Assembly
Figure 3-65. Disassembly Of Shut-Off Lever
Figure 3-67. Speed Droop Governor
Figure 3-68. Disengaging Governor Linkage (Typical)
Figure 3-70. Removing Vent Wire Screw
Figure 3-72. Removing Transfer Pump End Cap
Figure 3-73. Fuel Injection Pump Hydraulic Head Assembly
Figure 3-74. Transfer Pump Regulator Components
Figure 3-76. Removing End Cap Seal
Figure 3-78. Removing Advance Screw Hole Plug
Figure 3-80. Disassembling Governor
Figure 3-82. Removing Governor Arm
Figure 3-84. Removing Cam Ring (Typical)
Figure 3-86. Removing Leaf Spring (Typical)
Figure 3-88. Removing Pumping Plungers (Typical)
3-27.4.3 Hydraulic Head
3-27.4.7 Cam Rollers And Shoes
3-27.5.5 Rotor
Upon Completion Of Installation Of Clips
Figure 3-89. Delivery Valve Replacement
Figure 3-90. Installing Rollers And Shoes (Typical)
Figure 3-91. Measuring Roller-To-Roller Dimension
To Prevent Excessive Transfer Pump Pressure
Figure 3-92. Installing Seals And Bearing
Figure 3-93. Installing Protection Tube
Figure 3-95. Installing Weights
Figure 3-97. Inserting Hydraulic Head (Typical)
Figure 3-98. Installing Metering Valve
Figure 3-100. Alignment Of Spacer
Figure 3-101. Alignment Of Shutoff Arm
Using Deep Well Socket
Figure 3-103. Checking Clearance At Linkage Hook
Figure 3-104. Installing Shutoff Cam
Figure 3-105. Installing End Cap
Figure 3-107. Installing Locking Head Bolts
If Incorrect Connector Is Used
Transfer Pump Pressure Gage
Table 3-4. Fuel Injection Pump Specifications
Fuel Injection Pump Specifications - Continued
Fuel Injection Pump Specifications - Continued
Figure 3-109. Fuel Injection Pump Installation
Tighten Nut To 95 Ft-Lbs (130 Nm)
3-28. Fuel Injfction Pump Timing
3-29. Fuel Injection No7zle
Figure 3-112. Fuel Injection Nozzle
3-29.3. Testing
3-29.3.3 Chatter And Spray Pattern Test.
Figure 3-113. Fuel Injection Nozzle Seals
3-30. After Engine Installation Testing
Diesel Fuel Is Flammable And Toxic
Section Ix. Cylinder Head Assembly Maintenance
Figure 3-115. Adjusting Valve Clearance
Figure 3-116. Checking Valve Clearance
3-33. Rocker Arm Assembly
Figure 3-118. Rocker Arm Assembly
3-33.4. Assembly
3-34. Cylinder Head Assembly
3-34.2. Inspect And Measure Prior To Disassembly
Figure 3-119. Cylinder Head Assembly
3-34.3. Disassembly
3-34.4. Inspection And Measure
Figure 3-120. Valve Face Angle
Figure 3-121. Measuring Cylinder Head Thickness
Knurl Valve Guides
If Valve Seat Width Is Too Narrow
If Valve With An Oversize Stem Is To Be Used
Figure 3-122. Valve Seat Bore Specifications
Figure 3-123. Measuring Cylinder Liner Height
Figure 3-124. Cylinder Head Capscrew Tightening Sequence
Retorque Of Cylinder Head Cap-Screws
Section X. Flywheel And Housing Assembly Maintenance
3-35.3. Installation
Figure 3-125. Flywheel And Housing Assembly
3-36.2. Installation
3-37.2. Inspect And Measure
Section Xi. Crankshaft Pulley And Timing Gear Cover Assembly Maintenance
3-39.2. Inspection
Figure 3-127. Timing Gear Cover
H. Install Timing Gear Cove
Section Xii. Camshaft Assembly Maintenance
Figure 3-128. Camshaft
Figure 3-129. Measuring Camshaft End Play
Figure 3-130. Measuring Thrust Plate Clearance
Figure 3-132. Measuring Camshaft Lobe Sight
Figure 3-133. Aligning Timing Mark And Camshaft Gear
Section Xiii. Idler Gears And Front Plate Assembly Maintenance
Figure 3-134. Idler Gears
Figure 3-135. Spring Pin Protrusion
Figure 3-136. Front Plate
3-42.3. Replacement
E. Install Idler Gears
Section Xiv. Crankshaft And Main Bearings Maintenance
Crankshaft Is Very Heavy
Figure 3-137. Crankshaft And Main Bearings
A. Inspect Gear
Figure 3-138. Critical Areas Of Crankshaft Load Stress
Figure 3-139. Measuring Main Thrust Journal And Thrust Bearing Width
3-43.3. Repair
3-43.4. Installation
Pneumatic Wrench
I. Check Crankshaft
Section Xv. Pistons, Connecting Rods, Cylinder Liners, And Engine Block Maintenance
Figure 3-141. Removing Carbon From Cylinder Liner
3-44.2. Cylinder Liner
Figure 3-143. Pistons, Connecting Rods, And Cylinder Liners
Figure 3-144. Use Of Cylinder Liner Puller
3-46. Inspect And Measure
Figure 3-146. Engine Block
Figure 3-147. Piston Inspection
Figure 3-149. Checking Piston Pin Clearance
Figure 3-150. Inspecting Cylinder Liner Pitting
Figure 3-152. Measuring Piston Skirt
Figure 3-153. Measuring Piston To Liner Clearance
Use Bearing Gage
Figure 3-154. Checking Piston Pin Bushing
Figure 3-155. Inspecting Piston Cooling Nozzles
Figure 3-156. Inspecting Cylinder Block
Figure 3-157. Measuring Main Bearing Bore Bitter
Figure 3-159. Measuring Camshaft Bore Diameter
3-47. Repair
Figure 3-161. Location Of Cylinder Liner Shim
3-48. Assembly
Figure 3-164. Compression Ring Identification Marks
3-49. Installation
Figure 3-166. Location Of Cylinder Liner Square Packing
Figure 3-167. Staggered Piston Ring Gaps
Figure 3-168. Installing Connecting Rod Bearing
Figure 3-171. Tightening Connecting Rod Caps
Figure 3-172. 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 6059t
Maintenance Allocation Chart For Diesel Engine Model 6059t
Maintenance Allocation Chart For Diesel Engine Model 6059t
Maintenance Allocation Chart For Diesel Engine Model 6059t
Maintenance Allocation Chart For Diesel Engine Model 6059t
Section Iii Tool And Test Equipment Requirements For Diesel Engine Model 6059t
Tool And Test Equipment Requirements For Diesel Engine Model 6059t - 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