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1. 0 907 Pound Feet Newton Meters 1 356 Pounds per Square Inch KilopascalS 6 895 Miles per Gallon Kilometers per Liter 0 425 Miles per Hour Kilometers per Hour 1 609 TO CHANGE TO MULTIPLY BY Centimeters se Inches alite eR seis 0 394 Meters 22 2 ae beet us nenne 3 280 Meters 0c eee eee ee Yatds ic nennen 1 094 Kilometers o o o o oommoo Miles ooo remm Rees 0 621 Square Centimeters Square Inches 0 155 Square Meters Square Feet 10 764 Square Meters Square Yards 1 196 Square Kilometers Square Miles 0 386 Square Hectometers ACTOS at data 2 471 Cubic Meters Cubic Feet 00 35 815 Cubic Meters sse Cubic Yards onnen 1 308 Milliliters Fluid Ounces 0 034 Liters a IARE Pia aida ses TAKEN 2 113 liters cse tre EE Pcr QUES os han E Peso te 1 057 Liters 2 0 ccc nnen Gallons 0 0 0 ccc cece eee 0 264 N Grams i enced eh OUNCES aus ans 0 035 I Kilograms 0000 0s POURS eio prr RR pen 2 205 O Metric TONS nuanean Short TONS 22a 1 102 Z Newton Meters Pound Feet sss 0 738 Ki
2. UOC APP CAP FILLER OPENING PART OF KIT P N 01228202 eee K Kn mA mk eS UOC APP O RING PART OF KIT P N 01228002 UOC APP TUBE ASSEMBLY METAL SCREW MACHINE eee APJ Item 7 QTY HMHPHUUPHPHPHPHUHHHNH 10 10 10 H HENE TM 9 2815 250 24 amp P SECTION II L PRONG TFT ORDNEN NNN DONES ONO AZ NN OS N Y rs E y ANA N 4 N t ANNA W 7 A N W ON aller SA Lg N NE 1 KSNK IS STK SNC NED mr m L E MI TITAN M p N WM U A x N Figure 10 Exhaust Manifold Mounting Hardware TM 9 2815 250 24 amp P col 1 2 3 4 5 6 7 ITEM SMR NSN PART DESCRIPTION AND NO CAGE NUMBER USABLE ON CODE UOC QTY GROUP 2918 MANIFOLDS FIGURE 10 EXHAUST MANIFOLD MOUNTING HARDWARE 1 PAOZZ 5310 01 101 2028 61080 40028400 NUT SELF LOCKING HE 2 PAOZZ 5330 01 455 7566 61080 01285500 GASKET SET PART OF KIT P N 01247702 END OF FIGURE 10 1 TM 9 2815 250 24 amp P SECTION II r er Pee OE nn Pa A v ISE N s f fiic ose PR ex y ERN SO DN NOS a Lae YOON N Ws VNNNSSNNSS Y eS NEUN UN KI SANS TMT ns Ye V CSS S NS Ir T a Na 229222149935 v np NS ade en J Lu Ls Ja os N Pw A s N Y i REP Seta V ST y HRS A ILL Y TIT e CR EDU LUE in J LLEN py AO Y i t 11 Wil W D Ir v ev x Nijar nas VAG JIN i 2 NY N of Na N X M t ja pe O
3. eee H HHHNN H B amp B HHHNHHNH H SECTION II C01 TM 9 2815 250 24 amp P Part of Item 20 29i103 Figure 8 Camshaft and Valves I kkk kkk kkk kkk 1 TEM NO 12 13 14 15 16 17 18 18 19 19 20 21 22 23 24 24 25 26 27 28 29 30 30 30 31 32 33 34 35 EPA Version 1 Compliant Only 2 SMR PAFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFZZ PAOZZ PAOZZ PAOZZ PAOZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ KFFZZ PAFZZ KFFZZ PAFZZ 3 NSN 5325 01 399 4615 5365 01 399 5011 5365 01 455 0012 2815 01 455 0054 5310 01 078 8066 5305 01 405 9904 5310 01 101 2028 2815 01 455 0046 2815 01 455 0043 5310 01 078 8066 5305 01 405 9904 5305 01 405 9903 5310 01 415 2649 2815 01 454 8841 5330 01 400 5772 2815 01 455 0364 5310 01 456 2275 5360 01 414 8475 5310 01 399 7311 4820 01 407 0705 2805 01 407 0706 3010 01 455 2856 5310 01 400 3721 5340 01 400 1000 5305 01 406 0013 5365 01 100 5415 5365 01 100 5416 5325 01 245 3517 5365 01 400 3717 5310 01 399 6981 5315 01 102 7922 5325 01 399 4618 2815 01 454 8842 2815 01 455 0085 2815 01 454 8839 2815 12 330 5421 TM 4 CAGE 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 6
4. BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 82 ROCK ISLAND IL POSTAGE Will BE PAID BY ROCK ISLAND ARSENAL Director Armament and Chemical Acquisition and Logistics Activity ATTN AMSTA AC NML Rock Island IL 61201 9948 II mo asti me t Suin m P on vmm mini maat ee o hoola lolo O voe PP minin O ee e mu ven d BNI G34vdOdd3d SNOW HVIL po By Order of the Secretary of the Army DENNIS J REIMER General United States Army Chief of Staff Official JA BLAS JOEL B HUDSON Administrative Assistant to the Secretary of the Army 05170 DISTRIBUTION To be distributed in accordance with the initial distribution number IDN 381080 requirements for TM 9 2815 250 24 amp P U S GOVERNMENT PRINTING OFFICE 1999 746 025 800075 THE METRIC SYSTEM AND EQUIVALENTS LINEAR MEASURE 1 Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches 1 Meter 100 Centimeters 1000 Millimeters 39 37 Inches 1 Kilometer 1000 Meters 0 621 Miles WEIGHTS 1 Gram 0 001 Kilograms 1000 Milligrams 0 035 Ounces 1 Kilogram 1000 Grams 2 2 Lb 1 Metric Ton 1000 Kilograms 1 Megagram 1 1 Short Tons LIQUID MEASURE 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces 1 Liter 1000 Milliliters 33 82 Fluid Ounces APPROXIMATE CONVERSION FACTORS SQUARE MEASURE 1 Sq Centimeter 100 Sq Millimeters 0 155 Sq Inches 1 Sq
5. oocococonnccccccnonnconcnonnnnnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnrnnnnancnnnnns E 4 E 6 Fastener Grade da E 5 E 1 GENERAL This section provides general torque limits for screws used on the Diesel Engine Assembly Hatz 2 G 40 Special torque limits are indicated in the maintenance procedures for applicable components The general torque limits given in this appendix shall be used when specific torque limits are not indicated in the maintenance procedure These general torque limits cannot be applied to screws that retain rubber components The rubber components will be damaged before the correct torque limit is reached If a special torque limit is not given in the maintenance instructions tighten the screw or nut until it touches the metal bracket then tighten it one more turn E 2 TORQUE LIMITS Table E 1 p E 2 lists dry torque limits Dry torque limits are used on screws that do not have lubricants applied to threads Table E 2 p E 3 lists wet torque limits Wet torque limits are used on screws that have high pressure lubricants applied to threads E 3 HOW TO USE TORQUE TABLE 1 Measure the diameter of the screw to be installed 2 Count the number of threads per inch or use a A pitch gage 3 Under the heading SIZE and E2 look down the left hand column until the diameter of the screw to be installed is found there will usually be two lines beginning with the same size UNI
6. 2815 01 454 9103 5340 01 494 6423 5340 01 454 9940 5310 01 405 9911 5305 01 406 0005 5305 01 405 9908 5310 01 400 1002 5315 01 455 8935 5310 12 149 4353 5305 01 406 0000 5310 01 405 9890 5305 01 463 1028 TM 4 CAGE 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 END OF 9 2815 250 24 amp P 5 PART NUMBER 04031300 03975300 03792100 50311200 50310810 99400644 99400646 50145900 50093400 50311500 50310900 50195800 01239901 50303610 50336200 50144500 50092100 50144400 50026400 FIGURE col 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 2913 FLYWHEEL ASSEMBLY FIGURE 6 FLYWHEEL AND RELATED COMPONENTS NUT PLAIN HEXAGON o ooooo o WASHER FLAT oo ocean FLYWHEEL ENGINE o oo O RING PART OF KIT P N 01228002 HOUSING FLYWHEEL COVER ACCESS lees COVER ACCESS lees WASHER FLAT cee eee eee SCREW MACHINE 0 000000 eee GASKET PART OF KIT P N 01228002 SCREW MACHINE o oo eee WASHER FLAT o oo ooooooooooo o ROD PINION eee PIN STRAIGHT HEADLE WASHER FLAT eee ooo SCREW MACHINE eee NUT PLAIN HEXAGON s SCREW MACHINE kk b RR EYES 7 QTY H N PUocNHHPBHHPBUNNNHBHHBHHBHH SECTION II C01 TM 9 2815 250 24 amp P
7. 4 In the second column under SIZE find the number of threads per inch that matches the E number of threads counted in step 2 E 1 TM 9 2815 250 24 amp P E 3 HOW TO USE TORQUE TABLE continued 5 To find the grade of the screw that is to be installed match the markings on the head to the correct picture of CAPSCREW HEAD MARKINGS on the table CAPSCREW HEAD MARKINGS Manufacturer s marks may vary These are all SAE Grade No 5 3 lines 6 Look down the column under the picture found in step 5 until the torque limit in foot pounds for the diameter and threads per inch of the screw being Installed is found Table E 1 Torque Limits for Dry Fasteners SAE CAPSCREW HEAD MARKINGS DIA THREADS me FOOT IN PER INCH POUNDS 20 5 28 6 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 1233 96 1342 44 1064 80 1735 70 1193 30 1952 80 s 2467 90 2712 00 1979 80 3227 30 2278 10 3688 30 2630 60 4285 00 2963 20 4827 40 E 2 TM 9 2815 250 24 amp P E 3 HOW TO USE TORQUE TABLE continued Table E 2 Torque Limits for Wet Fasteners SAE CAPSCREW HEAD MARKINGS SAE GRADE No 10r2 9 76 12 20 22 54 23 18 37 84 42 71 59 80 67 12 91 53 103 73 134 24 146 45 183 06 207 47 329 51 360 20 482 06 530 87 720 04 1110 56 805 46 1208 20 976 32 1562 13 1073 97 1757 52 2221 11 2440 80 1781 82 2904 57 2050 29 3319 47 2367 54 3856 50 2684 88 4344
8. 44 45 46 kkk 47 48 49 50 k 51 52 2 SMR PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ KFFZZ PAFZZ PAFZZ PAFZZ KFFZZ PAFZZ PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 3 NSN 2990 01 454 7609 5315 01 399 6107 5360 01 399 5014 2990 01 454 8630 5331 01 399 6978 5325 01 400 0999 5305 01 406 0000 2990 01 454 9173 5305 01 406 0009 5310 01 405 9890 5305 01 455 1246 5360 01 399 5016 2990 01 454 9177 5310 01 405 9912 5310 01 455 8481 5305 01 274 1064 5330 01 120 2966 5999 01 116 8286 5305 01 406 0011 5305 01 406 0010 5305 01 406 0006 5305 01 406 0007 5305 01 455 1248 5310 01 399 7301 2990 01 454 9202 5365 01 455 0004 2990 01 454 9214 5360 01 399 5017 5340 01 454 9278 2990 01 454 8635 5340 01 406 1645 2990 01 455 0084 5315 01 081 4488 4730 01 103 3202 5310 01 090 0938 5305 01 406 0007 5305 01 455 1250 5340 01 526 2574 5310 01 525 7457 5305 01 264 6247 TM 9 2815 250 24 amp P 4 CAGE 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 6
9. NOTE Remove nuts and adjusting screws only if damaged 4 Remove two nuts 4 and adjusting screws 5 from two rocker arms 6 and 9 If damaged discard nuts and adjusting screws b INSTALLATION NOTE There are two rocker arm assemblies on the engine Repeat steps 1 through 4 to install both of them f nuts or adjusting screws need to be replaced do step 1 If not go to step 2 1 Install two new nuts 4 on two new adjusting screws 5 Install two adjusting screws 5 on two rocker arms 6 and 9 2 Place two rocker arms 6 and 9 on rocker arm bracket 8 and secure with two new retaining rings 1 3 To determine if shims 2 or 3 are needed A use a feeler gage to measure play between rocker arm bracket 8 point A and inside edge of rocker arm 6 or 9 point B This SER measurement should be between 0 004 and 2 0 008 inch 0 1 mm and 0 2 mm Remove 16 two retaining rings 1 from rocker arm N bracket 8 and install shims 2 or 3 as NS needed to achieve this distance Reinstall retaining rings 1 in rocker arm bracket 8 o CAUTION To ensure adequate lubrication rocker arm bracket must be installed with the oil hole on the bottom 4 Apply sealing compound Item 16 Appendix D to threads of studs 10 Install rocker arm bracket 8 on two fj studs 10 and secure with two new self locking nuts 7 Torque nuts to 17 ft lb 23 N m FOLLOW ON TASKS e Adjust valves para 3 18 In
10. 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 5 PART NUMBER 50315500 03787300 03784501 03791400 03171800 50405200 01247200 01247210 03785201 50038400 50065100 50128100 50231900 50279200 03792800 03792900 03793000 03793100 03793200 03793300 03793400 03971200 03971300 04090600 04090700 04110800 04110900 03781000 END OF FIGURE col 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 2911 CRANKCASE CYLINDER SLEEVE AND CYLINDER HEAD FIGURE CYLINDER HEAD BOLT EYE UOC APP WASHER FLAT o ooooooooooooo NUT PLAIN HEXAGON e SEAL CAP VALVE STEM CYLINDER HEAD DIESE CYLINDER HEAD DIESE GUIDE VALVE STEM STUD PLAIN ooooococoooo ooo STUD PLAIN 20 STUD PLAIN 6 ccc eee RR RRR RT BR STUD PLAIN o ooooooococooo eee STUD PLAIN o oooooooooo o ooo GASKET 0 01247702 GASKET 0 01247702 GASKET 0 GASKET 0 GASKET 1 GASKET 1 GASKET 1 GASKET 0 GASKET 0 GASKET 0 GASKET 0 GASKET 0 GASKET 0 60 MM PART OF KIT P N STUD PLAIN eee eee eee APJ Item 7 QTY lt III lt lt lt lt lt S lt S lt H B amp B amp NNN PENN p W O U H TM 9 2815 250 24 amp P C01 SECTION II 29i099 LASG W 7 off gy 5 J N KANT ja
11. LEVER SPEED CONTROL WASHER FLAT oo ocean WASHER LOCK lees SCREW MACHINE eee WIRE MESH KNITTED o SCREW MACHINE lese UOC APP SCREW MACHINE eee UOC APJ SCREW MACHINE eene SCREW MACHINE eee SCREW CAP SOCKET HE WASHER SPRING TENSI LEVER GOVERNOR oo ooooooooo SPACER STRAIGHT oo oooo oo LEVER GOVERNOR eee SPRING HELICAL COMP s PLATE MOUNTING eee GASKET PART OF KIT P N 01247702 STOP LEVER GOVERNOR STUD M6 X 16 see CLIP SPRING TENSION O RING PART OF KIT P N 01228002 LEVER ASSEMBLY POWE EXTRA FUEL DEVICE A SSEMBLY 2G40 14 PIN SPRING 00m ai 9 gra c6 a e BOLT FLUID PASSAGE WASHER FLAT oo con 0000 cece ee ooo PIPE OIL eset to tai ade eS SCREW CLOS 0 0 00 ln SUPPORT NUT PLAIN HEXAGON o oooo o SCREW GRUB lee SCREW GRUB eee SCREW ALLEN o oo oo oooooooooo SCREW SOCKET HEAD sees 7 QTY he H HpHBPHHNHHHHUHHHBHNH H HHHNHHH HH HBHHBpHH H tu QHpPHHHHHBHpBB BHBHBp BHBNHBHHBH SECTION II TM 9 2815 250 24 amp P J A E f E 1 M R4 A 3 p Vif GEN SG EL qi NT SA 1 2 N a A Ie Aj AUGE Sl ad A Ste SF ZA gt ea Wh ER SEA Pd S Ne EY pa
12. NOTE A note highlights an essential operating or maintenance procedure condition or statement 2 Warnings and cautions appear immediately preceding the step to which they pertain It is important to read and thoroughly understand the warnings and or cautions before beginning maintenance 3 Notes may precede or follow the steps to which they pertain depending on what makes the most sense TM 9 2815 250 24 amp P SAFETY SUMMARY This safety summary contains general safety precautions and hazardous materials warnings that must be understood and applied during maintenance to protect personnel and U S Department of Defense property Portions of this summary may be repeated elsewhere for emphasis WARNING and CAUTION statements appear throughout this manual prior to procedures practices or conditions that may endanger personnel WARNING or cause equipment and property damage CAUTION A warning or caution will apply each time the related step is repeated Before starting any task review and understand the warnings and cautions included in the text for that task This manual contains procedures that may require using chemicals solvents paints or other commercially available material that may pose a health or safety hazard Refer to the Materials Parts list at the beginning of a task to see which materials will be used during the task Obtain material safety data sheets Occupational Safety and Health Act OSHA Form 20 or equivalent
13. SMR PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAFZZ KFFZZ PAFZZ PAFZZ PAFZZ PAFZZ KFFZZ PAFZZ PAFZZ PAOZZ PAFZZ PAFZZ PAFZZ PAFZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAFZZ PAFZZ PAFZZ KFFZZ PAFZZ PAOFF PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ Refer to 3 NSN 5305 01 405 9906 5310 01 090 0938 4730 01 454 7549 4730 01 454 7692 4730 01 454 7693 4730 01 103 3202 4710 01 454 7687 2805 01 488 7755 5340 01 454 9280 5310 01 400 2139 5305 01 406 0004 4730 01 454 7461 2815 01 455 0042 5305 01 455 1243 5305 01 492 8775 5310 01 239 2390 5310 12 149 4353 2940 01 383 9739 5330 01 101 8076 4820 01 406 0343 5310 01 399 8386 5310 01 400 3719 5331 01 400 5778 2590 01 454 8941 4710 01 454 7688 5305 01 405 9998 5340 01 454 9281 5330 01 399 6976 TM 9 2350 292 24P and TM 9 2350 292 20 2 for UOC TM 9 2815 250 24 amp P 4 CAGE 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 END OF 5 PART NUMBER 50033300 50000900 03790001 03932100 03790100 50006100 01224900 01227910 50310500 50310400 50216300 50025200 50301400 50301500 03938610 50301601 50341900 50207900 50342000 500 812 00 50144500 50043800 50548200 50448100 50302800 50001
14. from crankshaft 2 6 Using relief valve puller remove relief valve 7 from lower crankcase 5 UPPER CRANKCASE 3 26 TM 9 2815 250 24 amp P 3 7 CRANKSHAFT AND BEARINGS REPAIR continued b INSPECTION Inspect crankshaft for scoring nicks and excessive wear Replace if necessary Inspect bushing 2 1 internal threads for damage Bushing 2 1 should not be removed unless damaged A C 1 2 2 1 2 2 INSTALLATION Install relief valve 7 in lower crankcase 5 with grooved side facing auxiliary drive side of engine Install crank gear 1 on crankshaft 2 Make sure timing mark is facing end of crankshaft 2 If installing bushing 2 1 apply primer Item 19 Appendix D to threads of bushing Apply loctite 271 Item 20 Appendix D to threads of bushing 2 1 Torque to 20 lb ft 27 Nem Allow to cure for 6 hours before assembly Apply sealing compound Item 16 Appendix D to new seal 3 Install seal 3 on crankshaft 2 with lip facing inward Install flow control valve 8 in lower crankcase 5 with eccentric at approximately the 11 o clock position Tighten flow control valve 8 into lower crankcase 5 until it projects 3 4 inch 1 9 1 mm from lower crankcase 5 Apply sealing compound Item 21 Appendix D to sleeve bearing halves 4 and bearing surfaces Install three new sleeve bearing halves 4 in three upper crank supports 9 and install three sleeve bearing
15. 04039100 40002500 40021400 40021500 40028400 49004400 49004700 50000900 sooo1100 50019800 n sooseno 50061700 Nimi sooes to 50114300 50146000 5330 01 415 6723 2815 01 455 0428 5330 01 415 6721 5365 01 100 5416 5365 01 100 5417 3120 01 416 3110 5365 01 455 001 1 5340 01 454 9272 5340 01 454 9273 5330 01 120 2966 5999 01 116 8286 5310 01 101 2028 5330 01 101 7264 5310 01 090 0938 5330 01 080 1776 5360 01 399 4615 5365 01 245 3517 5315 01 399 6107 5310 01 274 4387 5130 01 274 3165 5310 01 399 7305 5310 01 400 2138 Spring Tension Washer Crankcase Gasket Set Piston Ring Set Head Gasket Set Gasket Set Shim 0 2 mm Shim 0 3 mm Sleeve Bearing Gasket Shim 0 3 mm Cap Plug Cap Plug Blind Rivet Seal Wire Mesh Self Locking Nut Gasket O Ring Washer Gasket Retaining Ring Retaining Ring Cotter Pin Lockwasher Lockwasher Lockwasher Spring Tension Washer Appendix ppend Appendix Appendix ppend Appendix Appendix ppend Appendix Appendix ppend Appendix Appendix Appendix Appendix Appendix ppend Appendix Appendix ppend Appendix Appendix gt 2 ppendix C TM 9 2815 250 24 amp P Change 1 TM 9 2815 250 24 amp P F 4 TM 9 2815 250 24 amp P APPENDIX G TOOL IDENTIFICATION LIST Section I INTRODUCTION Paragraph Page Number Paragraph Title Number G 1 Generale IS G 1 G 2 Explanation of
16. 3 20 TM 9 2815 250 24 amp P 3 6 CRANKCASE REPAIR continued 4 Remove nut 21 two washers 3 and screw 4 from upper crankcase 23 and lower crankcase 22 on injection pump side of engine 5 Remove three nuts 5 washers 20 and screws 19 from upper crankcase 23 and lower crankcase 22 on injection pump side of engine 6 Remove three nuts 14 six washers 9 and three screws 8 from upper crankcase 23 and lower crankcase 22 on starter side of engine 7 Remove two nuts 10 four washers 11 two screws 13 and air duct bracket 12 from upper crankcase 23 and lower crankcase 22 3 21 TM 9 2815 250 24 amp P 3 6 CRANKCASE REPAIR continued 10 11 3 22 Remove upper crankcase 23 from eight studs 24 on lower crankcase 22 Set upper crankcase 23 top down on work surface Inspect eight studs 24 and remove any bent or damaged studs from lower crankcase 22 Discard removed studs Remove two gaskets 25 and 26 from upper crankcase 23 Discard gaskets Remove eight O rings 27 from eight grooves in upper crankcase 23 Discard O rings ASSEMBLY Apply grease to eight new O rings 27 Install eight O rings 27 on eight grooves in upper crankcase 23 Apply sealing compound to ends of two new gaskets 25 and 26 Lightly coat the rest of each gasket 25 and 26 with lubricating oil Install two gaskets 25 and 26 on upper cra
17. 3A 3B CLOSE FIT NOMINAL SIZE IT NO THREADS INCH THREAD SYMBOL ee EEE THREAD CLASS U U U U i 3 4 10 UNC 2A NOTE Unless followed with LH e g 314 10 UNC 2A LH threads are right hand LENGTH m BOLT SHANK THICKNESS 1 OR HEIGHT BODY LENGTH GRIP HEIGHT OF HEAD LENGTH OF NUT M N L m MN KU A zu E D LENGTH tt LENGTH TM 9 2815 250 24 amp P E 6 FASTENER GRADE In addition to being classified by thread type thread fasteners are also classified by material The most familiar fastener classification system is the SAE grading system Table E 5 Table E 5 SAE Screw and Bolt Markings SAE GRADE 2 SAE GRADE 6 NO MARKING 4 RADIAL DASHES 90 APART SAE GRADE 3 2 RADIAL DASHES SAE GRADE 7 180 APART 5 RADIAL DASHES 72 APART SAE GRADE 5 3 RADIAL DASHES SAE GRADE 8 120 APART 6 RADIAL DASHES 60 APART Markings on Hex Locknuts GRADE A No Marks GRADE A No Marks GRADE B 3 Marks GRADE B Letter B GRADE C 6 Marks GRADE C Letter C GRADE A No Notches GRADE B 1 Notch GRADE C 2 Notches E 5 E 6 blank TM 9 2815 250 24 amp P APPENDIX F MANDATORY REPLACEMENT PARTS Paragraph Page Number Paragraph Title Number F 1 ee 05 e O M ee F 1 F 2 Explanation Of Columns cS F 1 Table F 1 Mandatory Replacement Parts List eene a aan nnne nnne F 2 F 1 GENERAL This append
18. Cylinder alignment bracket Cylinder compression tester Cylinder ridge reamer Depth gage rule Drill set Electric drill Fuel test set Fuel testing device General mechanic s tool kit General mechanic s tool kit automotive Indicator dial Mechanical gear and bearing puller kit Mechanical hand held tachometer Multimeter Oil pressure test set Section Il TOOL IDENTIFICATION LIST 3 4 5 Stock Number Item Name Reference 3444 00 449 7295 5120 00 017 2849 6150 00 682 3460 4910 00 808 4300 5110 00 237 8598 5210 00 221 1902 5133 00 293 0983 5130 00 889 9004 5180 00 699 5273 5180 00 177 7033 5210 00 277 8840 5180 00 423 1569 6680 00 171 4584 6625 01 139 2512 A A 51194 98 11647741 62574700 62574801 62574200 MIL G 5353 Type 2 MIL C 82069 MC103A DB129B WD00661 60462890 66503191 SC 5180 90 CL N05 SC 5180 90 CL N26 196A GGG P 781 4800 T00377 62092692 TM 9 2815 250 24 amp P SC 4910 95 A31 SC 4910 95 CL A74 SC 4910 95 CL A74 TM 9 2815 250 24 amp P TM 9 2815 250 24 amp P NA SC 4940 95 B02 SC 4910 95 A63 SC 3470 95 A02 SC 4910 95 CL A72 SC 4910 95 CL A74 TM 9 2815 250 24 amp P TM 9 2815 250 24 amp P SC 5180 90 CL N05 SC 5180 90 CL N26 SC 4910 95 A63 SC 4910 95 A31 SC 4910 95 A31 SC 4910
19. Installation drawing diagram instruction sheet or field service drawing hat is identified by manufacturer s part number Item is not stocked Order an XD coded item through normal supply channels using the CAGEC and part number given if no NSN is available 2 Maintenance Code Maintenance codes tell you the level s of maintenance authorized to use and repair support items The maintenance codes are entered in the third and fourth positions of the SMR code as follows a The maintenance code entered in the third position tells you the lowest maintenance level authorized to remove replace and use an item The maintenance code entered in the third position will indicate authorization to one of the following levels of maintenance Code Application Explanation C Crew or Operator maintenance done within Unit maintenance or Aviation Unit maintenance O Unit maintenance or Aviation Unit can remove replace and use the item Direct Support or Aviation Intermediate level can remove replace and use F the item General Support level can remove replace and use the item H Specialized repair activity SRA can remove replace and use the item L Depot level can remove replace and use the item D NOTE If authorized by the maintenance allocation chart MAC and SMR codes some limited repair may be done on an item at a lower level of maintenance b The maintenance code entered in the fourth position tells whether the item is
20. Meter 10 000 Sq Centimeters 10 76 Sq Feet 1 Sq Kilometer 1 000 Sq Meters 0 386 Sq Miles CUBIC MEASURE 1 Cu Centimeter 1000 Cu Millimeters 0 06 Cu Inches 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet TEMPERATURE 5 9 F 32 C 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32 2 Celsius 32 Fahrenheit is equivalent to 0 Celsius 9 5 x C 32 F TO CHANGE TO MULTIPLY BY Inclies rca id Centimeters 2 540 Feet d cu eet Meters esee tied ewes 0 305 Yatds o sd RR e RA Meters ommaan nns 0 914 Miles wc ca eer Res Kilometers suse 1 609 Square Inches Square Centimeters 6 451 Square Feet ususue Square Meters 0 093 Square Yards Square Meters 0 836 Square Miles Square Kilometers 2 590 AGIOS t dia sea d Square Hectometers 0 405 Cubic Feet usa cant Cubic Meters 0 028 Cubic Yards sess Cubic Meters 0 765 Fluid Ounces Milimeters 29 573 A Lepus Liters a Len ete ea 0 473 Quarts ona retar LOS qua ener 0 946 Gallons eee eee eee EMOS ern Fd mex mni Minn 3 785 OUNCES sees nenne Grams aussen 28 349 Ponds 22 en Kilograms 22 0 454 Sh rt TONS uri Metric Tons
21. Remove screw 9 and speed control lever 6 from crankcase 10 Remove two nuts 11 and two screws 12 from speed control lever 6 Remove nut 13 and screw 14 UOC APP oa o Lac N C m LY NS m CO mu Dad 29i214m 3 54 Change 1 TM 9 2815 250 24 amp P 3 16 GOVERNOR CONTROL ASSEMBLY REPAIR continued op EN o DARONA 7 DISASSEMBLY Remove screw 15 spring tension washer 16 two levers 17 and 18 and bushing 19 from mounting plate 20 Discard spring tension washer Remove stop lever 21 and spring 22 from mounting plate 20 Remove O ring 23 from stop lever 21 Discard O ring Remove spring pin 24 lever 25 and spring 26 from extra fuel device 27 ASSEMBLY Install new O ring 23 to stop lever 21 Install stop lever 21 and spring 22 into mounting plate 20 Install screw 15 new spring tension washer 16 two levers 17 and 18 and bushing 19 into mounting plate 20 Install spring 26 lever 25 and spring pin 24 to extra fuel device 27 EPA compliant engines only 29i213m INSTALLATION Install two screws 12 and two nuts 11 on speed control lever 6 Install screw 14 and nut 13 UOC APP Install screw 9 and speed control lever 6 on crankcase 10 Install spring 5 lever 4 washer 3 new lockwasher 2 and screw 1 on speed control lev
22. The CAGEC is a five digit alphanumeric code used to identify the manufacturer distributor or Government agency tc that supplies the item PART NUMBER Column Indicates the primary number used by the manufacturer individual firm corporation or Government activity which controls the design and characteristics of the item by means of its engineering drawings specifications standards and inspection requirements to identify an item or range of items STOCK NUMBER Column This column lists the NSN for the associated part number and manufacturer identified in the PART NUMBER and CAGEC columns to the left FIG Column This column lists the number of the figure where the item is identified located in Section Il and Section III ITEM Column The item number is that number assigned to the item as it appears in the figure referenced in the adjacent figure number column C 5 SPECIAL INFORMATION C 6 Usable on Code Uncoded items are applicable to all models usable on code for the M88A2 HERCULES items is APJ Usable on code for all other applications is APP Fabrication Instructions Not applicable Assembly Instructions Not applicable Kits Not applicable Index Numbers Not applicable Change 1 TM 9 2815 250 24 amp P C 5 SPECIAL INFORMATION continued b Fabrication Instructions Not applicable C Assembly Instructions Not applicable d Kits Not applicable e Index Numbers Not applicable
23. automotive Item 15 e Screwdriver attachment 6 mm Item 24 e Socket wrench set 3 8 inch drive Item 27 Materials Parts e Gasket set 2 Item 4 Appendix F a REMOVAL TM 9 2815 250 24 amp P b Installation Gasket 2 Item 8 Appendix F Self locking nut 4 Item 15 Appendix F Spring tension washer 4 Item 25 Appendix F Spring tension washer 8 Item 31 Equipment Conditions e Valve vent removed para 2 22 e Airflow deflectors removed as needed to permit replacement of air intake manifold para 2 24 1 Remove four socket head screws 5 and spring tension washers 4 adapter 3 and four part gasket 2 from Intake manifold 1 Discard spring tension washers and gasket 2 15 TM 9 2815 250 24 amp P 2 21 INTAKE MANIFOLD REPLACEMENT continued 2 2 16 Remove two socket head screws 8 and socket head screws 9 four washers 7 spring tension washers 15 and nuts 16 access cover 14 and four part gasket 6 from intake manifold 1 Discard spring tension washers and gasket Remove four self locking nuts 10 and spring tension washers 11 intake manifold 1 and two gaskets 12 from four studs 13 Discard self locking nuts spring tension washers and gaskets INSTALLATION Install two new gaskets 12 intake manifold 1 and four new spring tension washers 11 and new self locking nuts 10 on four studs 13 Install new four part gasket 6 access c
24. automotive Filter element Item 35 Appendix F Item 15 e Strap wrench Item 29 Appendix G Materials Parts e Drycleaning solvent Item 4 Appendix D Lubricating oil Item 6 Appendix D a REMOVAL 1 Remove filter element 4 from filter mount 3 Discard filter element 2 Remove strainer element 1 from safety relief valve 2 Change 1 2 13 TM 9 2815 250 24 amp P Il 2 20 FILTER ELEMENT REPLACEMENT UOC APP continued b CLEANING WARNING Compressed air used for cleaning or drying purposes or for clearing restric tions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to personnel Clean strainer element 1 with compressed air WARNING Drycleaning solvent P D 680 is toxic and flammable Always wear protective goggles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open flame or excessive heat Clean sealing surface 5 with drycleaning solvent and rag INSTALLATION Install strainer element 1 on safety relief valve 2 Apply light coat of oil to sealing ring of new filter element 4 Install filter element 4 on filter mount 3 FOLLOW ON TASKS e None 2 14 Change 1 2 21 INTAKE MANIFOLD REPLACEMENT This Task Covers a Removal Initial Setup Tools Test Equipment e General mechanic s tool kit
25. some 2 13 Flow Control Valve Adjustment 006 cece need need ms 3 60 H Flywheel and Housing Replacement ssueeeeeee RR 3 28 FOM S udis A at dada Ser acme a desde Le Nor Resse pd rede he 1 1 A 1 Fuel Injector Replace ment wt sssusa Press EET set Lis LPRYGANBSOPRUSECRLhPRE al 3 48 2 SE MEE M Cc M P UE MED 3 66 Fuel Pressure Pipe Assemblies and Return Fuel Hose Replacement 0 cee eee eee eee es 2 20 G Governor Control Assembly Repair 00 cc cece tenet ene ee etna 3 54 H Hose and Tube Tagging Vitrina queso ter ated geal ade Qh ead ae eee Mar eta dt E eda eens 2 6 l Identification Plate Replacement soon 2 7 gold occ iv Injection Pump Replace Mensual a A A A e A 3 50 Ti a aaa tl e util MAL DIN Aii e SEE 3 65 Inspection Instr ctiolis erahnen een nds nica pair R ricca arg 2 2 2 5 Intake Manifold Replacement sos ssh 2 15 L Lubrication InStr CllOriS s s i e e PUER CER L dante e m FTN CURIE LAT 2 6 M Maintenance Allocation Chart oooooococ e rrr B 4 Maintenance Forms Records and Reports oooococccccc hes 1 1 Maintenance Function 2 vae Rer her ee ee ee ee a are a a Eee c B 1 Maintenance Procedures Direct Support and General Support A Auxiliary Drive Adapter Replacement sos tenet n 3 14 1 Gamshaft Rep lt nos cds bene ala e ae Dad Gata ios 3 40 Grankcase Repair xicos aras Gore Rare os RE lene Rcs Geb eeu da 3 20 Index 2 Change 1 TM 9 2815 250 24 amp P SUBJECT P
26. 11 03225504 1 1 04090700 3 11 03233200 8 24 04092800 8 30 03233300 8 24 04092810 8 30 03780800 12 9 04110800 3 11 03781000 3 12 04110900 3 11 03781100 7 7 04125000 9 28 03781300 7 6 2 05034900 4 10 PART NUMBER 05063800 05063900 05064010 05094600 05184200 05184800 05185400 05186900 12367094 12367105 12463204 12478232 12478232 2 12478232 3 12478232 4 12478232 5 12478240 3418502037 3715M 40002500 40021400 40021500 40028400 40085001 40092600 49003500 49003900 49004300 49004400 49004700 49061200 500 812 00 500 254 00 50000900 50001100 50001200 50006100 50010500 50011200 50015700 50015800 50019800 50020000 50025200 50026400 50033300 50034100 50036000 50038400 50043800 50052000 50052100 50054300 50055100 50061700 50065100 50092100 FIG 16 13 16 16 13 13 13 13 BULK oO W N U N b TM 9 2815 250 24 amp P C01 CROSS REFERENCE INDEXES PART NUMBER INDEX ITEM 1 23 16 14 40 1 47 46 41 1 2 Oo Ov Wes W aun FP HH H r m ANF v 17 17 1 51 17 11 16 PART NUMBER 50093400 50095100 50098300 50098500 50114300 50128100 50137000 50139201 50144400 50144500 50145900 50146000 50146300 50148000 50148100 50149100 50157800 50162900 50165500 50170600 50170700 50170800 50170900 50175900 50177500 50180400 50183100 50195800 50206300 50207900 50208400 50208500 50216300 50225501 50231900 50268600 50274500
27. 135 mutaa Iesus 1 nad her tt 0 icon esr el 0 DA nimaan naita maito 1 3518 eiit it tio 0 Qa se cnet D M ote 1 PE EE tesis 0 319 EE AN 1 eE E trey Ul br T 1 2 16 ARE Eu 0 3 20 zia da 0 a 1 DAT E 0 A iia 0 ds ex dis 1 2 18 ize ek RE 0 Sana ETA idit eios 1 JTD OS stc o a 0 Zero in this column indicates an original page Change 1 A TM 9 2815 250 24 amp P Page Change No No DO an 0 9 5B ne tete ATA 0 Cols nc tede dtes 0 Seinen 1 Sol rien 0 tiara da 0 SOI ELS 0 S204 CES 1 Cr E 1 QD iret ertet uds 1 airada ade 0 9 09 16 erhife rotura uds 1 S269 EEE ENS 1 SAO m at aide 0 ltda 0 3 72 blank 0 Bd cats eus 1 BED ups Iu 1 Bla ate 0 Bane mata lite 0 Do dida 0 BA ena ito 0 E AAE 0 a E 0 Cal EE P A TETTA 0 ED ieaie Aa 0 CSa a isa 0 TERR 0 Conrad 0 Orto 1 Oia atiende 1 Figure Nun en 0 Ile aid 0 Figure 2 sess 1 La 1 Figura 3 a 1 Slate 1 Figure Asasina n 1 B Change 1 Page Change No No A d siete tete 1 Figure Dina 1 Bells la ie 1 Figure 6 nahe 1 Mean 1 FOUE 7 ee 1 7 1 Figure Biene 1 Ola etes 1 RA sedet eu 1 95d nts docete 1 Figure 10 riait 0 TOT inu atteinte rct derit 1 Figure A e niaan nnen 0 o E 1 Figure 12 ueenessnenennnnnnnennnnnn 1 TON a ech 1 12 2 blank added 1 Figure 13 SH 1 of 2 1 Figure 13 SH 2 of 2 added 1 it ie ret hes 1 13 2 blank added 1 Figure 14 SH 1 of 2 0 Figure 14 S
28. 2 of injection pump 3 WARNING Fuel spray on hot components is an extreme fire hazard Control leakage immediately to prevent serious injury to personnel d Crank engine and observe indicator dial 1 Reading should be between 250 and 258 bars lf reading is incorrect replace injection pump para 3 15 E e Remove indicator dial 1 tube assembly Sy 5 and extension tube 4 from flywheel EI side port 2 of injection pump 3 i iE f Install fuel injector on engine para 3 14 S g Install fuel pressure pipe assembly and fuel pressure pipe clamp para 2 23 h Repeat steps a through g for port on auxiliary drive side of injection pump FOLLOW ON TASKS e Install airflow deflectors UOC APP para 2 24 Install airflow deflectors UOC APJ TM 9 2350 292 20 2 Change 1 3 65 TM 9 2815 250 24 amp P 3 21 FUEL INJECTOR TEST This Task Covers Test Initial Setup Tools Test Equipment Equipment Conditions Fuel test set Item 12 Appendix G e Airflow deflectors removed as needed UOC e General mechanic s tool kit automotive APP para 2 24 Item 15 Appendix G e Air flow deflectors removed as needed UOC APJ TM 9 2350 292 20 2 e Injection pump test performed para 3 20 TEST NOTE There are two fuel injectors on the engine Use this procedure to test either one a Remove fuel pressure pipe clamp and fuel pressure pipe assembly from fuel injector to be tested para 2 23 b Remo
29. 40 NSN 2815 01 446 3500 NSN 2815 01 465 4321 REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication If you find any mistakes or if you know of a way to improve the procedures please let us know Submit your DA Form 2028 Recommended Changes to Equipment Technical Publications through the Internet on the Army Electronic Product Support AEPS website The Internet address is https aeps ria army mil The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page Fill out the form and click on SUBMIT Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program You may also mail fax or E mail your letter or DA Form 2028 direct to AMSTA LC LMIT TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 The email address is TACOM TECH PUBS ria army mil The fax number is DSN 793 0726 or Commercial 309 782 0726 Approved for public release distribution is unlimited TABLE OF CONTENTS Page HOW TO USE THIS MANUAL ssssssssse RII hh INTRODUCTION Section General Information ooo ees Section II Equipment Description and Data ooo n 1 4 Section III Principles of Operation moon 1 9 Change 1 i CHAPTER 2 Section Section II Section III Section IV CHAPTER 3 Section Section II Section III APPENDIX A APPENDIX B Section
30. 454 8843 2590 01 454 8941 2815 01 454 9103 2990 01 454 9173 2990 01 454 9177 2990 01 454 9202 2815 01 454 9210 2990 01 454 9214 2815 01 454 9237 5340 01 454 9270 TM 9 2815 250 24 amp P C01 CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX FIGURE NO 13 13 13 8 4 9 13 12 5 3 12 8 8 12 H o O N 09 0 0 W N 13 13 14 13 14 14 ITEM NO 8 1 18 18 23 5 22 30 36 7 8 13 18 19 19 6 16 1 11 1 20 N Wr WAIODOWNHA PHN H H wo v STOCK NUMBER 5340 01 454 9271 5340 01 454 9272 5340 01 454 9273 5340 01 454 9275 5340 01 454 9277 5340 01 454 9278 5340 01 454 9280 5340 01 454 9281 5340 01 454 9284 2815 01 454 9344 5340 01 454 9940 5365 01 455 0004 5340 01 455 0010 5365 01 455 0011 5365 01 455 0012 2815 01 455 0039 2815 01 455 0040 2815 01 455 0041 2815 01 455 0042 2815 01 455 0043 2815 01 455 0046 2815 01 455 0054 2815 01 455 0056 2990 01 455 0084 2815 01 455 0085 2815 01 455 0364 2815 01 455 0371 2815 01 455 0376 2815 01 455 0423 2815 01 455 0428 5305 01 455 1242 5305 01 455 1243 5305 01 455 1245 5305 01 455 1246 5305 01 455 1247 5305 01 455 1248 5307 01 455 1249 5305 01 455 1250 5305 01 455 1251 5305 01 455 1613 5305 01 455 1615 5305 01 455 1619 5305 01 455 1622 5307 01 455 2205 5305 01 455 2206 5305 01 455 2207 5307 01 455 2210 5306 01 455 2212 5340 01 455 2343 3020 01 455 2798 3040 01 455 2816 3010 01 455 2856 4820 01 455 5017 4820 01 455 5
31. 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 END OF 9 2815 250 24 amp P 5 PART NUMBER 50334600 50315400 50144500 50333800 03784400 01133200 50170900 50170700 50208500 50098500 50289200 01129900 03920100 99400648 01133300 50334800 50317800 50165500 03784300 01226100 01445200 50144400 03958100 50293200 50405600 50170600 50408500 FIGURE 14 1 col 6 DESCRIPTION AND USABLE ON CODE UOC EET ENGINE COWLING ENGINE COWLING DUCTS AND SHROUD SCREW MACHINE ooooooooo oo ooo WASHER SPLIT o o ooooooooooo WASHER FLAT sores tuce tert EEROR E EEEE E SCREW MACHINE oooooooooo ooo DEFLECTOR AIRFLOW UOC APP BRACKET AIR DUCT o ooooooo o UOC APP WASHER SPRING TENSI SCREW MACHINE oooooocooooo ooo WASHER SPRING TENSI SCREN MACHINE e e nn ms SCREW MACHINE ooooooooooo ooo DEFLECTOR AIRFLOW UOC APP SPACER SLEEVE celeres UOC APP DEFLECTOR AIRFLOW UOC APP BRACKET AIR DUCT ees UOC APP SLEEVE REINFORCING SCREW CAP HEXAGON H UOC APP SCREW CAP HEXAGON H s BRACKET AIR DUCT oo ooooo SHEET CLAMPING eee DEFLECTOR AIRFLOW eese UOC APP N
32. 66 E 4 TIGHTENING METAL FASTENERS When torguing a fastener select a torgue wrench whose range Table E 3 p E 4 fits the reguired torgue value A torgue wrench is most accurate from 25 percent to 75 percent of its stated range A torque wrench with a stated range of 0 to 100 will be most accurate from 25 to 75 foot pounds The accuracy of readings will decrease as you approach 0 foot pounds or 100 foot pounds The ranges in Table E 3 are based on this principle E 3 TM 9 2815 250 24 amp P E 4 TIGHTENING METAL FASTENERS continued Table E 3 Torque Ranges STATED RANGE MOST EFFECTIVE RANGE 0 600 ft lb 150 450 ft lb 0 170 ft lb 44 131 ft lb 15 75 ft lb 30 60 ft lb E 5 FASTENER SIZE AND THREAD PATTERN Threaded fasteners are categorized according to diameter of the fastener shank Thread styles are divided into broad groups the two most common being coarse Unified Coarse UNC and fine Unified Fine UNF These groups are defined by the number of threads per inch on the bolt shanks In addition threads are categorized by thread class E 4 which is a measure of the degree between threads of bolt or screw external threads and threads of the attaching nut or tapped hole internal threads of the attaching nut or tapped hole internal threads The most common thread class for bolts and screws is Class 2 Table E 4 Thread Classes and Description EXTERNAL INTERNAL INTERNAL 1A 1B LOOSE FIT 2A 2B MEDIUM FIT
33. 7 Appendix DJ 2 Remove grease and accumulated deposits with a stiff bristled brush TM 9 2815 250 24 amp P 2 9 CLEANING INSTRUCTIONS continued WARNING Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing goggles shield gloves etc and use caution to avoid injury to personnel 3 Clear out all threaded holes with compressed air to remove dirt and cleaning fluids CAUTION Do not wash oil seals electrical cables and flexible hoses with drycleaning solvent or mineral spirits Serious damage or destruction of material would result d Oil Seals Electrical Cables and Flexible Hoses Wash electrical cables and flexible hoses with a solution of water and dishwashing soap and wipe dry e Bearings Clean bearings in accordance with TM 9 214 2 10 INSPECTION INSTRUCTIONS NOTE All damaged areas should be marked for repair or replacement a All components and parts must be checked carefully to determine if they are serviceable for reuse can be repaired or must be scrapped b Inspect drilled and tapped threaded holes for the following 1 In or around holes wear distortion stretching cracks and any other damage 2 Threaded areas wear distortion stretching and evidence of cross threading c Inspect metal lines tubes flexible lines hoses and metal fittings and connectors for the following 1 Metal lines
34. 9 5 PAOZZ 61080 50333400 NIPPLE HOSE eee 10 PAOZZ 5330 01 405 9900 61080 50313100 GASKET PART OF KIT P N 01247702 11 PAOZZ 4730 01 399 4254 61080 50313000 BOLT FLUID PASSAGE 12 PAFFF 2910 12 338 8683 61080 50355400 PUMP FUEL METERING 12 PAFFF 61080 50493200 PUMP FUEL METERING 13 PAFZZ 4820 01 406 6143 61080 49061200 BODY VALVE ll 000 c cece ee 14 PAFZA 5331 01 101 8063 61080 49004700 PO RING san sans 15 PAFZZ 5340 01 100 4991 61080 49003900 PLUG VENT o ooooooooo nn 16 PAFZZ 5365 01 101 5938 61080 49004300 SHIM lees ee 17 PAFZZ 5360 01 458 0666 61080 49003500 SPRING HELICAL COMP 18 PAFZA 5330 01 101 7264 61080 49004400 JGASKET usd ore rbd 19 PAFZZ 4820 01 407 1908 53867 3418502037 VALVE PRESSURE EQUA 20 PAFZZ 61080 50312500 GASKET 0 30 MM none V 21 KFFZZ 61080 50312400 GASKET 0 20 MM PART OF KIT P N 01228002 l l 21 PAFZZ 61080 50552200 GASKET 0 30 MM 2G40 17 2G40 18 PART OF KIT P N 01228002 22 KFFZZ 61080 50312300 GASKET 0 10 MM PART OF KIT P N 01228002 2000 ines ERR RET SERES 22 1 PAFZZ 5307 01 405 9905 61080 50098300 STUD PLAIN enn 23 PAFZZ 5315 01 400 0445 61080 50312200 PIN STRAIGHT HEADLE 24 PAFZZ 4820 01 455 5018 61080 01231501 VALVE FLOW CONTROL 25 PAOZZ 5330 01 080 1776 61080 50001100 GASKET PART OF KIT P N 01228002 UOC APP 25
35. 95 A31 TM 9 2815 250 24 amp P TM 9 2815 250 24 amp P Section Il TOOL IDENTIFICATION LIST continued 1 2 3 4 5 Item National Number Part Number Stock Number Item Name Reference 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Piston ring com pressor Relief valve puller Screwdriver attachment 6 mm Screwdriver attachment 8 mm Snapring pliers Socket wrench set 3 8 inch drive Steel rule 12 inch Strap wrench Torque wrench 3 8 inch drive Torque wrench 1 2 inch drive Torque wrench 3 8 inch drive Valve face grinding machine Valve seat grinding kit Valve spring lifter Wrench Piston ring expander 5120 00 223 8848 5120 00 857 3190 5120 01 102 1670 5120 01 101 1943 5120 00 789 0492 5120 00 322 6231 5210 00 234 5224 5120 00 020 2947 5120 00 554 7292 5120 00 640 6364 5120 01 112 9531 44910 00 540 4679 4910 00 060 9983 5120 00 239 8686 51230 01 309 2048 J3272 03 PRS 8 62568902 J3516 A GIT 17595 4440R 512000 17510 GGG R 791 A91C GGG W 00686 1753 LDF TESI60 K403CM WG690 GGG L 350 3715M This torque wrench may be used instead of Item 30 if a metric torque reading is preferred SC 4910 95 A63 SC 4910 95 A31 TM 9 2815 250 24 amp P SC 4910
36. A Part of item 1 B Part of item 3 C Part of item 6 29i095 Figure 7 Pistons and Connecting Rods ITEM kkk kkk kkk kkk 1 NO J NN HOoOHrH H U p R W W W NHH H w 2 SMR PAFFF PAFFF PAFZZ PAFFF PAFFF PAFFF PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFFF PAFZZ XDFZZ XDFZZ PAFZZ 3 NSN 2835 01 414 8480 5365 01 455 0011 2815 01 455 0428 5325 01 455 8936 2815 01 414 1273 5305 01 406 0001 EPA Version 1 Compliant Only TM 4 CAGE 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 END OF 9 2815 250 24 amp P 5 PART NUMBER 01247100 01247110 03958000 01240203 01240211 01248303 01248311 01240301 01248701 50359110 50359000 50359010 01262200 03785300 03781300 03785600 03781100 FIGURE col 6 DESCRIPTION AND USABLE ON CODE UOC 7 QTY GROUP 2914 PISTONS AND CONNECTING RODS FIGURE 7 PISTONS AND CONNECTING RODS LINER COMBUSTION LINER COMBUSTION PISTON INTERNAL PISTON INTERNAL PISTON INTERNAL RING SET PISTON s RING SET PISTON OVERSIZE 0 5 MM RING RETAINING lees PIN PISTON 26G40 10 PIN PISTON o o ooooooooo ooo CONNECTING ROD PIST BEARING SLEEVE eese BEARING SLEEVE leere BEARING SLEEVE OVERSIZE 0 5 MM SCREW MACHINE
37. Assemblies Replacement 000 0 cece cece e 2 11 2 20 Filter Element Replacement UOC APP 0000 cece eee eens 2 13 Intake Manifold Replacement 00cc cece cece II een 2 15 Valve Vent Repair on wee sweet nae care o xx CARVER ER RA LESER Er CER ee 2 18 2 23 Fuel Pressure Pipe Assemblies and Return Fuel Hose Replacement 2 20 Airflow Deflectors Replacement UOC APP 0 00 c cece eee L 2 24 2 25 Oil Pressure Switch Replacement oooocccccccccc e ees 2 28 Thermostatic Switch Replacement 22 vad an ea 2 29 2 27 Solenoid Replacement and Adjustment UOC APP 000 nen 2 30 2 15 IDENTIFICATION PLATE REPLACEMENT This Task Covers a Removal b Installation Initial Setup Tools Test Equipment e Blind hand riveter Item 2 Cable assembly Item 3 Appendix G Drill set Item 10 Appendix G Electric drill Item 11 Appendix G General mechanic s tool kit automotive Item 15 a REMOVAL Remove four rivets 2 and identification plate 1 from airflow deflector 3 b INSTALLATION Install identification plate 1 on airflow deflector 3 and secure with four rivets 2 FOLLOW ON TASKS Install airflow deflector on engine installation steps 11 13 Materials Parts e Blind rivet 4 Item 12 Equipment Conditions Airflow deflector removed from engine UOC APP para 2 24 Jremoval steps 1 3 Airflow deflector removed f
38. COMP WASHER SPRING TENSI VALVE EXHAUST CONTR o VALVE EXHAUST CONTR VALVE POPPET ENGINE VALVE POPPET ENGINE GEAR ASSY CAMSHAFT oo o NUT PLAIN HEXAGON sess PLATE MOUNTING eee eee SCREW MACHINE eese RING RETAINING oooooo o o SPACER SLEEVE lees WASHER FLAT celle RING RETAINING CAMSHAFT ENGINE CAMSHAFT ENGINE CAMSHAFT ENGINE 2640 10 2640 11 TAPPET ENGINE POPPE O RING PART OF KIT P N 01247702 GUIDE ENGINE POPPET O RING PART OF KIT P N 01247702 PUSH ROD ENGINE POP H PNNBARP H gt N MN N BH H H H H H H H H H U P U P N N N N EEE 8 TM 9 2815 250 24 amp P C01 SECTION II US lt ESSA ae un Sit AU W W E AN SR yah EN SE E WW N SS N m v DN LR Ez um hy 27 1 28 v EM TAM 2 de SE NN Ja SN ESA 27 22 18 21 291104 Figure 9 Engine Lubrication System k k k k k k 1 ITEM NO 0 JAU BW N H 15 1 16 16 17 17 17 1 17 2 17 3 18 21 22 23 24 25 26 27 27 1 28 30 31 32 33 2
39. Follow steps 1 and 2 for each of them e Part numbers are different for the intake and exhaust valves but the valves are installed the same way This procedure describes the installation of an exhaust valve Install exhaust valve 16 in cylinder head 6 Place base spring washer 15 over exhaust valve 16 Install valve spring 14 over exhaust valve 16 so it is seated on base spring washer 15 Place valve spring retainer washer 13 on valve spring 14 Using a valve spring lifter compress valve spring 14 and install two valve spring retainer locks 12 in valve spring retainer washer 13 Install two new O rings 10 in two grooves on each of two guides 1 Install two guides 1 in two recesses in crankcase 11 TM 9 2815 250 24 amp P TM 9 2815 250 24 amp P 3 5 CYLINDER HEADS REPAIR continued 5 Install two push rods 2 in two guides 1 Make sure each push rod 2 rests on a tappet 22 6 Place two cylinderheads 6 on two combustion chamber liners 9 making sure two gaskets 7 are in place 7 Install eight washers 3 five extended plain nuts 4 and three plain nuts 5 on eight studs 8 Torque nuts to 40 ft lb 55 Nom See diagram below for correct placement of extended plain nuts 4 and plain nuts 5 FOLLOW ON TASKS Install thermostatic switch para 2 26 e Install exhaust manifold UOC APJ TM 9 2350 292 20 2 Install oil tube assemblies para 2 19
40. Install fuel injectors para 3 14 Install intake manifold para 2 21 Install airflow deflectors UOC APP para 2 24 Install airflow deflectors UOC APJ TM 9 2350 292 20 2 e Install rocker arm assemblies para 3 10 Install eyebolt UOC APP para 2 16 e Install lifting bracket UOC APJ TM 9 2350 292 20 2 Change 1 3 19 TM 9 2815 250 24 amp P 3 6 CRANKCASE REPAIR This Task Covers a Disassembly c Test b Assembly Initial Setup Tools Test Equipment General mechanic s tool kit automotive Item 15 Appendix G Steel rule Item 28 Appendix G Materials Parts Grease automotive Item 5 Appendix D Lubricating oil Item 6 Appendix D Sealing compound Item 10 Appendix D Crankcase gasket set Item 1 Appendix F Shim Item 5 or 6 Appendix F Spring tension washer 2 Item 31 Appendix F Personnel Required Two Equipment Conditions Pistons and combustion chamber liners removed para 3 9 Flywheel auxiliary drive hardware and flywheel housing removed para 3 8 Solenoid removed para 2 27 Governor control assembly removed para 3 16 a DISASSEMBLY 1 Remove shim 2 from camshaft gear 1 N 2 Remove hose coupling 6 and gasket 7 from upper crankcase 23 Discard gasket 3 Remove two screws 18 and spring tension washers 17 access cover 16 and gasket 15 from upper crankcase 23 Discard gasket and spring tension washers
41. PAOZZ 5330 01 080 1776 61080 50001100 GASKET PART OF KIT P N 01228002 UOC APJ 25 1 PAOZZ 5310 01 494 3769 61080 03966300 WASHER FLAT lees UOC APJ 26 PAOZZ 4730 01 454 7573 61080 40092600 FITTING RING PIECE UOC APP 26 PAOZZ 4730 01 494 7219 61080 50015800 CONNECTOR MULTIPLE UOC APJ 27 PAOZZ 4730 01 454 7560 61080 01223200 ADAPTER STRAIGHT TU o o 28 PAOZZ 5310 01 090 0938 61080 50000900 WASHER FLAT PART OF KIT P N 01247702 29 PAOZZ 4730 01 454 7567 61080 50015700 FITTING RING PIECE 30 PAOZZ 4730 01 454 7569 61080 50311700 BOLT FLUID PASSAGE UOC APP 31 MOOZZ 19207 12478232 2 HOSE ASSEMBLY NONME MAKE FROM HOSE P N 12478232 0 0 oooooooomo ooo 35 MOOZZ 19207 12478232 5 HOSE ASSEMBLY NONME MAKE FROM HOSE P N 12478232 cene 36 PAOZZ 5340 01 406 1646 61080 50314100 CLAMP LOOP lees END OF FIGURE 12 1 12 2 bank EPA Version 1 Compliant Only N ONNNNHHNNNNNNOaAHrH HH H H N N NNNNNNHHN BND SECTION Il C01 TM 9 2815 250 24 amp P 29i069 Figure 13 Governor and Controls SH 1 of 2 SECTION II C01 TM 9 2815 250 24 amp P Note EPA Compliant Version 1 Shown 29i105 Figure 13 Governor and Controls SH 2 of 2 1 ITEM NO N 19 20 21 22 23 24 25 26 27 28 29 29 1 30 31 32 33 kkk 34 35 36 37 38 39 40 40 1 41 42 43
42. Remove two fluid passage bolts 4 and four washers 5 from two cylinder heads 6 and oil tube assembly 9 Discard washers Remove screw 1 fluid passage bolt 3 d 1 connector 17 bushing 16 six washers 2 and two oil tube assemblies 9 and 15 from crankcase 8 Discard washers TM 9 2815 250 24 amp P 2 19 OIL TUBE ASSEMBLIES REPLACEMENT continued b INSTALLATION 1 Install two oil tube assemblies 9 and 15 fluid passage bolt 3 connector 17 bushing 16 and six new washers 2 on crankcase 8 Loosely install screw 1 in fluid passage bolt 3 2 Install four new washers 5 on two cylinder heads 6 and oil tube assembly 15 and secure loosely with two fluid passage bolts 4 3 Install new O ring 10 on plate 11 Install plate 11 and two screws 13 on timing cover 7 4 Install two new washers 12 and fluid passage bolt 14 on plate 11 and oil tube assembly 15 5 Tighten screw 1 and two fluid passage bolts 4 w tab TA TER EA HI Ss E N FOLLOW ON TASKS e Install fuel pressure pipe assemblies para 2 23 e Install oil switch para 2 25 e Install airflow deflectors para 2 24 if any were removed 2 12 TM 9 2815 250 24 amp P 2 20 FILTER ELEMENT REPLACEMENT UOC APP i This Task Covers a Removal b Cleaning c Installation Initial Setup Tools Test Equipment e Rag Item 7 Appendix D e General mechanic s tool kit
43. Rocker Arm Covers 2 Protect rocker arm assemblies 4 Fuel Pressure Pipes 2 Provide fuel to fuel injectors 5 Filler Cap Allows access to filler neck 6 Filter Element Removes impurities from lubrication system 7 Solenoid Opens and closes fuel supply 8 TM 9 2815 250 24 amp P 1 12 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS continued Component 10 Oil Tube Assemblies 2 Supply oil to various parts of engine 11 Oil Switch Shuts off engine if oil pressure is not high enough 12 Engine Mounts 2 Secure engine to auxiliary power unit APU TM 9 2815 250 24 amp P 1 12 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS continued SS Bor N Q vi AN W FT o J 7 EN A Be 32 a c o o o n o A c o 2 E o o gt x Removes excess fuel from engine Injection Pump Pumps fuel to injectors Governor Control Assembly Controls engine speed TM 9 2815 250 24 amp P 1 13 EQUIPMENT DATA GENERAL SPECIFICATIONS Model atera oe eq Um cA is 2G 40 Manufacturer 42 dune aer cashed Ghee E ep REB delat ea hp Hatz Diesel of America M de of Operations cosi ssi esseet en Rene 4 cycle COMD STION bitacora tada heed ese tepore ton Dry car eee a res ia Method direct injection Number of Cylinders oossoo III 2 Bore StrokKe idee od Lebe ree aesti e us 3 622 2 935 in 92 75 mm Cubic Capacity omita ia pida 60 79 cu in 997 cc Compression R
44. TM 9 2350 293 34 Storage and Materials Handling sos eee ene teen eee eee TM 743 200 1 Procedures for Destruction of Tank Automotive Equipment to Prevent Enemy Use TM 750 244 6 Change 1 A 1 TM 9 2815 250 24 amp P A 3 MANUALS CONTINUED Operator s Manual Recovery Vehicle Heavy Full Tracked M88A2 Unit Maintenance Manual Recovery Vehicle Heavy Full Tracked M88A2 Direct and General Support Maintenance Manual Recovery Vehicle Full Tracked Heavy M88A2 NSN 2350 01 390 4683 ooocococoooccconcoor ees Unit Direct Support and General Support Maintenance Repair Parts and Special Tools List for Recovery Vehicle Heavy Full Tracked M88A2 lusus id usd es TM 9 2350 292 10 SER UD TM 9 2350 292 20 piget TM 9 2350 292 34 T TM 9 2350 292 24P A 4 PAMPHLETS AND CIRCULARS Consolidated Index of Army Publications and Blank Forms 000 cece eee eee eee nenn DA Pam 25 30 Functional User s Manual for The Army Maintenance Management System TAMMS DA Pam 738 750 Operator s Circular Welding Theory and Application oooooccccccccccoonocac mI TC 9 237 A 5 REGULATIONS Product Quality Deficiency Report Program 0 cece nn AR 702 7 Army Medical Department Expendable Durable Items 00 nnen CTA 8 100 Expendable Durable Items Except Medical Class V Repair Parts and Kleraldichtems ier R
45. addition to Section I this RPSTL is divided into the following sections a Section Il Repair Parts List A list of spares and repair parts authorized by this RPSTL for use in the performance of maintenance The list also includes parts that must be removed for replacement of the authorized parts Parts lists are composed of functional groups In ascending alphanumeric sequence with the parts in each group listed in ascending figure and item number sequence Bulk materials are listed in item name sequence Repair parts kits are listed separately In their own functional group within Section II Section Ill Special Tools List A list of special tools special TMDE and other special support equipment authorized by this RPSTL for the performance of maintenance Section IV Cross reference Indexes There are two indexes The first is a list in national item identification number NIIN sequence of all national stock numbered items appearing in the listings the second is a list in alphanumeric sequence of all part numbers appearing in the listings National stock numbers NSNs and part numbers are cross referenced to each illustration figure and item number appearance TM 9 2815 250 24 amp P C 3 EXPLANATION OF COLUMNS SECTIONS II AND III a ITEM NO Column 1 Indicates the number used to identify items called out in the illustration b SMR CODE Column 2 The SMR code is a five position code containing supply requisitioning inform
46. cap plugs 12 on eight studs 13 Install bracket 8 and clamping sheet 10 on two studs 13 Tighten screw 7 to secure NOTE There are two pistons and combustion chamber liners on the engine Follow steps 4 through 9 for each of them Apply light coat of lubricating oil to three piston rings 14 and piston 15 Clamp piston ring compressor over piston rings 14 Tighten piston ring compressor Install combustion chamber liner 2 in crankcase 3 Make sure notched corners on combustion chamber liner 2 are facing injection pump side of engine Turn crankshaft 4 so crankshaft journal for piston to be installed is at the bottom of crankcase 3 TM 9 2815 250 24 amp P 3 9 PISTON AND COMBUSTION CHAMBER LINER REPAIR continued AN us CAUTION INJECTION PUMP SIDE OF ENGINE O Pocket in piston and notches in connecting rod must face starter access plate side of engine 7 Slide piston 15 into combustion chamber liner 2 Make sure pocket in piston 15 is facing toward starter access plate side of engine 8 Tap piston 15 into combustion chamber liner 2 with hammer handle Make sure connecting rod 1 is aligned with crankshaft journal CAUTION Each connecting rod and connecting rod cap is stamped with a number and also has a notch on one side Each connecting rod cap must be installed on the connecting rod stamped with the same number and with the notches on the
47. column identifies the lowest level of maintenance that requires the listed item C Operator Crew O Unit F Direct Support H General Support National Stock Number This is the national stock number assigned to the item use it to request or requisition the item Description CAGEC This column contains the Federal item name and if required a description to identify the item The last line for each item indicates the commercial and government entity code CAGEC in parentheses followed by the part number if applicable U M Unit of Measure Indicates the measure used in performing the actual maintenance function This measure is expressed by a two character alphabetical abbreviation BT bottle BX box CN can GL gallon LB pound OZ ounce PT pint QT quart and TU tube If the unit of measure differs from the unit of issue requisition the lowest unit of issue that will satisfy your requirements TM 9 2815 250 24 amp P Section Il EXPENDABLE AND DURABLE ITEMS LIST 3 d 2 National 4 5 Level Stock TE Number Number Description CAGEC U M E 8040 00 833 9563 Adhesive Kit BT 71984 RTV 732 2 O 8030 00 597 5367 Antiseize Compound 2 5 Pound Can LB 73165 51008 3 F 6850 01 085 1423 Carbon Removing Compound 13 Ounce OZ Aerosol Can 01326 7450 4 O 6850 00 281 1985 MINAS SON Gaona GL 58536 A A 59601 5 E 9150 01 197 7690 reasez u
48. eX N ON Figure 4 Crankcase Assembly 1 ITEM NO O 0 JA ULB UN 12 12 13 14 15 16 17 18 19 20 21 22 E Refer to TM 9 2350 292 24P and TM 9 2350 292 20 2 for UOC 2 SMR PAFFF PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAOZZ PAFZZ PAFZZ PAFZZ PAOZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ KFFZZ PAFZZ PAOZZ PAFZZ PAFZZ KFFZZ KFFZZ 3 NSN 5315 01 399 6105 5307 01 405 9997 5307 01 405 9905 5305 01 406 0014 5310 12 149 4353 5310 01 405 9890 5315 01 400 0444 4730 01 454 7542 4730 01 454 7545 4820 01 455 5017 5307 01 455 2205 5315 01 399 6106 5340 01 454 9272 5340 01 454 9273 5305 01 455 1615 5310 01 399 7303 5340 01 455 2343 5330 01 400 5766 TM 9 2815 250 24 amp P 4 CAGE 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 END OF EPA Version 1 Compliant Only 5 PART NUMBER 01227410 01227420 50290500 50128100 50098300 50137000 50144500 50144400 50300700 50302700 05034900 01221803 50139201 50307000 50301000 04038200 04039100 50301200 50052100 50208500 99400645 50291400 50301100 50275000 FIGURE col 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 2911 CRANKCASE CYLINDER SLEEVE AND CYLINDER HEAD FIGURE 4 CRANKCASE ASSEMBLY CRANKCASE ASSEMBLY 2G40 13 2640 14 2G40 15 oooooooo
49. f Associated Publications Operator s Manual Unit Maintenance Manual Direct Support TM 9 2350 293 10 and General Support Maintenance Manual and Repair Parts TM 9 2350 293 20 1 and 2 and Special Tools List For Carrier Ammunition Tracked as M992A2 NSN 2350 01 368 9500 TM 9 2350 293 34 TM 9 2350 293 24P Operator s Manual Unit Maintenance Manual Direct Support TM 9 2350 292 10 and General Support Maintenance Manual and Repair Parts TM 9 2350 292 20 1 and 2 and Special Tools List For Recovery Vehicle Full Tracked Heavy M88A2 NSN 2350 01 390 4683 TM 9 2350 292 34 TM 9 2350 292 24P C 6 HOW TO LOCATE REPAIR PARTS a When the NSN or part number is not known you can locate a repair part by following these steps 1 First Using the Table of Contents determine the assembly group or subassembly group to which the item belongs This is necessary because figures are prepared for assembly groups and subassembly groups and listings are divided into the same groups 2 Second Find the figure covering the assembly group or subassembly group to which the item belongs 3 Third Identify the item on the figure and note the item number of the item 4 Fourth Refer to the Repair parts List for the figure to find the line item entry for the item number noted on the figure b When the NSN or part number is known you can locate a repair part by following these steps 1 First Using the National Stock Number Index or th
50. figure column indicates the quantity of the item used in the breakout shown on the illustration figure which is prepared for a functional group subfunctional group or an assembly A V appearing in this column in lieu of a quantity indicates that the quantity is variable and may vary from application to application TM 9 2815 250 24 amp P C 4 EXPLANATION OF COLUMNS SECTION IV a National Stock Number NSN Index 1 3 STOCK NUMBER Column This column lists the NSN by NIN sequence The NUN consists of the last nine digits of the NSN i e NSN 5305 01 674 1467 When using this column to locate an item ignore the first four digits NIIN of the NSN However the complete NSN should be used when ordering items by stock number FIG Column This column lists the number of the figure where the item is identified located The figures are in numerical order in Section Il and Section Ill ITEM Column The item number identifies the item associated with the figure listed in the adjacent FIG column This item is also identified by the NSN listed on the same line Part Number Index Part numbers in this index are listed by part number in ascending alphanumeric sequence i e vertical arrangement of letter and number combination that places the first letter or digit of each group in order a through Z followed by the numbers 0 through 9 and each following letter or digit in like order 1 2 CAGEC Column
51. halves 4 in three lower crank supports 6 Keep matching bearings together Apply light coat of lubricating oil to crankshaft 2 Install crankshaft 2 in lower crankcase 5 CROSS SECTION OF SEAL 3 4 INCH 19 1 d 29i211m FOLLOW ON TASKS e Install camshaft para 3 11 Assemble crankcasd para 3 6 e Adjust engine speedl para 3 18 Change 1 3 27 TM 9 2815 250 24 amp P N 3 8 FLYWHEEL AND HOUSING REPLACEMENT This Task Covers a Removal b Installation Initial Setup Tools Test Equipment e General mechanic s tool kit automotive Item 15 Appendix a gear and bearing puller kit Item 17 Appendix e Torque wrench 1 2 inch drive Item 31 Appendix Gl Materials Parts e Crankcase gasket set Item 1 Appendix F e O ring item 44 Appendix F e Spring tension washer Item 27 Appendix F Equipment Conditions Oil tube assemblies removed para 2 19 Airflow deflectors removed UOC APP para 2 24 Airflow deflectors removed UOC APJ TM 9 2350 292 20 2 a REMOVAL 1 Remove nut 1 and washer 2 from crankshaft 8 2 Using mechanical gear puller remove flywheel 3 from crankshatt 8 3 Remove key 9 from crankshaft 8 3 28 Change 1 I U NON Sl NS KS AE PGS La EA BA a TM 9 2815 250 24 amp P 3 8 FLYWHEEL AND HOUSING REPLACEMENT co
52. into position a spare repair part or module component or assembly in a manner to allow the proper functioning of an end Item or system Replace To remove an unserviceable item and install a serviceable counterpart in its place Replace is authorized by the MAC and is shown as the third position of the source maintenance and recoverability SMR code Repair To apply maintenance services including fault location troubleshooting removal installation and disassembly assembly procedures and maintenance actions to identify troubles and restore serviceability to an item by correcting any specific damage fault malfunction or failure in a part subassembly module component or assembly end Item or system Overhaul To perform that maintenance effort service action required to restore an item to a completely serviceable operational condition as required by maintenance standards in an appropriate technical publication e g depot maintenance work requirement Overhaul is normally the highest degree of maintenance performed by the Army Overhaul does not normally return an item to like new condition Rebuild To perform those services actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards Rebuild is the highest degree of materiel maintenance applied to Army equipment The rebuild operation includes the act of returning to zero those age measurements e
53. is the name or identification of the tool or test equipment Column 4 National Stock Number This is the national stock number of the tool or test equipment Column 5 Tool Number This is the manufacturer s part number B 3 B 4 1 Group No 22 2210 29 2910 2911 2912 2913 2914 2915 2916 2918 2932 Section Il MAINTENANCE ALLOCATION CHART FOR ENGINE ASSEMBLY DIESEL HATZ 2 G 40 2 Component Assembly BODY CHASSIS AND HULL ACCESSORY ITEMS Engine Identification Plate AUXILIARY GENERATOR AND ENGINE AND CONTROLS Engine Assembly Crankcase Cylinder Sleeve Cylinder Head and Block Crankshaft Flywheel Assembly Pistons and Connecting Rods Valves Camshaft and Timing System Engine Lubrication System Oil Filter Manifolds Injector Pump Nozzles and Fuel Lines 3 Maintenance Function Replace Inspect Service Test Adjust Repair Replace Repair Replace Replace Replace Repair Adjust Replace Repair Test Replace Replace Replace Adjust Replace Maintenance Level 0 5 oouo 2 0 0 5 0 2 1 0 1 0 3 0 3 0 8 0 2 0 1 0 2 0 3 0 TM 9 2815 250 24 amp P 5 6 Tools and Remarks Equipment 1 2 7 2 3 10 16 2 5 10 1 Group No 2936 2952 2960 2968 Section Il MAINTENANCE ALLOCATION CHART FOR ENGINE ASSEMBLY DIESEL HATZ 2 G 40 continued 3 2 Compon
54. lever 26 on upper crankcase 15 3 Install new retaining ring 28 on acceleration lever 26 4 Install four tappets 25 in upper crankcase 15 5 Install washer 17 and spacer 18 on camshaft 16 Make sure tapered end of spacer 18 is facing away from washer 17 6 Install new retaining ring 22 in groove on camshaft 16 3 43 3 11 7 3 44 TM 9 2815 250 24 amp P CAMSHAFT REPAIR continued Install key 23 on camshaft 16 Using arbor press install camshaft gear 4 on camshaft 16 making sure timing marks on camshaft gear 4 are facing toward near end of camshaft 16 Press camshaft gear 4 onto camshaft 16 until camshaft gear 4 seats against retaining ring 22 Slide spacer 18 and washer 17 toward camshaft gear 4 Install new retaining ring 24 in groove on camshaft 16 Install mounting plate 20 on camshaft gear 4 and secure with three screws 21 and nuts 19 Set upper crankcase 15 on end on work surface with opening for camshaft 16 facing up Install camshaft assembly 5 in upper crankcase 15 Position the timing marks on camshaft gear 4 in the 12 o clock position and insert camshaft assembly 5 into bearing bore When the first cam lobe drops down behind bearing bore turn camshaft gear 4 counterclockwise until timing marks are in the 10 o clock position insert camshaft assembly 5 the rest of the way Lay upper crankcase 15 on work surface Install
55. person is required to perform the procedure the number is specified under the heading Personnel Required e Procedures that must be followed prior to performing the engine maintenance procedure are listed under the heading Equipment Conditions TM 9 2815 250 24 amp P TEXT AND ILLUSTRATIONS continued 3 Maintenance procedures are to be performed in the sequence given in the text and illustrations 4 Illustrations are numbered clockwise beginning at the 11 o clock position Because an illustration is keyed to the text parts that are removed sequentially may not have sequential numbers For example Remove screw 4 lockwasher 6 washer 7 and bracket 5 from crankcase 2 5 Be sure to read the entire paragraph before beginning a maintenance procedure Also read the general information in Chapter 1 before beginning a procedure WARNINGS CAUTIONS AND NOTES 1 Throughout this manual you will see WARNING CAUTION and NOTE headings There are good reasons for every one of these notices WARNING A warning is used to alert the user to hazardous operating and maintenance procedures practices or conditions that could result in injury or death Warnings must be strictly observed CAUTION A caution is used to alert the user to hazardous operating and maintenance procedures practices or conditions that could result in damage to or destruction of equipment or mission effectiveness Cautions must be strictly observed
56. power and be difficult to start NOTE e There are two pistons on the engine Follow steps 1 through 4 to adjust the valve to piston clearance on each of them e Gaskets come in various thicknesses It may be necessary to try several different gaskets to achieve the desired valve to piston clearance Use only one gasket on each combustion chamber liner Install new gasket 7 with a thickness of 0 60 mm and cylinder alignment bracket 18 on combustion chamber liner 9 CROSS SECTION OF PISTON GASKET AND COMBUSTION CHAMBER LINER NOTE Make sure piston is as high as possible in the combustion chamber Place bottom of depth gage rule 17 across piston 20 and gasket 7 Loosen screw 19 and slide depth gage rule 17 down to crown of piston 20 Be sure to measure highest part of piston 20 Tighten screw 19 and read measurement Clearance should be no less than 0 024 inch 0 61 mm and no greater than 0 026 inch 0 66 mm If clearance is incorrect repeat steps 1 and 2 using a gasket with a different thickness When clearance is correct remove cylinder alignment bracket 18 from combustion chamber liner 9 leaving gasket 7 in place 3 17 3 5 d CYLINDER HEADS REPAIR continued MACHINING Grind exhaust valve 16 and valve seat 21 to a 45 degree angle If necessary repeat for other valves 3 18 INSTALLATION NOTE e There are two valves intake and exhaust in each of two cylinder heads
57. same side 9 Install two connecting rod caps 5 on two connecting rods 1 and secure loosely with two screws 6 Torque screws to 30 ft lb 40 Nem FOLLOW ON TASKS e Install oil pan UOC APP para 3 13 e Install oil pan UOC APJ para 3 13 1 Turn engine upright e Install cylinder heads para 3 5 Change 1 3 37 TM 9 2815 250 24 amp P 3 10 ROCKER ARM ASSEMBLIES REPAIR This Task Covers a Removal b Installation Initial Setup Sealing compound Item 16 Self locking nut 4 Item 15 Appendix F Tools Test Equipment General mechanic s tool kit automotive Item 15 Shim 1 or 2 Item 42 or 43 Appendix F e Snapring pliers Item 26 Appendix G n E E z Equipment Conditions Torque wrench 1 2 inch drive Item 31 Appendix G s Rocker arm covers and gaskets removed Materials Parts i e Retaining ring 4 Item 20 Appendix F a REMOVAL NOTE There are two rocker arm assemblies on the engine each containing two rock er arms Repeat steps 1 through 4 to remove both assemblies 1 Remove two self locking nuts 7 and rocker arm bracket 8 from two studs 10 Discard self locking nuts 2 Remove two retaining rings 1 and any shims 2 or 3 from rocker arm bracket 8 Discard retaining rings and shims 3 38 Change 1 TM 9 2815 250 24 amp P 3 10 ROCKER ARM ASSEMBLIES REPAIR continued 3 Remove two rocker arms 6 and 9 from rocker arm bracket 8
58. whenever the diesel engine is operated for maintenance or tactical reasons Do not operate the engine in an enclosed area without adequate ventilation WARNING DRYCLEANING SOLVENT anes Drycleaning solvent P D680 is TOXIC and flammable Wear protective goggles and gloves use only in a well ventilated area avoid contact with skin eyes and clothes and DO NOT breathe vapors Keep away from heat or flame Never smoke when using drycleaning solvent Failure to follow this warning may result in injury or death to personnel If personnel become dizzy while using drycleaning solvent immediately get fresh air and medical help If solvent contacts skin or clothes flush with cold water If solvent contacts eyes immediately flush them with water and get immediate medical attention When drycleaning solvent is used notify the local medical authority preventive medicine and environmental coordinator concerning medical surveillance respiratory protection and disposal requirements Change 1 TM 9 2815 250 24 amp P WARNING COMPRESSED AIR W Compressed air used for cleaning or drying purposes or for clearing restrictions should never exceed 30 psi 207 kPa Wear protective clothing gloves etc and use caution particularly when drying or cleaning metal parts to avoid injury to personnel It is particularly important to wear eye protection goggles or a face shield to protect eyes from blowing particles and prevent ser
59. 0 01 120 2966 5310 01 239 2390 5325 01 245 3517 5305 01 264 6247 5305 01 274 1064 5310 01 274 4387 5930 01 348 9797 2940 01 383 9739 4730 01 399 4252 4730 01 399 4253 4730 01 399 4254 5325 01 399 4615 5325 01 399 4618 5365 01 399 5011 5365 01 399 5013 5360 01 399 5014 5360 01 399 5016 5360 01 399 5017 4720 01 399 5578 4820 01 399 5579 5315 01 399 6105 5315 01 399 6106 5315 01 399 6107 4730 01 399 6267 5330 01 399 6976 5331 01 399 6978 5310 01 399 6981 5310 01 399 7301 5310 01 399 7303 5310 01 399 7305 5310 01 399 7311 5310 01 399 7312 TM 9 2815 250 24 amp P col CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX FIGURE NO ITEM NO 9 N b N H H UI J VI STOCK NUMBER 4710 01 399 7358 4710 01 399 7359 5310 01 399 8358 5310 01 399 8386 5315 01 400 0441 5315 01 400 0444 5315 01 400 0445 5310 01 400 0995 5325 01 400 0999 5340 01 400 1000 5310 01 400 1002 5310 01 400 2138 5310 01 400 2139 5310 01 400 2140 5310 01 400 2141 5310 01 400 3715 5365 01 400 3717 5310 01 400 3719 5310 01 400 3720 5310 01 400 3721 5330 01 400 5766 5330 01 400 5772 5330 01 400 5773 5331 01 400 5778 5305 01 401 3694 5310 01 405 9890 5305 01 405 9892 5305 01 405 9894 5305 01 405 9895 5305 01 405 9897 5305 01 405 9898 5307 01 405 9899 5330 01 405 9900 5305 01 405 9901 5305 01 405 9903 5305 01 405 9904 5307 01 405 9905 5305 01 405 9906 5307 01 405 9907 5305 01 405 9908 5307 01 405 9909 5310 01 4
60. 000 cece cence nee ene eens 3 47 Deep Oil Pan and Gasket Replacement UOC APU 0c cece eee e eee 3 47 1 Fuel Injector Replacement ooccccccccccocccccc en 3 48 Injection Pump Replace Me Deicide 3 50 3 16 Governor Control Assembly Repair ssa 3 54 3 4 MOUNTING PLATES REPLACEMENT This Task Covers a Removal b Cleaning c Installation Initial Setup Tools Test Equipment Grease automotive Item 5 General mechanic s tool kit automotive Rag Item 7 Appendix D Item 15 e Sealing compound Item 10 Appendix D e Screwdriver attachment 6 mm Item 24 Appendix G Sealing compound Item 12 Appendix D e Socket wrench set 3 8 inch drive Item 27 Appendix G e Lockwasher 8 Item 23 Appendix F Materials Parts Seal Item 48 Appendix Fl e Drycleaning solvent Item 4 Appendix D Equipment Conditions Auxiliary Drive Adapter Removed para 3 4 1 a REMOVAL NOTE Mark position of engine mounting plate on crankcase before removing mount ing plate from crankcase 1 Remove eight screws 6 and lockwashers 7 and engine mounting plate 5 from crankcase 1 Discard lockwashers 2 Remove four screws 3 and mounting plate 2 from crankcase 1 3 Remove seal 4 from mounting plate 2 Discard seal 3 12 Change 1 TM 9 2815 250 24 amp P 3 4 MOUNTING PLATES REPLACEMENT continued b CLEANING WARNING Drycleaning solvent P D 680 is toxic and flammable Always wear prote
61. 018 3120 01 455 7311 5330 01 455 7566 5330 01 455 7819 5330 01 455 7822 5330 01 455 7823 5310 01 455 8479 5310 01 455 8480 5310 01 455 8481 FIGURE NO 11 4 4 16 16 13 9 9 16 14 6 13 5 7 8 14 14 H H H Ui OH JU OY W OO OO W W OO OO OO L ITEM NO 17 14 15 16 3 27 10 32 2 21 6 24 TM 9 2815 250 24 amp P C01 CROSS REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX STOCK NUMBER FIGURE NO ITEM NO STOCK NUMBER FIGURE NO ITEM NO 5310 01 455 8482 14 27 5340 01 494 6423 6 5 1 5315 01 455 8935 6 13 4730 01 494 7219 12 26 5325 01 455 8936 7 5 2990 01 497 9561 15 1 5310 01 456 0736 16 15 4710 01 518 8125 12 2 5310 01 456 2275 8 15 4710 01 518 8127 12 1 9905 01 456 3828 1 1 5310 01 525 7457 13 48 5331 01 457 3350 16 4 5340 01 526 2574 13 44 5360 01 458 0666 12 17 5310 12 130 4938 2 7 5120 01 458 3944 17 5 5305 12 146 1760 2 6 5340 01 458 8159 14 15 5310 12 149 4353 4 6 5340 01 459 1403 14 6 6 15 5305 01 463 1028 6 18 9 17 2815 01 465 4321 2 1 14 3 5935 01 480 9543 2 2 16 7 2805 01 488 7755 9 8 2815 12 330 5421 8 35 5305 01 492 8775 9 16 2910 12 337 7727 12 7 5310 01 494 3769 12 25 1 2910 12 338 8683 12 12 TM 9 2815 250 24 amp P C01 CROSS REFERENCE INDEXES PART NUMBER INDEX PART NUMBER FIG ITEM PART NUMBER FIG ITEM 01129900 14 12 03781800 8 33 01133200 14 6 03783000 8 5 01133300 14 15 8 8 3 01160500 15 1 03783200 8 19 01198900 11 8 03783210 8 19 01221803 4 11 03783300 8 18 01222100
62. 05 9911 5310 01 405 9912 5307 01 405 9997 5305 01 405 9998 5305 01 406 0000 5305 01 406 0001 5305 01 406 0003 5305 01 406 0004 5305 01 406 0005 5305 01 406 0006 5305 01 406 0007 FIGURE NO 12 12 3 9 5 4 12 12 13 oo H Ho H PRA BPRPRPRPRPRPRPR r 0 O0 4 N N WBB BB BO BW O iS OY O UI O amp O N H E 00 Ba A LO UI OY H H r m OB JW E O amp W W EO W AO W W N BO ITEM NO N N o UI W 0 U W BB N H H PN H w ho H O ON BAJOHW OW IAN OHH H BW VI N No STOCK NUMBER 5305 01 406 0009 5305 01 406 0010 5305 01 406 0011 5305 01 406 0013 5305 01 406 0014 4820 01 406 0343 5340 01 406 1645 5340 01 406 1646 5365 01 406 4171 5307 01 406 5443 4820 01 406 6143 4820 01 407 0705 2805 01 407 0706 4820 01 407 1908 2815 01 414 1273 5360 01 414 8475 2835 01 414 8480 5310 01 415 2649 5330 01 415 6721 4730 01 415 7923 5120 01 428 5525 2815 01 439 3916 5930 01 441 0097 2815 01 446 3500 5120 01 454 5885 5120 01 454 5886 5120 01 454 5887 5120 01 454 5888 4910 01 454 5889 5120 01 454 5890 4730 01 454 7461 4730 01 454 7542 4730 01 454 7545 4730 01 454 7549 4730 01 454 7560 4730 01 454 7567 4730 01 454 7569 4730 01 454 7573 2990 01 454 7609 4710 01 454 7687 4710 01 454 7688 4730 01 454 7692 4730 01 454 7693 5945 01 454 8223 5945 01 454 8230 5945 01 454 8238 2815 01 454 8626 2990 01 454 8630 5340 01 454 8631 2990 01 454 8635 2815 01 454 8839 2815 01 454 8841 2815 01 454 8842 2990 01
63. 10 00 754 0654 5180 00 754 0655 4910 00 808 4300 TM 9 2815 250 24 amp P Tool Number SC 4910 95 CL A72 SC 5180 90 N26 SC 5180 90 CL N05 SC 3470 95 A02 SC 4910 95 A31 SC 4910 95 CL A63 SC4910 95 A74 SC5180 95 B08 SC 4940 95 B02 61372800 62574200 62574801 62569902 62574700 66503091 60462890 62092692 TM 9 2815 250 24 amp P APPENDIX C REPAIR PARTS AND SPECIAL TOOLS LIST Section I INTRODUCTION Paragraph Page Number Paragraph Title Number C 1 O teas C 1 C 2 GONG Al ick O C 1 C 3 Explanation of Columns Sections II and lll sssini niaaa aaaeen C 2 C 4 Explanation of Columns Section IV sessen ienien NEA REE EREA A C 6 C 5 Special Information ridus indue ew einen C 6 C 6 How To Locate Repair Parts ssssssssssssssseseneee mene nnne nnne hh nn then nnns C 7 C 7 Peers C 7 C 1 SCOPE This repair parts and special tools list RPSTL lists and authorizes spares and repair parts special tools special test measurement and diagnostic equipment TMDE and other special support equipment required for the performance of Unit Direct Support and General Support maintenance of the Diesel Engine Assembly Hatz 2 G 40 This RPSTL authorizes the requisitioning issue and disposition of spares repair parts and special tools as indicated by the source maintenance and recoverability SMR code C 2 GENERAL In
64. 1080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 END OF 9 2815 250 24 amp P 5 PART NUMBER 50019800 50315900 50316000 01224400 03173100 03783000 40028400 01224600 01224500 03173100 03783000 50177500 50162900 03783800 50290200 03786300 03783600 03783500 03783401 03783300 03783301 03783200 03783210 01222100 50305400 01244800 50305300 03233200 03233300 50020000 50305700 50306001 50010500 50305000 04092800 04092810 50304900 50302000 50290100 03781800 50208400 01224001 FIGURE col 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 2915 VALVES CAMSHAFT AND TIMING SYSTEM FIGURE 8 CAMSHAFT AND VALVES ROCKER ARM ENGINE P NUT PLAIN HEXAGON PART OF KIT P N 01228202 ee en SCREW MACHINE o oooo oooooo NUT SELF LOCKING HE BRACKET ROCKER ARM oo ROCKER ARM ENGINE P NUT PLAIN HEXAGON PART OF KIT P N 01228202 os etude is wasn evans SCREW MACHINE o ooooooooooo o SCREW MACHINE eee WASHER FLAT PART OF KIT P N 01228202 y 0124770200 o vivi liv ida COVER ENGINE POPPET O RING PART OF KIT P N 01228202 A TN LOCK VALVE SPRING R WASHER SPRING TENSI SPRING HELICAL
65. 1080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 13 1 13 2 bank EPA Version 1 Compliant Only END OF 5 PART NUMBER 01222400 50036000 04020200 04086300 04088300 50306500 50308800 50092100 50308901 50309100 50144400 50309200 50309300 50309400 50309500 50114300 500 254 00 40021400 40021500 03791600 50344900 50146300 50306900 50170800 50170900 05063900 03125800 01266500 50306600 50306200 50307100 01222300 50139201 50308500 50308100 01222510 01665610 01665600 50034100 01665000 04021800 50006100 50000900 01670100 05184200 05186900 50306900 50149100 50500800 50511000 05185400 05184800 50328300 50507800 50286300 50052000 50323800 FIGURE col 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 2936 ENGINE SPEED GOVERNOR AND CONTROLS FIGURE GOVERNOR AND CONTROLS LEVER ASSEMBLY POWE PIN COTTER 0 0 0 0 cece eee cece eee SPRING HELICAL COMP UOC APP SPRING HELICAL COMP UOC APJ LEVER THROTTLE eee O RING PART OF KIT P N 01228002 RING RETAINING eee SCREW MACHINE eee LEVER SPEED CONTROL SCREW MACHINE UOC APP NUT PLAIN HEXAGON oo ooooo SCREW MACHINE eee SPRING HELICAL COMP
66. 13 50548200 9 50552200 12 57K3263 17 57K3264 17 62568902 17 62574200 17 62574700 17 62574801 17 66503091 17 99400638 5 99400639 2 99400640 2 99400641 2 99400642 2 99400644 6 99400645 4 99400646 6 99400648 14 DIN7980 10 FST 2 DIN7984 M10X30 1 2 0 9 A3P J1508 M 04 12 M10X55DIN912 8 8 5 MS35756 15 5 ITEM 12 1 15 1 H HH PROD ou 4J ON UHHH JN H N N OI UI J 0 17 3 H J J N AAA H PNUWO BR JN uo Ho an O JB OY OH UP UN OO UW BN OO 4 TM 9 2815 250 24 amp P APPENDIX D EXPENDABLE AND DURABLE ITEMS LIST Section I INTRODUCTION Paragraph Page Number Paragraph Title Number D 1 SCONE ss PT Rm D 1 Explanation of Colamne decet desde ee AIR D 1 SCOPE This appendix lists expendable durable supplies and materials you will need to operate and maintain the Diesel En gine Assembly Hatz G 2 40 This listing is for informational purposes only nd is not authority to requisition the listed items These items are authorized to you by CTA 50 970 or CTA 8 100 D 2 EXPLANATION OF COLUMNS There are five columns in Section II Expendable and Durable Items List 1 2 3 4 5 Item Number This number is assigned to the entry in the listing and is referenced in the Initial Setup of maintenance paragraphs or narrative instructions to identify the material needed e g Drycleaning Solvent Item 4 Appendix D Level This
67. 200 50311000 03788800 50335300 50321900 50323500 03908201 01613100 04125000 50336300 50274500 50336400 50336500 FIGURE 9 1 col 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 2916 ENGINE LUBRICATION SYSTEM FIGURE 9 ENGINE LUBRICATION SYSTEM SCREW MACHINE 000000 eee WASHER FLAT PART OF KIT P N 01247702 BOLT FLUID PASSAGE CONNECTOR MULTIPLE BUSHING BOSS oo ooooooomooo BOLT FLUID PASSAGE TUBE ASSEMBLY METAL OIL PUMP ASSEMBLY E O RING PART OF KIT P N 01228002 COVER ACCESS 00000 cece eee WASHER FLAT 0000 cece ee eees SCREW MACHINE see STRAINER ELEMENT SE GASKET PART OF KIT P N 01228002 SUMP OIL DEEPB eee UOC APJ UOC APJ SCREW MACHINE eee UOC APP SCREW MACHINE eee UOC APJ WASHER LOCK ooooooooooomo ooo UOC APP WASHER FLAT eene UOC APJ PLUG RECESS lese UOC APJ UOC APJ WASHER 0 cee cece ee UOC APJ FILTER ELEMENT FLUI PART OF KIT P N 01228202 is the ont oes ote Soest UOC APP GASKET PART OF KIT P N 01228202 COCK POPPET DRAIN PART OF KIT P N 01228202 eee eee WASHER FLAT eese NUT PLAIN HEXAGON eee UOC APP STUD PLAIN rod v gd RS RM UOC APP O RING PART OF KIT P N 01228002 UOC APP FILLER NECK VEHICUL
68. 3 5 and 3 9 Verify problem is solved E Inspect valve openings in cylinder heads for burnt damaged or worn valve seats s Are valve openings in cylinder heads dirty or worn NO YES Repeatstep D Verify problemis solved If valve openings have burnt damaged orworn valve seats replace cylinderhead para 3 5 Verify problem is solved END OF TASK TM 9 2815 250 24 amp P 3 3 TROUBLESHOOTING CHART continued a ENGINE 3 FUEL CONSUMPTION IS EXCESSIVE AND THERE IS BLACK EXHAUST SMOKE A Perform fuel injector test para 3 21 Do fuel injectors pass test EUER IN EGTORS NO k YES Replace fuel injector s para 3 14 Verify problem is solved B Perform injection pump test para 3 2D Does Injection pump pass test NO YES Replace injection pump para 3 15 Verify problem is solved C Perform cylinder compression test para 3 17 Is compression reading between 350 and 400 psi 2413 and 2758 kPa NO YES Repair or replace pistons and o combustion chamber liners para 3 9 Verify problem Is solved D Inspect valves and valve seatk para 3 5 Are valves and or valve seats bumt bent or wom NO YES Repeatsteps AthroughC Verify problem is solved enlace or grind valves and valve seats para 3 5 Verify problem is solved END OF TASK INJECTION PUMP 3 3 a TM 9 2815 250 24 amp P TROUBLESHOOTING CHART continued ENGINE 4 EN
69. 3 63 thru 3 70 3 63 thru 3 70 A 1 and A 2 A 1 and A 2 C 5 and C 6 C 5 and C 6 C 7 thru 17 1 C 7 thru 17 1117 2 blank l 1 thru 1 9 I 1 thru 1 6 D 1 and D 2 thru D 3 D 4 blank F 3 F 4 blank F 3 and Index 1 thru Index 4 Index 1 thru Index 4 Cover Blank Cover Pin Distribution Statement A Approved for public release distribution is unlimited 4 File this change in front of the publication By Order of the Secretary of the Army PETER J SCHOOMAKER General United States Army Chief of Staff Official Stadia 38 SANDRA R RILEY Administrative Assistant to the Secretary of the Army 0524301 DISTRIBUTION To be distributed in accordance with the Initial Distribution Number IDN 381080 requirements for TM 9 2815 250 24 amp P TM 9 2815 250 24 amp P INSERT LATEST CHANGED PAGES DESTROY SUPERSEDED PAGES LIST OF EFFECTIVE PAGES Note The portion of the text affected by the changes is indicated by a vertical line in the outer margin of the page Changes to illustrations are indicated by miniature pointing hands Changes to wiring diagrams are indicated by shaded areas Date of issue for original and changed pages are Original Ones einen 11 September 1998 Change Mei 31 December 2005 TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 232 CONSISTING OF THE FOLLOWING Page Change Page Change Page Change No No No No No No COVE an 1 A AEA ETE 0 3 29 O 0 CE PE 1 2 20 t e
70. 305 01 455 1245 TM 4 CAGE 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 96906 61080 21969 61080 61080 61080 END OF 9 2815 250 24 amp P 5 PART NUMBER 50347500 50347600 50304400 01262701 50011200 50304300 50304100 50333900 50304500 99400638 MS35756 15 50146000 M10X55DIN912 8 8 50055100 50302100 50324200 FIGURE col 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 2912 CRANKCHSAFT ASSEMBLY FIGURE 5 CRANKSHAFT ASSEMBLY KEY MACHINE eene PLUG MACHINE THREAD BUSHING MACHINE THR SEAL PLAIN PART OF KIT P N 01228002 HUB BODY ll oll nn KEY WOODRUEF eene WASHER SPRING TENSI SCREW CAP SOCKET HME UOC APJ SCREW CAP SOCKET HME UOC APP BEARING SLEEVE o oo ooooo o BEARING SLEEVE oo ooooo o 7 QTY PRERRRRARNARRR E H w TM 9 2815 250 24 amp P C01 SECTION II DUA INS TKK K Ban 114 E A ME AS l C PTE U E OESTE AR A Nap ja n N RR n T S Y ATE VA T 7 Ki j AL Figure 6 Flywheel and Related Components 1 ITEM NO 0 JOH U B amp B W N H wo 2 SMR PAFZZ PAFZZ PAFZZ KFFZZ PAFZZ PAFFF PAOZZ PAFZZ PAOZZ KFFZZ PAFZZ PAFZZ XDFZZ PAFZZ XDFZZ PAOZZ PAFZZ PAFZZ PAFZZ 3 NSN 5310 01 400 2140 5310 01 400 2141 2815 01 455 0376
71. 50 to 400 psi 2410 to 2758 kPa If there is a pres sure difference between cylinders refer to paragraphs 3 5 and 3 9 for repair procedures for valves pistons piston rings and cylinders C Insert compression tester into fuel injector bore near cylinder no 1 2 on flywheel side of engine d Crank engine and note compression reading on compression tester gage 3 56 Change 1 TM 9 2815 250 24 amp P 3 17 CYLINDER COMPRESSION TEST continued lt I j A N PE e Remove compression tester from fuel injector bore for cylinder no 1 2 and repeat steps c and d for fuel injector bore for cylinder no 2 1 on auxiliary drive side of engine f Remove compression tester from fuel injector bore for cylinder no 2 1 g Install fuel injectors para 3 14 FOLLOW ON TASKS e None 3 57 TM 9 2815 250 24 amp P 3 18 VALVE ADJUSTMENT This Task Covers Adjustment Initial Setup Tools Test Equipment Equipment Conditions e General mechanic s tool kit automotive e Rocker arm cover removed para 2 17 Item 15 Appendix G ADJUSTMENT NOTE Cylinder no 1 is on the flywheel side of the engine Cylinder no 2 is on the auxiliary drive side of the engine e Allow engine to cool to room temperature approximately 75 F 24 C before adjusting the valves e Valves are in rocking position when the rocker arms are level and can be moved slightly a Turn flywheel 1 clockwise until valves in c
72. 50275000 50279200 50286300 50289200 50290100 50290200 50290300 50290500 50291400 50293200 FIG H H El E3 HR H H N wo N J JW JU OAO ON OAJA4HNDUWOLPBOECEH A U 0 I H H 10 PART NUMBER 50293810 50300700 50301000 50301100 50301200 50301400 50301500 50301601 50302000 50302100 50302700 50302800 50303000 50303610 50304100 50304300 50304400 50304500 50304900 50305000 50305300 50305400 50305700 50306001 50306200 50306500 50306600 50306900 50307000 50307100 50308100 50308500 50308800 50308901 50309100 50309200 50309300 50309400 50309500 50310400 50310500 50310810 50310900 50311000 50311200 50311500 50311700 50312200 50312300 50312400 50312500 50313000 50313100 50314100 50315400 50315500 50315900 50316000 50317800 50321900 50323500 50323800 FIG 0 00 0 00 0 U UI UT I OG H O 8 UI 0 O O LV ds les dS S UI TM 9 2815 250 24 amp P C01 CROSS REFERENCE INDEXES PART NUMBER INDEX ITEM PART NUMBER FIG 50324200 5 50326200 11 50328300 13 50328500 16 50333400 12 50333800 14 50333900 5 50334600 14 50334800 14 50335300 9 50336200 6 50336300 9 50336400 9 50336500 9 50341900 9 50342000 9 50344900 13 50347500 5 50347600 5 50355400 12 50355500 12 50355600 12 50359000 7 50359010 7 50359110 7 50365600 16 50405200 3 50405600 14 50408500 14 50431300 16 50446700 16 50448100 9 50493200 12 50493300 12 50493400 12 50500800 13 50507800 13 50511000
73. 7 and new gasket 16 on crankcase 14 Secure with three screws 18 and nut 19 Remove fuel testing device 13 adapter rod 12 and indicator dial 11 from injection pump outlet port 10 NE SI Install delivery valve 9 new gasket 8 spring 7 shim 6 spring guide 5 new O ring 4 and injector line fitting 3 on injection pump outlet port 10 Disconnect vehicle fuel supply from injection pump UOC APP refer to TM 9 2350 293 20 Disconnect vehicle fuel supply from injection pump UOC APJ TM 9 2350 292 20 2 Install fuel pressure pipes para 2 23 Install airflow deflectors UOC APP para 2 24 Install airflow deflectors UOC APJ TM 9 2350 292 20 2 64 Change 1 TM 9 2815 250 24 amp P 3 20 INJECTION PUMP TEST This Task Covers Test Initial Setup Tools Test Equipment Equipment Conditions Fuel test set Item 12 Appendix G e Airflow deflectors removed as needed UOC General mechanic s tool kit automotive APP para 2 24 Item 15 Appendix G e Air flow deflectors removed as needed UOC Wrench Item 36 Appendix G APJ TM 9 2350 292 20 2 TEST a Remove fuel pressure pipe clamp and fuel pressure pipe assembly from fuel injector on flywheel side of engine para 2 23 b Remove fuel injector from flywheel side of engine para 3 14 GC Install extension tube 4 tube assembly 5 and indicator dial 1 from fuel test set on flywheel side port
74. 8 20 03783301 8 18 01222300 13 29 03783401 8 17 01222400 13 1 03783500 8 16 01222510 13 32 03783600 8 15 01223200 12 27 03783800 8 12 01224001 8 35 03783902 11 11 01224400 8 3 1 03784001 11 15 01224500 8 8 1 03784300 14 19 01224600 8 8 03784400 14 5 01224900 9 7 03784501 3 3 01225610 11 16 03785201 3 6 2 01226100 14 20 03785300 7 6 1 01227410 4 1 03785600 7 6 2 01227420 4 1 03786300 8 14 01227910 9 8 03787300 3 2 01228002 KITS 2 03787402 11 1 01228202 KITS 3 03788800 9 23 01231501 12 24 03790001 9 3 01239901 6 12 03790100 9 5 01240203 7 3 03791400 3 4 01240211 7 3 03791600 13 18 01240301 7 4 03792100 6 3 01240900 12 1 03792400 12 6 01240910 12 1 03792800 3 11 01241000 12 2 03792900 3 11 01241010 12 2 03793000 3 11 01244800 8 22 03793100 3 11 01247100 7 1 03793200 3 11 01247110 7 1 03793300 3 11 01247200 3 6 1 03793400 3 11 01247210 3 6 1 03908201 9 27 01247702 KITS 1 03920100 14 13 01248303 7 3 03932100 9 4 01248311 7 3 03938610 9 15 01248701 7 4 03939700 11 17 01262200 7 6 03958000 7 2 01262701 5 3 03958100 14 23 01266500 13 25 03966300 12 25 1 01285500 10 2 03971200 3 11 01285600 11 7 03971300 3 11 01445200 14 21 03975300 6 2 01509110 16 11 04020200 13 3 01516900 16 9 04021800 13 37 01613100 9 27 1 04025800 12 8 01665000 13 36 04031300 6 1 01665600 13 34 04035700 12 5 01665610 13 33 04038200 4 14 01670100 13 40 04039100 4 15 03125800 13 24 04085001 12 8 03171800 3 5 04086300 13 3 03173100 8 4 04088300 13 4 8 8 2 04090600 3
75. 95 A31 SC 4910 95 A31 SC 5180 95 B08 SC 5181 95 B08 SC 3470 95 A02 SC 4910 95 A74 SC 4910 95 A74 SC 4910 95 A31 SC 4910 95 A31 SC 4910 95 A63 SC 4910 95 A63 SC 4910 95 A63 TM 9 2815 250 248P G 3 G 4 blank TM 9 2815 250 24 amp P INDEX SUBJECT PAGE A Abbreviations and Acronyms re croata id rd a adds 1 2 Adjustment Engine Speed 2 pa e OD LS ot Rite A yes ce AA A eh ds 3 69 Flow Control Valve tota a Dente e ics Pa A P ei A eae Oates 3 60 Solenoid UOC ABB da to caet ii A ia A rt as 2 30 MAING tna dao be nacida dk M lih M cU o iM EE pacien soda EE 3 58 Valve to Piston Clearance o o occcooocccccoonr eden hh 3 40 Airflow Deflectors Replacement UOC APP soomi nennen 2 24 Auxiliary Drive Adapter Replacement 0 cece eet enn nennen nenn 3 14 1 B Bearings Repair Crankshaft and o ocoocccccococ nennen nennen nennen nennen eae 3 26 C Gamshiatt Rebpall xoc eer cu Um LM MM iu 3 40 Cautions Notes and Warnings sssusa she V Gleaning lnstr clloris erste od prseter ee D E ee etta eA 2 4 Combustion Chamber Liner Repair Piston and sos eee nennen nenn nenn 3 32 Common Tools and Equipment occcccccc sr 2 1 Components Major Location and Description oss n 1 5 Corrosion Prevention and Control ooo 0 0 cece eee tenet hn 1 3 Grankcase Repair tas cios A Rn 3 20 Crankshaft and Bearings Repair sos nennen nennen nennen rennen nenn 3 26 Eylinder Compression T
76. 9501 BULK MATERIAL FIGURE BULK MATERIAL HOSE NONMETALLIC 2 SECTION II TM 9 2815 250 24 amp P Figure 17 Special Tools 1 ITEM NO W N J OAO Uu A 2 SMR PEOZZ PEFZZ PEFZZ PEFZZ PEFZZ PEFZZ PEFZZ PEFZZ 3 NSN 5120 01 428 5525 5120 01 454 5887 5120 01 454 5888 5120 01 454 5885 5120 01 458 3944 5120 01 454 5886 5120 01 454 5890 4910 01 454 5889 TM 9 2815 250 24 amp P 4 5 PART CAGE NUMBER 1CV0O5 3715M 61080 62574200 61080 62574801 61080 62574700 61080 66503091 61080 62568902 19207 57K3263 19207 57K3264 END OF FIGURE 17 1 17 2 bank col 6 7 DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 26 TOOLS AND TEST EQUIPMENT GROUP 2604 SPECIAL TOOLS FIGURE 17 SPECIAL TOOLS WRENCH OPEN END BOX BRACKET CYL ALINE 0 PULLER CRANK GEAR DRIVER CRANK GEAR TESTING DEVICE FUEL PULLER RELIEF VALVE TEST SET OIL PRESSU TESTER FUEL INJETOR STOCK NUMBER 5315 00 616 5530 5315 01 070 5656 5310 01 078 8066 5330 01 080 1776 5315 01 081 4488 5310 01 090 0938 5340 01 100 4991 5365 01 100 5415 5365 01 100 5416 5310 01 101 2028 5305 01 101 4830 5365 01 101 5938 5330 01 101 7264 5331 01 101 8063 5330 01 101 8076 5315 01 102 7922 5315 01 103 1522 4730 01 103 3202 5999 01 116 8286 533
77. AGE M continued Crankshaft and Bearings Repair 000 cece cent ene ene nn 3 26 Cylinder Heads Repair som ented eens 3 15 Deep Oil Pan and Gasket Replacement UOC APJ sn 3 48 1 Filler Neck Replacement UOC APP 0 0 cece eet e eee eee eens 3 46 Flywheel and Housing Replacement 006 ec cece teen eee nennen nennen nennen 3 28 Fuel Injector Replacement 2225 ek ee hae bee boned big DERE 3 48 2 Governor Control Assembly Repair 00000 cece hh 3 54 Injection Pump Replacement sedi aega tSS SEEE ETARE EEIN E eee ee tee mme 3 50 Mounting Plates Replacement oooocooccoconccn nent en EENE KEUS 3 12 Oil Pan and Gasket Replacement UOC APP nn 3 47 Piston and Combustion Chamber Liner Repair 060 000s cece cee eee es 3 32 Rocker Arm Assemblies Repair 00 cece ect hn 3 38 Maintenance Procedures Unit Airflow Deflectors Replacement UOC APP 2 ehe 2 24 Eyebolt Replacement UOC APP ooccccccccccc nn 2 8 Filter Opening Cap Replacement UOC APP nn 2 10 Filter Element Replacement UOC APP ooocccccccccccnc eee eens 2 13 Fuel Pressure Pipe Assemblies and Return Fuel Hose Replacement 0 c seen eee eee 2 20 General tarada sais tea e fel eer an e cpi M el dl ah Sa dd e ghee MADE E 2 3 Identification Plate Replacement ooccccccccccccr ene een eden ee 2 7 Intake Manifold Replacement ssssussssssssssssss es 2 15 Oil S
78. AS Pon E A SIITA 1 ES ELA N NV ISI y SE SI er CAS ee d N ISI add ITE LTD Seiser PEPA 1941 5 pc PAYA i Te Nr ASA A KON PN ES G MS LO IN Sch AS USAS NS Ke NA x NN Y ZEF q Ld Wo am HERNE VA Figure 14 Engine Cowling Ducts and Shroud SH 1 of 2 TM 9 2815 250 24 amp P SECTION II Figure 14 Engine Cowling Ducts and Shroud SH 2 of 2 k k kk k k k k kk k k 1 ITEM NO U amp W N H o 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Refer to TM 9 2350 292 24P and TM 9 2350 292 20 2 for UOC 2 SMR PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ 3 NSN 5305 01 405 9895 5310 01 400 3715 5310 12 149 4353 5305 01 405 9894 2815 01 455 0040 5340 01 459 1403 5310 01 399 7301 5305 01 405 9897 5310 01 399 7303 5305 01 405 9901 5305 01 455 1622 2815 01 454 9237 3120 01 455 7311 2815 01 454 9210 5340 01 458 8159 4720 01 399 5578 5305 01 455 1619 5305 01 405 9892 5340 01 454 9270 4730 01 415 7923 2815 01 454 9344 5310 01 405 9890 2815 01 439 3916 5305 01 406 0003 2815 01 455 0039 5305 01 405 9898 5310 01 455 8482 TM 4 CAGE 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080
79. Always wear protec tive goggles and gloves and use only in a well ventilated area Avoid con tact with skin eyes and clothes and do not breathe vapors Do not use near open flame or excessive heat Clean injection pump and cavity in crankcase with drycleaning solvent and rag Measure governor lever 8 It should measure 3 88 inches 0 03 inch 98 5 mm 0 8 mm If measurement is not correct adjust it by loosening jamnut and turning governor lever 8 in or out to shorten or lengthen it Tighten jamnut when length is correct JAMNUT 3 88 INCHES 0 03 INCH 98 5 mm 0 8 mm 3 51 TM 9 2815 250 24 amp P 3 15 INJECTION PUMP REPLACEMENT continued C 3 52 INSTALLATION NOTE The thickness of the gasket s to be installed is determined by the number stamped on the side of the crankcase next to the injection pump For example if the number 6 is stamped on the crankcase the total thickness of the gas kets should be 0 60 mm Gaskets come in sets of three gaskets of varying thickness Install enough new gaskets 10 on crankcase 4 to reach the thickness indicated by the number stamped on crankcase 4 NOTE To install injection pump in crankcase control rack of injection pump must be positioned over cutout in crankcase Position control rack of injection pump 7 over cutout and install injection pump 7 on crankcase 4 Turn flywheel 11 to allow injection pump 7 to sit all the w
80. Columns in Section ll oocooooncccononoccccnnnaccnononnconononncnncnnnncncnnnnncn cnn nnnnn nnne nnne G 1 G 1 GENERAL This appendix lists all of the common and special tools required to maintain the Diesel Engine Assembly Hatz 2 G 40 This appendix is for reference only To requisition special tools refer to Repair Parts and Special Tools List RPSTL G 2 EXPLANATION OF COLUMNS IN SECTION Il a Column 1 Item Number This number is assigned to the entry in the listing and is referenced in the initial setup in each maintenance procedure to identify the item e g General mechanic s tool kit Item 11 Appendix G b Column 2 Item Name This column lists the item by nomenclature and other descriptive features such as measurement C Column 3 National Stock Number This is the national stock number assigned to the item use it to requisition or request an item d Column 4 Part Number This indicates the primary number used by the manufacturer who controls the design and characteristics of the item by means of engineering drawings specification standards and inspection requirements e Column 5 Reference This column identifies the authorizing supply catalog SC or RPSTL for tems listed in this appendix Number 1 Item 10 11 12 13 14 15 16 17 18 19 20 2 National Part Number Arbor press Blind hand riveter Cable assembly Crank gear driver Crank gear puller
81. D PAFZZ PFFZZ PAFZZ PAFZZ PAFZZ PFFZZ PAFZZ PAFZZ PAFZZ PAFZZ 3 NSN 2815 01 465 4321 2815 01 446 3500 5935 01 480 9543 5340 01 454 8631 5305 01 455 2207 5330 01 455 7822 2990 01 454 8843 5305 12 146 1760 5305 01 455 2206 5310 01 274 4387 5310 12 130 4938 TM 9 2815 250 24 amp P 4 CAGE 19207 19207 19207 61080 61080 61080 19207 61080 4B948 61080 61080 D8286 END OF 5 PART NUMBER 12367094 12463204 12367105 99400639 99400642 99400641 12478240 99400640 DIN7984 M10X30 1 0 9 A3P 50054300 50061700 DIN7980 10 FST FIGURE col 6 DESCRIPTION AND USABLE ON CODE UOC 7 QTY GROUP 29 AUXILIARY GENERATOR AND ENGINE AND CONTROLS ENGINE ASSEMBLY ENGINE DIESEL GROUP 2910 FIGURE 2 ASSEMBLY ENGINE APU UOC APJ ENGINE DIESEL o ooooo UOC APP SPACER SPECIAL SHAP UOC APJ PLATE MOUNTING o oo oooooo UOC APP SCREW CAP SOCKET HE SEAL PLAIN ENCASED PLATE MOUNTING oo oooooooo UOC APJ PLATE MOUNTING ENGI UOC APP SCREW LOW HEAD CAP UOC APJ SCREW CAP SOCKET HE UOC APP WASHER SPRING TENSI UOC APP WASHER LOCK eese UOC APJ TM 9 2815 250 24 amp P C01 SECTION II 6 1 11 GEM DAN TE PE N N com wm c N Ex SEN a Vom
82. DAPTER INTAKE MANI UOC APP WASHER SPRING TENSI SCREW CAP SOCKET HME o GASKET PART OF KIT P N 01247702 COUPLING HOSE 2 1 0 nm mon n RR Rx HOSE PREFORMED oooooooooo UOC APJ APJ Item 7 QTY H N PENN BK H HHNNEo D Hur SECTION II C01 TM 9 2815 250 24 amp P 31 DUAL BANJO FITTINGS v 25 TRES a 6 26 25 25 1 25 BR z Ofc 9 6 1 Y p O EN JS Om W o IE 7 p E VID D 6 DES S 3 30 7 1 28 29 28 12 27 P ES 21 22 S 22 1 a 23 E IX yoy RB A AKT FAT EM Us LABS INA NES Y L NES LI Lm 5 Lo i l iz A tert gt TFT N J or WA o mnt EL er ZU EE Ti ill NA SIR N 4 z SEP AEN 9 Ne NASAL dmm EC NOTES IE AL ERE N RAS STE SR In ja c MER Pd We P a LT STN Peto ML Pine MES Ul Pa LIST TES VAN A NS M J WAN TIKIN ON TTL A SESS N LG TW E Wal Ip TIA OS gt LENT OXY WU m TEER A POLIS IBERIA a IAS c i N N E n np a i vo AER T ENS S V i A l FN AJ AC M a Part of item 12 W i i i i n N AS AOL Note Items 32 33 and 34 deleted gt M N eg GA meee 291096 Figure 12 Injection Pump Nozzles and Fuel Lines TM 9 2815 250 24 amp P col 1 2 3 4 5 6 7 ITEM SMR NSN PART DESCRIPTION AND NO CAGE NUMBER USABLE ON CODE UOC QTY GROUP 2932 ENGINE FUEL SYSTEM FIGURE 12 INJECTION PUMP NOZZLES AND FUEL LINES 1 PA
83. EID ee a Ru eg EX Due CTA 50 970 Abbreviations for Use on Drawings Specifications Standards and in Technical Documents 000 sn rr MIL STD 12 A 2 Change 1 TM 9 2815 250 24 amp P APPENDIX B MAINTENANCE ALLOCATION CHART Section I INTRODUCTION Paragraph Page Number Paragraph Title Number B 1 A A ee ee ee ee eee ee eee eee B 1 B 2 Maintenance F nctions comica A lea B 1 B 3 Explanation of Columns in Section II Maintenance Allocation Chart for Engine Assembly Di sel Eatiz2 0 4 UE B 2 B 4 Explanation of Columns in Section III Tools and Test Equipment Requirements B 3 B 1 GENERAL Appendix B consists of three sections a B 2 Section provides a general explanation of all maintenance and repair functions authorized at the various maintenance levels Section Il the maintenance allocation chart MAC designates overall authority and responsibility for the performance of maintenance functions on the identified end item or component The application of the maintenance functions to the end item or component will be consistent with the capacities and capabilities of the designated maintenance levels Section Ill lists the tools and test equipment both special tools and common tool sets required for each maintenance function as referenced from Section Il MAINTENANCE FUNCTIONS Maintenance functions are limited to and defined as follows Inspect To determine the serviceabili
84. GINE HAS LOW POWER OR MISFIRES FUEL A Inspect fuel lines and fittings for leaks INJECTORS Are there leaks NO YES Jei defective fuel lines andfittings 23 Verify problem is solved B Perform fuel injector fest para 3 21 Do fuel injectors pass test NO YES Replace fuel injecte a Verify problem is solved C Perform injection pump test para 2 20 Does injection pump pass test NO YES FITTINGS Replace injection pum 5 para 3 15 Verify problem is solved D Perform cylinder compression test para 3 17 Is compression reading between 350 and 400 psi 2413 and 2758 kPa NO e YES INJECTION PUMP Repair or replace pose os combustion chamber a 3 9 Verify problem is solved n Repeat steps B through D Verify problem is solved FOR PURPOSES OF CLARITY AIRFLOW DEFLECTORS AND INTAKE MANIFOLD ARE NOT SHOWN END OF TASK TM 9 2815 250 24 amp P 3 3 TROUBLESHOOTING CHART continued a ENGINE 5 ENGINE MAKES A KNOCKING SOUND FUEL INJECTORS A Inspect fuel lines and fittings for leaks Are there leaks NO YES FITTINGS Replace defective fuel lines and fittings Verify problem is solved B Perform fuel injector test Hara 3 21 Do fuel injectors pass test NO YES Replace fuel injector s para 3 14 FUEL LINES Verify problem is solved FITTINGS C Perform injection pump test para 3 20 Does inje
85. H 2 of 2 0 A eh teu 1 Figure 15 peiora 0 on dcr MEE 1 Figure 16 eeeesesss 0 10 1 sheets aa eee be 1 16 2 addeq 1 Me LEES 1 Kits 2 added 1 Bulk ee 1 FIgUre dinar 0 I ec RE 1 17 2 blank added 1 EE 1 TEE 1 Zero in this column indicates an original page Page Change No No po 1 Ada 1 diia 1 Ho 1 l 7 deleted 1 1 8 deleted 1 1 9 1 10 blank deleted 1 Dn ia ce 0 Deia an E 1 D 3 D 4 blank 1 Eli esie i detenta 0 ED made e ici 0 Ed s eite deed esed 0 EA 0 ED dad 0 E 6 blank ssessssss 0 Pad ated sates Matias ead eli aes 0 A TA EA A E 0 Abi 1 ti ads 1 Gisela 0 E p 0 dan id 0 CANTE AA 0 Index 1 re 1 la 6 Ce 1 Index 3 re 1 SA 1 Index 5 re 0 Index 6 blank 0 2028 Sample 0 2028 Sample Address 0 20285 urhe t nt 0 2028 Address 0 Metric Page sss 0 Plica tigen asa qiia deer 1 TM 9 2815 250 24 amp P HEADQUARTERS TECHNICAL MANUAL DEPARTMENT OF THE ARMY NO 9 2815 250 24 amp P WASHINGTON D C 11 September 1998 UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR ENGINE ASSEMBLY DIESEL HATZ 2 G
86. ING LIP PRIMARY de 7 SEALING LIP amp OUTBOARD INBOARD z 6 ENGINE it I CROSS SECTION OF SEAL 29i210m FOLLOW ON TASKS e install drive adapter 3 14 Change 1 TM 9 2815 250 24 amp P 3 4 4 AUXILIARY DRIVE ADAPTER REPLACEMENT This Task Covers a Removal b Installation Initial Setup Tools Test Equipment Materials Parts e General mechanic s tool kit automotive e Sealing compound Item 13 Item 15 Appendix G a REMOVAL Remove socket screw 1 lockwasher 2 woodruff key 3 and drive adapter 4 from crankshaft 5 b 1 INSTALLATION Install drive adapter 4 with woodruff key 3 onto crankshaft 5 Apply sealing compound Item 13 Appendix D to threads of socket screw 1 Install socket screw 1 lockwasher 2 into crankshaft 5 Torque screw to 37 ft Ib BO Nem 29i209m Change 1 3 14 1 3 14 2 blank TM 9 2815 250 24 amp P 3 5 CYLINDER HEADS REPAIR This Task Covers a Removal c Adjustment e Installation b Cleaning and Inspection d Machining Initial Setup Tools Test Equipment e Cylinder alignment bracket Item 6 Appendix G Depth gage rule Item 9 Appendix G General mechanic s tool kit automotive Item 15 Torque wrench 1 2 inch drive Item 31 Appendix G Valve face grinding machine Item 33 Appendix G Valve seat grinding kit Item 34 Valve spring lifter Irem 35 Materials Parts e Carbon removing
87. ION OF SEAL Change 1 TM 9 2815 250 24 amp P O 1 z 29i208m 3 31 Change 1 3 8 FLYWHEEL AND HOUSING REPLACEMENT continued Install key 9 in crankshaft 8 Install flywheel 3 washer 2 and nut 1 on crankshaft 8 Torque nut to 148 ft Ib 200 N m T FOLLOW ON TASKS LA Install airflow deflectors UOC APP p Install airflow deflectors UOC APJ TM 9 2350 292 20 2 e Install oil tube assemblies Kp TM 9 2815 250 24 amp P 3 9 PISTON AND COMBUSTION CHAMBER LINER REPAIR This Task Covers a Removal c Cleaning e Installation Disassembly Assembly Initial Setup Tools Test Equipment e Cylinder ridge reamer Item 8 Appendix G General mechanic s tool kit automotive Item 15 Appendixl Piston ring compressor Item 21 Appendix Gl Piston ring expander Item 22 Appendix G Snapring pliers Item 26 Appendix G Materials Parts e Carbon removing compound Item 3 a REMOVAL Screwdriver attachment 6 mm Item 24 Appendix Gil Socket wrench set 3 8 inch drive Item 27 Appendix G Torque wrench 3 8 inch drive Item 30 Drycleaning solvent Item 4 Appendix D Lubricating oil Item 6 Appendix D Rag Item 7 Appendix D Cap plug 2 Item 10 Appendix F Cap plug 4 Item 11 Appendix F Piston ring set 2 Item 2 Appendix F Retaining ring 4 Item 47 Appendix F Shim 2 Item 9 Appendix F Sleeve bear
88. MBER USABLE ON CODE UOC QTY GROUP 94 REPAIR KITS GROUP 9401 REPAIR KITS FIGURE KITS REPAIR KITS 1 PAFZZ 5330 01 415 6721 61080 01247702 GASKET SET 00 0 000 cc eens GASKET 0 70 MM 1 3 11 GASKET 0 60 MM 1 3 11 WASHER FLAT 4 8 11 O RING 2 8 13 O RING 2 8 32 O RING 2 8 34 WASHER FLAT 2 9 2 GASKET SET 2 10 2 GASKET 2 11 11 GASKET 2 12 8 JOINT 2 12 8 JOINT 2 12 8 GASKET 4 12 10 GASKET 1 13 28 GASKET 1 13A 20 2 PAFZZ 61080 01228002 GASKET SET leen GASKET 1 4 15 O RING 8 4 16 GASKET 1 4 15 1 SEAL PLAIN 1 5 8 O RING 1 6 4 GASKET 2 6 9 O RING 1 9 9 GASKET 1 9 14 O RING 1 9 26 O RING 1 9 28 GASKET 1 11 13 GASKET 0 20 MM 1 12 21 GASKET 0 30 MM 1 12 21 GASKET 0 10 MM 2 12 22 GASKET 2 12 25 GASKET 3 12 25 O RING 2 13 5 O RING 2 13 31 O RING 1 13A 7 3 PAFZZ 61080 01228202 MAINTENANCE KIT 2 000005 NUT PLAIN HEXAGON 1 8 4 WASHER FLAT 4 8 11 O RING 2 8 13 NUT PLAIN HEXAGON 1 8 8 2 FILTER ELEMENT FLUI 1 9 18 GASKET 9 21 COCK POPPET DRAIN 1 9 22 CAP FILLER OPENING 1 9 27 1 END OF FIGURE KITS 1 KITS 2 bank 1 ITEM NO 1 2 SMR PAFZZ TM 9 2815 250 24 amp P 3 4 5 NSN PART CAGE NUMBER 19207 12478232 END OF FIGURE BULK 1 col 6 7 DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 95 GENERAL USE STANDARDIZED PARTS GROUP
89. N M N ZS gt NNNNNNNNNN A NY 4 7 7 NN NS CONAN AY 1 NON MRR p ipe 41 7 IV PERRE i y j A KKK ft z RAE 3 NY n I est N N LIL YUMMY Lue AA NNUS Ammann LEN Zz EAN NS 5 AMITTIT n A 1 NV 11 li MA AS 11 Wyn AVAL s a Tignes NY I a SSS u l 1 MMII HMM y Jh NN _ 47 NUNNU N N SET MMMM YS 7 N WMA I NC N d Tu 5 Len at ff a 2 MUU E o PERE S eS Pil Am 111 WV Ay Ath M MANN vw AA ja N GT ZEN TN X N pure ANG A e SCHERE W 37 u a Ad j ALS Figure 3 Cylinder Head 1 ITEM NO k 1 k k N o o HN H o O0 1 N P Hn v BSW 6 Oo O Ho 11 11 11 11 11 11 11 11 11 11 11 11 12 KK Refer to TM 9 2350 292 24P and TM 9 2350 292 20 2 for UOC EPA Version 1 Compliant Only 2 SMR PAOZZ PAOZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFFF PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ KFFZZ KFFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 3 NSN 5306 01 455 2212 5365 01 399 5013 5310 01 455 8479 5310 01 399 8358 5310 01 399 7312 2815 01 455 0371 2815 01 455 0056 5307 01 405 9899 5307 01 406 5443 5307 01 405 9997 5307 01 405 9907 5307 01 405 9909 5307 01 455 2210 TM 9 2815 250 24 amp P 4 CAGE 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080
90. N br N 3 A ates 2N e nn wht N N ih MS ese AES an un STI hamaan Figure 11 Intake Manifold and Related Components 1 ITEM NO 0 J O U PB W N H k k 11 12 13 14 16 17 2 SMR PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAFZZ ak Refer to 3 NSN 2815 01 455 0041 5310 01 455 8480 5305 01 455 1242 5305 01 455 1247 5310 01 399 7305 5310 01 101 2028 5330 01 455 7823 2815 01 454 8626 5310 01 399 7303 5305 01 455 1613 5330 01 455 7819 5330 01 080 1776 4730 01 399 6267 4820 01 399 5579 5340 01 454 9271 5310 01 400 3720 TM 9 2350 292 24P and TM 9 2350 292 20 2 for UOC TM 4 CAGE 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 61080 END OF 9 2815 250 24 amp P 5 PART NUMBER 03787402 50148100 50175900 50183100 50095100 40028400 01285600 01198900 50208500 50206300 03783902 50326200 50001100 50303000 03784001 01225610 03939700 50148000 FIGURE 11 1 col 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 2918 MANIFOLDS FIGURE 11 INTAKE MANIFOLD AND RELATED COMPONENTS MANIFOLD INTAKE 0 000005 WASHER FLAT vele SCREW CAP SOCKET HE SCREW CAP SOCKET HE WASHER SPRING TENSI NUT SELF LOCKING HE A
91. NOCKING SOUND ENGINE SPEED IS ERRATIC TM 9 2815 250 24 amp P PARAGRAPH para 3 3h i para 3 3h 2 para 3 3a 3 para 3 3h 4 para 3 3h 5 para 3 3 TM 9 2815 250 24 amp P 3 3 TROUBLESHOOTING CHART a ENGINE 1 ENGINE CRANKS BUT STARTS HARD OR FAILS TO START A Inspect fuel lines and fittings for leaks Are there leaks NO FUEL INJECTORS YES FITTINGS lt Replace defective fuel lines and fittings para 2 23 Verify problem is solved B Perform fuel injector test para 3 21 Do fuel injectors pass test NO YES Replace fuel injector s para 3414 Verify problem is solved C Perform injection pump test para 3 20 Does injection pump pass test FUEL NO YES LINE Replace injection purnp para 3 15 Verify problem is solved FITTINGS GO TO STEP D INJECTION PUMP FOR PURPOSES OF CLARITY AIRFLOW DEFLECTORS AND INTAKE MANIFOLD ARE NOT SHOWN 3 3 3 3 TROUBLESHOOTING CHART continued a ENGINE TM 9 2815 250 24 amp P 1 ENGINE CRANKS BUT STARTS HARD OR FAILS TO START continued CONTINUED FROM STEP C D Perform cylinder compression test para 3 17 Is compression reading between 350 and 400 psi 2413 and 2758 kPa Inspect pistons and combustion chamber liners Repair or replace as needed Verify problem is solved E Check valve clearanc para 3 1B Is valve clearance 0 004 inch 0 102 mm Adju
92. OZZ 4710 01 399 7358 61080 01240900 PIPE ASSEMBLY METAL 1 PAOZZ 4710 01 518 8127 61080 01240910 TUBE ASSEMBLY METAL 2 PAOZZ 4710 01 399 7359 61080 01241000 PIPE ASSEMBLY METAL 2 PAOZZ 4710 01 518 8125 61080 01241010 TUBE ASSEMBLY METAL 3 PAFZZ 5310 01 400 3720 61080 50148000 NUT PLAIN HEXAGON o oooooo 4 PAFZZ 5310 01 399 7303 61080 50208500 WASHER SPRING TENSI 5 PAFZZ 5310 01 400 0995 61080 04035700 WASHER FLAT ononon eee cece o 6 PAFZZ 4730 01 399 4252 61080 03792400 CLAMP HOSE cece cee eee 6 1 PAFZZ 5307 01 405 9899 61080 50038400 STUD PLAIN 0 00000 c cece ee eee 7 PAFFF 2910 12 337 7727 61080 50355500 INJECTOR ASSEMBLY F 7 PAFFF 61080 50493300 INJECTOR ASSEMBLY 7 1 PAFZZ 61080 50355600 SA O A EV REIR e ena EE E 7 1 PAFZZ 61080 50493400 NOZZLE eee ee 8 PAFZZ 61080 04025800 JOINT PART OF KIT P N 01247702 8 PAFZZ 61080 04085001 JOINT PART OF KIT P N 01247702 8 KFFZZ 61080 40085001 GASKET PART OF KIT P N 01247702 9 PAOZZ 4730 01 399 4253 61080 03780800 NIPPLE HOSE eee 9 1 PAOZZ 81343 J1508 M 04 CLAMP HOSE eee 9 2 MOOZZ 19207 12478232 4 HOSE 2 2 MAKE FROM HOSE P N 12478232 c c eee nee 9 3 PAOZZ 61080 50157800 NIPPLE HOSE eee 9 4 MOOZZ 19207 12478232 3 HOSE 4 0 MAKE FROM HOSE P N 12478232 O ea RENS
93. Section II Section III APPENDIX C Section Section II Group 2210 TM 9 2815 250 24 amp P Table of Contents continued UNIT MAINTENANCE Repair Parts Special Tools Test Measurement and Diagnostic Equipment TMDE and Support Equipment 000 nn Service upon Receipt 00 en General Maintenance Procedures 0c cece cece ete ens Unit Maintenance Procedures zn cn nennen DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE Direct Support and General Support Troubleshooting 00 00 ee eee eee eee Direct Support and General Support Maintenance Procedures 000eseeeeeees Tesis and Adjustments 4 422424 Paista 24ER be idas REFERENCES 2 2 m 222 use er EC Ee aoe ew Ra eg a MAINTENANCE ALLOCATION CHART aue Uu coo eisernen Maintenance Allocation Chart for Engine Assembly Diesel Hatz 2 G 40 Tools and Test Equipment Requirements 000s cece eee eee teens REPAIR PARTS AND SPECIAL TOOLS LIST Introduction iuge re e A e outs Repair Parts List Page Body Chassis and Hull Accessory Items Data Plates and Instruction Holders 2210 Engine Identification Plate 00 cece eee eee 1 1 Auxiliary Generator and Engine and Controls 2910 Engine Assembly Engine Diesel ooo een 2 1 2911 Crankcase Cylinder Sleeve and Cylinder Head Cylinder Head scssi iarias awoni esiasio ee 3 1 Crankcase Assembly oossoo cece eee eee et
94. Setup Tools Test Equipment General mechanic s tool kit automotive Item 15 Oil pressure test set Item 20 Appendix G TEST a Remove screw 1 and washer 2 from fluid passage bolt 3 3 70 TM 9 2815 250 24 amp P 3 23 OIL PRESSURE TEST continued b Install oil pressure gage 4 on flexible connector 5 and install flexible connector 5 on fluid passage bolt 3 Start the engine and allow it to warm up Run the engine at the speeds indicated in Table 3 1 and check the oil pressure gage C Table 8 1 Oil Pressure Speed in rpm Normal Oil Pressure Minimum Oil Pressure 1 2 to 2 5 bar 17 4 to 36 3 psi 0 4 bar 5 8 psi 1 8 to 3 5 bar 26 1 to 50 8 psi 1 0 bar 14 5 psi 2 5 to 4 5 bar 36 3 to 65 3 psi 1 8 bar 26 1 psi 3 5 to 5 0 bar 50 8 to 72 5 psi 2 5 bar 36 3 psi FOLLOW ON TASKS e None 3 71 TM 9 2815 250 24 amp P APPENDIX A REFERENCES Paragraph Page Number Paragraph Title Number A 1 General 22e2tesn aan era Peg cae P qi iR Re hers A 1 A 2 FOL lS ne en nace hud awe pa Reb sepe ur ne RR A 1 A 3 Manuals lia ai eka iman dnc A 1 A 4 Pamphlets and Circulars 2 LAN A 1 A 5 Regulations ran aisa dius ir zt curio bee Lhe debt er bet ds A 2 A 1 GENERAL This appendix lists all forms pamphlets and regulations that are referenced in this technical manual DA Pam 25 30 should be consulted frequently for the latest changes or revisions and for new publications
95. Special TOS TT 17 1 Section IV Cross Reference Indexes National Stock Number Index sese 1 1 Part Number Index L oocooncccccccncocncocccocccncnoncnconononononononnonnnonnnnnnnnnnnnnnnnnnnnnnnos 1 4 Page APPENDIX D EXPENDABLE AND DURABLE ITEMS LIST Section UTOUC ii isommin ansa a ne a ee ee bipes Du ded D 1 Section II Expendable and Durable Items List sesssesesseee emen D 2 APPENDIX E TORQUE VALUES FOR THREADED FASTENERS sse E 1 APPENDIX F MANDATORY REPLACEMENT PARTS 0 ccccccccceeeseseeeeccceeesesaeeeeeeeeeeeseaseaeeeeeees F 1 APPENDIX G TOOL IDENTIFICATION LIST ooooococccccccncccccononococcnonononononoconcnnnnnnnnnonncnncnnnnnnnnnnnncnccnncocl G 1 n S Index 1 TM 9 2815 250 24 amp P HOW TO USE THIS MANUAL SCOPE This technical manual contains Unit Direct Support and General Support maintenance procedures for the Diesel Engine Assembly Hatz 2 G 40 Chapter 1 contains general information describes and illustrates Unit troubleshooting and maintenance procedures and nia describes and illustrates Direct Support and General Support troubleshooting and maintenance procedures Seven appendixes and a subject index are also included in this manual INDEXING Four Indexing procedures are used to help you locate information guickly e Cover index Lists chapter titles and important parts of this ma
96. T AND GENERAL SUPPORT MAINTENANCE Section I DIRECT SUPPORT AND GENERAL SUPPORT TROUBLESHOOTING Paragraph Page Number Paragraph Title Number 3 1 3 2 3 3 A aadeduveac Quick Guide to Troubleshooting ener nennen nenne nnns nnns Troubleshooting E n LEER o GENERAL This section provides information for identifying and correcting malfunctions that may develop while operating or maintaining the Diesel Engine Assembly Hatz 2 G 40 The Quick Guide to Troubleshooting lists common malfunctions of the diesel engine or its components and refers you to the appropriate paragraph in the Troubleshooting Chart TEKI You should perform the tests inspections and corrective actions in the order listed in the chart If you are unsure of the location of an item mentioned in troubleshooting refer to paragraph 1 12lor to the maintenance task where the item is replaced Before performing troubleshooting read and follow all safety instructions listed in the warning summary at the beginning of this manual This section cannot list all malfunctions that may occur or all tests or inspections and corrective actions If a malfunction is not listed or is not corrected by the corrective action listed notify your supervisor When troubleshooting a malfunction In the Quick Guide to Troubleshooting locate the symptom or symptoms that best describe the malfunction Turn to the subparagraph in the Troubleshooting Chart where the t
97. UT PLAIN HEXAGON o n o o nw UOC APP CONSOLE REGULATOR eee SCREW MACHINE eee DEFLECTOR AIRFLOW SCREW MACHINE o ooooooooo NUT PLAIN CLINCH eee eee APJ Item 7 QTY N H o RPRRER WHHN H TM 9 2815 250 24 amp P SECTION II ee RD a ME PP ae O P AY OX v FA ER DAY AS V TEST I N la SSA ON SN A 3 mo gt NVI y OMITA NIST AY iiy tee rr Figure 15 Sending Units 1 2 ITEM SMR NO 1 PAOZZ 1 PAOZZ 2 PAOZZ 3 NSN 2990 01 497 9561 5930 01 348 9797 5930 01 441 0097 TM 9 2815 250 24 amp P 4 5 PART CAGE NUMBER 61080 01160500 61080 50268600 61080 50293810 END OF FIGURE 15 1 col 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 2960 SENDING UNITS FIGURE 15 SENDING UNITS SWITCH ENGINE TEMPE UOC APJ SWITCH THERMOSTATIC oo UOC APP SWITCH PRESSURE 7 QTY TM 9 2815 250 24 amp P SECTION II K co MUN Pod NN Nut N pw E uj I AI b Figure 16 Fuel Shutoff Solenoid k k k k k k kk k k k k k k 1 ITEM NO a 011 FWD J 10 11 12 13 14 15 16 Refer to TM 9 2350 292 24P and TM 9 2350 292 20 2 for UOC 2 SMR PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAO
98. ZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ 3 NSN 3040 01 455 2816 5340 01 454 9284 5340 01 454 9277 5331 01 457 3350 5945 01 454 8223 5305 01 401 3694 5310 12 149 4353 5310 01 405 9890 5945 01 454 8230 5305 01 455 1251 5945 01 454 8238 5305 01 455 1250 5305 01 274 1064 5307 01 455 1249 5310 01 456 0736 5340 01 454 9275 TM 9 2815 250 24 amp P 4 5 PART CAGE NUMBER 61080 05063800 61080 61080 61080 61080 61080 50365600 50180400 50225501 50431300 50328500 61080 61080 50144500 50144400 61080 01516900 61080 50290300 61080 01509110 61080 50149100 61080 500 254 00 61080 05094600 61080 50446700 61080 05064010 END OF FIGURE 16 1 16 2 bank col 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 2968 SWITCHES CIRCUIT BREAKERS AND FUSES CONNECTING LINK RIG UOC APP CLIP RETAINING BELLOWS PROTECTION PLUNGER SOLENOID SCREW MACHINE UOC APP WASHER FLAT NUT PLAIN HEXAGON UOC APP BRACKET SOLENOID UOC APP SCREW CAP SOCKET HE UOC APP SOLENOID ELECTRICAL UOC APP SCREW CAP SOCKET HE UOC APP SCREW MACHINE UOC APP STUD PLAIN UOC APP NUT PLAIN HEXAGON UOC APP CONNECTOR ROD END UOC APP APJ Item FIGURE 16 FUEL SHUTOFF SOLENOID 7 QTY PS u TM 9 2815 250 24 amp P col 1 2 3 4 5 6 7 ITEM SMR NSN PART DESCRIPTION AND NO CAGE NU
99. and cylinder head 5 FOLLOW ON TASKS e None 2 9 TM 9 2815 250 24 amp P 2 18 FILLER OPENING CAP REPLACEMENT UOC APP This Task Covers a Removal b Installation Initial Setup Tools Test Equipment Materials Parts General mechanic s tool kit Grease automotive Item 5 Appendix D Item 14 Appendix G e O ring Item 28 Appendix F a REMOVAL 1 Remove filler opening cap 1 and O ring 3 from filler neck 2 2 Remove O ring 3 from cap 1 Discard O ring b INSTALLATION 1 Lightly coat new O ring 3 with grease Install O ring 3 on cap 1 2 Install cap 1 on filler neck 2 FOLLOW ON TASKS e None 2 10 Change 1 2 19 OIL TUBE ASSEMBLIES REPLACEMENT This Task Covers a Removal Initial Setup Tools Test Equipment e General mechanic s tool kit automotive Item 15 Appendix G Oil switch removedl para 2 25 Materials Parts e O ring Item 46 Appendix F e Washer 12 Item 18 Appendix F TM 9 2815 250 24 amp P b Installation Eguipment Conditions e Airflow deflectors removed only as many as needed to allow access to oil tubes para 2 24 e Fuel pressure pipe assemblies removed para 2 23 a REMOVAL 1 Remove fluid passage bolt 14 and two washers 12 from plate 11 and oil tube assembly 15 Discard washers 2 Remove two screws 13 and plate 11 from timing cover 7 Remove O ring 10 from plate 11 Discard O ring
100. ank TM 9 2815 250 24 amp P 3 13 1 This Task Covers a Removal DEEP OIL PAN AND GASKET REPLACEMENT UOC APJ Initial Setup Tools Test Equipment General mechanic s tool kit automotive item 14 Appendix G Materials Parts e Crankcase gasket set item 1 Appendix F a 1 REMOVAL Equipment Conditions e Engine mounting plate removedl para 3 4 Place a suitable container under drain plug 5 to catch oil then remove drain plug 5 from deep oil pan 4 Remove 10 screws 6 and flat washers 7 and oil pan 4 from crankcase 1 Discard lockwashers Remove strainer element 2 from crankcase 1 Remove gasket 3 from deep oil pan 4 Discard gasket INSTALLATION Install strainer element 2 in crankcase 1 Install new gasket 3 on deep oil pan 4 Install deep oil pan 4 on crankcase 1 and secure with two new flat washers 7 and screws 6 Install drain plug 5 FOLLOW ON TASKS Install engine mounting plate para 3 4 Refill with oil TM 9 2350 292 20 2 29i188m Change 1 3 48 1 TM 9 2815 250 24 amp P 3 14 FUEL INJECTOR REPLACEMENT This Task Covers a Removal b Cleaning c Inspection d Installation Initial Setup Rag Item 7 Appendix D e General mechanic s tool kit item 14 Appendix G essed onl thor Tp e Socket wrench set 3 8 inch drive Item 27 Appendix G Torque wrench 3 8 inch drive Item 30 Equipment Co
101. atio ssssesssssssssssess eens 18 1 Ignition Sequence Cylinder 1 Flywheel Side Lsse 1 2 Direction of Rotation 12 bert recane piian ma RS SERI EDU Hi uo Crankshaft power takeoff rotation is counterclockwise when facing power takeoff shaft Net Welght zit Tre cte a e Teen approx 196 Ib 90 kg Cooling air Required at 3000 rpm o occcccccccccccccc nenn 4 13 in min 10 5 cm min Combustion Air Required at 3000 rpm 1 2 ee eee ee 0 56 in mim 1 42 cm min Oil Capacity Including Filter Replacement 000000 approx 2 65 qt 2 5 L Oil Pressure sees hen ke ae eh aio min 14 5 psi 900 rpm min 1 bar 900 rpm Injection Pressure 0600 cece cette teens 3625 3741 psi 250 258 bar Tappet Clearance oo nennen nenn nennen nennen 0 004 in 0 10 mm Governor Speed asian naher ren 2200U 50 rpm Thermostatic Switch o ooooocooooccooocoo nenne nenn Closes at 446 F 18F 230 C 10 C Horsepower UOC APP 0060 c nennen eee 13 3 hp at 2000 rpm at 328 ft elevation at 77 F 25 C ambient temperature Horsepower UOC APJ oss nn 17 5 hp at 2650 rpm at 328 foot elevation at 77 F 25 C ambient temperature 1 8 Change 1 TM 9 2815 250 24 amp P Section Ill PRINCIPLES OF OPERATION 1 14 PRINCIPLES OF OPERATION The Diesel Engine Assembly Hatz 2 G 40 is an internal combustion power unit that converts heat energy to work energy inside the cyli
102. ation maintenance category authorization criteria and disposition instruction as shown in the following breakout Source Maintenance Recoverability Code Code Code XX 1st two positions How you get an item 4 s 3d position 4th position 5th position Who can install Who can do Who determines replace or use complete repair disposition action the item see note on on an unservice the item able item Complete Repair Maintenance capacity capability and authority to perform all corrective maintenance tasks of the Repair function in a use user environment in order to restore serviceability to a failed item 1 Source Code The source code tells you how to get an item needed for maintenance repair or overhaul of an end item equipment Explanations of source codes follow MO Made at UNIT AVUM Level MF Made at DS AVUM Level MH Made at GS Level MD Made at Depot AO Assembled by UNIT A VUM Leve AF Assembled by DS AVUM Level AH Assembled by GS Level AD Assembled at Depot C 2 Application Explanation Stocked Items use the applicable NSN to request requisition items with these source codes They are authorized to the category indicated by the code entered in the third position of the SMR code Items coded PC are subject to deterioration Items with these codes are not to be requested requisitioned individually They are part of a kit that is authorized to the maintenance category indica
103. ay down in the opening Apply sealing compound Item 17 Appendix D to threads of studs Install four nuts 9 on injection pump 7 Change 1 TM 9 2815 250 24 amp P 3 15 INJECTION PUMP REPLACEMENT continued 4 Install end of governor lever 8 on control rack of injection pump 7 and secure with new cotter pin 6 5 Install new gasket 3 on governor plate 2 6 Install governor plate 2 shown or extra fuel device if equipped on crankcase 4 and secure with nut 1 and B three screws 5 FOLLOW ON TASKS e Install fuel pressure pipe assemblies and return fuel hose para 2 23 Install airflow deflectors para 2 24 Change 1 3 53 TM 9 2815 250 24 amp P 3 16 GOVERNOR CONTROL ASSEMBLY REPAIR This Task Covers a Removal b Disassembly c Assembly d Installation Initial Setup Tools Test Equipment e General mechanic s tool kit automotive item 15 Appendix Gl Snapring pliers Item 26 Appendix G Materials Parts Lockwasher Item 26 Appendix F e O ring Item 37 Appendix F Seal Item 13 Appendix F Spring tension washer Item 30 Appendix F e Wire mesh Item 14 Appendix F References e a REMOVAL 1 Remove governor plate para 3 15 2 Remove screw 1 lockwasher 2 washer 3 lever 4 and spring 5 from speed control lever 6 Discard lockwasher Remove seal 7 and wire mesh 8 from speed control lever 6 Discard seal and wire mesh
104. ay holes Immerse the nozzle needle 4 in clean fuel The nozzle needle 4 must slide down under its own weight into the seat of nozzle body 3 Replace the nozzle needle 4 and the nozzle body 3 as an assembly if defective If other parts are defective replace entire fuel injector Assemble fuel injector parts 1 through 8 together as shown Torque nozzle retaining nut 1 to 44 ft lb 60 Nem Test fuel injector spray pattern para 3 21 ps 60 U 7 um 29i212m Change 1 TM 9 2815 250 24 amp P 3 14 FUEL INJECTOR REPLACEMENT continued d INSTALLATION NOTE Make sure that the soft graphite coated surface of the gasket is facing fuel injector 1 Install new gasket 6 on fuel injector 5 2 Install fuel injector 5 in bore in cylinder head 8 Make sure opening for screw faces rocker arm cover 7 NOTE Make sure tapered side of spacer is toward hose clamp and that tapered side of hose clamp is facing up 3 Install hose clamp 4 spacer 3 new spring tension washer 2 and nut 1 on stud 9 and fuel injector 5 Torque nut to 17 ft lb 23 Nem FOLLOW ON TASKS e Install fuel pressure pipe assemblies and return fuel hose para 2 23 Change 1 3 49 TM 9 2815 250 24 amp P 3 15 INJECTION PUMP REPLACEMENT This Task Covers a Removal c Installation b Cleaning and Inspection Initial Setup Tools Test Equipment General mechanic s tool ki
105. cluding any necessary disassembly assembly TM 9 2815 250 24 amp P EXPLANATION OF COLUMNS IN SECTION Il MAINTENANCE ALLOCATION CHART FOR ENGINE ASSEMBLY DIESEL HATZ 2 G 40 continued troubleshooting fault location time and quality assurance quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the MAC The symbol designations for the various maintenance levels are as follows Doria Operator Crew Din ne Le tege Unit ui eU Direct Support LEES General Support Dar Depot 5 Tools and Test Equipment Reference Code Column 5 specifies by code those common tool sets not individual tools common TMDE special tools special TMDE and special support equipment required to perform the designated maintenance function Codes are keyed to tools and test equipment listed in Section III 6 Remarks When applicable this column contains a lettercode in alphabetical order which is keyed to remarks contained in Section IV If there is nothing in the Remarks column there is no Section IV EXPLANATION OF COLUMNS IN SECTION Ill TOOLS AND TEST EQUIPMENT REQUIREMENTS Column 1 Tools and Test Equipment Reference Code This code correlates with the code used in Section II Column 5 Column 2 Maintenance Level The symbol designation shown indicates the lowest level of maintenance authorized to use the tool or test equipment Column 3 Nomenclature This
106. compound Item 3 Appendix D Drycleaning solvent Item 4 Appendix D Rag Item 7 Appendix D Head gasket set Irem 3 Appendix F a REMOVAL 1 Remove two push rods 2 from each of two guides 1 2 Remove five extended plain nuts 4 three plain nuts 5 and eight washers 3 from eight studs 8 3 Remove two cylinder heads 6 and gaskets 7 from two combustion chamber liners 9 Discard gaskets Equipment Conditions Eyebolt removed UOC APP Lifting bracket removed UOC APJ TM 9 2350 292 20 2 Rocker arm assemblies removed para 3 10 Airflow deflectors removed UOC APP para 2 24 Air flow deflectors removed UOC APJ TM 9 2350 292 20 2 Intake manifold removed para 2 21 Fuel injectors removed para 3 14 Oil tube assemblies removed para 2 19 Exhaust manifold removed UOC APJ Thermostatic switch removed para 2 26 Change 1 3 15 TM 9 2815 250 24 amp P 3 5 CYLINDER HEADS REPAIR continued 4 3 Remove two guides 1 from two recesses in crankcase 11 Remove two O rings 10 from two grooves in each of two guides 1 Discard O rings NOTE There are two valves intake and exhaust in each of two cylinder heads Follow steps 6 and 7 for each of them Part numbers are different for the intake and exhaust valves but the valves are removed the same way This procedure describes the removal of an exhaust valve Using a valve s
107. ction pump pass test FUEL LINE NO YES l FITTINGS Replace injection pump para 3 15 Verify problem is solved INJECTION PUMP GO TO STEP D FOR PURPOSES OF CLARITY AIRFLOW DEFLECTORS AND INTAKE MANIFOLD ARE NOT SHOWN 3 3 TROUBLESHOOTING CHART continued a ENGINE 5 CONTINUED FROM C D Check for engine overheating Does engine overheat NO YES Remove airflow deflectors and clean any obstructions Replace airflow deflectors para 2 24 Verify problem Is solved E Check to see if knocking sound is coming from crankcase Is knocking sound coming from crankcase NO YES Inspect piston assemblies and combustion chamber liners Replace any defective or worn parts Tighten any loose screws on Ed a md a Replace worn retaining rings Verify problem is solved Inspect camshaft valves and cylinder heads Replace any defective or worn ba aen and 3 11 Verify problem Is solved END OF TASK 3 10 TM 9 2815 250 24 amp P ENGINE MAKES A KNOCKING SOUND continued AIRFLOW DEFLECTORS AIRFLOW DEFLECTOR TM 9 2815 250 24 amp P 3 3 TROUBLESHOOTING CHART continued b GOVERNOR ENGINE SPEED IS ERRATIC FUEL LINES A Inspect fuel lines and fittings for leaks Are there leaks FITTINGS E NO YES FUEL LINE Tan a fuellines and fitting Verify problem is solved FITTINGS EZ B Check for air restrictions in the intake man
108. ctive goggles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open flame or excessive heat Using drycleaning solvent and a rag clean sealing compound from both mounting plates aah ee pl i 29i210ma Change 1 3 13 TM 9 2815 250 24 amp P 3 4 MOUNTING PLATES REPLACEMENT continued c INSTALLATION 1 Apply light coat of grease to new seal 4 Install seal 4 on mounting plate 2 with secondary sealing lip facing inboard and primary sealing lip facing outboard 2 Apply sealing compound Item 10 under four screws 3 and designated surface of crankcase 1 that will come in contact with mounting plate 2 W 2 1 Apply loctite 242 Item 18 Appendix D to threads of screws 3 CAUTION Use extreme caution not to damage new seal when installing mounting plate on crankcase 3 Install mounting plate 2 on crankcase 1 and secure with four screws 3 Torque screws 35 38 ft lbs 47 52 Nem NOTE Use marks made during removal to install engine mounting plate correctly 4 Apply sealing compound Item 12 Appendix D to eight screws 6 Install engine mounting plate 5 on crankcase 1 and secure with eight new lockwashers 7 and screws 6 Torque screws 35 38 ft lbs 47 52 Nem O O AREA FOR SEALING COMPOUND ITEM 10 APPENDIX D SECONDARY SEAL
109. e 2 r Install fuel injector para 3 14 s Install fuel pressure pipe assembly and fuel pressure pipe clamp para 2 23 FOLLOW ON TASKS e Install airflow deflectors UOC APP para 2 24 Install airflow deflectors UOC APJ TM 9 2350 292 20 2 3 68 Change 1 TM 9 2815 250 24 amp P 3 22 ENGINE SPEED ADJUSTMENT This Task Covers Adjustment Initial Setup Tools Test Equipment Personnel Required e General mechanic s tool kit automotive Two Item 15 e Mechanical hand held tachometer Item 18 ADJUSTMENT NOTE Engine speed is measured in revolutions per minute rpm a Start engine and let it run until warm b Have an assistant hold a hand held mechanical tachometer on end of crankshaft 1 on flywheel side of engine C The rpm reading on tachometer should be 2200 50 rpm UOC APP or 2650 50 rpm UOC APJ If itis A not loosen two nuts 2 and turn two adjusting screws 3 to move speed control lever 4 while assistant watches tachometer gage until correct rom reading is reached Moving speed control lever 4 to the left will decrease engine speed moving speed control lever 4 to the right will increase engine speed d Hold two adjusting screws 3 in place and tighten two nuts 2 HIDDEN e Recheck engine speed by repeating steps b through d FOLLOW ON TASKS None Change 1 3 69 TM 9 2815 250 24 amp P 3 23 OIL PRESSURE TEST This Task Covers Test Initial
110. e Part Number Index find the pertinent NSN or part number the National Stock Number Index is in NIIN sequence The part numbers in the Part Number Index are listed in ascending alphanumeric sequence Both indexes cross reference you to the figure number and item number of the item you are looking for 2 Second After finding the figure and item numbers verify that the item is the one you re looking for then locate the item number in the Repair Parts List for the figure C 7 ABBREVIATIONS For standard abbreviations see MIL STD 12 Military Standard Abbreviations for Use on Drawings Specifications Standards and in Technical Documents Change 1 C 7 TM 9 2815 250 24 amp P 2 E gy ct a o Y E Y E td amp 5 2 L mo TICA DIESEL MADE IN GERMANY m lh f bt O wd d y Figure 1 Engine Identification Plate 9905 01 456 3828 5315 01 070 5656 TM 9 2815 250 24 amp P 4 5 PART CAGE NUMBER 61080 03225504 61080 40002500 END OF FIGURE col 6 7 DESCRIPTION AND USABLE ON CODE UOC QTY GROUP 22 BODY CHASSIS AND HULL ACCESSORY ITEMS GROUP 2210 DATA PLATES AND INSTRUCTION HOLDERS FIGURE ENGINE IDENTIFICATION PLATE PLATE IDENTIFICATIO PIN GROOVED HEADED TM 9 2815 250 24 amp P C01 SECTION II 0000 291101 Figure 2 Engine Diesel 1 ITEM NO 2 SMR PAFFD PAOF
111. e nennen nn 4 1 2912 Crankcase Assembly Crankshaft Assembly 000 nen 5 1 2913 Flywheel Assembly Flywheel and Related Components o ooocccccccccccc 6 1 Page P B 4 Illus Fig El o led elle N TM 9 2815 250 24 amp P Table of Contents continued Illus Page Fig 2914 Pistons and Connecting Rods Pistons and Connecting Rods sseee 7 1 2915 Valves Camshaft and Timing System Camshaft and Valves coria iii a 8 1 2916 Engine Lubrication System Engine Lubrication System ettet atii naks maana vaa Radeon 9 1 9 2918 Manifolds Exhaust Manifold Mounting Hardware seeeeene Intake Manifold and Related Components eeeeces 11 1 2932 Engine Fuel System Injection Pump Nozzles and Fuel Lines ooononnccninacaconocaconananananon 12 1 2936 Engine Speed Governor and Controls Governor and Controls oococconnocconnccnonnccnonnonncnnonncnnonnonnnnnonncnnonnnns 13 1 2952 Engine Cowling Deflectors Air Ducts and Shrouds Engine Cowling Ducts and ShrQUd oococcccocccnoccconononcnonconananonanos 14 1 2960 Sending Units A 15 1 2968 Switches Circuit Breakers and Fuses Fuel Shutoff Solenoit ie 16 1 Repair Kits 9401 Repair Kits az er educ les KITS 1 General Use Standard Parts 9501 Bulk Material Bulk Matetlal one Rare BULK 1 Section Ill Special Tools List Tools and Test Equipment 2604 pecial Tools
112. ee screws 17 on air duct bracket 12 10 Install airflow deflector 9 on engine 3 and secure with two new spring tension washers 11 and screws 10 11 Install airflow deflector 4 on engine 3 and secure with five washers 8 and screws 7 12 Install three new split washers 5 and screws 6 on airflow deflector 4 13 Tighten all screws FOLLOW ON TASKS Install valve vent para 2 22 Change 1 2 27 TM 9 2815 250 24 amp P W 2 25 OIL PRESSURE SWITCH REPLACEMENT This Task Covers a Removal b Installation Initial Setup Tools Test Eguipment Materials Parts N General mechanic s tool kit automotive e Sealing compound Item 17 Appendix DI Item 15 Appendix G a REMOVAL NOTE For easy access to oil switch it may be necessary to loosen the screw 1 to turn manifold UOC APP H Remove oil switch 2 from adapter 3 b INSTALLATION H Coat threads of oil switch 2 with sealing compound Item 17 Appendix D Install switch 2 on adapter 3 FOLLOW ON TASKS e None 2 28 Change 1 TM 9 2815 250 24 amp P 2 26 THERMOSTATIC SWITCH REPLACEMENT This Task Covers a Removal b Cleaning Initial Setup Tools Test Equipment Materials Parts General mechanic s tool kit automotive Airflow deflectors removed as needed UOC Item 15 Appendix G APP para 2 24 Airflow deflectors removed as needed UOC APJ TM 9 2350 292 20 2 a REMOVAL R
113. emove thermostatic switch 2 from cylinder head 1 on auxiliary drive side of engine b INSTALLATION Install thermostatic switch 2 in cylinder head 1 on auxiliary drive side of engine FOLLOW ON TASKS e Install airflow deflectors para 2 24 if any were removed UOC APP Install airflow deflectors TM 9 2350 292 20 2 if any were removed UOC APJ Change 1 2 29 TM 9 2815 250 24 amp P W 2 27 SOLENOID REPLACEMENT AND ADJUSTMENT UOC APP This Task Covers a Removal b Installation c Adjustment Initial Setup Tools Test Eguipment Socket wrench set 3 8 inch drive Item 27 e General mechanic s tool kit automotive Item 15 Materials Parts Screwdriver attachment 6 mm Item 24 Appendix G lt O ring Item 32 Appendix F a REMOVAL 1 Remove two clips 2 from connecting link 1 Remove connecting link 1 from governor lever 4 plunger 8 and solenoid 8 2 Remove two screws 7 and washers 6 and solenoid 8 from bracket 5 3 Remove stud 10 from solenoid 8 Remove connector 12 and two nuts 9 and 11 from stud 10 2 30 Change 1 TM 9 2815 250 24 amp P 2 27 SOLENOID REPLACEMENT AND ADJUSTMENT UOC APP continued 4 Remove screw 17 and plunger 3 from bracket 5 5 Remove bellows 19 and O ring 18 from plunger 3 Discard O ring 6 Remove screw 16 from bracket 5 and crankcase 20 7 Remove nut 15 washer 14 and bracke
114. ent Assembly Engine Speed Governor and Controls Engine Cowling Deflectors Air Ducts and Shrouds Sending Units Switches Circuit Breakers and Fuses Fuel Shutoff Solonoid Maintenance Function Adjust Replace Replace Test Replace Adjust Replace Maintenance Level 4 TM 9 2815 250 24 amp P 5 6 Tools and Remarks Equipment B 5 Tools and Equipment Reference B 6 1 Test Code Section Ill TOOLS AND TEST EQUIPMENT REQUIREMENTS 2 Maintenance Level Nomenclature Shop Equipment Automotive Maintenance and Repair Organizational Maintenance Common No 2 Less Power Tool Kit General Mechanic s Automotive Tool Kit General Mechanic s Shop Equipment Machine Shop Field Maintenance Basic Shop Equipment Automotive Maintenance and Repair Field Maintenance Basic Less Power Shop Equipment Automotive Maintenance and Repair Field Maintenance Supplemental No 2 Shop Equipment Automotive Maintenance and Repair Organizational Maintenance Common No 1 Tool Kit Automotive Fuel and Electrical Systems Repair Tester Cylinder Compression Wrench Bracket Cylinder Alignment Puller Crank Gear Puller Relief Valve Driver Crank Gear Testing Device Fuel Test Set Fuel Test Set Oil Pressure 4 National Stock Number 4910 00 754 0650 5180 00 177 7033 5180 00 699 5273 3470 00 754 0708 4910 00 754 0705 4910 00 754 0707 49
115. equipment are issued to Unit maintenance personnel for maintaining the Diesel Engine Assembly Hatz 2 G 40 Common tools and equipment should not be used for purposes other than those prescribed and should be properly stored when not in use For authorized common tools and equipment refer to the Modified Table of Organization and Equipment MTOE CTA 50 970 or CTA 8 100 as applicable to your unit 2 3 SPECIAL TOOLS TMDE AND SUPPORT EQUIPMENT Special tools are listed and illustrated irl Appendix O of this manual 2 4 REPAIR PARTS Repair parts are listed and illustrated in Appendix C of this manual 2 1 TM 9 2815 250 24 amp P Section Il SERVICE UPON RECEIPT Paragraph Page Number Paragraph Title Number amp 23 A NT 2 2 Inspection Instructions icons A idea 2 2 2 5 GENERAL When a new used or reconditioned Diesel Engine Assembly Hatz 2 G 40 is received determine whether it has been properly prepared for service and is capable of accomplishing its mission by performing the inspection instructions in 2 6 INSPECTION INSTRUCTIONS a Refer to DD Form 1397 for procedures on unpacking the Diesel Engine Assembly Hatz 2 G 40 b Remove all straps plywood tape seals and wrappings WARNING Drycleaning solvent P D 680 is toxic and flammable Always wear protective goggles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open fla
116. er 6 Install governor plate para 3 15 Adjust engine speed para 3 22 29i214ma Install new wire mesh 8 and new seal 7 on speed control lever 6 FOLLOW ON TASKS e None Change 1 3 55 TM 9 2815 250 24 amp P SECTION Ill TESTS AND ADJUSTMENTS Paragraph Page Number Paragraph Title Number Cylinder Compression Test 000 cece cece cette ent e eee eens 3 56 3 18 Valve Adj stment 3 ovr be hee en ea ea ke anna Rex eee ie 3 58 Flow Control Valve Adjustment 000 eee cece es nn 3 60 3 20 Injection PUMP T ST 4s crias each ee dh or er eges 3 65 3 21 Fuel Injector Test iced Dee bebe a is a ea ea qs 3 66 Engine Speed Adjustment 1 s aaoa eaa 4840383 20 48 aka Bud bes das ea 3 69 3 23 Oil Pressure TeSt cia Janaa x Ree DRE Re KE KALAN DRE RR bite 3 70 Tr 3 71 3 17 CYLINDER COMPRESSION TEST This Task Covers Test Initial Setup Tools Test Equipment e Cylinder compression tester Item 7 Appendix Gl General mechanic s tool kit Item 14 Appendix G TEST NOTE The cylinder compression test is used to determine the condition of valves pistons piston rings and cylinders Any pressure difference between cylinders indicates a problem with one or more of these components a Run engine until thoroughly warm b Remove fuel injectors para 3 14 NOTE Compression tester gage reading for a new engine turning at about 300 rpm should be approximately 3
117. est pic uomaa s Maksa nea adas dae pitele abd eae Pb edad enters 3 56 Cylinder Heads Repa ss pet drets Valida ands ad ht n Mabe es 3 15 D Deep Oil Pan and Gasket Replacement UOC APJ 0 ooccccccccccccccc eens 3 48 1 Destruction of Army Materiel To Prevent Enemy Use 000 cece eee eee n 1 1 Direct Support and General Support Maintenance Procedures 0c cece ell a e re n 3 12 Quick Guide to Troubleshooting ssa nn 3 2 Troubleshooting Chart 0 0 nn 3 3 Troubleshooting General soma nent es 3 1 Durable Items List Expendable and nn D 2 E Engine Speed Adjustment 0 cece seems 3 69 Equipment Characteristics Capabilities and Features 0 00 e cece eee tenes 1 4 Equipment Data ici a eter deat te eee vert Ae rate AA Meee iter 1 8 Equipment Improvement Recommendations Reporting 0 cece eee eee 1 2 Eq ipment SUpport ta ete Rc 2 1 Change 1 Index 1 TM 9 2815 250 24 amp P SUBJECT PAGE E continued Emors FE POMING stos a be Nona say Gant ate egal A A EA Expendable and Durable Items List loose D 2 H Eyebolt Replacement UOC APP 2 sos n 2 8 F Fastener Grade 20000 Aa A ka At had er ed Vd vi wd herd A assa ad ER E 5 Fastener Size and Thread Pattern 0 nn E 4 Filler Neck Replacement UOC APPI sico ee ra 3 46 Filler Opening Cap Replacement UOC APP 000 nn 2 10 Filter Element Replacement UOC APP
118. ew 18 to position line on control rod rack at edge of opening Open fuel shutoff valve refer to technical manual for vehicle Set indicator dial 11 at 0 Turn flywheel 2 clockwise until the dimension specified on engine data plate 23 is reached In this position fuel should come out of spill device outlet 22 at the rate of approximately one drop every five seconds EDGE OF OPENING SAK CONTROL ROD RACK e MOIORENFABRIK HATZ KG Y M D 94099 RUHSTORF ESTERO Or E ota rri zm rir amer DIESEL MADE IN GERMANW TM 9 2815 250 24 amp P 3 19 FLOW CONTROL VALVE ADJUSTMENT continued NOTE If fuel comes out of spill device outlet before the dimension specified on en gine data plate is reached fuel quantity is set too low If no fuel comes out of the spill device outlet at the specified dimension fuel quantity is set too high h If fuel quantity is incorrect loosen nut on flow control valve 24 Turn knob to the right to increase fuel quanti ty or to the left to decrease fuel quantity i Tighten nut and repeat steps g and h until fuel quantity is correct j Close fuel shutoff valve refer to technical manual for vehicle k Remove rubber band 20 from governor lever pad 21 and screw 18 Remove screw 18 from crankcase 14 3 63 TM 9 2815 250 24 amp P 3 19 FLOW CONTROL VALVE ADJUSTMENT continued FOLLOW ON TASKS 3 Install mounting plate 1
119. from the manufacturer or supplier of the material to be used Become completely familiar with the information and manufacturer supplier procedures recommendations warnings and cautions for the safe use handling storage and disposal of these materials Following the General Safety Precautions list is a list of Hazardous Materials Warnings These warnings are designed to warn personnel of dangers associated with hazardous materials For each hazardous material used a material safety data sheet is required to be provided and available for review by personnel Consult your local safety and health staff concerning questions on hazardous chemicals personnel protective equipment requirements and appropriate handling and emergency procedures GENERAL SAFETY PRECAUTIONS e Always use the same fastener part number or equivalent when replacing fasteners Do not risk using a fastener of less quality do not mix metric and inch customary fasteners Mismatched or incorrect fasteners can result in damage malfunction or injury e Fuel and oil are slippery and can cause falls To avoid injury wipe up spilled fuel or oil with rags e Make sure equipment will not move while repairing or inspecting it For powered equipment block or chock wheels or tracks and red tag the starter Prevent a quick fix from becoming a quick injury e When adjustment or service requires a running engine two people are needed one at the controls and one at the ser
120. g hours miles considered In classifying Army equipment components EXPLANATION OF COLUMNS IN SECTION Il MAINTENANCE ALLOCATION CHART FOR ENGINE ASSEMBLY DIESEL HATZ 2 G 40 1 Group Number Column 1 lists functional group code numbers whose purpose is to identify maintenance significant components assemblies subassembies and modules with the next higher assembly The end Item group number is 00 2 Component Assembly Column 2 contains the names of components assemblies subassemblies and modules for which maintenance is authorized 3 Maintenance Function Column 3 lists the functions to be performed on the item listed in Column 2 Fora detailed explanation of these functions refer to para B 2 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 If the number or complexity of the tasks within the listed maintenance function varies at different maintenance levels appropriate work time figures will be shown for each level The work time figure represents the average time required to restore an item assembly subassembly component module end item or system to a serviceable condition under typical field operating conditions This time includes preparation time in
121. gainst slipping 2 9 CLEANING INSTRUCTIONS WARNING Improper cleaning methods and the use of unauthorized cleaning liquids or solvents can injure personnel and damage equipment To prevent this refer to TM 9 247 for further instructions a General Cleaning instructions will be the same for a majority of the parts and components that make up the Diesel Engine Assembly Hatz 2 G 40 The following should apply to all cleaning inspection repair and assembly operations 1 Clean all parts before inspection after repair and before assembly 2 Keep hands free of grease which can collect dust dirt and grit 3 After cleaning cover or wrap all parts to protect them from dust and dirt Parts that are subject to rust should be lightly oiled b Steam Cleaning 1 Before steam cleaning exterior of engine protect all electrical equipment that could be damaged by steam or moisture 2 Place disassembled parts in a suitable container to steam clean Parts that are subject to rust should be dried and lightly oiled after cleaning c Castings Forgings and Machined Metal Parts WARNING Drycleaning solvent P D 680 is toxic and flammable Always wear protective goggles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open flame or excessive heat 1 Clean inner and outer surfaces with drycleaning solvent Item 4 Appendix D and rag Item
122. ge to a threaded capscrew hole with thread tap of same size to prevent cutting the hole too large 2 12 HOSE AND TUBE TAGGING a As soon as the first hose or tube is disconnected write the number 1 on two tags Secure one tag to the hose or tube and the other tag to the nipple or fitting After disconnecting the second hose or tube write the number 2 on two tags Secure one tag to the hose or tube and the other tag to the nipple or fitting Do the same for all hoses and tubes b Note which numbers you used in pencil on the art in this manual This will help you retag properly when you remove tags from some parts to perform cleaning and maintenance work c Remove all tags when finished 2 13 LUBRICATION INSTRUCTIONS To prevent corrosion apply a light coat of lubricating oil to metal parts after they are cleaned and before they are assembled 2 14 TORQUE VALUES Follow the torque values given in the maintenance procedures which apply to unlubricated threads If no torque value is given refer to Appendix El TM 9 2815 250 24 amp P SECTION IV UNIT MAINTENANCE PROCEDURES Paragraph Page Number Paragraph Title Number Identification Plate Replacement 0 0 00 0 cece cece e 2 7 Eye Bolt Replacement UOC APP x siis suun sada osaan laa N KN ana 2 8 2 17 Rocker Arm Cover and O ring Replacement o ooccccccccccccccc no 2 9 Filler Opening Cap Replacement UOC APP 0 0c cece eee eee ee 2 10 Oil Tube
123. ifold or airflow deflectors Are there any restrictions INJECTION PUMP NO Clear out restrictions FOR PURPOSES OF CLARITY AIRFLOW DEFLECTORS Verify problem is solved AND INTAKE MANIFOLD ARE NOT SHOWN AIRFLOW INTAKE DEFLECTOR MANIFOLD lt m o C Check engine governor speed Is governor speed within limits specified para 3 22 NO YES Adjust governor speed fpara 3 22 Verify problem is solved Repair or replace governor control assembly para 3 T6 Verify problem is solved END OF TASK AIRFLOW DEFLECTORS Change 1 3 11 TM 9 2815 250 24 amp P SECTION Il DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE PROCEDURES Paragraph Paragraph Title Page Number Number 3 4 Mounting Plates Replacement knn 3 12 3 4 1 Auxiliary Drive Adapter Replacement 0 00 cece cece eee ence enna 3 14 1 3 5 Cylinder Heads Repair sussa aN ee kd pe de Lek d Rx a 3 15 3 6 Grankcase Repalr iue meu ia beca bus pend WEA ae egt od ew had Ai heed ea Di 3 20 3 7 Crankshaft and Bearings Repair oss nn 3 26 3 8 Flywheel and Housing Replacement 0 cece cece esee 3 28 3 9 Piston and Combustion Chamber Liner Repair 0 0c cece cece ee 3 10 Rocker Arm Assemblies Repair 000 c cece eee nh 3 38 Camshaft Repair 0 0 nn ADEE EOE nan 3 40 Filler Neck Replacement UOC APP 0 00 ccc ccc cence n 3 46 Oil Pan and Gasket Replacement UOC APP 2
124. ing 2 Item 7 Appendix F Personnel Required Equipment Conditions Cylinder heads removed para 3 5 Engine placed on side Oil pan removed UOC APP para 3 13 Oil pan removed UOC APJ para 3 13 1 There are two connecting rod caps on the engine Repeat steps 1 and 2 to re move each of them 1 Turn crankshaft 4 so crankshaft journal for connecting rod cap 5 to be removed is in its lowest position 2 Remove two connecting rod screws 6 and connecting rod cap 5 from connecting rod 1 3 Remove two combustion chamber liners 2 with two pistons inside from crankcase 3 3 32 Change 1 3 9 TM 9 2815 250 24 amp P PISTON AND COMBUSTION CHAMBER LINER REPAIR continued CAUTION Each connecting rod and connecting rod cap is stamped with a number and each also has a notch on one side Each connecting rod cap must be installed on the connecting rod stamped with the same number and with the notches on the same side Using the numbers stamped on the two connecting rods 1 and connecting rod caps 5 loosely install connecting rod cap 5 and two screws 6 on each connecting rod 1 making sure the notches are on the same side Loosen screw 7 on bracket 8 and clamping sheet 10 Remove bracket 8 and clamping sheet 10 by lifting them straight up until they are free of two studs 13 Remove two cap plugs 11 and four cap plugs 12 from eight studs 13 Discard cap plugs Remove two shi
125. iomoiveriz75 E0un0 027281549 CN M 10924 C 6 O 9150 00 186 6681 Lubricating Oil 1 Quart Can QT 15958 ALLIEDC030 7 O 7920 00 205 1711 Rag Wiping 50 Pound Bale LB 80244 7920 00 205 1711 8 E 7510 00 243 3437 RGDDerBandw1 4 Pound Box BX 88001 0385B 9 F 1015 01 255 4144 Sealant Pipe Teflon 50 Milliliter Tube TU 19207 12297953 10 F 8030 00 252 3391 Sealing Compound 11 Ounce Tube TU 80064 1756371 11 F 8030 00 081 2335 Sealing Compound 10 Cubic Centimeter bottle BT 05970 85 14 12 O 303000275 S15 Sealing Compound 1 Pint Can er 81349 MIL S 46163 13 O 8040 01 250 3969 Sealing Compound ML 05972 242 14 F Primer Grade N 500 ML ML 05972 50223001 15 E 8030 01 060 0015 Sealing Compound ML 05972 573 16 P 8030 01 231 7156 eding Compound ML 05972 601 17 F Sealing Compound ML 05972 221 18 E 8030 01 475 2445 Sealing Compound ML 05972 648 19 E 8030201238825604 9 Sealing Compound ML 05972 T7471 D 2 Change 1 TM 9 2815 250 24 amp P Change 1 D 3 D 4 blank TM 9 2815 250 24 amp P APPENDIX E TORQUE VALUES FOR THREADED FASTENERS Paragraph Page Number Paragraph Title Number E 1 C M ee At M een E 1 E 2 Torque Limits een E 1 E 3 How To Use Torque Tabla ET E 1 E 4 Tightening Metal Fasteners ooooonccccccnoccccnnnonnncnnnnnnncnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnananens E 3 E 5 Fastener Size and Thread Pattern
126. ious eye injury WARNING LIFTING Use extreme caution when handling heavy parts The diesel engine weighs about 200 pounds 90 kg Use a suitable lifting device to place the engine on the stand Failure to follow this warning may result in serious injury or death to personnel TM 9 2815 250 24 amp P C1 HEADQUARTERS CHANGE DEPARTMENT OF THE ARMY NO 1 WASHINGTON D C 31 December 2005 TECHNICAL MANUAL UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR ENGINE ASSEMBLY DIESEL HATZ 2G 40 NSN 2815 01 446 3500 NSN 2815 01 465 4321 TM 9 2815 250 248P September 1998 is changed as follows 1 The purpose of this change is to update TM 9 2815 250 24 amp P 2 New or changed material is indicated by a vertical bar in the outside margin of text changes and by a hand symbol beside illustration changes 3 Remove the old page and insert the new page as indicated below Remove Pages Insert Pages a andb a and b A and B Aland B i and ii iJanalii 1 3 and 1 4 1 3 and 1 4 1 7 and 1 8 1 7 and 1 8 2 7 thru 2 10 2 7 thru 2 10 2 13 and 2 14 2 13 and 2 14 2 19 thru 2 32 thru 2 32 3 11 thru 3 14 3 11 thrul3 14 1 3 14 2 blank 3 15 and 3 16 3 15 and 3 16 3 19 thru 3 22 thru 3 22 3 27 thru 3 32 thru 3 32 3 37 thru 3 40 thru 3 40 3 45 and 3 46 3 45 and 3 46 3 47 thru 3 56 3 47 3 48 blank thru 3 59 and 3 60 3 59 and 3 60
127. ix is a cross reference of item numbers to part numbers and is included for that purpose only F 2 EXPLANATION OF COLUMNS There are five columns in Mandatory Replacement Parts List p F 2 1 2 3 4 5 Item Number This number is assigned to the entry in Table F 1 for cross referencing to the part number The item number appears in the Materials Parts listing of a maintenance procedure Part Number This is the primary number used by the manufacturer which controls the design and characteristics of the item by means of its engineering drawings specifications standards and inspection requirements to identify an item or a range of items National Stock Number When available the national stock number is listed for each part Item Name This is the name given each item in the Materials Parts listing of a maintenance procedure Reference This is the Repair Parts and Special Tools List RPSTL appendix in which the referenced replacement part can be found The RPSTL is the authorization for requisitioning replacement parts F 1 TM 9 2815 250 24 amp P Table F 1 MANDATORY REPLACEMENT PARTS LIST 1 2 3 4 5 Item National Number Part Number Stock Number Item Name Reference O o N O 060 A WO N D NP nm no NPN n PDN NPN a a 2 ao N O 0 Bb WO N E O N O 60 0 N O 01228000 01240300 01247700 01285600 03233200 03233300 03781300 03783902 03958000 04038200
128. l governor control assembly para 3 16 Install solenoid para 2 27 Install flywheel auxiliary drive hardware and flywheel housing para 3 8 Install pistons and combustion chamber liners para 3 9 3 25 TM 9 2815 250 24 amp P 3 7 CRANKSHAFT AND BEARINGS REPAIR This Task Covers a Removal b Inspection c Installation Initial Setup Tools Test Equipment Materials Parts e Crank gear driver Item 4 Appendix G e Lubricating oil Item 6 Appendix D e Crank gear puller Item 5 Appendix G e Sealing compound Item 12 Appendix D e General mechanic s tool kit Item 14 e Crankcase gasket set Item 1 Appendix Fl e Sleeve bearing 3 Item 34 e Relief valve puller Item 23 e Screwdriver attachment 8 mm ltem 25 Eguipment Conditions e Crankcase disassembled para 3 6 e Socket wrench set 3 8 inch drive Item 27 e Camshaft removed para 3 11 a REMOVAL 1 Remove seal 3 from auxiliary drive end of crankshaft 2 Discard seal CAUTION To prevent warping crankshaft must be placed standing up in flywheel 2 Remove crankshaft 2 from lower crankcase 5 3 Remove three sleeve bearing halves 4 from three upper crank supports 9 upper crankcase and remove three sleeve bearing halves 4 from three lower crank supports 6 lower crankcase Discard sleeve bearing halves CRANKCASE 4 Remove flow control valve 8 from lower p crankcase 5 5 Using crank gear puller remove crank gear 1
129. lopascals Pounds per Square Inch 0 145 O Kilometers per Liter Miles per Gallon 2 354 Kilometers per Hour Miles per Hour PIN 076853 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
130. lventilated area If adhesive gets in your eyes try to keep them open flush with water for 15 minutes and get immediate medical attention e Adhesive sealant MIL S 46163 Loctite can damage your eyes Wear safety goggles glasses when using sealant and avoid contact with eyes If sealant contacts your eyes flush them with water and get immediate medical attention e Drycleaning solvent P D 680 is TOXIC and flammable Wear protective goggles and gloves use only in a well ventilated area avoid contact with skin eyes and clothes and do not breathe vapors Keep away from heat or flame Never smoke when using drycleaning solvent Failure to follow this warning may result in injury or death to personnel e f personnel become dizzy while using cleaning solvent immediately get fresh air and medical help If solvent contacts skin or clothes flush with cold water If solvent contacts eyes immediately flush with water and get immediate medical attention vii viii blank TM 9 2815 250 24 amp P CHAPTER 1 INTRODUCTION Section I GENERAL INFORMATION Paragraph Page Number Paragraph Title Number 1 1 E o AE HX 1 1 1 2 Maintenance Forms Records and ReportS ooocooccccoccconnncnnccccnncnnnnnnnoncnconnnnnnnnncnncnnnnnnnnnencnnnos 1 1 Destruction of Army Materiel To Prevent Enemy Use 1 1 1 4 Preparation for Storage or Shipment uusnsssnsnnnssenennnsnnnnnnnnnnnnnnnnnnn
131. marks are in the 12 o clock position Pull camshaft assembly 5 the rest of the way out of upper crankcase 15 CAUTION Do not lay camshaft flat on table while it is attached to camshaft gear Stand camshaft and camshaft gear assembly on camshaft gear to prevent warping Remove three screws 21 and nuts 19 and mounting plate 20 from camshaft gear 4 Remove retaining ring 24 from groove on camshaft 16 and slide spacer 18 and washer 17 away from camshaft gear 4 Discard retaining ring Remove camshaft gear 4 and key 23 from camshaft 16 Remove retaining ring 22 from groove on camshaft 16 Discard retaining ring Remove spacer 18 and washer 17 from camshaft 16 3 41 TM 9 2815 250 24 amp P 3 11 CAMSHAFT REPAIR continued 13 Remove four tappets 25 from upper crankcase 15 14 Remove retaining ring 28 from acceleration lever 26 Discard retaining ring 15 Remove acceleration lever 26 from upper crankcase 15 Remove O ring 27 from acceleration lever 26 Discard O ring NOTE Pin for pinion assembly may have come off with flywheel housing a 16 Remove pin 29 pinion assembly 30 and washer 31 from upper crankcase 15 b INSTALLATION 1 Install washer 31 pinion assembly 30 and pin 29 in upper crankcase 15 3 42 TM 9 2815 250 24 amp P 3 11 CAMSHAFT REPAIR continued 2 Install new O ring 27 on acceleration lever 26 Install acceleration
132. me or excessive heat c Remove rust preventive compound from coated exterior parts of the engine using drycleaning solvent Item 4 Appendix D and rags Item 7 Appendix D d Inspect engine for damage incurred during shipment TM 9 2815 250 24 amp P Section Ill GENERAL MAINTENANCE PROCEDURES Paragraph Page Number Paragraph Title Number 2 7 AS AA Work Safety aus ee a a E 2 4 Cleaning A A 2 4 2 10 Inspection Instructions 0 2 0 eee eeeeeee cece aa naakka naa ana n aak a an aa akan naa aan aa aa aan aan aa EEEN 2 5 2 11 Repair Instruccion 2 6 2 12 Hose and Tube Tagging ee da 26 2 13 L brication Instructi ns une asa aaa Tea ein near ana 2 6 2 14 REA cc nenne 2 6 2 7 GENERAL a These general maintenance procedures and instructions contain general shop practices and specific methods you must be familiar with to properly maintain your Diesel Engine Assembly Hatz 2 G 40 You should read and understand these practices and methods before performing any maintenance task Before beginning a task find out how much repair modification or replacement is needed to fix the equipment as described in this manual Sometimes the reason for equipment failure can be seen right away and complete tear down is not necessary Disassemble equipment only as far as necessary to repair or replace damaged or broken parts The following applies to the Initial Setup section contained in all the maintenance task paragraphs 1 Materials pa
133. mm millimeter MTOE Modified Table of Organization and Equipment NIIN national item identification number Nem newton meter NSN national stock number OZ ounce p page Pam pamphlet para paragraph psi pounds per square inch qt QT quart rpm revolutions per minute RPSTL repair parts and special tools list SF standard form SMR source maintenance and recoverability TC technical circular TM technial manual TMDE test measurement and diagnostic equipment TU tube U M unit of measure UOC usable on code 1 8 WARRANTY INFORMATION The Diesel Engine Assembly Hatz 2 G 40 is not covered by a warranty 1 9 SAFETY CARE AND HANDLING For information on general safety precautions and regulations review the warning summary and the safety summary at the beginning of this manual In addition observe all warnings and cautions that appear in the maintenance proce dures 1 10 CORROSION PREVENTION AND CONTROL Corrosion prevention and control CPC of Army materiel is a continuing concern It is important that any corrion problem be reported so it can be corrected and improvements can be made to prevent the problem in the future While corrision is typically associated with the rusting of metals it can also include deterioration of other materi als such as rubber and plastic Unusual cracking softening swelling or breaking or materials may indicat a corrosion problem If a corrosion problem is identified it can be
134. mp P 2 23 FUEL PRESSURE PIPE ASSEMBLIES AND RETURN FUEL HOSE REPLACEMENT This Task Covers a Removal b Installation Initial Setup Tools Test Equipment Materials Parts General mechanic s tool kit Gasket 2 Item 19 Appendix F Item 14 e Gasket 4 Item 40 Appendix F Torque wrench 1 2 inch drive Item 31 Spring tension washer Item 31 Appendix F e Washer 2 Item 18 Appendix F e Wrench Item 36 Appendix G a REMOVAL NOTE Fuel pressure pipe nuts will stay on fuel pressure pipe assemblies when they are removed 1 Loosen two fuel pressure pipe nuts on each of two fuel pressure pipe assemblies 9 and 12 2 Remove two fuel pressure pipe assemblies 9 and 12 and clamp 7 from two injection pump fittings 11 and fuel injector fittings 10 3 Remove screw 8 and nut 6 from clamp 7 Remove clamp 7 from two fuel pressure pipe assemblies 9 and 12 NOTE ITEMS 1 THROUGH 5 DELETED NOTE FOR PURPOSES OF CLARITY AIRFOW DEFLECTORS ARE NOT SHOWN 29i206m 2 20 Change 1 TM 9 2815 250 24 amp P 2 23 FUEL PRESSURE PIPE ASSEMBLIES AND RETURN FUEL HOSE REPLACEMENT continued NOTE Steps 6 7 are done only if equipment has dual banjo fittings Steps 8 and 9 are done only for single banjo fittings 4 Remove fluid passage bolt 13 two washers 14 strap clamp 14 1 return fuel hose 4 adapter 15 two gaskets 23 and fitting 16 and fitting 20 fr
135. ms 9 from crankcase 3 Discard shims 3 33 3 9 3 34 TM 9 2815 250 24 amp P PISTON AND COMBUSTION CHAMBER LINER REPAIR continued Remove two pistons 15 and connecting rods 1 from two combustion chamber liners 2 DISASSEMBLY Remove two connecting rod caps 5 and four screws 6 from two connecting rods 1 Remove two sleeve bearing halves 18 from each of two connecting rods 1 and connecting rod caps 5 Discard bearing halves Loosely install two connecting rod caps 5 and four screws 6 on two connecting rods 1 Remove three piston rings 14 from each of two pistons 15 Discard piston rings NOTE If any pistons piston pins retaining rings or connecting rods are damaged and need to be replaced do steps 3 and 4 Otherwise go to step 3 in subparagraph d Remove two retaining rings 17 and piston pin 16 from piston 15 and connecting rod 1 Discard retaining rings Remove piston 15 from connecting rod 1 Replace piston piston pin and or connecting rod if damaged Repeat for other piston if necessary CLEANING WARNING Drycleaning solvent P D 680 is toxic and flammable Always wear protective goggles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open flame or excessive heat Remove carbon from pistons piston ring grooves and combustion chamber liners with carbon removing compound Clean all pa
136. nders This particular engine has a four stroke cycle A four stroke engine completes one cycle every other time the piston goes up and down up being one stroke down being the return stroke e The first stroke is intake the piston goes down in the cylinder and the intake valve opens allowing air to flow into the cylinder e The second stroke is compression the piston comes up and both valves close so the air in the cylinder is compressed While the air is compressed the fuel injector releases a spray of fuel into the cylinder e The compression heats the air enough to ignite the fuel e The third stroke is power the fuel burns forcing the piston down e The fourth stroke is exhaust the piston comes up in the cylinder and the exhaust valve opens allowing exhaust gas to escape 1 9 1 10 blank TM 9 2815 250 24 amp P CHAPTER 2 UNIT MAINTENANCE Section I REPAIR PARTS TOOLS SPECIAL TOOLS TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT TMDE AND SUPPORT EQUIPMENT Paragraph Page Number Paragraph Title Number 2 1 A S 2 1 2 2 Common Tools and EuP eresie E nennen mene nn enn nnne nnne 2 1 2 3 Special Tools TMDE and Support Equipment sesssesseee e 2 1 2 4 Repair Pa cem 2 1 2 1 GENERAL This chapter describes the Unit maintenance tasks to be performed on the Diesel Engine Assembly Hatz 2 G 40 2 2 COMMON TOOLS AND EQUIPMENT Common tools and
137. nditions Materials Parts Fuel pressure pipe assemblies and return fuel Drycleaning solvent Item 4 Appendix D hose removed para 2 23 Tools Test Equipment NOTE There are two fuel injectors on the engine Use this procedure to replace either one The injector on the flywheel side of the engine is shown a REMOVAL T Remove nut 1 spring tension washer 2 spacer 3 and hose clamp 4 from fuel injector 5 and stud 9 Discard spring tension washer 2 Remove fuel injector 5 from bore in cylinder head 8 NOTE Gasket may stay in bore in cylinder head check bore if gasket is not on the end of the fuel injector 3 Remove gasket 6 from fuel injector 5 or bore in cylinder head 8 Discard gaset b CLEANING Drycleaning solvent P D 680 is toxic and flammable Always wear protective goggles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and do not breathe vapors Do not use near open flame or excessive heat 1 Clean bore in cylinder head 8 with drycleaning solvent and rag 3 48 2 Change 1 TM 9 2815 250 24 amp P 3 14 FUEL INJECTOR REPLACEMENT continued Change 1 3 48 3 TM 9 2815 250 24 amp P 3 14 FUEL INJECTOR REPLACEMENT continued 3 48 4 INSPECTION Remove the nozzle retaining nut 1 from the fuel injector body 2 Check the nozzle body 3 and nozzle needle 4 for overheating damage scoring and coked up spr
138. ng 20 and fluid passage bolt 13 on injection pump 22 Torque adapter to 26 ft lb 85 Nem Torque fluid passage bolt to 18 5 ft lb 25 Nem Secure return fuel hose 4 to fitting 20 with strap clamp 14 1 3 1 Connect fuel hose 4 to fitting 21 or tee 21 1 and secure with strap clamps 18 1 3 2 Install six strap clamps 18 1 to secure fuel return hoses 24 and 25 to tees 21 1 and single banjo 21 2 3 3 Install two fluid passage bolts 17 four gaskets 18 and single banjo fittings 21 2 to two fuel injectors 19 NOTE FOR PURPOSES OF CLARITY AIRFLOW DEFLECTORS ARE NOT SHOWN DUAL BANJO FITTINGS SINGLE BANJO FITTINGS 29i207m 2 22 Change 1 TM 9 2815 250 24 amp P 2 23 FUEL PRESSURE PIPE ASSEMBLIES AND RETURN FUEL HOSE REPLACEMENT continued 4 Install clamp 7 onto fuel pressure pipe assemblies 9 and 12 and secure with nut 6 and screw 8 5 Install two fuel pressure pipe assemblies 9 and 12 and clamp 7 on two injection pump fittings 11 and fuel injector fittings 10 Secure by tightening two fuel pressure pipe nuts on each of two fuel pressure pipe assemblies 9 and 12 NOTE ITEMS 1 THROUGH 5 DELETED NOTE FOR PURPOSES OF CLARITY AIRFOW DEFLECTORS ARE NOT SHOWN 29i206m Change 1 2 23 TM 9 2815 250 24 amp P 2 24 AIRFLOW DEFLECTORS REPLACEMENT UOC APP This Task Covers a Removal b Installation Initial Setup Tools Te
139. nkcase 23 Apply GAA Item 5 to threads of studs 24 Install eight new studs 24 if removed CAUTION During installation of upper crankcase rotate crank gear so timing mark on crank gear is between two timing marks on camshaft gear Failure to align tim ing marks correctly may cause damage to the engine With the aid of an assistant install upper crankcase 23 on eight studs 24 and lower crankcase 22 Make sure timing marks on crankshaft gear 28 and camshaft gear 1 are aligned and that two gaskets 25 and 26 and eight O rings 27 stay in place Change 1 3 6 TM 9 2815 250 24 amp P CRANKCASE REPAIR continued Install air duct bracket 12 on upper crankcase 23 and lower crankcase 22 Secure loosely with two screws 13 four washers 11 and two nuts 10 Install three screws 8 six washers 9 and three nuts 14 loosely securing upper crankcase 23 to lower crankcase 22 on starter side of engine Install three screws 19 washers 20 and nuts 5 loosely securing upper crankcase 23 to lower crankcase 22 on injection pump side of engine Install screw 4 two washers 3 and nut 21 loosely securing upper crankcase 23 to lower crankcase 22 on injection pump side of engine Tighten nine screws 13 8 19 and 4 starting with the center front and back of the engine Install new gasket 15 access cover 16 and two new spring tension washers 17 and screws 18 on upper crankca
140. nnnnnnnnnnnnnnnnnnnnnnnnnn 1 1 1 5 SNEIWEICIICud eii a 1 1 Reporting Equipment Improvement Recommendations occooccconcccnnccccnncncnnnnnoncnconnnnnnnnncnncncnns 1 2 1 7 List of Abbreviations and Acronyms ceceee enoaan ee eeeeeeeeeeeeeeeaeeeeeeaaeeeeeeaaaeeeeeaaeeeeeeaaaeees 1 2 1 8 Warranty IOMA et ie Ace OA REO 1 3 1 9 Safety Care and Handling en 1 3 1 10 Corrosion Prevention and Control sessesssssssseeee m enne ene nnne nennen nns 1 3 1 1 SCOPE This technical manual describes Unit Direct Support and General Support maintenance for the Diesel Engine Assembly Hatz 2 G 40 The manual also contains the repair parts and special tools list RPSTL for the engine assembly 1 2 MAINTENANCE FORMS RECORDS AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738 750 1 3 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE Refer to TM 750 244 6 for procedures on the destruction of military vehicles to prevent enemy use 1 4 PREPARATION FOR STORAGE OR SHIPMENT Refer to TM 743 200 1 for information on preparing the Diesel Engine Assembly Hatz 2 G 40 for storage or shipment 1 5 QUALITY ASSURANCE a No specific quality assurance manual pertains to the Diesel Engine Assembly Hatz 2 G 40 1 1 TM 9 2815 250 24 amp P 1 5 QUALITY ASSURANCE continued b Defective material received through the supply system should be repo
141. ntinued 4 Remove oil drain plug 17 and gasket 18 from flywheel housing 19 Discard gasket NOTE Pin for intermediate gear may come off with flywheel housing 5 Remove screw 14 18 screws 15 19 washers 13 and flywheel housing 19 from crankcase 10 NOTE There may be one or two gaskets on flywheel housing Remove all of them and note how many gaskets are removed from flywheel housing 6 Remove one or two gaskets 11 from flywheel housing 19 Discard gasket s T Remove O ring 12 from flywheel housing 19 Discard O ring 8 Remove seal 16 from crankshaft opening 20 Discard seal 9 Remove two screws 23 and washers 22 and plate 21 from flywheel housing 19 Change 1 3 29 TM 9 2815 250 24 amp P 3 8 FLYWHEEL AND HOUSING REPLACEMENT continued b 1 3 30 INSTALLATION Install two screws 23 and washers 22 and plate 21 on flywheel housing 19 Install new seal 16 in crankshaft opening 20 with lip of seal 16 facing inward Install new O ring 12 on flywheel housing 19 Apply sealing compound Item 17 Appendix D to surfaces of gasket s 11 Depending on the number removed install one or two new gaskets 11 on flywheel housing 19 Install flywheel housing 19 on crankcase 10 and secure with screw 14 18 screws 15 and 19 washers 13 Install oil drain plug 17 and new gasket 18 in flywheel housing 19 and crankcase 10 CROSS SECT
142. nual with corresponding page numbers Each chapter or part listed is boxed in with a black outer edge that is in line with the first page of that chapter or part e Table of contents The table of contents follows the summary of warnings Theltable of contents lists all chapters and sections numerically with corresponding page numbers e Section indexes Each section starts with a numerical listing of all paragraphs in that section e Alphabetical index The alphabetically arranged subject index starts or page Index 1 TEXT AND ILLUSTRATIONS 1 Each chapter is divided into sections each section begins with a numencal listing of all paragraphs 2 Each paragraph in the maintenance chapters 2 and 3 contains the following information as appropriate e The common or special tools and test equipment required to perform the procedures are listed under the heading Tools Test Equipment Information e g part numbers and national stock numbers for all common and special tools is given in e Materials and mandatory replacement parts that will be discarded during performance of the procedure are listed under the heading Materials Parts A materials parts list does not contain items that may be replaced If found defective during inspection Also the list does not contain the item cited in the paragraph title Information on the materials is In and information on the mandatory replacement parts is inlAppendax E e f more than one
143. o CRANKCASE ASSEMBLY 2G40 16 2640 17 2G40 18 ooooooo oo PIN STRAIGHT HEADLE STUD PLAIN 0 0 00 ccc eee eee ooo STUD PLAIN 0 0 0 0 cece ee SCREW MACHINE sese WASHER FLAT oo ooooooooo oo NUT PLAIN HEXAGON oooo PIN STRAIGHT HEADLE NIPPLE PIPE 0 0 00 cece cece eens STRAINER ELEMENT SE VALVE SAFETY RELIEF STUD M6 X 16 2 eee STUD PLAIN 0 0 0 0 cece cece eens PIN SPRING 0000 cece cece eens CAP PLUG PROTECTIVE CAP PLUG PROTECTIVE GASKET PART OF KIT P N 01228002 SCREW CAP SOCKET HE UOC APP WASHER SPRING TENSI COVER ACCESS 5 kx n n RR XR ORO CNRC X UOC APP GASKET PART OF KIT P N 01228002 O RING PART OF KIT P N 01228002 APJ Item 7 QTY NRANDNRRRARRER N H SECTION II C01 TM 9 2815 250 24 amp P 1 6 2 NE S 291100 Figure 5 Crankshaft Assembly 1 ITEM NO wo Pr H OH O 04 Oa U BW N H H H H H N 12 1 2 SMR PAFZZ PAFZZ PAFZZ PAFFF PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ XDFZZ PAFZZ PAFZZ PAFZZ PAFZZ XDFZZ XDFZZ 3 NSN 3020 01 455 2798 2815 01 455 0423 5315 01 103 1522 5315 01 400 0441 5340 01 455 0010 5365 01 406 4171 5330 01 400 5773 5315 00 616 5530 5310 01 400 2138 5305 01 101 4830 5
144. om injection pump 22 Discard washers and gaskets 5 Remove strap clamp 18 1 and hose 4 from fitting 21 or tee 21 1 6 Remove two fluid passage bolts 17 four gaskets 18 and fuel hose 4 1 from two fuel injectors 19 Discard gaskets 7 Remove two hose nipples 21 and two strap clamps 18 1 from return fuel hose 4 1 8 Remove two fluid passage bolts 17 four gaskets 18 and two single banjo fittings 21 2 from two fuel injectors 19 Discard gaskets 9 Remove six strap clamps 18 1 securing fuel return hoses 24 and 25 to tees 21 1 and separate hoses 24 and 25 from tees 21 1 and single banjo fitting 21 2 NOTE FOR PURPOSES OF CLARITY AIRFLOW DEFLECTORS ARE NOT SHOWN 14 14 DUAL BANJO FITTINGS SINGLE BANJO FITTINGS 29i207m Change 1 2 21 TM 9 2815 250 24 amp P 2 23 FUEL PRESSURE PIPE ASSEMBLIES AND RETURN FUEL HOSE REPLACEMENT continued NOTE Steps 1 and 2 are done only if equipment has dual banjo fittings Steps 3 2 and 3 3 are done only if equipment has single banjo fittings b INSTALLATION 1 Install two hose nipples 21 on return fuel hose 4 1 and secure with two strap clamps 18 1 2 Install return fuel hose 4 1 and two fittings 21 on two fuel injectors 19 and secure with two fluid passage bolts 17 and four new gaskets 18 3 Install two new gaskets 23 fitting 16 adapter 15 two new washers 14 return fuel hose 4 and fitti
145. orage or Shipment Preparation for oooccooccccocccc nennen nennen nennen nennen 1 1 T Tagg ng Hlose and Tube ra A ER ENIM E 2 6 Technical Manuals eiere riaa REE E e TESSEN a A 1 Test Measurement and Diagnostic Equipment TMDE sssseseeee II 2 1 Tests Cylinder Compression stato ta e fine e er a wt a Paced eines 3 56 F el InJector Sissies cane wnt Cokie pert ae eth dd Amiel te 3 66 Injection PUMP seat aaa 3 65 Oil PreSSUIE sio ee rara A a idas 3 70 Index 4 Change 1 TM 9 2815 250 24 amp P SUBJECT PAGE T continued Text and MUStrations 00 dat iv Thermostatic Switch Replacement cececcseeeeeeeeeeeeeeeeeeeeeeeaaeeeeceaaeeeeeeaaeeeeeeaaeeeeeaaaeeeeseaaeeeaaaaeeeeseaaeeeeseaaeeeeaeages 2 29 Tightening Metal Fasteners ud lo Ta ERR RE Lore ERR VASA lied alados uk dilo E 3 Tool Identification BEL EEE E EE A E AEA AAN EE A G 1 Fools and Eguipment Ee Tub uror caia aan el a dees 2 1 Tools and Test Equipment Requirements seeren eiae Aa annan aa annan AEA NEFAS PEE EEEE PARAE REIED R B 6 AS NOA 2 3 De Anc EE E 1 Torque Table HowTo Us rta rias E 1 NA O 2 6 Troubleshooting Direct Support and General Support Chat zie iab ida 3 3 uc m W ss 3 1 eme seam 3 2 Tube and Hose Tagging 3 iiie anna e aa a Ron eR d es 2 6 V Valve Adjustmlent 5 ede e tes etr eb
146. over 14 four nuts 16 new spring tension washers 15 and washers 7 and two socket head screws 8 and socket head screws 9 on intake manifold 1 TM 9 2815 250 24 amp P 2 21 INTAKE MANIFOLD REPLACEMENT continued Install new four part gasket 2 adapter 3 and four new spring tension washers 4 and socket head screws 5 on intake manifold 1 e Install airflow deflectors para 2 24 if removed e Install valve vent para 2 22 FOLLOW ON TASKS 2 17 TM 9 2815 250 24 amp P 2 22 VALVE VENT REPAIR This Task Covers a Removal c Assembly Initial Setup Tools Test Equipment e General mechanic s tool kit automotive Item 15 Appendix G a REMOVAL Remove valve vent 2 from intake manifold 5 2 Remove hose 3 from hose coupling 4 b Disassembly d Installation Materials Parts e Grease automotive Item 5 Appendix D e O ring 2 Item 45 Appendix F 2 18 TM 9 2815 250 24 amp P 2 22 VALVE VENT REPAIR continued b DISASSEMBLY 1 Remove two O rings 1 from valve vent 2 Discard O rings 2 Remove hose 3 from valve vent 2 c ASSEMBLY 1 Install hose 3 on valve vent 2 2 Apply light coat of grease on two new O rings 1 Install two O rings 1 on valve vent 2 d INSTALLATION 1 Install hose 3 on hose coupling 4 2 Install valve vent 2 on intake manifold 5 FOLLOW ON TASKS None 2 19 TM 9 2815 250 24 a
147. ply connected to injection pump refer to TM 9 2350 293 20 UOC APP Vehicle fuel supply connected to injection pump UOC APJ TM 9 2350 292 20 2 The flow control valve should be adjusted only if any of the following conditions exist The flow control valve has been replaced the engine lacks power or the engine emits smoke after start up during operation The fuel quantity injected is determined by the travel of the pump plunger between start and end of delivery This dimension is specified in millimeters on the engine data plate located on the flywheel air duct deflector 1 Turn flywheel 2 clockwise until 26 degree mark on flywheel 2 is aligned with PM mark on flywheel airflow Change 1 3 19 FLOW CONTROL VALVE ADJUSTMENT continued b Remove injector line fitting 8 O ring 4 spring guide 5 shim 6 spring 7 gasket 8 and delivery valve 9 from injection pump outlet port 10 Discard O ring and gasket C Install fuel testing device 13 adapter rod 12 and indicator dial 11 in injection pump outlet port 10 d Remove three screws 18 nut 19 mounting plate 17 and gasket 16 from crankcase 14 Install screw 18 on auxiliary drive side of mounting plate opening 15 Discard gasket TM 9 2815 250 24 amp P 3 61 TM 9 2815 250 24 amp P 3 19 FLOW CONTROL VALVE ADJUSTMENT continued 3 62 Place rubber band 20 around governor lever pad 21 and scr
148. pring lifter compress valve spring 14 and remove two valve spring retainer locks 12 from valve spring 14 and exhaust valve 16 Remove valve spring retainer washer 13 valve spring 14 and base spring washer 15 from exhaust valve 16 Remove exhaust valve 16 from bottom of cylinder head 6 CLEANING AND INSPECTION Inspect four push rods for bends or wear on four sockets at ends of push rods Replace any push rods if bent or if sockets are worn Clean valves and valve seats with carbon removing compound WARNING Drycleaning solvent P D 680 is toxic and flammable Always wear protec tive goggles and gloves and use only in a well ventilated area Avoid con tact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open flame or excessive heat Using drycleaning solvent and rag clean valves springs washers locks and valve seat 3 5 TM 9 2815 250 24 amp P CYLINDER HEADS REPAIR continued Inspect valves and valve seats for cracks burns or bends Replace any cracked burned or bent valves If valve seats are cracked or burned replace cylinder head ADJUSTMENT CAUTION If after removing the cylinder head you have replaced the combustion chamber liner piston connecting rod or crankshaft the valve to piston clearance must be checked Too little clearance will result in damage to pistons cylinder heads and valves Too much clearance will cause the engine to lose
149. relevant to material cov ered in this manual A 2 FORMS Refer to DA Pam 738 750 for instructions on the use of maintenance forms Recommended Changes to Publications and Blank Forms n saaana naaraan DA Form 2028 Recommended Changes to Equipment Technical Publications llle DA Form 2028 2 Processing and Deprocessing Record for Shipment Storage and Issue of Vehicles and Spare Engines occcocccccccccccc n DD Form 1397 Product Quality Deficiency Report oooooccoocococcnn as SF Form 368 A 3 MANUALS First Aid for Soldiers nung FM 4 25 11 Marine Corps EET MCRP 3 02G Inspection Care and Maintenance of Antifriction Bearings ooooccccocccccoonrcnn nenn TM 9 214 Materials Used for Cleaning Preserving Abrading and Cementing Ordnance Materiel and Related Materials Including Chemicals ooooccccccccccoccccc TM 9 247 Operator s Manual for Carrier Ammunition Tracked M992A2 NSN 2350 01 368 9500 0 0oooccccc haa TM 9 2350 293 10 Unit Maintenance Manual for Carrier Ammunition Tracked M992A2 NSN 2350 01 368 9500 sms een TM 9 2350 293 20 1 and 2 Unit Direct Support and General Support Maintenance Repair Parts and Special Tools List for Carrier Ammunition Tracked M992A2 2350 01 368 9500 coco TM 9 2350 293 24P Direct Support and General Support Maintenance Manual for Carrier Ammunition Tracked M992A2 NSN 2350 01 368 9500 0 00 cece eee eee
150. reported using an SF Form 368 The use of key words such as corrision rust deterioration or cracking will ensure that the information is identified as a CPC problem The form should be submitted to the address specified in DA Pam 738 750 Change 1 1 3 TM 9 2815 250 24 amp P SECTION Il EQUIPMENT DESCRIPTION AND DATA Paragraph Paragraph Title Page Number Number 1 11 Equipment Characteristics Capabilities and Features ooooccccoccccccono o 1 4 1 12 Location and Description of Major Components ooocccccccccc elles 1 5 1 13 Equipment Data bei by are ken 1 8 1 11 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES a TheDiesel Engine Assembly Hatz 2 G 40 is an air cooled four stroke diesel engine with vertical cylinders and direct fuel injection b The engine is a lightweight all purpose industrial engine C Later models of Hatz 2 G 40 come EPA version 1 compliant Differences in configuration affect fuel control on these engines Examine the serial number on the ID plate to determine which style you have Also look for state ment EPA compliant at bottom of tag EXAMPLE 091 XX 02028520 MODEL 2640 00 to 13 are non EPA 14 and above are EPA compliant 1 4 Change 1 TM 9 2815 250 24 amp P 1 12 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Description 1 Intake Manifold Provides fresh air to cylinders for combustion 2 Fuel Injectors 2 Supply fuel to cylinders 3
151. rettet ab 3 58 Valve to Piston Clearance Adjustment seesssesssssssssessseseseeenen nennen enne sh Kanaa ana annan ana a naan Kaanaan AAEE annene 3 40 Valve Vent Ral vita A kaa lavedee TAA Lae A ae ae derer 2 18 Ww Warnings Gautions and Notes unorder tr entere RE emi ea aT a e pape ette dx ace ed ed d V Watnitg SutmtTlal yes cc coo a Waranty Information vem 1 3 Work Safety EIC D EI T E RBRUM URN M 2 4 Index 5 Index 6 blank RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH THIS PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS THEN JOT DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT OUT FOLD PUBLICATION NUMBER PUBLICATION DATE PUBLICATION TITLE TM 9 2815 250 24 amp P ENGINE ASSEMBLY DIESEL HATZ 2 G 40 BE BE EXACT PIN POINT WHERE ITIS PIN POINT WHEREITIS IN THIS SPACE TELL WHAT IS WRONG AND PARA TABLE WHAT SHOULD BE DONE ABOUT IT GRAPH NO PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER DA FORM 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR 1 JUL 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEDQUARTERS REVERSE OF DA FORM 2022 2 AMSMC OP 103 85 FILL IN YOUR UNITS ADDRESS maia Y ne PP PP e NO POSTAGE OFFICIAL BUSINESS NECESSARY IF MAILED IN THE UNITED STATES
152. rom engine UOC APJ TM 9 2350 292 20 2 MOTORENFASRIK HATZ KG v 094099 HORE Change 1 2 7 TM 9 2815 250 24 amp P W 2 16 EYEBOLT REPLACEMENT UOC APP This Task Covers a Removal b Installation Initial Setup Tools Test Eguipment e General mechanic s tool kit automotive Item 14 Appendix G a REMOVAL Remove eyebolt 1 and shim 2 from collar nut 3 b INSTALLATION Install shim 2 and eyebolt 1 in collar nut 3 FOLLOW ON TASKS e None 2 8 Change 1 TM 9 2815 250 24 amp P 2 17 ROCKER ARM COVER AND O RING REPLACEMENT This Task Covers a Removal b Installation Initial Setup Tools Test Equipment Materials Parts General mechanic s tool kit automotive Grease automotive Item 5 Item 15 Appendix G O ring Item 33 Appendix F e Washer 2 Item 29 Appendix F NOTE The Diesel Engine Assembly has two rocker arm covers Use this procedure to remove either one a REMOVAL 1 Remove two screws 1 and washers 2 from rocker arm cover 3 and cylinder head 5 Discard washers 2 Remove rocker arm cover 3 from cylinder head 5 3 Remove O ring 4 from groove in rocker arm cover 3 Discard O ring b INSTALLATION 1 Lightly coat new O ring 4 with grease and install in groove in rocker arm cover 3 2 Install rocker arm cover 3 on cylinder head 5 3 Install two screws 1 and new washers 2 on rocker arm cover 3
153. roubleshooting procedures for the malfunction in guestion are described Perform each step in the order listed until the malfunction is corrected DO NOT perform any maintenance task unless the troubleshooting procedure tells you to do so When troubleshooting any electrical system or component exercise extreme care in order to prevent electric shock WARNING e To prevent injury due to electric shock throughout troubleshooting of the electrical system or electrical components be certain MASTER switch is turned off between every step unless otherwise directed e To prevent injury due to electric shock remove all jewelry and metal objects when working on the electrical system The multimeter is used throughout troubleshooting of the electrical system When using the multimeter make sure it is used with a probe kit When performing a continuity check connect the meter probes to both terminals of the circuit you are testing Read the meter and interpret the results If the needle swings to near O on the top scale the circuit has continuity If the needle does not move the circuit is open If the needle jumps or flickers there is a loose connection 3 2 QUICK GUIDE TO TROUBLESHOOTING ITEM ENGINE GOVERNOR 3 2 SYMPTOM ENGINE CRANKS BUT STARTS HARD OR FAILS TO START OIL CONSUMPTION IS EXCESSIVE FUEL CONSUMPTION IS EXCESSIVE AND THERE IS BLACK EXHAUST SMOKE ENGINE HAS LOW POWER OR MISFIRES ENGINE MAKES A K
154. rted on SF Form 368 Instructions for preparing the reports are provided in AR 702 7 Mail your completed form directly to Commander U S Army Tank automotive and Armaments Command ATTN AMSTA TR E MPA 267 Warren MI 48397 5000 1 6 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS If your Diesel Engine Assembly Hatz 2 G 40 needs improvement let us know Send us an equipment improvement recommendation EIR You the user are the only one who can tell us what you do not like about the equipment Let us know why you don t like the design or performance Put it on an SF Form 368 and mail it to Commander U S Army Tank automotive and Armaments Command ATTN AMSTA TR E MPA 267 Warren MI 48397 5000 1 7 LIST OF ABBREVIATIONS AND ACRONYMS approx approximately APU auxiliary power unit AR Army regulation ATTN attention BT bottle BX box C Celsius CAGEC commercial and government entity code cc cubic centimeter cm centimeter CN can CPC corrosion prevention and control cu in cubic inch DA Department of the Army DD Form Department of Defense Form DOD Department of Defense DSN defense switching network EIR equipment improvement recommendation F Fahrenheit ft foot ft Ib foot pound GL gallon in inch kg kilogram km kilometer kPa kilopascal L liter TM 9 2815 250 24 amp P 1 7 LIST OF ABBREVIATIONS AND ACRONYMS continued lb LB pound MAC maintenance allocation chart min minimum minute
155. rts and tools are not listed unless they apply to the procedure 2 Personnel are listed under Personnel Required only if more than one technician is needed in order to complete the task If Personnel Required is not listed it means that one technician can perform the task Check all tags and forms attached to the Diesel Engine Assembly for any information about the reason it was removed from service Modification work orders and technical bulletins must also be checked for equipment changes and updates In some cases a part may be damaged by removal If the part appears to be good and other parts behind it are not defective leave it on and continue with the procedure Here are a few simple rules 1 Do not remove dowel pins or studs unless loose bent broken or otherwise damaged 2 Do not remove bearings or bushings unless damaged If you need to remove them to access parts pull out bearings and bushings carefully 3 Replace all gaskets seals lockwashers cotter pins preformed packings and other locking hardware TM 9 2815 250 24 amp P 2 8 WORK SAFETY a Observe all WARNINGs and CAUTIONs Always use power tools carefully b Protect yourself against injury Wear protective gear such as safety goggles or lenses safety shoes a rubber apron and gloves c When lifting heavy parts have someone help you Make sure lifting and jacking equipment is working properly is suitable for the assigned task and is secure a
156. rts with drycleaning solvent and rag Using cylinder ridge reamer remove ridge from top of combustion chamber liner TM 9 2815 250 24 amp P 3 9 PISTON AND COMBUSTION CHAMBER LINER REPAIR continued d ASSEMBLY NOTE Piston head must be installed so the pocket is on the same side of the piston assembly as the notches in the connecting rod and connecting rod cap 1 If piston 15 is being replaced place piston 15 on connecting rod 1 with pocket in piston 15 facing the same direction as notches in connecting rod 1 Install piston pin 16 in piston 15 and connecting rod 1 and secure with two new retaining rings 17 Repeat for other piston if necessary NOTE There are two pistons on the engine Repeat steps 2 and 3 for each of them 2 Install three piston rings 14 on piston 15 See diagram for correct location and orientation of piston rings Stagger three ring gaps so they are 120 degrees apart and no ring gap is over piston pin 16 or directly above or below other ring gaps ro 5 IE BOTTOM PLACEMENT OF PISTON RINGS 3 Remove two screws 6 and connecting rod cap b from connecting rod 1 Place two new sleeve bearing halves 18 in connecting rod 1 and connecting rod cap 5 3 35 3 9 3 36 TM 9 2815 250 24 amp P PISTON AND COMBUSTION CHAMBER LINER REPAIR continued INSTALLATION Install two new shims 9 on crankcase 3 Install two new cap plugs 11 and four new
157. s VA TM 9 2815 250 24 amp P TECHNICAL MANUAL UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR ENGINE ASSEMBLY DIESEL HATZ 2G 40 NSN 2815 01 446 3500 NSN 2815 01 465 4321 HOW TO USE THIS MANUAL El INTRODUCTION EI UNIT MAINTENANCE PROCEDURES 2 7 DIRECT SUPPORT AND GENERAL SUPPORT TROUBLESHOOTING 3 1 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE PROCEDURES 3 12 TESTS AND ADJUSTMENTS REFERENCES MAINTENANCE ALLOCATION CHART B1 REPAIR PARTS AND SPECIAL TOOLS LIST EXPENDABLE AND DURABLE ITEMS LIST D 1 TORQUE VALUES FOR THREADED FASTENERS E 1 MANDATORY REPLACEMENT PARTS TOOL IDENTIFICATION LIST A CJ lt I INDEX Approved for public release distribution is unlimited HEADOUARTERS DEPARTMENT OF THE ARMY SEPTEMBER 1998 TM 9 2815 250 24 amp P FOR INFORMATION ON FIRST AID REFER TO FM 4 25 11 WARNING CARBON MONOXIDE e Carbon monoxide is a colorless odorless deadly poisonous gas that when breathed deprives the body of oxygen and causes suffocation Exposure to carbon monoxide can cause headache dizziness loss of muscle control drowsiness and coma Permanent brain damage or death can result from serious exposure Carbon monoxide is present in the exhaust fumes of diesel engines inadequate ventilation causes dangerous concentrations of this gas Precautions must be observed to ensure the safety of personnel
158. s of Operation irano ve o Ri La enki o ete Rob dee ob so obo En tar d Eie KMS Rd a o Rea 1 9 Pump Replacement Injection ooocooococonocooorr el n 3 50 Pump Test Inj amp ecti n ss seh oer rar sr Serena Vieki SN et 3 65 Q Quality Assurance DC cc 1 1 Quick Guide to Troubleshooting oooooccccccnccn Rr een nn eae 3 2 R Records and Reports Maintenance oocoococ ernennen een een nennen 1 1 References x3 aat mit n ae it A A 1 Regulations ra ee a ai A 2 Repair Instructions veintena arar 2 6 Repair Parts 223 san a A A 2 1 0 1 Repair Parts and Special Tools List Abbreviations 222 25 a AAA ead ea ee dea Ae ein ead AA A C 7 Explanation of Columns coco C 2 Repair Parts How To Locate 0 0 cece e hh C 7 SCOPE M ER C 1 Special Information cota ERI ED c n e D CERO e e A Chee ERA AO RU ERA d C 6 Return Fuel Hose and Fuel Pressure Pipes Replacement 0 cece eee teen een een 2 20 Rocker Arm Assemblies Repair rrr criant r rekri R EERE ell hh hh 3 38 Rocker Arm Cover and O Ring Replacement 000 cece es 2 9 S Safety Care and Handing 2 14 us ra er Rue elis tt bh ia P ROIG SO idi 1 3 Safety Summary aiii i hls rhtubPsbeenii e a Mahar hilo dade ata obs vi Salety WOIK da A nr A a ba Ceo 2 4 Service upon Receipt i zoe Jaksa ia is rere 2 2 Solenoid Replacement And Adjustment UOC APP ssuusssssesssssses sn 2 30 Special Tools TMDE and Support Equipment 0 00 n 2 1 St
159. se 23 Install new gasket 7 and hose coupling 6 on upper crankcase 23 3 23 TM 9 2815 250 24 amp P 3 6 CRANKCASE REPAIR continued c TEST NOTE e This test procedure determines the offset between the camshaft gear and the crankshaft gear and gives instruction about how to correct the offset if necessary e Perform this test only if the camshaft camshaft gear crankshaft or crankshaft gear has been replaced 1 Place steel rule 29 across crankshaft gear 28 and camshaft gear 1 Using feeler gage measure any distance at point A between steel rule 29 and camshaft gear 1 There should be 0 00 inch gap POINTA 2 On camshaft gear 1 install shim s 2 of appropriate thickness to completely fill any distance measured in step 1 3 24 3 6 TM 9 2815 250 24 amp P CRANKCASE REPAIR continued NOTE When correct size and number of shim s are used steel rule will be in contact with both crankshaft gear and top shim on camshaft gear Place steel rule 29 across crankshaft gear 28 and camshaft gear 1 Measure the distance at point B and point C between crankcase sealing surfaces 30 and steel rule 29 If measurement is between 0 00 inch and 0 0039 inch 0 00 mm and 0 10 mm install gasket on flywheel housing para 3 8 If measurement is between 0 0043 inch and 1 18 inches 0 11 and 0 30 mm install two gaskets on flywheel housing para 3 8 POINT C FOLLOW ON TASKS Instal
160. sharp kinks cracks bad bends and dents 2 Flexible lines fraying evidence of leakage and loose metal fittings or connectors 3 Metal fittings and connectors thread damage and worn or rounded hex heads d Inspect castings forgings and machined metal parts for the following 1 Machined surfaces nicks burrs raised metal wear and other damage 2 Inner and outer surfaces breaks and cracks e Inspect bearings in accordance with TM 9 214 2 5 TM 9 2815 250 24 amp P 2 11 REPAIR INSTRUCTIONS a Any repair procedure peculiar to a specific part or component is covered in the section or paragraph relating to that item After repair clean all parts thoroughly to prevent dirt metal chips or other foreign material from entering any working parts b Repair castings forgings and machined parts using the following instructions 1 Refer to TC 9 237 for instructions on repairing minor cracked castings or forgings WARNING Drycleaning solvent P D 680 is toxic and flammable Always wear protective goggles and gloves and use only in a well ventilated area Avoid contact with skin eyes and clothes and DO NOT breathe vapors DO NOT use near open flame or excessive heat 2 Repair minor damage to machined surfaces with a fine mill file or abrasive cloth dipped in drycleaning solvent Item 4 Appendix DJ 3 Replace any deeply nicked machined surface that could affect the operation of the Diesel Engine Assembly 4 Repair minor dama
161. st Equipment e Spring tension washer 6 Item 30 Appendix F General mechanic s tool kit automotive e Spring tension washer 2 Item 31 Appendix F Item 15 Appendix G Equipment Conditions Materials Parts Valve vent removed Split washer 3 Item 41 Appendix F a REMOVAL 1 Remove five screws 7 and washers 8 from airflow deflector 4 2 Remove three screws 6 and split washers 5 from airflow deflector 4 Discard split washers 3 Remove airflow deflector 4 from engine 3 4 Remove two screws 10 and spring tension washers 11 and airflow deflector 9 from engine 3 Discard spring tension washers ALLS da JR WUE n 2 24 Change 1 TM 9 2815 250 24 amp P 2 24 AIRFLOW DEFLECTORS REPLACEMENT UOC APP continued 5 Remove three screws 17 from air duct bracket 12 6 Remove two screws 15 and spring tension washers 16 from air duct bracket 12 Discard spring tension CAUTION Be careful not to damage fuel line when removing air duct 7 Remove two screws 14 and spring tension washers 13 clip 1 fuel hose 2 and air duct bracket 12 from engine 3 Discard spring tension washers 8 Remove three screws 24 from air duct bracket 23 9 Remove two screws 26 and spring tension washers 25 from air duct bracket 23 Discard spring tension washers 10 Remove two screws 19 washers 18 and spacers 32 and airflow deflector 22 from airflo
162. st valve pla i iia 18 Verify problem is solved F Inspect valves para 3 5 Are valves defective Grindorreplace valves Replace any otherdefective d eae 5 Venfy problem is solved Repeatsteps Athrough E Verify problem is solved END OF TASK 3 3 TROUBLESHOOTING CHART continued a ENGINE Replace any de fective oil tube assemblies and 2 19 Verify problem is solved B Check two oil seals on crankshaft oil pan gasket and O rings on filler neck and oil pump cover for leaks Are there any leaks Replace any defective oil seals Q rings or basket paras 3 6 3 12 and 3 13 Verify problem is solved C Check thermostatic switch for continuity by placing red lead of multimeter on connector of switch and grounding black lead Is there continuity Replace thermostatic switch para 2 26 Verify problem is solved GO TO STEP D TM 9 2815 250 24 amp P 2 OIL CONSUMPTION IS EXCESSIVE FITTINGS FITTINGS PLACE BLACK LEAD HERE PLACE RED LEAD HERE 3 5 TM 9 2815 250 24 amp P 3 3 TROUBLESHOOTING CHART continued a ENGINE 3 6 2 OIL CONSUMPTION IS EXCESSIVE continued CONTINUED FROM STEP C D Perform cylinder compression test para 3 17 Is compression reading between 350 and 400 psi 2413 and 2758 kPa NO YES Repair or replace pistons and or combustion chamber liners and or cylind ras
163. stall rocker arm covers and gaskets para 2 17 Change 1 3 39 TM 9 2815 250 24 amp P 3 11 CAMSHAFT REPAIR This Task Covers a Removal b Installation Initial Setup Tools Test Equipment Arbor press Item 1 Appendix G General mechanic s tool kit Item 14 Appendix G Snapring pliers Item 26 Appendix G Materials Parts e Clip Item 38 Appendix F a REMOVAL 8 and accelerator lever 8 Discard clip Crankcase gasket set Item 1 Appendix F Retaining ring Item 21 Appendix F Retaining ring Item 36 Appendix F Retaining ring Item 39 Appendix F Equipment Conditions Crankcase disassembled para 3 6 Remove three screws 14 and washers 13 and oil pump cover 12 from upper crankcase 15 Remove O ring 11 from oil pump cover 12 Discard O ring Remove rotor 9 and oil pump gear 10 from upper crankcase 15 Remove clip 2 from governor spring 1 Remove governor spring 1 from governor control lever assembly 3 40 3 11 TM 9 2815 250 24 amp P CAMSHAFT REPAIR continued Remove governor control lever assembly pin 6 and governor control lever assembly 3 from upper crankcase 15 Remove two O rings 7 from pin 6 Discard O rings Remove camshaft assembly 5 from upper crankcase 15 Position the timing marks on camshaft gear 4 at the 10 o clock position Pull camshaft assembly 5 toward you until it stops Turn camshaft gear 4 until timing
164. t 5 from screw 13 and crankcase 20 b INSTALLATION Install bracket 5 washer 14 and nut 15 on screw 13 and crankcase 20 2 Install screw 16 on bracket 5 and crankcase 20 3 Install new O ring 18 and bellows 19 on plunger 3 4 Install plunger 3 and screw 17 on bracket 5 5 A Change 1 2 31 TM 9 2815 250 24 amp P ll 2 27 SOLENOID REPLACEMENT AND ADJUSTMENT UOC APP continued 5 Install two nuts 9 and 11 and connector 12 on stud 10 Install stud 10 on solenoid 8 6 Install solenoid 8 and two washers 6 and screws 7 on bracket 5 7 Install connecting link 1 in plunger 3 governor lever 4 and solenoid 8 Secure connecting link 1 with two clips 2 C ADJUSTMENT 1 Loosen two nuts 9 and 11 on stud 10 2 Remove top clip 2 from connecting link 1 Remove connecting link 1 from governor lever 4 and plunger 3 3 Rotate governor lever 4 fully counterclockwise to the off position and push stud 10 all the way down 4 Turn stud 10 until connecting link 1 reaches governor lever 4 while stud 10 remains pushed all the way down Install connecting link 1 in governor lever 4 and plunger 3 5 Tighten two nuts 9 and 11 6 Install top clip 2 on connecting link 1 FOLLOW ON TASKS None 2 32 Change 1 iz OR K CA TM 9 2815 250 24 amp P CHAPTER 3 DIRECT SUPPOR
165. t automotive item 14 Materials Parts Drycleaning solvent Item 4 Appendix D Rag Item 7 Appendix Dj e Cotter pin Item 22 Appendix F a REMOVAL crankcase 4 e Sealing compound Item 17 Appendix D Crankcase gasket set Item 1 Appendix F e Head gasket set Item 3 Equipment Conditions e Airflow deflectors removed UOC APP para 2 24 Airflow deflectors removed UOC APJ TM 9 2350 292 20 2 Fuel pressure pipe assemblies and return fuel hose removed para 2 23 Remove three screws 5 nut 1 and governor plate 2 shown or extra fuel device if equipped from 2 Remove gasket 3 from governor plate 2 Discard gasket 3 50 Change 1 TM 9 2815 250 24 amp P 3 15 INJECTION PUMP REPLACEMENT continued Remove cotter pin 6 from control rack of injection pump 7 Discard cotter pin Remove end of governor lever 8 from control rack of injection pump 7 Remove four nuts 9 from injection pump 7 NOTE To remove injection pump from crankcase control rack of injection pump must be positioned under cutout in crankcase The number of gaskets to be removed will vary Refer to the first note in sub paragraph c Position control rack of injection pump 7 under cutout in crankcase 4 and remove injection pump 7 and gaskets 10 from crankcase 4 Discard gaskets CLEANING AND INSPECTION WARNING Drycleaning solvent P D 680 is toxic and flammable
166. ted in the third position of the SMR code The complete kit must be requisitioned and applied Items with these codes are not to be requested requisitioned individually They must be made from bulk material that is identified by the part number in the DESCRIPTION AND USABLE ON CODE UOC column and listed in the bulk material group of the repair parts list in this RPSTL If the item is authorized to you by the third position code of the SMR code but the source code indicates it is made at a higher level order the item from the higher level of maintenance Items with these codes are not to be requested requisitioned individually The parts that make up the assembled item must be requisitioned or fabricated and assembled at the level of maintenance indicated by the source code If the third position code of the SMR code authorizes you to replace the item but the source code indicates that the item is assembled at a higher level order the item from the higher level of maintenance C 3 XA XB XC XD TM 9 2815 250 24 amp P EXPLANATION OF COLUMNS SECTIONS II AND III continued NOTE Cannibalization or controlled exchange when authorized may be used as a source of supply for items with the preceding source codes except for those source coded XA DO NOT requisition an XA coded item Order its next higher assembly If an XB item is not available from salvage order it using the CAGEC and part number given
167. tie rette dietus 1 9 24 oa iced tiet 0 oreet M EE 0 2 24 ut ete etes 1 Ta 0 De e A eos 1 Dd ist betis 1 A N 0 A oes 0 2 29 A 1 9 2 ase NN 1 TIE TER savers 0 2 24 uet eir detis 1 39 28 Latine teta 1 Wi a 0 PLAS EEP E Ti 1 O 1 Vi cues cious maneesi tamista HUE 0 2 20 FREE RENNER 1 Sta dett 1 EE 0 LY TER E TES NES 1 BAB d etes tate et eettisin 1 vii viii blank 0 2 2 EEE eet o Leod 1 9 82 cd A t tette 1 uu 0 EVA RI O 1 A tate lek better 0 ML trees cases Es esta 0 Leda 1 A ett lettre 0 ERN 1 2 31 EEE RATTE RER 1 9 35 m Soccer d ILI 0 qos xtti dents 1 EVER EEE E et ot esee 1 SO iman atm sa sumeaan 0 do o er 0 A O 0 VAN 1 ne HE 0 EN RETTEN 0 SPS EEE REEL aos 1 dean hse Cur e o er 0 poc E ed 0 SSI uestes een HAIN 1 Ue ERE S 1 D p 0 340 ccs non erede tto edes 0 JE EP 0 ipud letit ammat e REST 0 RI aep 0 1 10 blank nen 0 Orcadas 0 SAD d 0 2e A toto 0 Cry P 0 RI oM 0 V RETE 0 Op PET TEN 0 SAA ee lt EEE RR FERRLEREEE 0 e E eet iat 0 RET 0 RI PT 0 p ETE 0 MIU IP 0 9 40 5 oe eddie edis 1 e ee 0 Sen T 1 RI rA 1 no than tras 0 g2 TS 1 3 48 blank added 1 PLT Pere Ester scc dris 1 3 13 sanken 1 3 48 1 added 1 Dd 1 CAE itecto ens 1 3 48 2 added 1 DO 0 A te T 1 3 48 3 added 1 DN nda 1 3 14 2 blank added 1 3 48 4 added 1 DAM 0 lt 1 3 49 cain eot eiit 1 DASEIN E 0 3 10 tee S 0 SEM EHE 1 2
168. to be repaired and identifies the lowest maintenance level with the capability to do complete repair i e perform all authorized Repair functions This position will contain one of the following maintenance codes TM 9 2815 250 24 amp P C 3 EXPLANATION OF COLUMNS SECTIONS II AND III continued Code O 3 Recoverability Code Application Explanation Unit maintenance or Aviation Unit is the lowest level that can do complete repair of the item Direct Support or Aviation Intermediate is the lowest level than can do complete repair of the item General Support is the lowest level that can do complete repair of the item SRA is the lowest level that can do complete repair of the Item Depot is the lowest level that can do complete repair of the item Nonrepairable No repair is authorized No repair is authorized No parts or special tools are authorized for the maintenance of a B coded item However the item may be reconditioned by adjusting lubricating and so on at the user level Recoverability codes are assigned to Items to indicate the disposition action on unserviceable items The recoverability code is entered in the fifth position of the SMR code as follows Code Z C NSN Column 3 Application Explanation Nonrepairable item When unserviceable condemn and dispose of the item at the level of maintenance shown In the third position of the SMR code Repairable item When uneconomicall
169. tuds 4 2 Remove filler neck 3 from crankcase 5 3 Remove O ring 6 from groove of filler neck 3 Discard O ring b INSTALLATION 1 Lightly coat new O ring 6 with grease Install Oring 6 in groove in filler neck 3 2 Apply sealing compound Item 13 Appendix D to four studs 4 3 Install filler neck 3 on crankcase 5 4 Install four washers 1 and nuts 2 on four studs 4 FOLLOW ON TASKS e Install airflow deflectors para 2 24 Install filler cap para 2 18 3 46 Change 1 TM 9 2815 250 24 amp P 3 13 OIL PAN AND GASKET REPLACEMENT UOC APP This Task Covers a Removal b Installation Initial Setup Tools Test Equipment General mechanic s tool kit automotive Equipment Conditions item 15 Appendix G Engine mounting plate removed para 3 4 Materials Parts e Crankcase gasket set item 1 Appendix F e Lockwasher 10 Item 24 Appendix FI a REMOVAL 1 Remove 10 screws 5 and lockwashers 6 and oil pan 4 from crankcase 1 Discard lockwashers 2 Remove strainer element 2 from crankcase 1 3 Remove gasket 3 from oil pan 4 Discard gasket b INSTALLATION 1 Install strainer element 2 in crankcase 1 2 Install new gasket 3 on oil pan 4 3 Install oil pan 4 on crankcase 1 and secure with 10 new lockwashers 6 and screws 5 FOLLOW ON TASKS Install engine mounting plate para 3 4 Change 1 3 47 3 48 bl
170. two new O rings 7 on governor control lever assembly pin 6 Position governor control lever assembly 3 in upper crankcase 15 TM 9 2815 250 24 amp P 3 11 CAMSHAFT REPAIR continued 13 Install pin 6 on governor control lever assembly 3 and upper crankcase 15 14 Install governor spring 1 on governor control lever assembly 3 and accelerator lever 8 Secure governor spring 1 with new clip 2 15 Place oil pump gear 10 and rotor 9 in upper crankcase 15 Make sure beveled edge of rotor 9 is facing toward inside of upper crankcase 15 16 Install new O ring 11 in oil pump cover 12 17 Install oil pump cover 12 on upper crankcase 15 and secure with three screws 14 and washers 13 Turn camshaft gear 4 to be sure camshaft assembly 5 turns freely TIMING MARKS FOLLOW ON TASKS Assemble crankcasd para 3 6 3 45 TM 9 2815 250 24 amp P W 3 12 FILLER NECK REPLACEMENT UOC APP This Task Covers a Removal b Installation Initial Setup Tools Test Eguipment Crankcase gasket set Item 1 General mechanic s tool kit automotive Eguipment Conditions item 15 Appendix G e Filler cap removed para 2 18 Materials Parts Airflow deflectors removed as needed to allow access to oil filler assembly para 2 24 Grease compound Item 5 Appendix D e Sealing compound Item 13 a REMOVAL 1 Remove four nuts 2 and washers 1 from four s
171. ty of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination e g by sight sound or feel Test To verify serviceability by measuring the mechanical pneumatic hydraulic or electrical characteristics of an item and comparing those characteristics with prescribed standards Service To keep an item in proper operating condition by periodically cleaning including decontaminating when required preserving draining painting or replenishing fuel lubricants chemical fluids or gases Adjust To maintain or regulate within prescribed limits by bringing into proper or exact position or by setting the operating characteristics to specified parameters Align To adjust specified variable elements of an item to bring about optimum or desired performance B 1 TM 9 2815 250 24 amp P MAINTENANCE FUNCTIONS continued Calibrate To determine the accuracy of and cause corrections or adjustments to be made on instruments or test measuring and diagnostic equipment TMDE used in precision measurement Calibration consists of comparisons of two instruments one of which is a certified standard of known accuracy to detect and adjust any discrepancy In the accuracy of the instrument being compared Remove Install To remove and Install the same item when required to perform service or other maintenance functions Install may be the act of emplacing seating or fixing
172. ve fuel injector to be tested para 3 14 C Remove two blank plugs 1 from test tube 2 d Install extension tube 4 of fuel test set on injection pump port 5 e Install test tube 2 on extension tube 4 f Install indicator dial 3 of fuel test set on test tube 2 3 66 Change 1 TM 9 2815 250 24 amp P 3 21 FUEL INJECTOR TEST continued Install fuel injector 6 on test tube 2 WARNING Fuel spray on hot components is an extreme fire hazard Control leakage im mediately to prevent serious injury to personnel Keep hands away from fuel injector after installing it on test tube Fuel spray can penetrate the skin causing blood poisoning Failure to follow this warn ing may result In serious injury or death Crank engine Check pressure reading at indicator dial 3 Correct pressure is 250 to 258 bar If pressure is not correct replace fuel injector para 3 14 Check spray pattern Fuel should spray evenly in a diffuse pattern rather than in a stream or dripping If spray pattern is not correct replace fuel injector 6 para 3 14 Remove fuel injector 6 from test tube 2 LLILLU LEE r 4 3 67 TM 9 2815 250 24 amp P 3 21 FUEL INJECTOR TEST continued n Remove indicator dial 3 from test tube 2 O Remove test tube 2 from extension tube 4 p Remove extension tube 4 from injection pump port 5 q Install blank two plugs 1 on test tub
173. vice point This helps prevent accidental movement of controls e Sharp edges can cut hands Use rags or a brush to lubricate parts Do not use equipment for other than its intended use unless authorized by the National Inventory Control Point commodity command e Remove rings bracelets wristwatches and neck chains before working on the engine Jewelry can catch on equipment and result in injury vi TM 9 2815 250 24 amp P GENERAL SAFETY PRECAUTIONS continued e Keep clear of equipment when it is being raised or lowered Equipment may fall and cause serious injury or death to personnel e Do not work on any item supported only by lift jacks or a hoist Always use blocks or trestles to support the item prior to any work Equipment may fall and cause injury or death to personnel e Do not allow heavy components to swing while hanging from a lifting device Equipment may strike personnel and cause injury or death e Exercise extreme caution when working near a cable or chain under tension A snapped cable or a swinging or shifting load may result in injury or death to personnel e When working on a running engine provide shielding for exposed rotating parts Tools clothing or hands can get caught and cause serious injury to personnel HAZARDOUS MATERIALS WARNINGS is e Adhesive causes immediate bonding on contact with eyes skin or clothing and also gives off harmful vapors Wear protective goggles and use in a wel
174. w deflector 21 11 Remove two screws 20 and airflow deflector 21 from engine 3 12 Remove air duct bracket 23 from engine 3 13 Remove four screws 30 washers 29 and nuts 27 and airflow deflector 31 from flywheel 28 Change 1 2 25 TM 9 2815 250 24 amp P 2 24 AIRFLOW DEFLECTORS REPLACEMENT UOC APP continued b 2 26 INSTALLATION NOTE Install screws loosely to allow some movement of air ducts brackets and air flow deflectors during installation procedure Install four screws 30 washers 29 and nuts 27 and airflow deflector 31 on flywheel 28 Install air duct bracket 23 on engine 3 Install airflow deflector 21 and two screws 20 on engine 3 Install two spacers 32 washers 18 and screws 19 and airflow deflector 22 on airflow deflector 21 Change 1 TM 9 2815 250 24 amp P 2 24 AIRFLOW DEFLECTORS REPLACEMENT UOC APP continued 5 Install two new spring tension washers 25 and screws 26 on air duct bracket 23 6 Install three screws 24 on air duct bracket 23 CAUTION Be careful not to damage fuel line when installing air duct bracket on engine 7 Install air duct bracket 12 on engine 3 and secure with two new spring tension washers 16 and screws 15 8 Position clip 1 and fuel hose 2 on air duct bracket 12 Install two new spring tension washers 13 and screws 14 on air duct bracket 12 9 Install thr
175. witch Replacement 000 a amia nri a aa nn 2 28 Oil Tube Assemblies Replacement 006 0 cece teen nee een eens 2 11 Rocker Arm Cover and O Ring Replacement 000 cece eee es n 2 9 Solenoid Replacement and Adjustment UOC APP 0000 c cece teens 2 30 Thermostatic Switch Replacement sssssussssssssssels hen 2 29 Valve Vent RODAM aii oe pe Med bi tad epee senate A aS ene ee 2 18 Major Components Location and Description of 00 0 0 c cece eet tenes 1 5 Mandatory Replacement Parts List 0 eect enn mh F 2 Manual HowTo US ri iei adsl a grece daw Fe SR gee aah Make d Sc PRECOR RUE iv Manuals 2 2 MATE A 1 Materiel Destr ction Of i uot even ere a gae Eau E aid E Are ER d dan a Tae UR AER TC 1 1 Mounting Plates Replacement o oooocccocccoonccr ee hh hh nhe 3 12 N Notes Warnings and Cautions ooe V O Oil Pan and Gasket Replacement UOC APP 00 00 cece nett hn 3 47 Oil Pressure Test saa t abensis Roe a HE RP ehe n 3 70 Oil Switch Replacement iai ene rbd gt eine ee nite viem V h t k d RR B REP ds gs 2 28 Oil Tube Assemblies Replacement oooccccccccc hens 2 11 Operation Principles Of Sanan adanan A Neary d a era rer d p rv der earl ate eared 1 9 Change 1 Index 3 TM 9 2815 250 24 amp P SUBJECT PAGE P Pamphlets and Circulars T npero kesari a ENEE ehh hh hn A 2 Piston and Combustion Chamber Liner Repair soo een 3 32 Principle
176. y means of its engineering drawings specifications standards and inspection requirements to identify an item or range of items DESCRIPTION AND USABLE ON CODE UOC Column 6 This column includes the following information 1 The Federal item name and when required a minimum description to identify the item 2 Physical security classification Not applicable 3 Items that are included in kits and sets are listed below the name of the kit or set on Figure KIT 3 Spare repair parts that make up an assembled item are listed immediately following the assembled item line entry 4 Part numbers for bulk materials are referenced in this column in the line item entry for the item to be manufactured fabricated 5 When the item is not used with all serial numbers of the same model the effective serial numbers are shown on the last line s of the description before the UOC 7 The UOC when applicable see para C 5 Special Information 8 In the Special Tools List section the Basis of Issue BOI appears as the last line s in the entry for each special tool special TMDE and other special support equipment when density of equipments supported exceeds density spread indicated in the BOI the total authorization is increased proportionately 6 The statement END OF FIGURE appears just below the last item description in Column 5 for a given figure in both Section II and Section III QTY Column 7 The QTY quantity per
177. y repairable condemn and dispose of the item at Unit maintenance or Aviation Unit level Repairable item When uneconomically repairable condemn and dispose of the item at the Direct Support or Aviation Intermediate level Repairable item When uneconomically repairable condemn and dispose of the item at the General Support level Repairable Item When beyond lower level repair capability return to Depot Condemnation and disposal of the item is not authorized below Depot level Repairable item Condemnation and disposal of the Item is not authorized below SRA Item requires special handling or condemnation procedures for specific reasons e g precious metal content high dollar value critical material or hazardous material Refer to appropriate manuals directives for specific instructions The NSNs for the Items are listed in this column TM 9 2815 250 24 amp P C 3 EXPLANATION OF COLUMNS d CAGEC Column 4 The commercial and government entity code CAGEC is a five digit alphanumeric code used to identify the manufacturer distributor or Government agency etc that supplies the item NOTE When you use an NSN to requisition an item the item you receive may have a part number different from the part ordered e PART NUMBER COLUMN 5 Indicates the primary number used by the manufacturer individual company firm corporation of Government activity which controls the design and characteristics of the item b
178. ylinder no 2 are in rocking position then turn flywheel 180 degrees further 3 58 TM 9 2815 250 24 amp P 3 18 VALVE ADJUSTMENT continued b Using feeler gage measure the clearance between rocker arm 4 and valve stem 5 on intake valve 3 and exhaust valve 6 of cylinder no 1 Clearance should be 0 004 inch 0 102 mm C To adjust clearance loosen nut 7 and turn adjusting screw 2 so that after tightening nut 7 clearance is correct d Rotate flywheel 1 clockwise 180 degrees Intake valve 3 and exhaust valve 6 of cylinder no 2 will be fully closed Repeat steps b and c for both valves 3 and 6 in cylinder no 2 FOLLOW ON TASKS Install rocker arm cover para 2 17 3 59 TM 9 2815 250 24 amp P This Task Covers Adjustment 3 19 FLOW CONTROL VALVE ADJUSTMENT 3 60 Initial Setup Tools Test Equipment Fuel test set Item 12 Appendix G Fuel testing device Item 13 Appendix G Indicator dial Item 16 Wrench Item 36 Appendix G Materials Parts e Rubber band Item 8 Crankcase gasket set Item 1 Appendix F ADJUSTMENT General mechanic s tool kit Item 14 NOTE Gasket 2 Item 16 Appendix F O ring 2 Item 17 Appendix F Equipment Conditions Airflow deflectors removed as needed UOC APP para 2 24 Airflow deflectors removed as needed UOC APJ TM 9 2350 292 20 2 Fuel pressure pipes removed para 2 23 Vehicle fuel sup

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