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army tm 9-2815-538-24&p air force to 38g1-129

1. nS RR ASEE RR REA FUEL INJECTION PUMP ASSEMBLY FUEL FILTER AND FUEL HOSES tina nica dria et ta ri da D eL D RI EC REDE X RE S RE DEA ARE OIL COOLER ASSEMBLY AND OIL PRESSURE 24 0 STARTER MOTOR FUEL INJECTION LINES AND RETURN HOSE VALVE COVER ASSEMBLY coitu cii d ionis cine RO d o FE E CX e E KO E EE AR ADR RN EX E FUEL INJECTORS ciii Ora scd as ex aud Xo ca dida iia COMPRESSION TEST CYLINDER HEAD ASSEMBLY siciliana ECRANS BEY RARE LASH VALVE ADJUSTMENT n o cx te ie FLYWHEEL ASSEMBLY AND FLYWHEEL 244 0 08 PREPARATION FOR STORAGE OR TORQUE LIMITS VR REO LEGE KR o DOLEO A ER KR AR XA E AEN ER ER EA AK WP Sequence No um 0006 00 ET 0032 00 TM 9 2815 538 24 amp P 0006 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 SERVICE UPON RECEIPT INITIAL SETUP Tools and Special Tools References Tool kit general
2. 0001 00 2 General Maintenance Cleaning Instructions 0009 00 2 Castings Forgings and Machined Metal 0009 00 2 Electrical Cable and Rubber 0009 00 2 Inspeetion Instructions oli tetro heat 0009 00 2 Castings Forgings and Machined Metal 0009 00 3 Drilled and Tapped Threaded Holes 0009 00 3 ett Ui te rte a Rm hr eb a Mie vate 0009 00 3 Castings Forgings and Machined Metal 0009 00 3 Em 0009 00 1 Tagging Instr ctioris s t tbe etn ete UE bg UA EE EIER nes 0009 00 3 Work Safety pt bai ra edet oe 0009 00 1 LJ K L Idle Gear Assembly ISPS CHO LE 0015 00 3 Idle Gear Shaft and Bushing Figure 2 0015 00 3 Installation vies a dd 0015 00 4 Idle Gear Assembly Figure 1 0015 00 2 Removal e nte m eter e a a e ede erat ah 0015 00 2 Idle Gear Assembly Figure 1 enne 0015 00 2 TAN 0015 00 3 Repair Parts Wii lid dt ernten 0042 00 1 Intake Manifold Air Inlet Hose and Air Heaters
3. 0054 00 1 Part Number Indexes e eati ecce ee ten fan 0063 00 1 Rocker Arm Shaft 0039 00 1 Special Tools List 45s tal etr eie cede eite 0060 00 1 Starter Motor 2 4 1 4 24 1 0058 00 1 Turbocharger sse 0057 00 1 Valve Cover Assembly 0041 00 1 S Service Upon anne ana un e ERR nn 0006 00 1 Starter Motor Assembly Descriptions omne M m 0002 00 1 0019 00 2 atts de eee aue en deret 0019 00 2 Starter Motor Assembly Figure 1 0019 00 2 eren PM 0002 00 1 c sette nA deter de t e MUS 0019 00 2 Starter Motor Assembly Figure 1 0019 00 2 0019 00 2 0058 00 1 7 TM 9 2815 538 24 amp P INDEX Continued Subject WP Sequence No Page No T U Theory of Operation Air Inlet and Exhaust 0003 00 5 Engine Cooling System 2 1 0 0 10011 indiana 0003 00 3 Engine engeren aA 0003 00 1 Engine Starting and Battery Charging Components 0003 00 1 Fuel System nu den v LR el e ende ne 0003 00 2 A OOO 0003 00 1 LUDFICAT
4. 22230 END OF FIGURE 0041 2 TM 9 2815 538 24 amp P 0042 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 CONNECTING ROD AND PISTON ASSEMBLY REPAIR PARTS LIST 15KW 2815 24P 13 Figure 6 Connecting Rod and Piston Assembly 0042 1 TM 9 2815 538 24 amp P 0042 00 1 2 3 4 5 6 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN _ NUMBER CODE UOC GROUP 0104 CONNECTING ROD AND PISTON ASSEMBLY 6 ROD AND PISTON ASSEMBLY PAHZZ 5340 01 546 6859 0AK42 22252 000260 CLIP RETAINING PBHHH 2815 01 538 0978 0AK42 129508 22080 PISTON ASSEMBLY PAHZZ 2815 01 546 4717 0AK42 129004 22500 PAHZZ 2815 01 546 8047 0AK42 129004 22950 PAHZZ 2815 01 546 4721 0AK42 129202 22300 PIN PISTON PBHHH 2815 01 538 0835 0AK42 729402 23100 ROD ASSEMBLY CONNECTING PAHZZ 5365 01 546 8936 0AK42 129100 23910 BUSH PISTON PIN PAHZZ 3120 01 455 5082 0AK42 129150 23600 BEARING SLEEVE HALF PAHZZ 3120 01 546 9268 0AK42 129150 23610 BEARING SLEEVE PAHZZ 5306 01 546 4275 OAK42 121550 23200 BOLT MACHINE 1 2 3 3 4 5 6 7 7 8 END OF FIGURE 0042 2 TM 9 2815 538 24 amp P 0043 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 CAMSHAFT DRIVING GEAR AND IDLE GEAR ASSEMBLIES REPAIR PARTS LIST 15KW 2815 24P 16 Figure 7 Camshaft Driving Gear and Idle Gear Ass
5. irre ict ma ttes 0002 00 2 petto toute e ee reati demde 0021 00 2 Valve Cover Assembly Figure 1 eee 0021 00 2 MEC 0021 00 3 Repair Parts List Fuel Injection Line 0050 00 1 Valve Cover 0041 00 1 Valve Lash RE e ERR TR n nn 0025 00 2 Lock Nut Tightening Figure 4 0025 00 3 No 1 Cylinder at TDC Figure 1 0025 00 2 Valve Bridge Clearance Figure 2 0025 00 2 Clearance Gap Figure 3 sse nennen 0025 00 3 W X Y 2 Water Pump Assembly Description reer a ere eden ii 0002 00 2 IniSDecHone nenne dee 0012 00 3 Installation 0012 00 4 Water Pump Assembly Figure 1 seme 0012 00 3 LOCO EET 0002 00 2 Removal ii 0012 00 2 Water Pump Assembly Figure 1 seme 0012 00 3 o a fue ene a 0012 00 3 Repair iere ae 0047 00 1 Index 9 10 blank RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part reverse for Repair Parts and DATE BLANK FORMS Special Tool Lists RPSTL and Supply For use of this form see AR 25 30 the proponent agency is OAASA Catalogs Supply Manuals SC SM 30 August 2002 TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location In
6. 0008 00 3 PMCS Including Lubrication 0008 00 1 Air Intake Diaphragm 1 500 0008 00 2 Battery Charging Alternator 24 Vdc 300 0008 00 2 300 HOUES aient dt 0008 00 1 Engine 1 200 HOUTE Jarris riaa AoE aR AAAS AAEE RTE AS RAT 0008 00 2 Engine Oil and Filter First 50 0008 00 1 Engine Oil and Filter 300 Hours sse 0008 00 1 Fan V Belts First 50 0008 00 1 Fan V Belts 300 0008 00 2 Fan V Belts 1 500 0008 00 2 Fuel Filter 300 0008 00 2 Fuel Injection Nozzles 1 500 0008 00 2 Fuel Injectors 3 000 0008 00 2 Fuel System 300 Hours caia 0008 00 2 Starter Cables 300 0008 00 1 Vake Lasn 1 500 EloUrs nie ee nn 0008 00 2 Preparation for Storage or 0031 00 1 R aaa 0033 00 1 Rocker Arm Shaft Assembly Repair Parts 0039 00 1 Index 6 TM 9 2815 538 24 amp P INDEX Continued Subject WP Sequence No Page No R Continued Repair Parts and Special Tools List Bulk Material List n
7. 2 590 sacred a NI Square Hectometers 0 405 Cubic Feet Cubic Meters 0 028 Cubic Yards Cubic Meters 0 765 Fluid Ounces Milliliters 29 573 AN AA Liers dos 0 473 ue a 0 946 Gallons Liters tia 3 785 OUNCES A t ek bu Sie oe hn 28 349 Pounds c sess Kilograms 0 454 Short Tons Metric Tons 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 MULTIPLY BY Centimeters A a 0 394 Meters A 3 280 Meters i s orte ms Yards scree 1 094 Kilometers Miles Conte dea 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 POSE OPERA ue E 2 741 Cubic Meters 5 Cubic Feet 35 315 Cubic Meters Cubic Yards 1 308 Milliliters Fluid Ounces 0 034 Eiter Aet ee ee Pints uu Dante 2 113 a Soe US ee ee te
8. 0002 00 1 Fuel Injection Pump 0002 00 1 Gear Case Assembly tee ie e die RE D pis 0002 00 2 Battery Charging Alternator 24 0002 00 1 E el Or E on 0002 00 1 0002 00 2 oM 0002 00 1 Sensor Switch s tta tige eite his ie 0002 00 2 Starter Motor Assembly acer het 0002 00 1 Turbocharger Assembly t bao ctt ee t t e abes 0002 00 1 Water Pump 0002 00 2 Expendable and Durable Items 0064 00 1 F Fan V Pulley and V Belt 0011 00 2 Installation hr e eater eae d eed 0011 00 3 Fan V Pulley and V Belt Figure 1 0011 00 2 REMOVAL M 0011 00 2 Fan V Pulley and V Belt Figure 1 0011 00 2 Repair tar a aa dare ea cet d et det eate a sedata 0011 00 2 Repair Parts rn 0048 00 1 Flywheel Assembly and Flywheel Housing mE 0002 00 1 InSpectione nr 0030 00 3 Flywheel Assembly and Flywheel Housing Figure 1 0030 00 2 Installation 0030 00 3 Flywheel Assembly and Flywheel Housing Figure 1 0030
9. 1 ez de 0047 0 Fan Assembly Repair Parts 1 11 a nnne da annes dantes snas nan 0048 0 Fuel System Repair Parts List een eine et tete aee id 0049 0 Fuel Injection Valve System Repair Parts 16 0050 0 Fuel Injection Assembly Repair Parts 14 sse enne 0051 0 Oil Filter and Oil Cooler Repair Parts nnnm nnne 0052 0 Oil Bypass Valve Repair Parts Oil Pump Assembly Repair Parts Crankcase Assembly Repair Parts Intake Manifold Repair Parts Turbocharger Assembly Repair Parts 1 Starter Motor Assembly Repair Parts Generator Repair Parts Special Tools list EET Bulk Material uc EE esp TE Expendable and Durable Items TM 9 2815 538 24 amp P HOW TO USE THIS MANUAL This manual contains maintenance instructions for the Diesel
10. 15KW 2815 24P 08 1 Figure 13 Fuel System 1 2 3 4 6 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC__ NUMBER CODE UOC GROUP 03 FUEL SYSTEM FIG 13JFUEL SYSTEM PAOZZ 2910 01 546 4727 0AK42 119802 55800 FILTER FUEL XBOZZ 0AK42 129004 55610 BRACKET FUEL FILTER PAFZZ 5306 01 546 8037 0AK42 26106 080302 BOLT MACHINE AOOOO 0AK42 129210 59160 HOSE ASSEMBLY NONMETALLIC PAOZZ 4720 01 546 8050 0AK42 129612 59520 HOSE NONMETALLIC PAOZZ 4730 01 546 8975 0AK42 124766 59050 CLAMP HOSE AOOOO 0AK42 129210 59110 HOSE ASSEMBLY NONMETALLIC PAOZZ 4730 01 546 8975 0AK42 124766 59050 CLAMP HOSE PAOZZ 4720 01 546 6890 0AK42 105025 59560 HOSE NONMETALLIC 4 2 3 4 5 6 7 8 9 END OF FIGURE 0049 1 2 blank 0050 00 TM 9 2815 538 24 amp P FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FUEL INJECTION VALVE SYSTEM REPAIR PARTS LIST 15KW 2815 24P 08 2B Figure 14 Fuel Injection Valve System 0050 1 Y S V Ya S7 ER t7 gt BUT RY SS TM 9 2815 538 24 amp P 0050 00 1 2 3 4 5 6 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN _ NUMBER CODE UOC GROUP 03 FUEL SYSTEM FIG 14 FUEL INJECTION VALVE SYSTEM PAFZZ 2915 01 546 8222 0AK42 729508 53100 INJECTOR FUEL PAFZZ 5306 01 546 3527 0AK42 123907 59540 BOLT MACHINE PAFZZ 4710 01 546
11. 1 2 3 4 5 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC X NUMBER CODE UOC GROUP 0107 FLYWHEEL HOUSING ASSEMBLY FIG 8 FLYWHEEL ASSEMBLY PAFZZ 5306 01 546 9973 0AK42 121111 21501 BOLT MACHINE XBFZZ 0AK42 129649 21590 FLYWHEEL PAFZZ 5306 99 450 7012 0AK42 26206 100252 BOLT MACHINE PAFZZ 5315 01 546 9902 0AK42 129100 01580 PIN PARALLEL XBFZZ 0AK42 119620 01750 CAP FLYWHEEL COVER XBFZZ 0AK42 171420 01600 HOUSING FLYWHEEL PAFZZ 5306 01 431 7460 0AK42 26206 100302 BOLT MACHINE END OF FIGURE 0044 1 2 blank TM 9 2815 538 24 amp P 0045 00 1 ITEM NO 4 2 3 4 5 6 7 8 2 SMR CODE PBHHH PAHZZ PAHZZ PAHZZ PAHZZ PAHZZ PAHZZ PAHZZ 3 NSN 2815 01 537 9999 5315 01 546 9902 5315 01 465 9931 3020 01 547 4629 5315 01 546 8877 3020 01 547 4625 5310 01 546 9888 5306 01 546 9891 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 CRANKSHAFT ASSEMBLY REPAIR PARTS LIST 15KW 2815 24P 12 Figure 9 Crankshaft Assembly 4 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 5 6 PART DESCRIPTION AND USABLE ON NUMBER CODE UOC GROUP 0108 CRANKSHAFT ASSEMBLY FIG 9 CRANKSHAFT ASSEMBLY 129508 21002 CRANKSHAFT ASSEMBLY 129100 01580 PIN PARALLEL 22512 070140 KEY MACHINE 119802 21202 GEAR CRANKSHAFT 22351 030010 PIN SPRING 119802 21660 PULLEY CRANKSHAFT 129795 21661 WASHER FLAT 121850 21680 BOLT MACHI
12. 3rd position who can install replace or use the item Recoverability Code X 4th position 5th position Who can do Who complete determines repair on disposition the item action on unserviceable items Complete Repair Maintenance capacity capability and authority to perform all corrective maintenance tasks of the iRepairf function in use user environment in order to restore serviceability to a failed item Source Code The source code tells you how you get an item needed for maintenance repair or overhaul of an end item equipment Explanations of source codes follows Source Code MO Made at unit AVUM level MF Made at DS AVIM level MH Made at GS level ML Made at SRA MD Made at depot 0036 2 Application Explanation Stock items use the applicable NSN to requisition request items with these source codes They are authorized to the level indicated by the code entered in the 3rd position of the SMR code NOTE Items coded PC are subject to deterioration Items with these codes are not to be requested requisitioned individually They are part of a kit which is authorized to the maintenance level indicated in the 3rd 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 which is identified by the P N in the DESCRIPTION AND USABLE ON CODE UOC column and liste
13. Fan V belts 1 Check fan V belts for wear or Fan V belts worn cracks 0011 00 or cracked Check fan V belt tension and Fan V belts out of adjust tension required adjustment WP 0010 00 1 200 hours i Engine Clean engine exterior paying atten Engine exterior tion to areas that reveal leakage or dirty so leaks or 0009 00 damage cannot be detected 11 1 500 hours 1 0 Fuel injection Check fuel injection nozzle Nozzle pressure nozzles pressure and replace as required out of tolerance WP 0022 00 12 1 500 hours 0 2 Air intake Inspect air intake diaphragm and Air intake diaph diaphragm replace if damaged WP 0021 00 ragm damaged 13 1 500 hours 0 8 Fan V belts Replace fan V belts WP 0011 00 Fan V belts not replaced as required 14 1 500 hours 3 0 Valve lash Check adjust engine valve lash Valve lash out of WP 0025 00 adjustment 15 3 000 hours 4 0 Fuel injectors Replace fuel injectors Fuel injectors not WP 0022 00 replaced as required 0008 2 TM 9 2815 538 24 amp P 0008 00 PMCS Continued MANDATORY REPLACEMENT PARTS There are no mandatory replacement parts required for these PMCS procedures LUBRICATION INSTRUCTIONS External lubrication is not required Internal lubrication is handled by the end item configuration END OF WORK PACKAGE 0008 3 4 blank TM 9 2815 538 24 amp P 0009 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 GENERAL
14. mb td eed 0029 00 2 Crankcase Assembly and Dipstick Figure 1 0029 00 3 enmt E Ne 0029 00 4 Repair Parts List Grankcase Het 0055 00 1 L bricating NozZle nia ld teh aa eb 0052 00 1 Cylinder Head Assembly INSPECHON tete e pti la rice 0024 00 3 Installation Auen sinne cpa Gee e eU LU de Ur 0024 00 4 Cylinder Head Assembly Figure 1 esee 0024 00 2 Removal ada oo 0024 00 2 Cylinder Head Assembly Figure 1 sme 0024 00 2 Cylinder Head Bolts Figure 2 essem eem 0024 00 3 utem ates ltda dida 0024 00 3 Repair Parts List Cylinder Head 2 41 72 21 1 42 1 14 44411 0040 00 1 Index 1 TM 9 2815 538 24 amp P INDEX Continued Subject WP Sequence No Page No E Equipment Description and Data Equipment Characteristics Capabilities and Features 0002 00 1 Equipment ken dee eA TR a da o ren 0002 00 5 Engine Diesel Equipment Data Table 1 0002 00 5 Location and Description of Major Components 0002 00 1 Engine Diesel Figure 1 n ai a 0002 00 2 ElywheelAssoemibly teni 0002 00 1 Fuel Filter 2
15. 0053 1 1 ITEM NO 4 2 3 4 5 6 7 8 9 2 SMR CODE PAFZZ PAFZZ XBFZZ PAHZZ PAHZZ PAHZZ XBFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ PAFZZ 3 NSN 5305 01 388 6229 5331 01 546 8932 4810 01 546 8874 2835 01 546 7876 5315 01 546 8877 5310 01 546 8875 5306 01 546 9263 5310 01 546 8875 5310 01 388 8826 4710 01 546 9222 5306 01 546 9886 5310 01 546 9316 5305 14 469 7436 5330 01 546 8869 5306 01 529 1138 4 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 TM 9 2815 538 24 amp P 5 PART NUMBER 26106 060162 24314 000160 129508 39600 129792 39410 129553 39650 22351 030010 129005 59830 22190 080002 23857 030000 22190 080002 26366 060002 129508 39450 124160 39140 22190 100002 26106 080122 23414 100000 121252 39150 0053 2 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 04 LUBRICATION SYSTEM FIG 17 OIL BYPASS VALVE SCREW CAP HEXAGON HEAD TUBE OIL RETURN VALVE ASSEMBLY CHECK NOZZLE LUBRICATING PIN SPRING BOLT ASSEMBLY JOINT SEAL WASHER BOLT MACHINE SEAL WASHER NUT PLAIN HEXAGON HEAD PIPE ASSEMBLY OIL BOLT MACHINE SEAL WASHER BOLT MACHINE BOLT MACHINE END OF FIGURE 0053 00 aSNaNaaaaaanhhdhoapn TM 9 2815 538 24 amp P 0054 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 OIL PUM
16. 6 Install cooler out pipe figure 1 item 3 onto oil cooler assembly 5 and water pump assembly figure 1 item 4 with two spring clamps figure 1 item 2 7 Install oil filter figure 1 item 1 END OF WORK PACKAGE 0018 4 TM 9 2815 538 24 amp P 0019 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 STARTER MOTOR ASSEMBLY REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Personnel Required Tool kit general mechanic s One item 5 WP 0035 00 Materials Parts Marker tags item 7j WP 0064 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0019 1 TM 9 2815 538 24 amp P 0019 00 REMOVAL 1 Slide terminal covers figure 1 i
17. WP 0028 00 MALFUNCTION Poor spray pattern from fuel injection nozzle CORRECTIVE ACTION Check fuel injectors adjust as required WP 0022 00 MALFUNCTION Uneven volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injection pump assembly and fuel injectors repair replace as required WP 0022 00 MALFUNCTION Too late timing of fuel injection pump assembly CORRECTIVE ACTION Check fuel injection pump assembly adjust timing WP 0016 00 0005 11 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Excessive white smoke while under load Continued MALFUNCTION Excessive cooling effect of radiator CORRECTIVE ACTION Check thermostat replace as required WP 0013 00 MALFUNCTION Clogged or deformed oil return line to turbocharger CORRECTIVE ACTION Repair replace oil line WP 0027 00 SYMPTOM Excessive black smoke while under load MALFUNCTION Clogged air filter CORRECTIVE ACTION Clean replace air filter end item configuration manual MALFUNCTION Fouled turbocharger assembly CORRECTIVE ACTION Inspect turbocharger assembly clean as required WP 0028 00 MALFUNCTION Incorrect fuel grade type for ambient temperature range CORRECTIVE ACTION Drain fuel system fill with correct fuel end item configuration manual MALFUNCTION Clogged exhaust pipe CORRECTIVE ACTION Clean exhaust pipe end item configuration manual MALFUNCTION Engine u
18. ee 24 Excessive blow by JAS A aaa inne 25 Engine OVerheals trier ad cada 26 Low coolant lemiperalure u a 27 Air intake press re drops rete te debe rhet RO AN TVA REDE Ta pi a a Te dead 2B AUF intake press te SES dd diria pe Uma 29 Exhaust temperature ise ds 0004 1 2 blank TM 9 2815 538 24 amp P 0005 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 TROUBLESHOOTING PROCEDURES INITIAL SETUP Tools and Special Tools References Tool kit general mechanic s item 5 WP 0035 00 Shop equipment automotive common no 1 item 2 WP 0035 00 Shop 2 2507 0055 00 automotive supplemental WP 0013 00 0017 00 ang WP 0020 00 set no 2 item 1 WP 0035 00 and WP 0025 00 WP 0028 00 Personnel Required End item configuration manual One INTRODUCTION This work package contains troubleshooting information with a list of symptoms malfunctions tests inspections and corrective actions required to return the diesel engine to normal operation The tests inspections and corrective actions should be performed in the order listed If the first corrective action step is normal proceed to the next step The corrective actions will refer to a work package in this manual or the end item configuration manual Troubleshooting procedures in this manual cannot list all possible malfunctions or tests inspections required for corrective action If a symptom
19. setters O 0026 00 4 Installation ren 0026 00 4 Intake Manifold Air Inlet Hose and Air Heaters Figure 1 0026 00 3 Removal eama he 0026 00 2 Intake Manifold Air Inlet Hose and Air Heaters Figure 1 0026 00 3 o M E T 0026 00 4 Parts 0056 00 1 iTestlrig zt o Dear e aet oe tae E 0026 00 4 m ETE E Oan s eI I 0026 00 4 M N Maintenance Allocation 0035 00 1 Malfunction Symptom Index 0004 00 1 Index 5 TM 9 2815 538 24 amp P INDEX Continued Subject WP Sequence No Page No Oil Cooler Assembly Pressure Switch Description oim 0002 00 1 INSPECTION EE 0018 00 4 He chen i d dk 0018 00 4 Oil Cooler Assembly and Oil Pressure Switch Figure 1 0018 00 3 Location ellc 0002 00 1 EET 0018 00 2 Oil Cooler Assembly and Oil Pressure Switch Figure 1 0018 00 3 ceteris nocte food reta iste d 0018 00 4 Repair 8 2 02 iita leti bo elec alten 0052 00 1 Oil Pump Assembly Repair Parts 0054 00 1 P Q PMCS Introduction o ETE 0007 00 1 Lubrication 0008 00 3 Mandatory Replacement
20. 0016 12 TM 9 2815 538 24 amp P 0017 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FUEL FILTER AND FUEL HOSES REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Personnel Required Tool kit general mechanic s One item 5 WP 0035 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0017 1 TM 9 2815 538 24 amp P 0017 00 REMOVAL 1 Remove fuel filter figure 1 item 1 2 Squeeze two spring clamps figure 1 item 2 and slide clamps up onto fuel hose figure 1 item 3 3 Remove fuel hose figure 1 item 3 from filter bracket figure 1 item 4 and fuel injection pump assembly figure 1 item 5 4 Squeeze two spring clamps figure
21. 129210 59160 129240 01500 129350 49530 129400 01730 129403 13120 TM 9 2815 538 24 amp P STOCK NUMBER 5340 01 323 7844 4730 01 546 8975 3120 01 547 0495 5306 01 547 0001 2815 01 546 4717 2815 01 546 8047 4720 01 546 8893 4720 01 546 8124 4730 01 546 4701 5315 01 546 9902 5365 01 546 8936 5330 01 547 0629 2990 01 546 4578 5330 01 477 4043 4730 01 546 8861 2930 01 546 7913 5330 01 454 4384 5306 01 547 0465 5306 01 546 4269 2815 01 546 4309 3120 01 546 8480 3120 01 454 6117 3120 01 546 8931 5315 01 546 8568 5310 01 546 8916 3020 01 455 4443 2815 01 546 7688 2920 01 546 4582 3120 01 455 5082 3120 01 546 9268 5306 01 546 4266 5330 01 546 6844 5330 01 546 7545 2940 01 546 5058 5330 01 547 0461 5330 01 419 5480 6685 01 546 3005 2815 01 546 4721 0063 2 ITEM o aa O ORAN ANAR ORO 0063 00 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 PART NUMBER 129417 33110 129417 35150 129418 18320 129418 32320 129470 77340 129486 01670 129486 42021
22. 129486 42140 129489 01770 129508 01330 129508 03010 129508 11100 129508 11110 129508 11130 129508 11180 129508 11241 129508 11250 129508 11260 129508 11270 129508 11280 129508 11310 129508 11350 129508 11650 129508 11660 129508 11700 129508 11800 129508 11820 129508 11840 129508 11900 129508 11920 129508 12110 129508 12120 129508 14580 129508 18010 129508 18080 129508 18090 129508 21002 129508 22080 129508 32111 129508 32120 129508 33010 129508 39450 129508 39600 129508 42000 129508 49030 129508 49040 129508 51250 129508 59510 129508 59550 129508 59570 129508 59910 129508 59920 129508 59930 129508 59940 129550 13110 129550 59120 129553 39650 129612 59520 129612 77011 129646 77330 129649 21590 129693 44310 129792 39410 129795 01800 129795 01950 129795 02411 TM 9 2815 538 24 amp P STOCK NUMBER 5310 01 546 8881 5307 01 547 0405 5307 01 546 8878 5306 01 546 8899 5330 01 546 8895 5331 01 547 0466 2815 01 546 8227 5330 01 546 7537 2815 01 546 9997 4820 01 546 3548 5360 01 547 0442 2815 01 546 4567 5310 01 546 8918 5330 01 546 8924 5315 01 546 4572 4820 01 546 4246 5330 01 546 4259 2815 01 538 0974 2950 01 537 9970 5330 01 546 6855 5330 01 546 8879 2815 01 537 9999 2815 01 538 0978 3020 01 546 8538 3020 01 547 4658 2930 01 546 8053 4710 01 546 9222 4720 01 546 8857 4720 01 546 8868 4720 01 546 7874 4710 01 546 8886 4710 01 546 4250 4710 01 546 9905 4710 01 546 3530
23. Army Logistics Readiness and Sustainability 2 Air Force Maintenance forms and records used by Air Force personnel are prescribed in AFI 21 101 and the applicableTO 00 20 Series Technical Orders REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIR 1 Army If your equipment needs improvement let us know Send us an EIR You the user are the only one who can tell us what you don t like about your equipment Let us know why you don t like the design or performance If you have Internet access the easiest and fastest way to report problems or suggestions is to goto https aeps ria army mil aepsublic cfm scroll down and choose the Submit Quality Deficiency Report bar The Internet form lets you choose to submit an Equipment Improvement Recommendation EIR a Product Quality Deficiency Report PQDR or a Warranty Claim Action WCA You may also submit your information using an SF 368 Product Quality Deficiency Report You can send your SF 368 via e mail regular mail or facsimile using the addresses facsimile numbers specified in DA PAM 750 8 The Army Maintenance Management System TAMMS Users Manual We will send you a reply 2 Air Force Air Force personnel are encouraged to submit EIR s in accordance withAFR 900 4 CORROSION PREVENTION AND CONTROL CPC Corrosion Prevention and Control CPC of Army materiel is a continuing concern It is important that any corrosion problems with this item be reported so that the problem
24. Defective governor CORRECTIVE ACTION Adjust replace governor as required end item configuration manual MALFUNCTION Poor spray pattern from fuel injection nozzle CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 0005 17 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Excessive engine vibration Continued MALFUNCTION Uneven volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injection pump assembly and fuel injectors replace as required WP 0016 00 WP 0022 00 SYMPTOM Excessive turbocharger assembly vibration or noise MALFUNCTION Clogged nozzle in turbine wheel chamber CORRECTIVE ACTION Inspect turbocharger assembly clean as required WP 0028 00 MALFUNCTION Damaged turbocharger assembly bearing chipped turbine wheel or blower vane contact between rotating and nonrotating parts or foreign material in turbine CORRECTIVE ACTION Inspect turbocharger assembly replace as WP 0028 00 MALFUNCTION Loosened intake exhaust or oil pipe connection with turbocharger assembly CORRECTIVE ACTION Tighten replace loose parts WP 0028 00 SYMPTOM Slow turbocharger assembly response MALFUNCTION Hard carbon deposit on turbine side CORRECTIVE ACTION Inspect turbocharger assembly clean as required WP 0028 00 SYMPTOM Difficulty with engine when returning from high speed to low speed MALFUNCTION
25. MALFUNCTION Leakage from oil lines CORRECTIVE ACTION Inspect oil lines repair as required WP 0018 00 and WP 0028 00 MALFUNCTION Worn intake exhaust valve guides CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual MALFUNCTION Excessive volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 SYMPTOM Fuel in engine oil MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual SYMPTOM Oil mixed with coolant MALFUNCTION Leaking cylinder head assembly gasket CORRECTIVE ACTION 1 Replace cylinder head assembly gasket WP 0024 00 2 Flush cooling system fill as required end item configuration manual 3 Flush lubricating system fill as required end item configuration manual 4 Operate engine and check for coolant in oil or oil in coolant end item configuration manual 0005 20 TM 9 2815 538 24 amp P TROUBLESHOOTING Continued SYMPTOM Continued Oil mixed with coolant Continued MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual SYMPTOM Low oil pressure MALFUNCTION Insufficient oil level CORRECTIVE ACTION Add oil to proper level end item configuration manual MALFUNCTION Incorrect oil grade type fo
26. No 1 Cylinder at TDC 3 Loosen lock nut figure 2 and push down and hold selected rocker arm figure 2 and adjust clearance to zero figure 2 Tighten lock nut using adjustable wrench to hold valve bridge ROCKER ARM PUSH DOWN ADJUSTING SCREW LOCK NUT ADJUSTING CLEARANCE TO ZERO VAVLE BRIDGE 15KW 2815 24M 323A Figure 2 Valve Bridge Clearance 0025 2 TM 9 2815 538 24 amp P 0026 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 INTAKE MANIFOLD AIR INLET HOSE AND AIR HEATERS REMOVAL INSPECTION TESTING REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Personnel Required Tool kit general mechanic s One item 5 WP 0035 00 References Materials Parts End item configuration manual Marker tags item 7j WP 0064 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Nev
27. WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0025 1 TM 9 2815 538 24 amp P 0025 00 VALVE LASH ADJUSTMENT 1 Determine if cylinder no 1 or cylinder no 4 is in compression Top Dead Center TDC by rotating crank shaft pulley timing mark to align with arrow on engine block figure 1 Check that both rocker arms for selected cylinder are loose which means that all valves for that cylinder are closed compression cycle 2 When cylinder no 1 or cylinder no 4 has been determined cylinder no 2 or cylinder no 3 can be selected by rotating crankshaft pulley timing mark 180 degrees from engine block arrow CRANKSHAFT ARROW PULLEY TDC MARK 15KW 2815 24M 319A Figure 1
28. c 15KW 2815 24P 09 Figure 15 Fuel Injection Assembly 0051 1 1 ITEM NO 2 SMR CODE PBFHH XBFZZ PAFZZ PAFZZ 3 NSN 2910 01 538 0115 5306 01 546 8913 5306 01 546 8037 4 CAGEC 0AK42 0AK42 0AK42 0AK42 TM 9 2815 538 24 amp P 0051 00 5 PART NUMBER 729508 51310 129508 51250 26106 080202 26106 080302 0051 2 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0301 FUEL INJECTION ASSEMBLY FIG 15 FUEL INJECTION ASSEMBLY FUEL INJECTION ASSEMBLY BRACKET MOUNTING BOLT MACHINE BOLT MACHINE END OF FIGURE TM 9 2815 538 24 amp P 0052 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 OIL FILTER AND OIL COOLER REPAIR PARTS LIST 5 12 17 13 141 19 15KW 2815 24P RL 07 1B Figure 16 Oil Filter and Oil Cooler 0052 1 1 ITEM NO 4 2 3 4 5 6 7 8 9 20 21 2 SMR CODE PAHZZ XBHZZ PAHZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAFZZ PAFZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ PAOZZ XBFFF PAFZZ XBFZZ PAFZZ PAFZZ 3 NSN 5330 01 546 6844 5306 01 431 7461 4730 01 546 8861 4720 01 546 8868 4730 01 546 9221 3120 01 546 8851 4730 01 546 7538 2930 01 546 8053 5310 01 546 8881 2940 01 546 5058 4720 01 546 8857 4730 01 546 7538 4730 01 546 8864 5365 01 546 9878 4730 01 546 4701 5307 01 547 0405 5330 01 546 7545 5306 01 546 8913 4 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42
29. item configuration manual 4 300 hours 0 7 Engine Check engine to include hoses Engine parts manifolds etc for damage damaged corrosion missing parts and secure corroded or mounting WP 0006 00 thru missing loose WP 0032 00 5 300 hours 0 3 Starter cables 1 Check starter cable connections Cables parts for damage rusted corrosion damaged rusted missing parts and secure corroded or mounting end item missing loose configuration manual 0008 1 TM 9 2815 538 24 amp P 0008 00 PMCS Continued Table 1 Preventive Maintenance Checks and Services Continued ITEM TO BE EQUIPMENT ITEM MAN CHECKED OR NOT READY INTERVAL HOUR SERVICED PROCEDURE AVAILABLE IF 2 Check cables for fraying cuts Cables frayed cut or nicks end item configuration or nicked manual 300 hours Fuel system Check fuel system for leaks secure Fuel system leaks mounting and damaged lines or or defects that WP 0017 004 WP 0020 00 would prevent WP 0022 00 operation 300 hours Fuel filter Check fuel filter for leaks and Fuel filter leaks replace fuel filter element that would prevent WP 0017 00 operation fuel filter not replaced as required 300 hours 1 Battery charging Check battery charging alternator Alternator parts alternator for damage wear rust corrosion damaged worn 24 Vdc missing parts and secure mounting rusted corroded WP 0010 00 or missing loose 300 hours
30. with excessive exhaust 5 Insufficient engine output with normal exhaust color 6 Insufficient engine output with white exhaust smoke sss 7 Insufficient engine output with black exhaust 8 Excessive white smoke while under load entren tnnt 9 Excessive black smoke while under 10 High knocking sound during combustion esses nrn 11 Abnormal combustion Sound cronica een Roy chau E Rhod rn 12 Uneven combustion irn irren eere rn enn enses 13 Uneven engine speed hunting while idling sescenti 14 Uneven engine speed hunting while under load 15 Excessive engine vibration 16 Excessive turbocharger assembly vibration or noise sess 17 Slow turbocharger assembly 18 Difficulty with engine when returning from high speed to low 19 Excessive fuel consumption esses eene ennt 20 Excessive oil consumption enne enn enne nennen rre trente en 21 Fuel in engine Oil RENDIR 22 Oil mixed with coolant 23 WALD Eee ea
31. 00 MAC Continued Table 1 Maintenance Allocation Chart Continued 1 2 6 4 5 6 TOOLS AND GROUP COMPONENT MAINTENANCE MAINTENANCE EQUIPMENT REMARKS NUMBER ASSEMBLY FUNCTION LEVEL REF CODE CODE FIELD SUSTAINMENT BELOW CREW SERVICE FIELD DEPOT DEPOT IEC RE 06 ELECTRICAL Inspect 0 1 SYSTEM Test 0 2 1 0601 STARTER MOTOR Inspect ASSEMBLY Test 1 Remove Install 5 Replace 5 0602 GENERATOR Inspect Test 1 Remove lnstall 5 Replace 5 TOOLS AND TEST EQUIPMENT REQUIREMENTS Table 2 Tools and Test Equipment Requirements NOMENCLATURE Shop equipment automotive maintenance and repair field maintenance supplemental set no 2 less power Shop equipment automotive maintenance and repair organiz ational maintenance common no 1 less power Shop equipment automotive vehicle Shop equipment fuel and electrical system engine field maintenance basic less power Tool kit general mechanic s TOOL OR TEST EQUIPMENT MAINTENANCE REF CODE 1 F 2 3 F 4 F 5 6 F Tool set basic field maintenance NATIONAL STOCK NUMBER 4910 00 754 0707 4910 00 754 0654 4910 01 490 6453 4940 00 754 0714 5160 00 177 7033 4910 00 754 0705 TOOL NUMBER SC4910 95 CL A63 SC4910 95 CL A74 SC4910 95 A81 SC4910 95 CL 820 SC5180 90 CL N26 SC4910 95 CL A31 0035 3 TM 9 2815 538 24 amp P 0035 00 REMARKS Table 3 Remarks REMARKS C
32. 00 2 aie TER 0002 00 1 REIN he an ee d ED eh Ya en 0030 00 2 Flywheel Assembly and Flywheel Housing Figure 1 0030 00 2 Lc DA e ARO 0030 00 3 Repair Parts List Flywheel Assembly and Flywheel 0044 00 1 Rear OIL Seal 0055 00 1 Index 2 TM 9 2815 538 24 amp P INDEX Continued Subject WP Sequence No Page No F Continued Fuel Filter and Fuel Hoses De SCriptlON pM 0002 00 1 jeep c 0017 00 3 INnStallation cn 0017 00 3 Fuel Filter and Fuel Hoses Figure 1 0017 00 2 Location M E 0002 00 1 Removal Usted idco Haste Metal 0017 00 2 Fuel Filter and Fuel Hoses Figure 1 0017 00 2 ne 0017 00 3 Repair Parts 6 0049 00 1 Fuel Injection Lines and Return Hose INnSPECtION 0020 00 4 ipe e PD Le e Rt ede le Pre oet bee fabas 0020 00 4 Fuel Injection Lines and Return Hose Figure 1 0020 00 3 oet seine ba 0020 00 2 Fuel Injection Lines and Return Hose Figure 1 0020 00 3 tdt A A A EN 0020 00 4 Repair Parts List sis i eea rer ade 0050 00 1 Fuel Injection Pump Assembly Description iunt id
33. 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 TM 9 2815 538 24 amp P 5 PART NUMBER 129150 35042 129150 35091 26106 080352 129103 49301 129508 49040 23080 018000 119940 59130 23080 015000 129508 33010 129417 33110 129150 35152 129508 49030 23080 015000 171008 03990 171056 49120 129006 44480 129006 35100 129417 35150 119802 35110 129150 35111 26106 080202 0052 2 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 04 LUBRICATION SYSTEM FIG 16 OIL FILTER AND OIL COOLER GASKET PIPE METAL BOLT MACHINE ELBOW PIPE TO TUBE HOSE NONMETALLIC CLAMP HOSE COVER PIPE PROTECTOR CLAMP HOSE COOLER ASSEMBLY OIL NUT PLAIN HEXAGON HEAD FILTER OIL COOLER HOSE NONMETALLIC CLAMP HOSE CLAMP HOSE PLUG DRAIN ADAPTER SPECIAL OIL COOLER BRACKET ASSEMBLY FILTER STUD THREADED BRACKET FILTER BOLT MACHINE END OF FIGURE 0052 00 cA L Li Li ci c3 23 TM 9 2815 538 24 amp P 0053 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 OIL BYPASS VALVE REPAIR PARTS LIST Se Or LIZ FR CG ANN At Ro a NZ 32 T LA MD V N gt rs x x TY 25 IT 2 NN ds 5 SS S Q N 15KW 2815 24P 07 2C Figure 17 Oil Bypass Valve
34. 1 item 6 and slide clamps up onto fuel hose figure 1 item 7 5 Remove fuel hose figure 1 item 7 from filter bracket figure 1 item 4 and fuel injection pump assembly figure 1 item 5 6 Remove two bolts figure 1 item 8 and filter bracket figure 1 item 4 15KW 2815 24M 305 Figure 1 Fuel Filter and Fuel Hoses 0017 2 TM 9 2815 538 24 amp P 0017 00 INSPECTION 1 Inspect all parts for wear cracks and corrosion 2 Inspect all hardware for stripped or damaged threads 3 Inspect for signs of leakage REPAIR Repair of this item is limited to removal and replacement INSTALLATION 1 Install filter bracket figure 1 item 4 and two bolts figure 1 item 8 Torque bolts to 16 7 21 0 Ib ft 22 6 28 4 Nm 2 Install fuel hose figure 1 item 7 onto fuel injection pump assembly figure 1 item 5 and filter bracket figure 1 item 4 with two spring clamps figure 1 item 6 3 Install fuel hose figure 1 item 3 onto fuel injection pump assembly figure 1 item 5 and filter bracket figure 1 item 4 with two spring clamps figure 1 item 2 4 Install fuel filter figure 1 item 1 END OF WORK PACKAGE 0017 3 4 blank TM 9 2815 538 24 amp P 0018 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 OIL COOLER ASSEMBLY AND OIL PRESSURE SWITCH REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Personnel Required Tool kit general mechanic s On
35. 1 tension WP 0010 00 END OF WORK PACKAGE 0011 3 4 blank TM 9 2815 538 24 amp P 0012 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 WATER PUMP ASSEMBLY REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Equipment Condition Tool kit general mechanic s Fan V pulley and V belt removed tem 5 WP 0035 00 Thermostat cover and temperature Personnel Required switch removed WP 0013 00 One Coolant hoses removed end item configuration manual References End item configuration manual WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0012 1 TM 9 2815 538 24 amp P 0012 00 REMOVAL 1 10 Squeeze spring clamp figure
36. 1 057 Eiter SS Be Gallons oiim 0 264 Grams oo Mees Bek 0 035 Kilograms Pounds 2 205 Metric Tons Short Tons 1 102 Newton Meters Pound Feet 0 738 Kilopascals Pounds per Square Inch 0 145 Kilometers per Liter Miles per Gallon 2 354 Kilometers per Hour Miles per Hour 0 621 PIN 084922 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 lt A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chud
37. 11 7 Remove alignment pin figure 1 item 12 only if damaged 15KW 2815 24M 330 Figure 1 Flywheel Assembly and Flywheel Housing 0030 2 TM 9 2815 538 24 amp P 0030 00 INSPECTION 1 Inspect all parts for damage wear cracks and corrosion 2 Inspect all hardware for stripped or damaged threads 3 Inspect ring gear on flywheel assembly figure 1 item 2 for damaged or missing teeth 4 Inspect mating surfaces for damage REPAIR Repair of this item is limited to removal and replacement INSTALLATION 1 Install alignment pin figure 1 item 12 into oil seal case assembly figure 1 item 10 2 Install new oil seal figure 1 item 11 into oil seal case assembly figure 1 item 10 WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated area only Failure to comply may result in serious injury to personnel 3 Clean mating surface of oil seal case assembly figure 1 item 10 with breakthrough cleaning solvent and a wiping rag CAUTION Ensure gasket forming compound is not applied to oil seal or damage to oil seal will result 4 Apply gasket forming compound to mating surface of oil seal case assembly figure 1 item 10 and install oil seal case assembly with three bolts figure 1 item 9 5 Install six bolts figure 1 item 8 6 Install alignme
38. 3 NSN 5306 01 431 7461 5306 0 1 546 8899 5315 01 546 9902 5306 01 547 2404 5306 01 388 6230 2815 01 546 8227 4730 01 322 4956 5330 01 326 2669 5305 01 158 0835 5330 01 454 4384 4 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 00U12 0AK42 0AK42 0AK42 0AK42 00U12 30554 30554 00U12 5 PART NUMBER 26106 080352 129486 01670 129100 01580 129400 01730 26106 080252 26106 080452 129489 01770 105425 01690 22190 160002 26106 080162 22190 220002 BELFER3 129100 01640 129795 01780 22190 140002 23857 080000 BELFER2 97 24115 88 20260 32 BELFER1 0055 2 TM 9 2815 538 24 amp P 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0402 CRANKCASE ASSEMBLY FIG 19 ASSEMBLY BOLT MACHINE BOLT MACHINE PIN PARALLEL SPACER STRAIGHT BOLT MACHINE BOLT MACHINE PLUG PIPE SCREW CAP HEXAGON HEAD SEAL WASHER PLUG DRAIN CASE ASSEMBLY OIL SEAL SEAL PLAIN SEAL WASHER PLUG OIL GUIDE DIPSTICK SPACER DIPSTICK BOLT MACHINE GAGE ROD LIQUID LEVEL END OF FIGURE 0055 00 0056 00 TM 9 2815 538 24 amp P uz gt In E EX SyYo J gt iL gt 5 0 24 d a 99554 ER 2 oax uz 10 T n z x o Figure 20 Intake Manifold 0056 1 TM 9 2815 538
39. 31 11 2 11 o TM 9 2815 538 24 amp P 0062 00 STOCK NUMBER FIG ITEM STOCK NUMBER FIG ITEM 5330 01 546 9903 14 16 4710 01 546 9905 14 14 4730 01 546 9935 14 6 5306 01 546 9973 8 1 2815 01 546 9997 4 15 5306 01 547 0001 10 14 5306 01 547 0056 21 7 5306 01 547 0081 7 16 5307 01 547 0090 3 3 5315 01 547 0091 4 14 5307 01 547 0405 16 18 5360 01 547 0442 4 10 5310 01 547 0460 23 5 5330 01 547 0461 11 10 5306 01 547 0465 2 13 5331 01 547 0466 11 4 5340 01 547 0471 14 12 3120 01 547 0495 2 8 5306 01 547 0515 11 15 20 3 5331 01 547 0529 10 16 5365 01 547 0544 7 14 5365 01 547 0563 4 7 5306 01 547 0595 3 7 5330 01 547 0629 11 18 5306 01 547 2404 19 5 3 11 3020 01 547 4625 9 6 3020 01 547 4629 9 4 3020 01 547 4658 18 2 3030 01 547 4661 12 5 5305 14 469 7436 11 14 17 15 5306 99 450 7012 8 3 3120 99 549 3927 2 4 5330 99 727 8075 11 8 0062 3 4 blank TM 9 2815 538 24 amp P 0063 00 CAGEC 0AK42 56161 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 PART NUMBER 105025 59560 10502560 105425 01690 119131 18320 119305 59120 119609 32040 119620 01750 119625 11
40. CALM AND INACTIVE GET MEDICAL HELP If anyone stops breathing give artificial respiration See FM 4 25 11 for first aid i j blank TM 9 2815 538 24 amp P LIST OF EFFECTIVE PAGES WORK PACKAGES NOTE This manual supersedes TM 9 2815 538 24 amp P dated 15 June 2008 Zero in the Change No column indicates an original page or work package Dates of issue for original manual is Original 15 February 2009 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 30 AND TOTAL NUMBER OF WORK PACKAGES IS 64 CONSISTING OF THE FOLLOWING Page WP No Change No Page WP No Change No Front Cover WP 0024 4 pgs Inside Front Cover WP 0025 2 pgs Warning Summary 10 pgs WP 0026 4 pgs i v WP 0027 4 pgs WP 0028 8 pgs xe 9 WP 0029 4 pgs WP 0030 4 pgs Chp 1 Index Page Blank WP 0031 2 pgs WP 0001 6 pgs WP 0002 6 pgs WP 0003 6 pgs Chp 2 Title Page Blank Chp 2 Index Page Blank WP 0004 2 pg WP 0005 26 pgs Chp 3 Title Page Blank Chp 3 Index Page Blank WP 0006 2 pgs WP 0007 4 pgs WP 0008 4 pgs WP 0009 4 pgs WP 0010 6 pgs WP 0011 4 pgs WP 0012 4 pgs WP 0013 4 pgs WP 0014 4 pgs WP 0015 4 pgs WP 0016 12 pgs WP 0017 4 pgs WP 0018 4 pgs WP 0019 2 pgs WP 0020 4 pgs WP 0021 4 pgs WP 0022 4 pgs WP 0023 4 pgs WP 0032 4 pgs Chp 4 Title Page Blank Chp 4 Index
41. Defective governor CORRECTIVE ACTION Adjust replace governor as required end item configuration manual 0005 18 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Excessive fuel consumption MALFUNCTION Engine used at high temperatures or at high altitude CORRECTIVE ACTION Check output drop and load matching requirements reduce load as required end item configuration manual MALFUNCTION Compression leakage from valve seat CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Excessive cooling effect of radiator CORRECTIVE ACTION Check thermostat replace as required WP 0013 00 MALFUNCTION Too late timing of fuel injection pump assembly CORRECTIVE ACTION Check fuel injection pump assembly adjust timing WP 0016 00 MALFUNCTION Poor spray pattern from fuel injection nozzle CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 MALFUNCTION Excessive volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injection pump assembly and fuel injectors replace as required WP 0016 00 WP 0022 00 SYMPTOM Excessive oil consumption MALFUNCTION Incorrect oil grade type for ambient temperature range CORRECTIVE ACTION Drain oil fill with correct oil end item configuration manual 0005 19 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Excessive oil consumption Continued
42. FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 IDLE GEAR ASSEMBLY REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Equipment Condition Tool kit general mechanic s Battery charging alternator 24 Vdc tem 0035 00 removed WP 0010 00 Fan V pulley and V belt removed Materials Parts Engine lubricating oil item 4 WP 0064 00 Gear case assembly removed Personnel Required One References 0012 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless itis properly grounded Failure to comply may result in serious injury or death to personnel 0015 1 TM 9 2815 538 24 amp P 0015 00 REMOVAL 1 Measure backlash of idle gear Backlash for all gears must be 0 002 to 0 005 inches 0 07 to 0 15 mm with maximum limit of 0 006 i
43. GATE ACTUATOR PRESSURE GAGE COMPRESSED AIR lt 5 kg cm 0 49 Mpa ADAPTER WASTE GATE VALVE MANOMETER 7 PRESSURE PRESSURE amp REDUCING REGULATING NOTE VALVE VALVE Pc CONTROL PRESSURE VARIES WITH SET OUTPUT IN RANGE BETWEEN 600 AND 750 mmHg 15KW 2815 24M 344A Figure 4 Waste Gate Actuator Leak Test Setup 2 Apply 17 psi 0 12 MPa to actuator and hold for 1 minute If pressure drop after 1 minute is less than 15 9 psi 0 11 MPa replace turbocharger assembly figure 1 item 2 REPAIR Repair of this item is limited to removal and replacement 0028 6 TM 9 2815 538 24 amp P 0028 00 INSTALLATION 1 Ensure exhaust manifold figure 1 item 4 and cylinder head assembly figure 1 item 11 mating surfaces are clean and smooth Install exhaust manifold gasket figure 1 item 10 exhaust manifold figure 1 item 4 four bolts figure 1 item 9 three bolts figure 1 item 8 and bolt figure 1 item 7 Torque bolts to 16 7 to 21 0 Ib ft 22 6 to 28 4 Nm Install stud bolt figure 1 item 6 and turbocharger gasket figure 1 item 5 onto turbocharger assembly figure 1 item 2 Ensure exhaust manifold figure 1 item 4 and turbocharger assembly figure 1 item 2 mating surfaces are clean and smooth Install gasket figure 1 item 3 turbocharger assembly figure 1 item 2 and four nuts figure 1 item 1 Install exhaust and air inlet hoses end item configuration manual
44. Index 3 TM 9 2815 538 24 amp P INDEX Continued Subject WP Sequence No Page No F Continued Fuel Injectors INSPEC c ren DR ee 0022 00 3 Fuel Injector Nozzle Pressure 0022 00 3 Fuel Injector Test Figure 2 22 4 22 01 0022 00 3 Fuel Injectors Figure 1 rn ne ea 0022 00 2 Injector Leak Test ne ee ee 0022 00 3 Spray Pattern Inspection acu 0022 00 4 Normal and Abnormal Spray Patterns Figure 3 0022 00 4 Installati n LP re d eoa P e t OR 0022 00 4 Fuel Injectors Figure 1 iino iiec tht E dero Rate a aide Eulen 0022 00 2 iit tec eta 0022 00 2 Fuel Injectors Figure 1 2 iiit ti eio heh ater 0022 00 2 meom 0022 00 4 Repair Parts List c i reise sese 0050 00 1 Fuel Injector Nozzle Protect l srs stenna nnne nnn 0040 00 1 Fuel Injector Nozzle 0040 00 1 G H Gear Case Assembly Deseripti n S 0002 00 2 hn oed 0014 00 3 Installation nte tae A Hl 0014 00 4 Gear Case Assembly Figure 1 0014 00 3 metil tilda ita 0002 00 2 5
45. LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 GENERAL INFORMATION SCOPE This Technical Manual TM contains description checks and adjustments theory of operation troubleshooting and corrective maintenance for the Yanmar Diesel Engine 4TNV84T DFM Type of Manual Field Level Maintenance with Field and Sustainment Level Repair Parts and Special Tools List Model Number and Equipment Name Diesel Engine 4TNV84T Purpose of Equipment The diesel engine provides primary power for the 15 kW Tactical Quiet TQ Generator sets MEP 804B and MEP 814B and other military applications offering the mobility and operational characteristics demanded by modern armed forces Operational characteristics include the ability to operate at all possible humidity levels at ambient temperature levels from 25 F to 120 F 32 C to 49 C and at altitudes up to 10 000 feet 3 048m CONSOLIDATED INDEX OF ARMY PUBLICATIONS AND BLANK FORMS Refer to the latest issue of DA PAM 25 30 to determine whether there are new additions changes or additional publications pertaining to the equipment MAINTENANCE FORMS RECORDS AND REPORTS 1 Army Department of the Army forms and procedures used for equipment maintenance will be those prescribed by as applicable DA PAM 750 8 The Army Maintenance Management System TAMMS User Manual DA PAM 738 751 Functional users Manual for the Army Maintenance Management Systems Aviation TAMMS A or AR 700 138
46. MAINTENANCE INITIAL SETUP Tools and Special Tools Personnel Required Shop equipment automotive common One no 1 item 2 WP 0035 00 Tool kit general mechanic s References item 5 WP 0035 00 WP 0036 09 thru WP 0064 00 TC 9 237 Materials Parts Breakthrough cleaning solvent Crocus cloth item 1 Marker tags item 7 SCOPE General maintenance consists of general shop practices and specific methods you must be familiar with to properly maintain the diesel engine You should read and understand these practices and methods before starting maintenance tasks WORK SAFETY WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel Before starting any task find out how much repair or repl
47. Page Blank WP 0033 2 pgs WP 0034 4 pgs WP 0035 4 pgs WP 0036 8 pgs WP 0037 2 pgs WP 0041 2 pgs WP 0043 2 pgs WP 0044 2 pgs WP 0045 2 pgs WP 0046 2 pgs WP 0047 2 pgs WP 0048 2 pgs WP 0049 2 pgs WP 0039 2 pgs WP 0051 2 pgs WP 0055 2 pgs WP 0053 2 pgs WP 0057 2 pgs WP 0059 2 pgs Page WP No WP 0060 2 pgs WP 0061 2 pgs WP 0062 4 pgs WP 0063 6 pgs WP 0064 2 pgs INDEX 1 INDEX 9 INDEX 10 blank Inside Back Cover Back Cover un TM 9 2815 538 24 amp P Change No ARMY TM 9 2815 538 24 amp P AIR FORCE TO 38G1 129 3 HEADQUARTERS DEPARTMENTS OF THE ARMY AND THE AIR FORCE WASHINGTON DC 15 FEBRUARY 2009 TECHNICAL MANUAL FIELD AND SUSTAINMENT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR YANMAR DIESEL ENGINE 4TNV84T DEM 4 CYLINDER 2 0 LITER NSN 2815 01 538 4257 EIC N A REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual If you find any mistakes or if you know of a way to improve the procedures please let us know Reports as applicable by the requiring Service should be submitted as follows a A Army Mail your letter or DA Form 2028 Recommended Changes to Publications and Blan
48. SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 COOLING SYSTEM REPAIR PARTS LIST 24 15KW 2815 24P 02 Figure 11 Cooling System 0047 1 TM 9 2815 538 24 amp P 0047 00 1 2 3 4 5 6 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN _ NUMBER CODE UOC GROUP 02 COOLING SYSTEM FIG 11 COOLING SYSTEM PAOZZ 5330 01 546 3538 0AK42 124395 49840 XBOZZ 0AK42 129004 42040 PAFZZ 5306 01 388 6230 0AK42 26106 080452 PAOZZ 5331 01 547 0466 0AK42 129486 42140 PAFZZ 5305 01 158 0835 0AK42 26106 080162 SCREW CAP HEXAGON HEAD PAOZZ 5306 01 546 8052 0AK42 26106 080222 BOLT MACHINE XBOZZ 0AK42 129350 49530 PAOZZ 5330 99 727 8075 0AK42 129795 49551 PAOZZ 6685 01 546 3005 0AK42 129155 49801 PAOZZ 5330 01 547 0461 0AK42 129150 49811 PAFZZ 5330 01 546 8898 0AK42 124465 44950 PAOZZ 4730 01 546 4242 0AK42 121450 42450 PAOZZ 5330 01 454 6389 0AK42 23414 080000 PAFZZ 5305 14 469 7436 0AK42 26106 080122 BOLT MACHINE PAFZZ 5306 01 547 0515 0AK42 26106 080602 BOLT MACHINE PAOOO 0AK42 129508 42000 PUMP ASSEMBLY COOLANT PAOZZ 4730 01 546 9253 0AK42 119802 49113 PIPE JOINT PAOZZ 5330 01 547 0629 0AK42 129100 42051 XBOZZ 0AK42 129100 42121 PLATE COVER PAOZZ 5305 01 546 8870 0AK42 121850 42410 SCREW MACHINE PAOZZ 4730 01 546 4247 0AK42 23876 020000 PAOZZ 4730 01 546 8903 0AK42 129916 49740 PAOZZ 5365 01 526 7332 0AK42 23876 010000 AOOOO 0AK42 129004 49610 HOSE ASSEMBLY NONMETA
49. Service Maintenance O and Field Maintenance F Sustainment includes two sub columns Below Depot H and Depot D The tools and test equipment requirements immediately following the MAC list the tools and test equipment both special tools and common tool sets required for each maintenance function as referenced from the MAC The remarks immediately following the tools and test equipment requirements contain supplemental instructions and explanatory notes for a particular maintenance function Maintenance Functions Section I Maintenance functions are to be limited to and defined as below 1 Inspect To determine the serviceability of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination e g by sight sound or feel This includes scheduled inspection and gaging and evaluation of cannon tubes 2 Test To verify serviceability by measuring the mechanical pneumatic hydraulic or electrical characteristics of an item and comparing those characteristics with prescribed standards on a scheduled basis i e load testing of lift devices and hydrostatic testing of pressure hoses 3 Service Operations required periodically keeping an item in proper operating condition e g clean includes decontaminate when required to preserve to drain to paint or to replenish fuel chemical fluids or gases This includes scheduled exercising and purging of r
50. Torque nut to 7 2 8 7 lb ft 9 8 11 8 Nm 5 Seoure retainer figure 1 item 6 to cylinder head assembly figure 1 item 7 with bolt figure 1 item 5 Torque bolt to 16 7 21 0 Ib ft 22 6 28 4 Nm 6 Install O ring figure 1 item 3 onto oil return line figure 1 item 2 7 Install oil return line figure 1 item 2 onto turbocharger figure 1 item 4 with two bolts figure 1 item 1 Torque bolt to 7 2 8 7 lb ft 9 8 11 8 Nm END OF WORK PACKAGE 0027 4 TM 9 2815 538 24 amp P 0028 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 TURBOCHARGER ASSEMBLY AND EXHAUST MANIFOLD REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools References Tool kit general mechanic s WP 0027 00 item 5 WP 00354 00 End item configuration manual Materials Parts Equipment Condition Pressure sensitive tape item 8 WP 0064 00 Turbocharger oil lines removed WP 0027 00 Personnel Required Exhaust and air inlet hoses removed One end item configuration manual WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is com
51. amp P 0010 00 ADJUSTMENT Continued RADIATOR FAN SET BOLT GENERATOR DEFLECTION V BELT m CRANKSHAFT PRESS WITH THUMB V PULLEY 7 15KW 2815 24M 301 3A Figure 3 V Belt Tension Check Table 1 V Belt Deflection Limits Used V belt 0 39 0 56 inch 0 28 0 39 inch 0 35 0 51 inch used more than 5 10 14 mm 7 10 mm 9 13 mm minutes New V belt 0 31 0 47 inch 0 2 0 31 inch 0 28 0 43 inch used less than 5 8 12 mm 5 8 mm 7 11 mm minutes END OF WORK PACKAGE 0010 5 6 blank TM 9 2815 538 24 amp P 0011 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FAN V PULLEY AND V BELT REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools References Tool kit general mechanic s item 5 WP 0035 00 Equipment Condition Personnel Required V belt tension relieved One WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel
52. fetch anb ti da tidad 0014 00 2 Gear Case Assembly 1 0014 00 3 md ced etre AA ne 0014 00 4 Parts ti ar 0046 00 1 General Information Common Tools and Test 0001 00 4 Consolidated Index of Army Publications and Blank Forms 0001 00 1 Corrosion Prevention and 0001 00 1 Destruction of Army Materiel to Prevent Enemy 0001 00 1 List of 0001 00 2 Maintenance Forms Records and 0001 00 1 Preparation for Storage or 0001 00 2 Quality 0001 00 4 Partss he a 0001 00 5 Reporting Equipment Improvement Recommendations 0001 00 1 Safety Care and 0001 00 4 OO N 0001 00 1 Index 4 TM 9 2815 538 24 amp P INDEX Continued Subject WP Sequence No Page No G H Continued General Information Continued Special Tools Test Measurement and Diagnostic Equipment TMDE and Support Equipment caciones 0001 00 4 Warranty
53. figure 1 item 3 from crankcase figure 1 item 4 Remove four bolts figure 1 item 6 22 bolts figure 1 item 5 and crankcase figure 1 item 4 Remove two bolts figure 1 item 7 two bolts figure 1 item 8 and spacer figure 1 item 9 Remove plug figure 1 item 10 and seal figure 1 item 11 0029 2 0029 00 TM 9 2815 538 24 amp P REMOVAL Continued 15KW 2815 24M 331A Figure 1 Crankcase Assembly and Dipstick 0029 3 TM 9 2815 538 24 amp P 0029 00 INSPECTION 1 Inspect all parts for damage wear cracks and corrosion 2 Inspect all hardware for stripped or damaged threads 3 Check oil drain holes for obstructions WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated area only Failure to comply may result in serious injury or death to personnel 4 Thoroughly clean crankcase figure 1 item 4 with breakthrough cleaning solvent brush and a wiping rag REPAIR Repair of this item is limited to removal and replacement INSTALLATION 1 Install seal figure 1 item 11 and plug figure 1 item 10 WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated are
54. for remaining cylinders 8 Install fuel injectors WP 0022 00 9 Install valve cover assembly WP 0021 00 10 Install fuel injection lines WP 0020 00 0023 2 0023 00 TM 9 2815 538 24 amp P COMPRESSION TEST Continued 15KW 2815 24M 348B Figure 1 Compression Test Setup END OF WORK PACKAGE 0023 3 4 blank TM 9 2815 538 24 amp P 0024 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 CYLINDER HEAD ASSEMBLY REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools References Continued Tool kit general mechanic s item 5 WP 0035 00 Materials Parts Equipment Condition Engine lubricating oil item 4 0064 00 Fuel injection lines removed Personnel Required Valve cover assembly removed One Water pump assembly removed References Intake manifold and air inlet hose WP 0020 0021 09 removed WP 0026 00 Exhaust manifold removed WP 0028 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repai
55. for use with the diesel engine FIELD MANUALS 4 25 11 nun FM 9 207 10 67 1 EM21 30 tic FORMS DA Form 2028 DA Form 2028 DA Form 2062 DA Form 2404 DA Form 2407 DA Form 2408 DA Form 2408 9 DA Form 2408 20 DA Form 5988 DD Form 314 DD Form 518 DD Form 1397 TECHNICAL BULLETINS 9 6116 643 24 43 0213 Chemical and Biological Contamination Avoidance Nuclear Contamination Avoidance NBC Protection NBC Decontamination First Aid Operation and Maintenance of Ordnance Materiel in Cold Weather 0 to 65 Concepts and Equipment of Petroleum Operations Military Symbols Recommended Changes to Publications and Blank Forms Recommended Changes to Publications and Blank Forms EGA Hand Receipt Equipment Inspection and Maintenance Worksheet Maintenance Request Equipment Log Assembly Records Equipment Control Record Oil Analysis Log Equipment Inspection and Maintenance Worksheet Preventive Maintenance Schedule and Record Accident Identification Card Processing and Deprocessing Record for Shipment Storage and
56. gear case assembly during removal severe damage to engine may result when operated if hardware is not retrieved Gear case assembly must be removed to retrieve hardware Be careful when removing hardware NOTE It may be necessary to hold crankshaft pulley bolt with a socket and breaker bar when loosening drive gear nut 6 Remove center nut figure 4 item 1 and lockwasher figure 4 item 2 Install a two bolt type gear puller or equivalent figure 4 item 3 onto fuel injection pump assembly drive gear figure 4 item 4 Gear puller should be perpendicular to drive gear when installed correctly 0016 4 TM 9 2815 538 24 amp P 0016 00 REMOVAL Continued CAUTION Be careful when pulling drive gear assembly Outside bolts on drive gear may damage inside of gear housing when drive gear breaks loose 8 Pull fuel injection pump assembly drive gear figure 4 item 4 from fuel injection pump assembly drive shaft figure 4 item 5 Drive gear figure 4 item 4 will remain inside gear case assembly with gear puller attached 15KW 2815 24M 354 Figure 4 Gear Puller NOTE Tag all hoses before disconnecting to aid during reconnection Some fluid fuel coolant or oil may spill when specific lines or hoses are removed from fuel injection pump assembly Be prepared to contain spilled fluid 9 Release two spring clamps figure 5 item 1 and remove two coolant hoses figure 5 it
57. is typically associated with rusting of metals it can also include deterioration of other materials such as rubber and plastic Unusual cracking softening swelling or breaking of these materials may be a corrosion problem If a corrosion problem is identified it can be reported using SF 368 Product Quality Deficiency Report Use of key words such as corrosion 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 INSPECTION Look for signs of a problem or trouble You can feel smell hear or see many problems Be alert when in or around the engine Inspect the engine to see if items are in good condition Are they correctly assembled stowed and secured excessively worn leaking or corroded or properly lubricated Correct any problems found or notify sustainment level maintenance Class III leak s require the end item unit to be taken out of service There are some common items to check all over the engine These include the following WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated area only Failure to comply may result in serious injury or death to personnel 1 Dirt grease oil and debris They only get in the way and may cover up a seri
58. malfunction is not listed or is not corrected by the listed corrective action refer to the end item configuration manual troubleshooting procedures TROUBLESHOOTING PROCEDURES SYMPTOM Engine does not start slow starter motor assembly rotation or no starter motor assembly rotation MALFUNCTION Battery charging alternator 24 Vdc malfunction 7 2 Gain access to batteries end item configuration manual 2 Start engine end item configuration manual Set engine speed to at least 1 000 rpm 3 Measure Direct Current DC voltage across batteries Voltage should be 26 4 to 31 0 4 If voltage is above or below limit replace battery charging alternator 24 Vdc WP 0010 00 MALFUNCTION Battery voltage drop CORRECTIVE ACTION 1 Inspect connections end item configuration manual 2 Charge battery end item configuration manual 3 Replace battery end item configuration manual 0005 1 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Engine does not start slow starter motor assembly rotation or no starter motor assembly rotation Continued MALFUNCTION Starter circuit defect CORRECTIVE ACTION 1 Check starter motor assembly cables connections for looseness corrosion tighten clean as required 2 Temporarily connect starter motor assembly SWITCH terminal to battery positive terminal a If starter motor assembly spins starter motor assembly is operatin
59. may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0021 1 TM 9 2815 538 24 amp P 0021 00 REMOVAL 1 Disconnect breather hose figure 1 item 1 2 Remove three knobs figure 1 item 2 and O rings figure 1 item 3 3 Gently pry out four seals figure 1 item 4 from valve cover assembly figure 1 item 5 Discard seals if deteriorated or damaged 4 Remove valve cover assembly figure 1 item 5 and valve cover gasket figure 1 item 6 1 2 3 4 N 8 Ne ES I lt 15KW 2815 24M 310B Figure 1 Valve Cover Assembly DISASSEMBLY Remove four screws figure 1 item 7 baffle plate figure 1 item 8 and two breather baffles figure 1 items 9 and 10 0021 2 TM 9 2815 538 24 amp P 0021 00 INSPECTION 1 2 3 Inspect all parts for wear cracks and corrosion Inspect all hardware for stripped or damaged threads Inspect for signs of leakage REPAIR Repair of this item is limited to removal and replacement ASSEMBLY 1 Install two breather baffl
60. mechanic s item 5 0035 00 DA Form 2404 DA Form 5988 E Materials Parts DA PAM 738 750 Breakthrough cleaning solvent DD Form 1397 item 6 WP 0064 00 DD Form 314 Wiping rag item 5 WP 0064 00 SF 361 SF 368 Personnel Required One SERVICE UPON RECEIPT OF MATERIEL 1 2 Read and follow all instruction on DD Form 1397 attached to conspicuous part of engine Remove metal strapping plywood tapes seals and wrappings if necessary WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated area only Failure to comply may result in serious injury or death to personnel Remove rust preventive compound from coated exterior parts with breakthrough cleaning solvent and wiping rag Inspect equipment for damage incurred during shipment If equipment has been damaged report damage on SF 361 Transportation Discrepancy Report Check equipment against packing slip to see if shipment is complete Report all discrepancies in accordance with applicable service instructions DA PAM 738 750 Check to see if equipment has been modified 0006 1 TM 9 2815 538 24 amp P 0006 00 PRELIMINARY CHECKS AND ADJUSTMENT OF EQUIPMENT 1 Inspect equipment for possible damage incurred during shipment If equipment has been damaged report damage on SF 368 Product Q
61. periods of time when a shortage of maintenance effort exists Items should be in mission readiness within 24 hours or within the time factors as determined by the directing authority Before placing the equipment in administrative storage current preventive maintenance checks and services should be completed shortcomings and deficiencies should be corrected and all Modification Work Orders MW Os and Modification Instructions MI should be applied Inside storage is preferred for items selected for administrative storage If inside storage is not available trucks vans CONEX containers and other containers may be used For storage information refer to TM 740 90 1 0031 1 2 blank TM 9 2815 538 24 amp P 0032 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 TORQUE LIMITS INTRODUCTION This work package contains the torque standards for specific types and sizes of hardware It defines the different types of bolts by grade Special torque values and sequences are listed in the specific maintenance procedure TORQUE TABLES How To Use Torque Tables 1 Measure diameter of screw being installed figure 1 2 Count number of threads per inch or use a pitch grade um 15KW 2815 24M 324 Figure 1 Measuring Screw 0032 1 TM 9 2815 538 24 amp P 0032 00 TORQUE TABLES Continued 3 Under heading SIZE look down DIA IN column until you find diameter of screw being installed table 1 or tabl
62. pump assembly shaft figure 4 item 5 and remove gear puller figure 4 item 3 CAUTION If nut or lockwasher is dropped into gear case assembly during removal severe damage to engine may result when operated if hardware is not retrieved Gear case assembly must be removed to retrieve hardware Be careful when removing hardware Secure drive gear figure 4 item 4 with lockwasher figure 4 item 2 and nut figure 4 item 1 Hold crankshaft pulley nut with socket and breaker bar and torque nut figure 4 item 1 to 57 5 to 64 9 Ib ft 78 to 88 Nm WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated area only Failure to comply may result in serious injury or death to personnel Remove all traces of old gasket and thoroughly clean mating surfaces of cover plate figure 2 item 2 and gear case assembly figure 2 item 3 with breakthrough cleaning solvent and a wiping rag Apply gasket forming compound to mating surface of cover plate figure 2 item 2 0016 11 TM 9 2815 538 24 amp P 0016 00 INSTALLATION Continued 21 Install cover plate figure 2 item 2 onto gear case assembly figure 2 item 3 with four bolts figure 2 item 1 22 Install fuel injection lines WP 0020 00 23 Install fan V pulley and V belt WP 0011 00 END OF WORK PACKAGE
63. pump forces coolant through passages cooling jackets in the engine block and cylinder head where the coolant absorbs heat from the engine When the engine reaches normal operating temperature the thermostat opens and the heated coolant flows out of the engine through the upper coolant hose assembly to a fluid cooler radiator A belt driven cooling fan on the front of the engine is used to draw air through the radiator to reduce the temperature of the engine coolant Coolant is drawn from the bottom of the external cooling device by the water pump and circulated through the engine THERMOSTAT ENGINE DRIVEN FAN AIR 4 FLOW COOLING DEVICE RADIATOR EXTERNAL OIL COOLER 15KW 2815 24M 106A Figure 2 Engine Cooling System 0003 3 TM 9 2815 538 24 amp P 0003 00 LUBRICATION SYSTEM The engine oil pump figure 3 is located inside the gear case assembly and is driven directly by the crankshaft The engine oil pump pulls oil from the engine oil pan through the oil suction pipe and pushes the oil through the regulator valve bypass valve and oil cooler to the oil filter The regulator valve regulates and stabilizes the engine oil pressure with the engine running at rated rpm The bypass valve allows oil to flow through the engine if the oil filter becomes clogged From the oil filter oil flows to the main oil gallery in the cylinder head The main oil gallery distributes oil to crankshaft journals camsha
64. so that the ammunition can be identified and protected The color indicating primary use is applied preferably to the entire exterior surface as the background color of the item Other markings are to be repainted as original so as to retain proper ammunition identification 9 Replace To remove an unserviceable item and install a serviceable counterpart in its place Replace is authorized by the MAC and assigned maintenance level is shown as the third position code of the Source Maintenance and Recoverability SMR code 10 Repair The application of maintenance services including fault location troubleshooting removal installation disassembly assembly procedures and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage fault malfunction or failure in a part subassembly module component or assembly end item or system NOTE The following definitions are applicable to the repair maintenance function Services Inspect test service adjust align calibrate and or replace Fault location troubleshooting The process of investigating and detecting the case of equipment malfunctioning the act of isolating a fault within a system or Unit Under Test UUT Disassembly assembly The step by step breakdown taking apart of a spare functional group coded item to the level of its least component that is assigned an SMR code for the level of maintenance under consideration
65. working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless itis properly grounded Failure to comply may result in serious injury or death to personnel 0016 1 0016 00 TM 9 2815 538 24 amp P REMOVAL NOTE Some fuel may spill when plunger plug is removed from fuel injection pump assembly Be prepared to contain spilled fuel Clean top of fuel injection pump assembly figure 1 and remove plunger plug figure 1 1 PLUNGER PLUG 15 2815 24 557 FUEL INJECTION PUMP ASSEMBLY Figure 1 Fuel Injection Pump Assembly Plunger Plug 0016 2 TM 9 2815 538 24 amp P 0016 00 REMOVAL Continued NOTE All references to crankshaft rotation are from water pump end of engine and are performed by turning crankshaft pulley bolt with a socket Some fuel may spill when plunger plug is removed from fuel injection pump assembly Be prepared to contain spilled fuel 2 Use suitable clean dry probe ins
66. 0 0AK42 129150 02870 5306 01 546 4269 0AK42 129150 02020 0AK42 124060 01050 0AK42 129001 01250 0AK42 129004 01190 SPACER SPECIAL SHAPED 5306 01 547 0465 0AK42 129150 01200 BOLT MACHINE 5330 01 546 7537 0AK42 129508 01330 GASKET CYLINDER HEAD NOAINNON 0 4 2 3 4 5 6 7 7 8 8 9 END OF FIGURE 0038 2 TM 9 2815 538 24 amp P 0039 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 ROCKER ARM SHAFT ASSEMBLY REPAIR PARTS LIST 1 4 8 3 6 8 10 11 14 17 14 15KW 2815 24P 10 2A Figure 3 Rocker Arm Shaft Assembly 0039 1 1 ITEM NO 2 SMR CODE 3 NSN 5306 01 546 4263 5307 01 547 0090 5315 01 546 8568 5310 01 546 8916 5306 01 547 0595 5315 01 546 8568 5310 01 546 8916 5306 01 547 2404 5310 01 546 8918 4 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 OAK42 0AK42 0AK42 0AK42 0AK42 OAK42 OAK42 TM 9 2815 538 24 amp P 5 PART NUMBER 129508 11241 26106 080502 26226 080352 129508 11660 129150 11230 129150 11750 129907 11950 129508 11650 129150 11230 129150 11750 26106 080252 129508 11270 129508 11280 129508 11260 129508 11920 129508 11900 129508 11250 0039 2 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0101 ROCKER ARM ASSEMBLY FIG 3 ARM SHAFT ASSEMBLY SHAFT ASSEMBLY ROCKER BOLT MACHINE STUD THREADED AR
67. 01 546 7545 2815 01 546 7688 4720 01 546 7874 2835 01 546 7876 2930 01 546 7913 2920 01 546 8025 5306 01 546 8037 5306 01 546 8037 2815 01 546 8047 4720 01 546 8050 5306 01 546 8052 2930 01 546 8053 4720 01 546 8124 5331 01 546 8126 5330 01 546 8128 2915 01 546 8222 2815 01 546 8227 3120 01 546 8480 5331 01 546 8510 5331 01 546 8517 3020 01 546 8538 5306 01 546 8540 5306 01 546 8565 5315 01 546 8568 5305 01 546 8629 5306 01 546 8846 3120 01 546 8851 4720 01 546 8857 4730 01 546 8861 4730 01 546 8864 4720 01 546 8868 5330 01 546 8869 5305 01 546 8870 4810 01 546 8874 5310 01 546 8875 5315 01 546 8877 5307 01 546 8878 5330 01 546 8879 5310 01 546 8881 TM 9 2815 538 24 amp P FIG ITEM o o o Ni STR 0062 2 STOCK NUMBER 4710 01 546 8886 5310 01 546 8889 4720 01 546 8893 5330 01 546 8895 5330 01 546 8898 5306 01 546 8899 5330 01 546 8902 4730 01 546 8903 5305 01 546 8908 5306 01 546 8910 5305 01 546 8911 5306 01 546 8913 5310 01 546 8916 5340 01 546 8917 5310 01 546 8918 5330 01 546 8924 5310 01 546 8927 5306 01 546 8929 3120 01 546 8931 5331 01 546 8932 5365 01 546 8936 4730 01 546 8975 5940 01 546 8988 4730 01 546 9221 4710 01 546 9222 4730 01 546 9253 5306 01 546 9263 3120 01 546 9268 5310 01 546 9272 5310 01 546 9316 5355 01 546 9841 5365 01 546 9878 5306 01 546 9886 5310 01 546 9888 5306 01 546 9891 5315 01 546 9902 0062 00 FIG_ITEM 3 6 27
68. 1 item 1 with pliers and slide clamp back onto pipe assembly figure 1 item 2 Remove pipe assembly figure 1 item 2 from elbow figure 1 item 3 Remove elbow figure 1 item 3 only if damaged Squeeze spring clamp figure 1 item 5 with pliers and slide clamp back onto pipe assembly figure 1 item 6 Remove pipe assembly figure 1 item 6 from nipple figure 1 item 7 Squeeze spring clamp figure 1 item 8 with pliers and slide clamp back onto pipe assembly figure 1 item 9 Remove pipe assembly figure 1 item 9 from nipple figure 1 item 10 Remove three bolts figure 1 item 11 water pump assembly figure 1 item 12 gasket figure 1 item 13 and O ring figure 1 item 14 Remove three bolts figure 1 item 15 adapter figure 1 item 16 and gasket figure 1 item 17 If replacing water pump assembly figure 1 item 12 remove plug figure 1 item 18 gasket figure 1 item 19 bolt figure 1 item 20 and gasket figure 1 item 21 0012 2 TM 9 2815 538 24 amp P 0012 00 REMOVAL Continued 15KW 2815 24M 303A Figure 1 Water Pump Assembly INSPECTION 1 Inspect all parts for wear cracks and corrosion 2 Inspect all hardware for stripped or damaged threads 3 Inspect for signs of leakage REPAIR Repair of this item is limited to removal and replacement 0012 3 TM 9 2815 538 24 amp P 0012 00 INSTALLATION 1 Ifreplacing water pump assembly figure 1 item 12 insta
69. 11 is larger than timing index number of new fuel injection pump assembly fuel injection pump assembly timing must be delayed rotated toward engine figure 9 by amount determined from step 5 above figure 10 For example if new fuel injection pump assembly timing index number is larger than old fuel injection pump assembly timing index number and resulting difference is 0 5 rotate fuel injection pump assembly figure 5 item 11 away from engine to advance timing by 0 5 degrees as referenced to standard mark on timing index sticker figure 10 Hold fuel injection pump assembly at correct timing mark figure 10 and tighten three nuts figure 5 item 10 Install spacer figure 5 item 9 Install intake manifold and air inlet hose WP 0026 00 Install bracket figure 5 item 8 with two bolts figure 5 items 7 and 6 Connect electrical connector figure 5 item 5 to engine harness end item configuration manual Install turbocharger oil line WP 0027 00 Install three fuel hoses figure 5 item 4 and three spring clamps figure 5 item 3 Install two coolant hoses figure 5 item 2 and two spring clamps figure 5 item 1 Align drive gear figure 4 item 4 with key on fuel injection pump assembly shaft figure 4 item 5 and also match alignment marks on drive gear and bore on gear case assembly opening Install drive gear onto fuel injection pump assembly shaft Ensure drive gear figure 4 item 4 is snug on fuel injection
70. 17 11340 SEAL VALVE STEM PAHZZ 2815 01 546 4327 0AK42 119717 11800 GUIDE VALVE XBFZZ 4730 01 546 4247 0AK42 23876 020000 PAHZZ 5315 01 547 0091 0AK42 22351 060012 PAHZZ 2815 01 546 9997 0AK42 129508 11100 PAHZZ 4820 01 546 3548 0AK42 129508 11110 XBHZZ 0AK42 27241 400000 PAFZZ 4720 01 546 3578 0AK42 119802 11870 PROTECTOR NOZZLE PAFZZ 2815 01 546 4587 0AK42 119625 11880 SEAT NOZZLE PAHZZ 5330 01 546 8128 0AK42 119717 11350 SEAL VALVE STEM 4 2 3 4 5 6 7 8 9 ORANDAADANAQHAHNA HPA 0 END OF FIGURE 0040 2 TM 9 2815 538 24 amp P 0041 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 VALVE COVER ASSEMBLY REPAIR PARTS LIST 15KW 2815 24P 10 1A Figure 5 Valve Cover Assembly 0041 1 TM 9 2815 538 24 amp P 0041 00 1 2 3 4 5 6 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN X NUMBER CODE UOC GROUP 0103 VALVE COVER ASSEMBLY FIG 5 VALVE COVER ASSEMBLY 0AK42 129508 11350 VALVE COVER ASSEMBLY 5305 01 546 8629 0AK42 22857 500100 SCREW TAPPING 0AK42 129006 03120 COVER DIAPHRAGM 5331 01 546 4260 OAK42 24341 000400 5330 01 546 8924 OAK42 129508 11310 GASKET BONNET 0AK42 129150 03070 BAFFLE BREATHER 0AK42 129508 03010 PLATE BAFFLE 0AK42 119802 03070 BAFFLE BREATHER 0AK42 119807 11770 COVER FILLER 5355 01 546 9841 0AK42 124160 11360 5331 01 546 8517 0AK42 24311 000120 0AK42 129150 03090 1 2 3 4 5 6 7 8 9 9
71. 2 Level This column includes the lowest level of maintenance that requires the listed item O Unit F Direct Support D Depot Column 3 National Stock Number NSN This is the NSN assigned to the item which you can use to requisition it Column 4 Item Name Description Commercial and Government Entity Code CAGEC and Part Number P N This column provides the other information you need to identify the item Column 5 Unit of Issue Indicates the physical measurement or count of an item as issued per the National Stock Number shown in column 3 0064 1 1 ITEM NUMBER TM 9 2815 538 24 amp P 0064 00 Table 1 Expendable and Durable Items List 3 5350 00 221 0872 5330 01 438 1861 9150 00 250 0927 9150 01 152 4117 7920 00 205 3571 6850 01 378 0679 9905 00 537 8954 7150 00 778 6383 4 ITEM NAME DESCRIPTION CAGEC AND PART NUMBER Cloth abrasive crocus 58536 A A 1206 Compound gasket forming 11083 8C 8422 Jelly petroleum 81348 VV P 236 Oil lubricating engine 81349 MIL L 2104 Rag wiping cotton and cotton synthetic grade B 81348 DDD R 0030 Solvent cleaning compound breakthrough 5 gallon can OK209 Tag marker 50 each bundle 81349 MIL T 12755 Tape pressure sensitive 3 in wide green 36 yard roll 52152 471 0064 2 TM 9 2815 538 24 amp P INDEX Subject WP Sequence No Page No A B Battery Charging Alternator 24 Vd
72. 2 Fuel Injector Test 3 Operate nozzle tester lever slowly and read pressure at moment when fuel spray from nozzle starts 4 f measured injection pressure is less than 3 133 to 3 278 psi 21 6 to 22 6 MPa replace fuel injector figure 1 item 1 Injector Leak Test 1 Use nozzle tester to check spray pattern and injector nozzle valve when injection pressure is correct 2 Operate injector two or three times with nozzle tester and gradually increase pressure 3 Hold pressure for about 5 seconds at just below valve opening pressure of 284 psi 1 96 MPa and verify fuel does not drip from tip of nozzle 4 If fuel leaks continuously from top of injector torque nozzle case nut figure 1 item 3 to 28 9 to 32 5 Ib ft 39 2 to 44 1 Nm and retest 5 fuel continuously drips from tip of nozzle or top of injector leaks replace fuel injector figure 1 item 1 0022 3 TM 9 2815 538 24 amp P 0022 00 INSPECTION Continued Spray Pattern Inspection 1 Operate nozzle tester lever once or twice per second and compare spray pattern as follows figure 3 a b No extreme difference in angle 0 No extreme injection angle difference a Finely atomized spray Consistent spray volume NORMAL ABNORMAL 15KW 2815 24M 315A Figure 3 Normal and Abnormal Spray Patterns 2 If normal spray pattern is not observed replace fuel injector figure 1 item 1 REPAIR Repair of this item is limited to removal and replacem
73. 24 amp P 0036 00 EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES Continued NOTE When you use an NSN to requisition an item the item you receive may have a different P N from the number listed 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 P Ns of bulk materials are referenced in this column in the line entry to be manufactured or fabricated 3 Hardness Critical Item HCI A support item that provides the equipment with special protection from electromagnetic pulse EMP damage during a nuclear attack 4 The statement END OF FIGURE appears just below the last item description in column 6 for a given figure in both the repair parts list and special tools list work packages QTY Column 7 The QTY quantity per 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 iVi appearing in this column instead of a quantity indicates that the quantity is variable and may vary from application to application EXPLANATION OF CROSS REFERENCE INDEXES WORK PACKAGES FORMAT AND COLUMNS 1 National Stock Number NSN Index Work Package STOCK NUMBER Column This column lists the NSN in National item identification number NIIN sequence Th
74. 24 amp P 0056 00 1 2 3 4 5 6 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN _ NUMBER CODE UOC GROUP 05 EXHAUST SYSTEM FIG 201 INTAKE MANIFOLD XBFZZ 0AK42 171340 77520 ADAPTER INTAKE MANIFOLD DIESEL PAFZZ 5306 01 546 3581 0AK42 26106 081002 BOLT MACHINE PAFZZ 5306 01 547 0515 0AK42 26106 080602 BOLT MACHINE PAFZZ 5330 01 477 4043 0AK42 129100 77510 PAFZZ 2990 01 546 4578 0AK42 129100 77500 AIR DUCT ENGINE PAFZZ 5330 01 419 5480 0AK42 129150 77511 PAFZZ 5330 01 546 4259 0AK42 129508 12110 GASKET MANIFOLD XBFZZ 0AK42 129508 12120 MANIFOLD INTAKE PAFZZ 5306 01 546 8913 0AK42 26106 080202 BOLT MACHINE PAFZZ 5306 01 546 8565 0AK42 26106 080802 BOLT MACHINE 1 2 3 4 5 6 7 8 9 10 END OF FIGURE 0056 2 0057 00 TM 9 2815 538 24 amp P gt gt ua F bE SO 49722 aq 0 z2940 2 LI lt lt DILIT Q oa z zou uzg ao gt 15KW 2815 24P 06 2A Figure 21 Turbocharger Assembly 0057 1 1 ITEM NO 1 2 3 4 5 6 7 8 9 10 11 2 SMR CODE 3 NSN 5310 01 546 8927 2950 01 537 9970 5307 01 546 8878 5330 01 546 8879 5330 01 546 6855 5306 01 546 4268 5306 01 547 0056 5306 01 546 3568 5330 01 455 4061 5306 01 546 8540 4 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 TM 9 2815 53
75. 2792 5306 01 547 0595 4730 01 546 8903 3040 01 546 4092 4730 01 546 8864 5365 01 546 9878 5310 01 546 8889 5310 01 546 8875 5310 01 546 9316 5330 01 326 2669 5310 01 546 3576 5340 01 546 6859 5315 01 546 8877 5315 01 547 0091 5315 01 465 9931 5305 01 546 8629 4730 01 546 7538 4730 01 546 9221 5330 01 454 6389 5330 01 546 8869 5306 01 546 9263 5365 01 526 7332 4730 01 546 4247 5331 01 546 8517 5331 01 546 8126 5331 01 546 8932 5331 01 546 4255 5331 01 546 4260 3030 01 547 4661 5306 01 546 4273 5305 01 388 6229 5306 01 546 8910 5305 14 469 7436 5306 01 546 8929 5306 01 546 8913 5306 01 546 8052 5306 01 547 2404 5306 01 546 8037 5306 01 431 7461 0063 4 ITEM 2OROZ20IDONONXZ222N 09 00140 0063 00 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 30554 30554 00U12 00U12 00U12 PART NUMBER 26106 080402 26106 080452 26106 080502 26106 080552 26106 080602 26106 080802 26106 081002 26116 101202 26116 120252 26206 100252 26206 100302 26226 080352 26306 080002 26306 100002 26366 060002 26776 140002 27241 120000 27241 300000 27241 400000 729402 23100 729508 01560 729508 51310 729508 53100 88 20260 32 97 24115 BELFER1 BELFER2 BELFER3 TM 9 2815 538 24 amp P STOCK NUMBER 5306 01 547 0081 5306 01 388 6230 5306 01 546 4263 5
76. 3 5 Repair 4 0 1 4 5 Inspect 0 2 Removel Install 2 0 3 5 Replace 2 0 1 5 Inspect 0 5 Test 0 5 3 5 Remove Install 4 0 5 Replace 4 0 5 Repair 4 0 1 4 5 Inspect 0 2 Remove Install 1 0 15 Replace 1 0 15 Repair 0 1 1 3 5 0035 1 0035 00 MAC Continued Table 1 Maintenance Allocation Chart Continued 1 2 3 4 5 6 TOOLS AND GROUP COMPONENT MAINTENANCE MAINTENANCE EQUIPMENT REMARKS NUMBER ASSEMBLY FUNCTION LEVEL REF CODE CODE FIELD SUSTAINMENT BELOW CREW SERVICE FIELD DEPOT DEPOT Oe EA E oe 0108 CRANKSHAFT Inspect 0 3 ASSEM Remove Install 6 0 1 5 Repair 6 0 3 4 5 0111 GEAR CASE Inspect 0 3 0 5 ASSEMBLY Remove Install 1 0 Test 1 5 4 Repair 1 5 1 2 3 4 Overhaul 3 0 1 2 3 4 02 COOLING SYSTEM Inspect 0 1 Service 0 5 Repair 0 1 5 0201 FAN ASSEMBLY Inspect 0 Remove Install 0 1 5 Replace 0 1 5 03 FUEL SYSTEM Inspect 0 1 0 2 Service 0 0 1 5 Repair 1 1 2 5 0301 FUEL INJECTION Inspect 0 2 0 2 ASSEMBLY Test 0 2 0 2 Remove Install 0 0 6 Replace 0 0 6 Repair 3 0 1 5 04 LUBRICATION Inspect 0 0 1 SYSTEM Service 0 2 15 Repair 0 1 5 0401 OIL PUMP Inspect 0 2 ASSEMBLY Remove Install 0 5 1 5 Replace 0 5 15 0402 CRANKCASE Inspect 0 ASSEMBLY Remove Install 1 0 1 5 Repair 0 1 5 05 EXHAUST SYSTEM Inspect 0 1 0 2 Remove Install 1 1 5 Replace 1 1 5 0501 TURBOCHARGER Inspect 0 0 2 ASSEMBLY Test 0 5 0 5 2 Remove Install 0 0 7 1 5 Replace 1 1 0 1 5 Repair 25 15 0035 2 0035
77. 305 01 477 3508 5306 01 547 0515 5306 01 546 8565 5306 01 546 3581 5306 01 546 8846 5306 01 546 4272 5306 99 450 7012 5307 01 547 0090 5310 01 546 8927 5310 01 547 0460 5310 01 388 8826 5310 01 546 9272 2815 01 538 0835 2910 01 538 0115 2915 01 546 8222 5305 01 056 1501 FIG ITEM 7 16 11 3 19 6 3 2 10 9 11 15 20 3 20 10 20 2 23 8 22 2 8 3 8 7 3 3 10 2 21 1 23 5 17 11 7 9 2 5 2 2 4 17 6 5 2 1 15 1 14 1 19 19 19 18 19 20 19 17 19 12 0063 5 6 blank 0063 00 TM 9 2815 538 24 amp P 0064 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 EXPENDABLE AND DURABLE ITEMS LIST EXPENDABLE AND DURABLE ITEMS LIST INTRODUCTION Scope This work package lists expendable and durable items that you will need to operate and maintain the diesel engine This list is for information only and is not authority to requisition the listed items These items are authorized to you by CTA 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items or CTA 8 100 Army Medical Department Expendable Durable Items Even though MIL and Federal specifications are cited commercial equivalents may be used as required Explanation of Columns in the Expendable Durable Items List Column 1 Item Number This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the e g Use crocus cloth item 1 WP 0064 00 Column
78. 4710 01 546 4254 5330 01 455 4061 5340 01 546 3539 2835 01 546 7876 4720 01 546 8050 2920 01 546 8025 5306 01 546 3568 4810 01 546 8874 5330 01 454 4380 3120 99 549 3927 0063 3 ITEM ao 0063 00 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 S4163 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 PART NUMBER 129795 21661 129795 49551 129900 32130 129900 77240 129907 11950 129916 49740 158552 51151 171008 03990 171051 01921 171056 49120 171340 77520 171353 44760 171420 01600 22137 100000 22190 080002 22190 100002 22190 140002 22190 160002 22190 220002 22217 140000 22252 000260 22351 030010 22351 060012 22512 070140 22857 500100 23080 015000 23080 018000 23414 080000 23414 100000 23857 030000 23857 080000 23876 010000 23876 020000 23876 030000 23876 040000 24311 000120 24311 000320 24314 000160 24341 000240 24341 000400 25132 003800 26014 080252 26106 060162 26106 060402 26106 080122 26106 080142 26106 080202 26106 080222 26106 080252 26106 080302 26106 080352 TM 9 2815 538 24 amp P STOCK NUMBER 5310 01 546 9888 5330 99 727 8075 6115 01 546
79. 5 4 4 5 15KW 2815 24M 100 TM 9 2815 538 24 amp P WARNING SUMMARY Continued SAFETY AND HAZARDOUS MATERIAL This manual describes physical and chemical processes that may require the use of chemicals solvents paints or other commercially available material Users of the manual should obtain the material safety data sheets Occupational Safety and Health Act OSHA Form 20 or equivalent from the manufacturers or suppliers of materials to be used Users must be completely familiar with manufacturer supplier information and adhere to their procedures recommendations warnings and cautions for safe use handling storage and disposal of these materials EXPLANATION OF SAFETY WARNING ICONS ELECTRICAL electrical wire to hand with electricity symbol running through hand shows that shock hazard exists HOT AREA hand over object radiating heat shows that part or area is hot and can burn HEAVY OBJECT human figure stooping over heavy object shows physical injury potential from improper lifting technique or failure to share lifting task with other persons HEAVY PARTS hand with heavy object on top shows that heavy parts can crush and harm if dropped HEAVY PARTS foot with heavy object on top shows that heavy parts can crush and harm if dropped MOVING PARTS hand with figures caught between gears shows that the moving parts of the equipment present a danger to life or limb SHARP OBJECT pointed object in hand shows th
80. 5 Remove banjo bolt figure 1 item 14 and two seal washers figure 1 items 15 from cylinder block assembly figure 1 item 16 Discard seal washers 6 Remove banjo bolt figure 1 item 17 two gaskets figure 1 items 18 and oil line assembly figure 1 item 19 Discard gaskets 0027 2 0027 00 TM 9 2815 538 24 amp P REMOVAL Continued J LES Y OY N M IN Ne VARS RG gt LASS A NS M ay Y DD 2815 24 1 15KW Figure 1 Turbocharger Oil Lines 0027 3 TM 9 2815 538 24 amp P 0027 00 INSPECTION 1 2 3 Inspect all parts for wear cracks and corrosion Inspect all hardware for stripped or damaged threads Inspect for signs of leakage REPAIR Repair of this item is limited to removal and replacement INSTALLATION 1 Place oil line assembly figure 1 item 19 into position on turbocharger figure 1 item 4 and install two gaskets figure 1 item 18 and banjo bolt figure 1 item 17 2 Install two seal washers figure 1 item 15 and banjo bolt figure 1 item 14 to connect oil line assembly figure 1 item 19 to cylinder block assembly figure 1 item 16 3 Install two seal washers figure 1 items 11 and 12 to connect oil line assembly figure 1 item 19 to fuel injection pump assembly figure 1 item 13 4 Secure retainer figure 1 item 9 to fuel injection pump assembly figure 1 item 13 with nut figure 1 item 8
81. 5 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Insufficient engine output with white exhaust smoke Continued MALFUNCTION Too late timing of fuel injection pump assembly CORRECTIVE ACTION Check fuel injection pump assembly adjust timing WP 0016 00 MALFUNCTION Uneven volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injection pump assembly and fuel injectors replace as required WP 0016 00 WP 0022 00 MALFUNCTION Poor spray pattern from fuel injector nozzle CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 MALFUNCTION Worn intake exhaust valve guides CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Improper open or close timing of intake exhaust valves CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Worn turbocharger assembly bearing CORRECTIVE ACTION Replace turbocharger assembly WP 0028 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual 0005 8 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Insufficient engine output with black exhaust smoke MALFUNCTION Fouled turbocharger assembly CORRECTIVE ACTION Inspect turbocharger assembly clean as required WP 0028 00 MALFUNCTION Turbocharger assembly waste gate malfunction CORRECTIVE ACTION Test inspect turbocharger assembly waste gate rep
82. 7 0460 5310 01 546 8889 5306 01 546 8846 5306 01 546 4273 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 GENERATOR REPAIR PARTS LIST 4 CAGEC 0AK42 0AK42 OAK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 15KW 2815 24P 30 Figure 23 Generator 5 6 PART DESCRIPTION AND USABLE ON NUMBER CODE UOC GROUP 0602 GENERATOR FIG 23 GENERATOR 119810 77340 129646 77330 119940 77270 129900 77240 GENERATOR ENGINE ACCESSORY 26306 100002 NUT PLAIN HEXAGON HEAD 22137 100000 WASHER FLAT 129470 77340 26116 101202 26014 080252 END OF FIGURE 0059 1 2 blank TM 9 2815 538 24 amp P 0060 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 SPECIAL TOOLS LIST NOT APPLICABLE 0060 1 2 blank TM 9 2815 538 24 amp P 0061 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 BULK MATERIAL LIST NOT APPLICABLE 0061 1 2 blank TM 9 2815 538 24 amp P 0062 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 NATIONAL STOCK NUMBER INDEX STOCK NUMBER FIG ITEM STOCK NUMBER FIG ITEM 5305 01 158 0835 10 5 5340 01 546 3539 14 11 11 5 4820 01 546 3548 4 16 18 4 5307 01 546 3559 10 3 19 10 5306 01 546 3568 21 8 4730 01 322 4956 19 8 5310 01 546 3576 7 10 5340 01 323 7844 11 25 4720 01 546 3578 4 18 11 29 5306 01 546 3581 20 2 14 8 3040 01 546 4092 7 11 5330 01 326 2669 1
83. 8 24 amp P 5 PART NUMBER 26306 080002 129508 18010 129418 18320 129508 18090 129508 18080 119802 13670 119802 13650 129693 44310 129403 13120 129550 13110 119131 18320 0057 2 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0501 TURBINE ASSEMBLY FIG 21 TURBOCHARGER ASSEMBLY NUT PLAIN HEXAGON HEAD TURBOSUPERCHARGER ENGINE STUD THREADED GASKET TURBOCHARGER BOLT MACHINE BOLT MACHINE BOLT MACHINE MANIFOLD EXHAUST BOLT MACHINE END OF FIGURE 0057 00 TM 9 2815 538 24 amp P 0058 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 STARTER MOTOR ASSEMBLY REPAIR PARTS LIST 15KW 2815 24P 31A Figure 22 Starter Motor Assembly 1 2 3 4 5 6 7 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODE UOC QTY GROUP 0601 STARTER MOTOR ASSEMBLY FIG 22 5 MOTOR ASSEMBLY PAOZZ 2920 01 546 8025 0AK42 129612 77011 STARTING MOTOR PAOZZ 5306 01 546 4272 0AK42 26116 120252 BOLT MACHINE cuasi 2 PAOZZ 5940 01 546 8988 0AK42 121254 77810 COVER TERMINAL gt a END OF FIGURE A 0058 1 2 blank TM 9 2815 538 24 amp P 0059 00 1 ITEM NO 4 2 3 4 5 6 7 8 9 2 SMR CODE PAOZZ XBOZZ XBOZZ PAOZZ PAOZZ PAOZZ XBOZZ PAOZZ PAOZZ 3 NSN 5306 01 546 3532 6115 01 546 2792 5310 01 54
84. 880 119717 11190 119717 11340 119717 11350 119717 11800 119802 01520 119802 01560 119802 03070 119802 11870 119802 13650 119802 13670 119802 21202 119802 21660 119802 25051 119802 25070 119802 25100 119802 25901 119802 32070 119802 32100 119802 32130 119802 35110 119802 49113 119802 49730 119802 55800 119807 11770 119810 77340 119940 59130 119940 77270 121023 01550 121111 21501 121252 39150 121450 42450 121550 23200 121850 21680 121850 42410 121850 51960 123907 11601 123907 11830 123907 59540 123907 59550 123907 59560 124060 01050 124160 01751 124160 01910 124160 11360 124160 39140 124240 01871 124395 49840 124465 44950 124550 77030 124722 59050 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 PART NUMBER INDEX STOCK NUMBER 4720 01 546 6890 5305 01 158 0835 4730 01 322 4956 5306 01 546 8540 5340 01 547 0471 5331 01 547 0529 2815 01 546 4587 5365 01 547 0563 5330 01 546 8902 5330 01 546 8128 2815 01 546 4327 5307 01 546 3559 4720 01 546 3578 5306 01 547 0056 5306 01 546 4268 3020 01 547 4629 3020 01 547 4625 5365 01 547 0544 3020 01 538 0777 5340 01 546 4256 5305 01 546 8908 4730 01 546 9253 5340 01 546 8917 2910 01 546 4727 5306 01 546 3532 3120 01 546 8851 5306 01 546 9973 5306 01 529 1138 4730 01 546 4242 5306 01 546 4275 5306 01 546 9891 5305 01 546 8870 5331 01 546 8510 5330 01 546 9903 5305 01 546 8911 5306 01 546 3527 5330 01 546 8
85. 883 4730 01 546 9935 2590 01 546 4329 5355 01 546 9841 5306 01 546 9886 5330 01 546 3538 5330 01 546 8898 5940 01 546 8988 5340 01 323 7844 oo NN o wo o NN ao CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 S4163 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 PART NUMBER 124722 59050 124766 59050 129001 01250 129001 02930 129001 32330 129001 91841 129004 01190 129004 22500 129004 22950 129004 42040 129004 49610 129004 49620 129004 49711 129004 49721 129004 55610 129005 59830 129006 03120 129006 35100 129006 44480 129100 01580 129100 01640 129100 23910 129100 42051 129100 42121 129100 77500 129100 77510 129103 49301 129110 44740 129120 01780 129150 01200 129150 02020 129150 02450 129150 02870 129150 02930 129150 02940 129150 03070 129150 03090 129150 11230 129150 11750 129150 14101 129150 14200 129150 14400 129150 23600 129150 23610 129150 25301 129150 35042 129150 35091 129150 35111 129150 35152 129150 49811 129150 77511 129155 42350 129155 49801 129202 22300 129210 59110
86. 8886 0AK42 129508 59550 PIPE ASSEMBLY FUEL RETURN PAFZZ 5330 01 546 8883 0AK42 123907 59550 PACKING FUEL RETURN PAFZZ 5310 01 546 8875 0AK42 22190 080002 SEAL WASHER PAFZZ 4730 01 546 9935 0AK42 123907 59560 ADAPTER HOSE JOINT AFFFF 0AK42 129508 59570 HOSE ASSEMBLY NONMETALLIC PAFZZ 5340 01 323 7844 0AK42 124722 59050 CLAMP HOSE PAFZZ 4720 01 546 7874 0AK42 129508 59510 HOSE NONMETALLIC PAFZZ 4710 01 546 4254 0AK42 129508 59940 PIPE ASSEMBLY FUEL INJECTION PAFZZ 5340 01 546 3539 0AK42 129550 59120 CLAMP RETAINER PAFZZ 5340 01 547 0471 0AK42 119305 59120 CLAMP RETAINER PAFZZ 4710 01 546 4250 0AK42 129508 59910 PIPE ASSEMBLY FUEL INJECTION PAFZZ 4710 01 546 9905 0AK42 129508 59920 PIPE ASSEMBLY FUEL INJECTION PAFZZ 4710 01 546 3530 0AK42 129508 59930 PIPE ASSEMBLY FUEL INJECTION PAFZZ 5330 01 546 9903 0AK42 123907 11601 SEAL FUEL PIPE 4 2 3 4 5 6 7 8 9 amp END OF FIGURE 0050 2 TM 9 2815 538 24 amp P 0051 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FUEL INJECTION ASSEMBLY REPAIR PARTS LIST Y AA Net s VAN Sy N O Se y 2 IN NN a AM 4 2 A 7 27 7 BR IL 7 A BER 2 A y gt 2 S SS fh 2768 E N Ay
87. 9 if necessary 7 Remove nut figure 1 item 10 oil cooler assembly figure 1 item 5 and stud figure 1 item 11 8 Remove three bolts figure 1 item 12 filter bracket figure 1 item 13 and gasket figure 1 item 14 9 Remove oil pressure switch figure 1 item 15 0018 2 0018 00 TM 9 2815 538 24 amp P REMOVAL Continued IS N K gt AZ Si REN OX 24 aN Y 2 O CE LS A 2 Fy LLON EN TR Ky 15KW 2815 24M 306A Figure 1 Oil Cooler Assembly and Oil Pressure Switch 0018 3 TM 9 2815 538 24 amp P 0018 00 INSPECTION 1 2 3 Inspect all parts for wear cracks and corrosion Inspect all hardware for stripped or damaged threads Inspect for signs of leakage REPAIR Repair of this item is limited to removal and replacement INSTALLATION 1 Install oil pressure switch figure 1 item 15 2 Install gasket figure 1 item 14 filter bracket figure 1 item 13 and three bolts figure 1 item 12 Torque bolts to 16 7 21 0 Ib ft 22 6 28 4 Nm 3 Install stud figure 1 item 11 oil cooler assembly figure 1 item 5 and nut figure 1 item 10 4 Install drain plug figure 1 item 9 and adapter figure 1 item 8 5 Install cooler in pipe figure 1 item 7 onto adapter figure 1 item 8 and oil cooler assembly figure 1 item 5 with two spring clamps figure 1 item 6
88. 9 9 4730 01 546 4242 11 12 5305 01 388 6229 10 8 4820 01 546 4246 4 6 17 1 4730 01 546 4247 11 21 5306 01 388 6230 11 3 4 13 19 6 4710 01 546 4250 14 13 5310 01 388 8826 17 11 4710 01 546 4254 14 10 5330 01 419 5480 20 6 5331 01 546 4255 10 6 5306 01 431 7461 16 3 5340 01 546 4256 18 8 19 1 5330 01 546 4259 20 7 5330 01 454 4380 10 11 5331 01 546 4260 5 4 5330 01 454 4384 19 14 5306 01 546 4263 3 2 3120 01 454 6117 2 7 5306 01 546 4266 7 8 5330 01 454 6389 11 13 5306 01 546 4268 21 6 5330 01 455 4061 21 10 5306 01 546 4269 2 9 3020 01 455 4443 4 5306 01 546 4272 22 2 3120 01 455 5082 7 5306 01 546 4273 23 9 5315 01 465 9931 6 5306 01 546 4275 6 8 3 2815 01 546 4309 7 5 5305 01 477 3508 9 2815 01 546 4327 4 12 5330 01 477 4043 4 2590 01 546 4329 18 7 5365 01 526 7332 23 2815 01 546 4567 4 8 5306 01 529 1138 17 5315 01 546 4572 4 9 2950 01 537 9970 2 2990 01 546 4578 20 5 2815 01 537 9999 1 2920 01 546 4582 7 4 2910 01 538 0115 1 2815 01 546 4587 4 19 2815 01 538 0771 2 4730 01 546 4701 16 16 3020 01 538 0777 1 2815 01 546 4717 6 3 2815 01 538 0835 5 2815 01 546 4721 6 4 2815 01 538 0974 3 2910 01 546 4727 13 1 2815 01 538 0978 2 2940 01 546 5058 16 11 6115 01 546 2792 4 5330 01 546 6844 16 1 6685 01 546 3005 9 5330 01 546 6855 21 5 5306 01 546 3527 2 5340 01 546 6859 6 1 4710 01 546 3530 15 4720 01 546 6890 13 9 5306 01 546 3532 1 5330 01 546 7537 2 14 5330 01 546 3538 1 4730 01 546 7538 16 8 13 5330 01 546 8883 14 4 STOCK NUMBER 5330
89. A e ie At 0002 00 1 InSpectiOn 0016 00 9 INStallation ati ee etd inate 0016 00 9 Cover Plate Figure 2 0016 00 3 Fuel Injection Pump Assembly Figure 5 0016 00 6 Gear Puller Figure 4 11 1 1106 0016 00 5 Timing Adjustment Example Figure 9 0016 00 10 Timing Index Number Figure 8 0016 00 9 Timing Index Sticker Figure 10 0016 00 10 LOCO I ERE 0002 00 1 edente ee ea iet aee tertie ted 0016 00 2 Cover Plate Figure 2 0016 00 3 Drive Gear Reference Marks Figure 3 0016 00 4 Fuel Injection Pump Assembly Figure 5 0016 00 6 Fuel Injection Pump Assembly Plunger Plug Figure 1 0016 00 2 Gear Puller Figure 4 iron eno obrero e ean 0016 00 5 Timing Grid Sticker Location Figure 7 0016 00 8 Timing Index Number Figure 8 sse 0016 00 9 Timing Mark Location Figure 6 0016 00 7 si ni ML Lt LM dM D Le eT ree 0016 00 9 Repair Parts List Fuel Injection Lines and Return 0050 00 1 Gasket and Mounting 0046 00 1 E LP 0038 00 1 S pport Bracket iei ood ERI eee 0051 00 1 Timing Gea mE 0043 00 1
90. ARMY 9 2815 538 24 amp P AIR FORCE TO 38G1 129 3 TECHNICAL MANUAL FIELD AND SUSTAINMENT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST FOR YANMAR DIESEL ENGINE 4TNV84T DFM 4 CYLINDER 2 0 LITER NSN 2815 01 538 4257 EIC N A 15KW 2815 24M 327A This manual supersedes TM 9 2815 538 24 amp P dated 15 June 2008 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited DEPARTMENTS OF THE ARMY AND THE AIR FORCE 15 February 2009 TM 9 2815 538 24 amp P WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment Failure to observe these precautions may result in serious injury or death to personnel Also included are explanations of safety and hazardous material icons FIRST AID For first aid refer to FM 4 25 11 SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICAL SHOCK DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL IF POSSIBLE TURN OFF THE ELECTRICAL POWER IF YOU CANNOT TURN OFF THE ELECTRICAL POWER PULL PUSH OR LIFT THE PERSON TO SAFETY USING A DRY WOODEN POLE OR A DRY OR SOME OTHER INSULATING MATERIAL SEND FOR HELP AS SOON AS POSSIBLE AFTER THE INJURED PERSON IS FREE OF CONTACT WITH THE SOURCE OF ELECTRICAL SHOCK MOVE THE PERSON A SHORT DISTANCE AWAY AND IMMEDIATELY START ARTIFICIAL RESUSCITATION
91. Assembly The water pump assembly figure 1 sheet 3 item 10 is a belt driven pump used to pump coolant throughout the engine Cil Fill Cap The oil fill cap figure 1 sheet 3 item 11 is removed to allow refilling of the oil reservoir with engine oil Gear Case Assembly The gear case assembly figure 1 sheet 3 item 12 is a cover which contains the direct driven oil pump The gear case also covers protects the fuel injection pump assembly gear idle gear and camshaft gear BE gt Sa 15KW 2815 24M 349 Figure 1 Diesel Engine Sheet 1 of 3 0002 2 0002 00 TM 9 2815 538 24 amp P LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Continued 15 2815 24 350 Figure 1 Diesel Engine Sheet 2 of 3 0002 3 0002 00 TM 9 2815 538 24 amp P LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Continued 11 PS a 22e TEE 57 Ve a DEN TORO 27 SA KARE N POL ANS GE 50552 55 gt l KG SN LO y SS 355 PRE yf POLEO ple M Va CAEN VL IR 2 09 CIN ERA SS v NN ya LAS YA gt 15 24 351 15 2815 Figure 1 Diesel Engine Sheet of 3 0002 4 TM 9 2815 538 24 amp P 0002 00 EQUIPMENT DATA Table 1 lists equipment data for the diesel engine Table 1 Diesel Engine Equipment Data EQUIPM
92. ENT DATA Overall length 27 53 in 69 9 cm Width 20 18 in 51 3 cm Height 26 52 in 67 4 cm Weight dry 419 Ib 190 kg Manufacturer Yanmar Model 4TNV84T Part number 4TNV84T DFM Type Four cylinder in line four cycle turbocharged diesel Bore 3 307 in 84 mm Stroke 3 543 in 90 mm Displacement 121 7 in 1 995L Compression ratio 20 1 Valves per cylinder 4 2 inlet 2 exhaust Valve lash setting cold engine Inlet 0 0059 to 0 098 in 0 15 to 0 25 mm Exhaust 0 0059 to 0 098 in 0 15 to 0 25 mm Cooling system Type Designed for pressurized radiator and coolant pump Normal operating temperature 170 to 200 77 to 93 C Thermostat opening 157 to 162 5 69 5 to 72 5 6 Thermostat full open 185 85 C Lubrication system Type Forced lubrication Pump type Trochoid engine gear driven Capacity 6 at 5 7L Normal operating pressure 43 to 56 psi 294 to 391 kPa Fuel system Fuel type DF 1 DF 2 DF A JP 4 JP5 JP8 Fuel consumption rate 1 5 gph 5 7 Iph Rated loads 33 bhp at 1 500 rpm 40 bhp at 1 800 rpm 44 bhp at 2 000 rpm Torque available 116 Ib ft 157 3 Nm at 1 800 rpm 0002 5 EQUIPMENT DATA Continued Table 1 Diesel Engine Equipment Data Continued EQUIPMENT DATA Engine electrical system Batteries Starter motor assembly Manufacturer Part number Voltage rating Drive type Battery charging alternator 24 Vdc Manufacturer Part number Voltage rating Drive type Amperage Rating S
93. Engine 4TNV84T DFM The table of contents will help you understand the organization of the manual and will direct you to the major sections More detailed segments such as specific maintenance instructions can be located in the index at the end of the manual The References work package WP 0033 00 provides a listing of other related manuals The Maintenance Allocation Chart MAC work package 0035 00 provides tools and test equipment to perform maintenance The Expendable and Durable Items List work package WP 0064 00 provides supplies to perform maintenance The Repair Parts and Special Tools List RPSTL work packages WP 0036 00 thru WP 0063 00 list and authorize spares repair parts and special tools required for performance of maintenance While performing the procedures in this manual you may find that you are able to make suggestions that will improve the manual At the back of this manual you will find copies of DA Form 2028 which invite you to submit your suggestions TM 9 2815 538 24 amp P HOW TO USE THIS MANUAL Continued Read the INITIAL SETUP section carefully before you start any maintenance procedure Get the tools and supplies listed and the personnel needed TITLE FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 SUMMARY TURBOCHARGER ASSEMBLY AND EXHAUST MANIFOLD REMOVAL INSPECTION REPAIR INSTALLATION TOOLS ors PT SETUP SPECIAL TOOLS Tools and Special Tools References Tool kit
94. High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0011 1 TM 9 2815 538 24 amp P 0011 00 REMOVAL NOTE V belt may be removed without removing cooling fan 1 Release V belt tension by moving battery charging alternator 24 Vdc toward engine until V belt figure 1 item 1 can be removed from V pulley figure 1 item 2 2 Remove four bolts figure 1 item 3 cooling fan figure 1 item 4 spacer figure 1 item 5 and V pulley figure 1 item 2 from cooling water pump figure 1 item 6 15KW 2815 24M 302 Figure 1 Fan V Pulley and V Belt INSPECTION 1 Inspect all parts for wear cracks and corrosion 2 Inspect all hardware for stripped or damaged threads 3 Inspect V belt for cracks oiliness or wear REPAIR Repair of this item is limited to removal and replacement 0011 2 TM 9 2815 538 24 amp P 0011 00 INSTALLATION NOTE V belt may be installed with cooling fan installed 1 Install V pulley figure 1 item 2 spacer figure 1 item 5 cooling fan figure 1 item 4 and four bolts figure 1 item 3 onto cooling water pump figure 1 item 6 Torque bolts to 7 2 8 7 Ib ft 9 8 11 8 Nm 2 Install V belt figure 1 item 1 over V pulley figure 1 item 2 and ensure V belt is properly installed onto other pulleys 3 Adjust V belt figure 1 item
95. ION Check fuel injectors replace as required WP 0022 00 MALFUNCTION Improper intake exhaust valve clearance CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Compression leakage from valve seat CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual END OF WORK PACKAGE 0005 26 TM 9 2815 538 24 amp P CHAPTER 3 MAINTENANCE INSTRUCTIONS FOR DIESEL ENGINE TM 9 2815 538 24 amp P CHAPTER 3 MAINTENANCE INSTRUCTIONS FOR DIESEL ENGINE WORK PACKAGE INDEX Title SERVICE UPON RECEIPT niis cinis free rrt GR IR D a RC ELE RE RE E XA RA A PMCS INTRODUCTION RR EX FR RE RES REIR EN KR RE EE RA RDR ERR ER ARERR RR FAR RS DA n BATTERY CHARGING ALTERNATOR 24 FAN V PULLEY AND V BELT e eri oe e d ec ERG DO AE EX RE RERO EE ebenen EU RO EAR WATER PUMP ASSEMBLY apii rires ian RE ERR OUR DE ERR REA AUR RR RA SX RAE KR RA B XR XAR THERMOSTAT COVER AND TEMPERATURE SWITCH essere nennen nano GEAR CASE ASSEMBLY comi ecrit ca Dod d e eR i i ER AEG E D E RETE ED REDE SE EO E RAS IDLE GEAR ASSEMBLY crnatiesce cii nente xac b pr e
96. ION S YSIS 0003 00 4 Thermostat Cover and Temperature Switch 0013 00 2 Installation O REO td P E e E o m Bali 0013 00 3 Thermostat Cover and Temperature Switch Figure 1 0013 00 2 sei totae dta etiain A 0013 00 2 Thermostat Cover and Temperature Switch Figure 1 0013 00 2 O SO 0013 00 2 Repair Parts EISt iii cte tede dota 0047 00 1 Torque 0032 00 1 Troubleshooting Troubleshooting 0004 00 1 Troubleshooting 0005 00 1 Turbocharger Assembly Exhaust Manifold eii eier 0002 00 1 niati 0028 00 4 Rotor Play 0028 00 4 Axial Play Measurement Figure 2 0028 00 4 Radial Play Measurement Figure 3 0028 00 5 Turbocharger Assembly and Exhaust Manifold Figure 1 0028 00 3 Waste Gate Actuator Leak eee nen 0028 00 6 Required Test Equipment Table 1 0028 00 6 Waste Gate Actuator Leak Test Setup Figure 4 0028 00 6 Turbocharger Assembly and Exhaust Manifold Figure 1 0028 00 3 Waste Gate Actuator Opening Pressure and
97. IPTION AND DATA EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES The diesel engine is four cylinder four cycle fuel injected turbocharged and liquid cooled The firing order is 1 3 4 2 The number one cylinder is toward the flywheel end of the engine The serial number is located on the engine name plate on top of the valve cover assembly Rotation of the engine is Counterclockwise CCW as viewed from the flywheel end The engine can operate using diesel fuel or aviation fuel In accordance with U S Environmental Protection Agency USEPA requirements several features have been incorporated to reduce engine exhaust emissions and noise These include an oil pump built into the front gear assembly and driven by the gears optimal installation of the fuel injectors vertically and in the center of the cylinders low suction volume and multiple injection holes of the fuel injectors mono injection plunger with higher injection pressure on the injection pump and a new design of the combustion chamber LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Fuel Filter The fuel filter figure 1 sheet 1 item 1 provides additional filtering of the fuel before it enters the fuel injection pump Flywheel Assembly The flywheel assembly figure 1 sheet 1 item 2 is weighted and balanced to help reduce vibration and provide smooth output from the engine The flywheel is geared to engage the starter motor assembly Starter Motor Assembly The starter mo
98. Install turbocharger oil lines WP 0027 00 END OF WORK PACKAGE 0028 7 8 blank TM 9 2815 538 24 amp P 0029 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 CRANKCASE ASSEMBLY AND DIPSTICK REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Materials Parts Continued Tool kit general mechanic s Gasket forming compound item 5 WP 0035 00 item 2 WP 0064 00 Wiping rag item 5 Materials Parts Breakthrough cleaning solvent Personnel Required 6 W 0064 00 One WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless itis properly grounded Failure to comply may result in serious injury or death to personnel 0029 1 TM 9 2815 538 24 amp P 0029 00 REMOVAL 1 Remove screw figure 1 item 1 seal figure 1 item 2 and dipstick
99. Issue of Vehicles and Spare Engines Preservation and Packing Data Occupational Safety and Health Act OSHA Material Safety Data Sheet Transportation Discrepancy Report Report of Discrepancy Product Quality Deficiency Report Warranty Program for Generator Set Tactical Quiet 15 KW 50 60 and 400 HZ MEP 804A and MEP 814A Corrosion Prevention and Control 0033 1 TM 9 2815 538 24 amp P 0033 00 TECHNICAL MANUALS TM 55 1500 323 24 Installation Practices Aircraft Electric and Electronic Wiring 740 90 1 Administrative Storage of Equipment TM 750 244 6 Procedures for Destruction of Tank Automotive Materiel to Prevent Enemy Use TM 750 254 Cooling Systems Tactical Vehicles MISCELLANEOUS PUBLICATIONS AR 385 11 Safety lonizing Protection AR 700 138 Army Logistics Readiness and Sustainability 735 11 2 incas Reporting of Supply Discrepancies AR ai Army Materiel Maintenance Policy CTA 8 100 iiid Army Medical Department Expendable Durable Items 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items DA PAM 25 30 Consolidated Index of Army Publications and Blank Forms DA PAM 738 750 Functional Users Manual for The Army Maintenance Managem
100. LANK FORMS Special Tool Lists RPSTL and Supply For use of this form see AR 25 30 the proponent agency is OAASA Catalogs Supply Manuals SC SM TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER PARA FIGURE ITEM PAGE GRAPH LINE TABLE RECOMMENDED CHANGES AND REASON TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION FORM NUMBER DATE TITLE TOTAL NO OF MAJOR PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM ITEMS RECOMMENDED ACTION NO NO NO NUMBER NO NO NO SUPPORTED PART Ill REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part Il reverse for Repair Parts and BLANK FORMS Special Tool Lists RPSTL and Supply For use of this form see AR 25 30 the proponent agency is OAASA Catalo
101. LLIC PAOZZ 5340 01 323 7844 0AK42 124722 59050 CLAMP HOSE PAOZZ 5340 01 546 8917 0AK42 119802 49730 CLAMP LOOP PAOZZ 4720 01 546 8893 0AK42 129004 49711 HOSE NONMETALLIC AOOOO 0AK42 129004 49620 HOSE ASSEMBLY NONMETALLIC PAOZZ 5340 01 323 7844 0AK42 124722 59050 CLAMP HOSE PAOZZ 4720 01 546 8124 0AK42 129004 49721 HOSE NONMETALLIC PAOZZ 5330 01 546 8895 0AK42 129486 42021 aSsnaNanaNaaN202a3Nag0QaaaNaaaaN0aaa END OF FIGURE 0047 2 TM 9 2815 538 24 amp P 0048 00 REPAIR PARTS LIST 1 ITEM NO 2 SMR CODE PAOZZ PAOZZ XBOZZ XBOZZ PAOZZ 3 NSN 2930 01 546 7913 5306 01 546 8910 3030 01 547 4661 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FAN ASSEMBLY 15KW 2815 24P 32 Figure 12 Fan Assembly 4 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 5 PART NUMBER 129110 44740 26106 060402 171353 44760 129155 42350 25132 003800 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0201 FAN ASSEMBLY FIG 12 FAN ASSEMBLY FAN COOLING BOLT MACHINE SPACER FAN PULLEY BELT END OF FIGURE 0048 1 2 blank TM 9 2815 538 24 amp P 0049 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FUEL SYSTEM REPAIR PARTS LIST 9 x4 y Q Wee Ce T NG f 7 x ZN 778 1073 SA A E AS ex 22
102. Lift 0028 00 5 Installations A aidera od DE deed 0028 00 7 Turbocharger Assembly and Exhaust Manifold Figure 1 0028 00 3 0002 00 1 Removal cce Ate etie ia 0028 00 2 Turbocharger Assembly and Exhaust Manifold Figure 1 0028 00 3 tco RID cuc 0028 00 6 eret teni deuda 0057 00 1 Index 8 TM 9 2815 538 24 amp P INDEX Continued Subject WP Sequence No Page No T U Continued Turbocharger Oil Lines INSPECTION ae E A tee 0027 00 4 Installation 0027 00 4 Turbocharger Oil Lines 0027 00 3 re aa ee 0027 00 2 Turbocharger Oil Lines Figure 0027 00 3 O O 0027 00 4 A ROO 0053 00 1 V Valve Cover Assembly Description Oil Fill Cap ci tite Ritt ertet ci eet rt trial 0002 00 2 Assembly io EE Lo e E bo o E Ee Eee e ro o be 0021 00 3 Valve Cover Assembly Figure 1 eene 0021 00 2 DISASSEMBLY 0021 00 2 Valve Cover Assembly Figure 1 0021 00 2 NN 0021 00 3 Installation eiii aeree 0021 00 3 Valve Cover Assembly 0021 00 2 Location
103. M ASSEMBLY ROCKER SCREW VALVE NUT PLAIN HEXAGON HEAD BOLT MACHINE ARM ASSEMBLY ROCKER SCREW VALVE NUT PLAIN HEXAGON HEAD BOLT MACHINE SUPPORT ROCKER ARM WASHER SPECIAL SUPPORT ROCKER ARM PEDESTAL RETAINER END OF FIGURE 0039 00 1 7 3 4 1 1 4 4 1 1 3 3 8 2 4 4 1 0040 00 TM 9 2815 538 24 amp P uz gt f E 200 gt 254 lt 0 wm 5 amp QZ gt lt amp uozmu uz nn gt 4 5 3 5 7 13 15 17 20 15KW 2815 24P 10 3B Figure 4 Cylinder Head Assembly 0040 1 TM 9 2815 538 24 amp P 0040 00 1 2 3 4 5 6 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN _ NUMBER CODE UOC GROUP 0102 CYLINDER HEAD ASSEMBLY FIG 4 CYLINDER HEAD ASSEMBLY PAFZZ 5306 01 546 8929 0AK42 26106 080142 BOLT MACHINE XBFHH 2815 01 538 0771 0AK42 129508 11700 HEAD ASSEMBLY CYLINDER XBHHH 0AK42 129508 11800 BRIDGE ASSEMBLY VALVE PAHZZ 5310 01 546 8916 0AK42 129150 11750 NUT PLAIN HEXAGON HEAD PAHZZ 5305 01 546 8911 0AK42 123907 11830 SCREW VALVE BRIDGE PAHZZ 4820 01 546 4246 0AK42 129508 11840 SEAT VALVE BRIDGE PAHZZ 5365 01 547 0563 0AK42 119717 11190 COTTER VALVE PAHZZ 2815 01 546 4567 0AK42 129508 11180 RETAINER SPRING PAHZZ 5315 01 546 4572 0AK42 129508 11820 GUIDE VALVE BRIDGE PAHZZ 5360 01 547 0442 0AK42 129508 11130 SPRING VALVE PAHZZ 5330 01 546 8902 0AK42 1197
104. NE END OF FIGURE 0045 1 2 blank TM 9 2815 538 24 amp P 0046 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 GEAR CASE ASSEMBLY REPAIR PARTS LIST 10 Pax 12 131 15KW 2815 24P 14 Figure 10 Gear Case Assembly 0046 1 1 ITEM NO 4 2 3 4 5 6 7 8 9 2 SMR CODE PAFZZ PAFZZ PAHZZ XBHZZ PAFZZ PAFZZ XBFZZ PAFZZ PAFZZ XBFFF PAFZZ XBHZZ XBHZZ PAFZZ XBHZZ PAHZZ 3 NSN 5331 01 546 8510 5310 01 546 8927 5307 01 546 3559 5305 01 158 0835 5331 01 546 4255 5305 01 388 6229 5306 01 477 3508 5330 01 454 4380 5306 01 547 0001 5331 01 547 0529 4 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 TM 9 2815 538 24 amp P 5 PART NUMBER 121850 51960 26306 080002 119802 01560 119802 01520 26106 080162 24341 000240 121023 01550 26106 060162 26106 080552 129240 01500 129795 01800 23876 040000 23876 030000 129001 91841 129795 01950 119609 32040 0046 2 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0111 GEAR CASE ASSEMBLY FIG 10 GEAR CASE ASSEMBLY NUT PLAIN HEXAGON HEAD STUD THREADED FLANGE GEAR CASE SCREW CAP HEXAGON HEAD COVER BLIND SCREW CAP HEXAGON HEAD SCREW CAP HEXAGON HEAD BOLT MACHINE PIN ALIGNMENT END OF FIGURE 0046 00 2 TM 9 2815 538 24 amp P 0047 00 FIELD AND
105. ODE REMARKS 0035 4 TM 9 2815 538 24 amp P 0036 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 REPAIR PARTS AND SPECIAL TOOLS LIST INTRODUCTION SCOPE This RPSTL lists and authorizes spares and repair parts special tools special test measurement and diagnostic equipment TMDE and other special support equipment required for performance of field and sustainment level maintenance of diesel engine model 4TNV84T DFM It authorizes the requisitioning issue and disposition of spares repair parts and special tools as indicated by the source maintenance and recoverability SMR codes GENERAL In addition to the Introduction work package this RPSTL is divided into the following work packages 1 Repair Parts List Work Packages Work packages containing lists of spares and repair parts authorized by this RPSTL for use in the performance of maintenance These work packages also include parts which 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 Sending units brackets filters and bolts are listed with the component they mount on Bulk materials are listed by item name in FIG BULK at the end of the work packages Repair parts kits are listed separately in their own functional group and work package Repair parts for repairable spec
106. P ASSEMBLY REPAIR PARTS LIST 15KW 2815 24P 07 4B Figure 18 Oil Pump Assembly 0054 1 1 ITEM NO 4 2 3 4 5 6 7 8 9 2 SMR CODE PAHZZ PAHZZ PAHZZ PAFZZ XBFZZ PAOZZ PAOZZ PAHZZ XAHZZ XAHZZ XAHZZ XAHZZ 3 NSN 5305 01 546 8908 3020 01 547 4658 3020 01 546 8538 5305 01 158 0835 5331 01 546 8126 2590 01 546 4329 5340 01 546 4256 4 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 OAK42 OAK42 OAK42 5 PART NUMBER 119802 32130 129508 32120 129508 32111 26106 080162 124240 01871 24311 000320 124160 01751 119802 32100 129001 32330 129418 32320 129900 32130 119802 32070 0054 2 TM 9 2815 538 24 amp P 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0401 OIL PUMP ASSEMBLY FIG 18 OIL PUMP ASSEMBLY SCREW MACHINE ROTOR OUTER ROTOR INNER SCREW CAP HEXAGON HEAD COVER FILLER COVER ASSEMBLY PUMP VALVE RELIEF COVER LUBE OIL PUMP END OF FIGURE 0054 00 TM 9 2815 538 24 amp P 0055 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 CRANKCASE ASSEMBLY REPAIR PARTS LIST 20 15KW 2815 24P RL 07 3D Figure 19 Crankcase Assembly 0055 1 1 ITEM NO 4 2 3 4 5 6 7 8 9 2 SMR CODE PAHZZ PAFZZ PAFZZ XBFZZ PAHZZ PAFZZ PBFZZ PAFZZ PAFZZ PAFZZ PAOZZ PAOZZ XBFFF PAFZZ PAOZZ PAOZZ XBOZZ XBOZZ PADZZ PAOZZ
107. TION FOR DIESEL ENGINE WORK PACKAGE INDEX Title TURBOCHARGED DIESEL ENGINE REPAIR PARTS CYLINDER BLOCK ASSEMBLY REPAIR PARTS ROCKER ARM SHAFT ASSEMBLY REPAIR PARTS LIST CYLINDER HEAD ASSEMBLY REPAIR PARTS 5 VALVE COVER ASSEMBLY REPAIR PARTS LIST 0000 CONNECTING ROD AND PISTON ASSEMBLY REPAIR PARTS LIST CAMSHAFT DRIVING GEAR AND IDLE GEAR ASSEMBLIES REPAIR PARTS LIST FLYWHEEL ASSEMBLY REPAIR PARTS 1116 22222 5 0 0 CRANKSHAFT ASSEMBLY REPAIR PARTS GEAR CASE ASSEMBLY REPAIR PARTS ronca nana COOLING SYSTEM REPAIR PARTS cnn nn cnn ronca cnn canon FAN ASSEMBLY REPAIR PARTS FUEL SYSTEM REPAIR PARTS LIST 2 4 FUEL INJECTION VALVE SYSTEM REPAIR PARTS FUEL INJECTION ASSEMBLY REPAIR PARTS 118 444 44 10000 OIL FILTER AND OIL COOLER REPAIR PARTS OIL BYPASS VALVE REPAIR PARTS LIST OIL PUMP ASSEMBLY REPAIR PARTS LIST
108. TIVE ACTION Adjust fan V belt tension WP 0010 00 MALFUNCTION Water pump assembly leaking CORRECTIVE ACTION Replace water pump assembly WP 0012 00 0005 22 0005 00 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Engine overheats Continued MALFUNCTION Insufficient coolant level CORRECTIVE ACTION 1 Check coolant level fill with correct coolant end item configuration manual 2 Check cooling system for leaks repair as required WP 0012 00 and end item configuration manual MALFUNCTION Insufficient cooling effect of radiator CORRECTIVE ACTION 1 Check for defective thermostat replace as required WP 0013 00 2 Check for excessive slack in fan V belt adjust as required WP 0010 00 3 Check radiator for excessive debris on cooling fins clean as required end item configuration manual MALFUNCTION Defective thermostat CORRECTIVE ACTION Check thermostat replace as WP 0013 00 MALFUNCTION Excessive volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 MALFUNCTION Engine used at high temperatures or at high altitude CORRECTIVE ACTION Check output drop and load matching requirements reduce load as required end item configuration manual MALFUNCTION Leaking cylinder head assembly gasket mn ACTION Replace cylinder head assembly gasket WP 0024 00 2 Flush cooling sys
109. WP 0016 00 0005 13 TM 9 2815 538 24 amp P TROUBLESHOOTING Continued SYMPTOM Continued Excessive black smoke while under load Continued MALFUNCTION Too early timing of fuel injection pump assembly CORRECTIVE ACTION Check fuel injection pump assembly adjust timing WP 0016 00 SYMPTOM High knocking sound during combustion MALFUNCTION Too early timing of fuel injection pump assembly CORRECTIVE ACTION Check fuel injection pump assembly adjust timing WP 0016 00 SYMPTOM Abnormal combustion sound MALFUNCTION Improper intake exhaust valve clearance CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Compression leakage from valve seat CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Improper open or close timing of intake exhaust valves CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual 0005 14 0005 00 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Uneven combustion sound MALFUNCTION Incorrect fuel grade type for ambient temperature range CORRECTIVE ACTION Drain fuel system fill with correct fuel end item configuration manual MALFUNCTION Water in fuel system CORRECTIVE ACTION 1 Drain fuel tank and fuel lines and hoses WP 0017 00 WP 0020 00 and end item configuration manual Drain water fr
110. a only Failure to comply may result in serious injury or death to personnel 2 Clean top and bottom mating surfaces of spacer figure 1 item 9 with breakthrough cleaning solvent and a wiping rag 3 Clean mating surface of engine figure 1 item 4 with breakthrough cleaning solvent and a wiping rag 4 Apply gasket forming compound to top mating surface of spacer figure 1 item 9 5 Install spacer figure 1 item 9 and secure with two bolts figure 1 item 8 and two bolts figure 1 item 7 6 Apply gasket forming compound to mating surface of crankcase figure 1 item 4 7 Install crankcase figure 1 item 4 with four bolts figure 1 item 6 and 22 bolts figure 1 item 5 8 Install dipstick figure 1 item 3 seal figure 1 item 2 and screw figure 1 item 1 END OF WORK PACKAGE 0029 4 TM 9 2815 538 24 amp P 0030 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FLYWHEEL ASSEMBLY AND FLYWHEEL HOUSING REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Materials Parts Continued Tool kit general mechanic s Gasket forming compound item 5 WP 0035 00 item 2 WP 0064 00 Wiping rag item 5 Materials Parts Breakthrough cleaning solvent Personnel tem 6 WP 0064 00 One Engine lubricating oil item 4 WP 0064 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Fail
111. acement is needed to fix the equipment as described in this TM Sometimes the reason for equipment failure can be obvious and complete teardown is not necessary Disassemble equipment only as far as necessary to repair or replace damaged or broken parts All tags and forms attached to the equipment must be checked to learn the reason for removal from service Also check Technical Bulletins TB 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 the procedure 0009 1 TM 9 2815 538 24 amp P 0009 00 CLEANING INSTRUCTIONS Cleaning instructions will be the same for the majority of parts and components which make up the diesel engine Maintenance personnel must thoroughly understand the importance of cleaning Great care and effort are required during cleaning Dirt and foreign material are a constant threat to satisfactory maintenance The following should apply to all cleaning inspection repair and assembly operations 1 Clean all parts before inspection after repair and before assembly 2 Hands should be kept free of any accumulation of grease which can collect dust dirt and grit 3 After cleaning all parts should be covered or wrapped to protect them from dust and dirt Castings Forgings and Machined Metal Parts WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory
112. aged threads 3 Inspect air heaters for signs of burning or damage 4 Listen for any abnormal sounds generated during turbocharger assembly figure 1 item 2 operation Abnormal sounds could mean damaged or worn bearings 5 Measure axial play of turbine shaft figure 2 Move turbine shaft in axial direction Axial play must be within 0 001 to 0 002 inches 0 03 to 0 06 mm with maximum limit of 0 003 inches 0 09 mm MAGNET BASE TURBINE WHEEL CHAMBER MOVE THE TURBINE SHAFT IN THE AXIAL DIRECTION DIAL GAGE AXIAL PLAY 15KW 2815 24M 342 Figure 2 Axial Play Measurement 6 If axial play exceeds limit replace turbocharger assembly figure 1 item 2 0028 4 9 2815 538 24 amp P 0028 00 INSPECTION Continued 7 Measure radial play of turbine shaft figure 3 Move turbine shaft in radial direction Radial play must be within 0 003 to 0 005 inches 0 08 to 0 13 mm with maximum limit of 0 006 inches 0 17 mm DIAL GAGE MAGNET BASE MOVE THE TURBINE SHAFT IN THE RADIAL DIRECTION AT THE SAME TIME ON THE LEFT AND RIGHT SIDES 1 OIL INLET 15KW 2815 24M 343 Figure 3 Radial Play Measurement 8 If radial play exceeds limit replace turbocharger assembly figure 1 item 2 Waste Gate Actuator Opening Pressure and Lift Test NOTE Set dial gage on extension line of actuator rod Piping and joints must be completely free from leakage Secure turbocharger and dial gage tightly If an electric manometer
113. ance NOTE The L maintenance level is not included in column 4 of the MAC Functions to this level of maintenance are identified by work time figure in the H column of column 4 and an associated reference code is used in the REMARKS column 6 This code is keyed to the remarks and the SRA complete repair application is explained there Column 5 Tools and Test Equipment Reference Code Column 5 specifies by code those common tools sets not individual tools Common Test Measurement and Diagnostic Equipment TMDE and special tools special TMDE and special support equipment required to perform the designated function Codes are keyed to the entries in the tools and test equipment table Column 6 Remarks Code When applicable this column contains a letter code in alphabetical order which is keyed to the remarks table entries 0034 3 TM 9 2815 538 24 amp P 0034 00 Explanation of Columns in the Tools and Test Equipment Requirements Section lll Column 1 Tool or Test Equipment Reference Code The tool and test equipment reference code correlates with a code used in column 5 Section of the MAC Column 2 Maintenance Level The lowest level of maintenance authorized to use the tool or test equipment Column 3 Nomenclature Name or identification of the tool or test equipment Column 4 National Stock Number NSN The NSN of the tool or test equipment Column 5 Tool Number The manufactureris part number model nu
114. and corrosion 2 Inspect all hardware for stripped or damaged threads 3 Inspect for signs of leakage REPAIR Repair of this item is limited to removal and replacement 0013 2 TM 9 2815 538 24 amp P 0013 00 INSTALLATION 1 Install gasket figure 1 item 8 and temperature switch figure 1 item 7 onto water pump assembly figure 1 item 6 2 Install O ring figure 1 item 5 thermostat figure 1 item 4 gasket figure 1 item 3 thermostat cover figure 1 item 2 and two bolts figure 1 item 1 onto water pump assembly figure 1 item 6 Torque bolts to 16 7 21 0 Ib ft 22 6 28 4 Nm 3 Install coolant hose end item configuration manual END OF WORK PACKAGE 0013 3 4 blank TM 9 2815 538 24 amp P 0014 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 GEAR CASE ASSEMBLY REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Personnel Required Tool kit general mechanic s One item 5 WP 0035 00 References Materials Parts WP 0010 00Jand WP 0011 00 Breakthrough cleaning solvent 22 Equipment Condition Q 2 Battery charging alternator 24 removed WWE 0010 00 asket forming compoun Fari V pull V belt d item 2 WP 0064 00 an V pulley and V belt remove WP 0011 00 Wiping rag item 5 WP 0064 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when wo
115. at a sharp object presents a danger to limb TM 9 2815 538 24 amp P WARNING SUMMARY Continued EXPLANATION OF SAFETY WARNING ICONS Continued e N E EXPLOSION flame and burst shows that material can explode if subjected to high temperatures sources of ignition or high pressure EYE PROTECTION human figure with goggles shows that material can injure eyes GENERAL SAFETY WARNINGS DESCRIPTION WARNINGS Metal jewelry will conduct electricity All jewelry can become entangled in unit components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel by electrocution WARNING DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel WARNING High voltage is produced when this unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel WARNING High voltage is produced when unit is in operation Never attempt to start or maintain unit unless itis properly grounded Failure to comply may result in serious injury or death to personnel WARNING High voltage is produced when unit is in operation Never attempt to connect or disconnect load cables while unit is running Failure to comply may result in serious injury or d
116. ation Include ZIP Code PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER PARA FIGURE ITEM PAGE GRAPH LINE TABLE RECOMMENDED CHANGES AND REASON TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION FORM NUMBER DATE TITLE TOTAL NO OF MAJOR PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM ITEMS RECOMMENDED ACTION NO NO NO NUMBER NO NO NO SUPPORTED PART Ill REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 By Order of the Secretary of the Army Official GEORGE W CASEY JR J YCE E MORROW N eg Army Administrative Assistant to the ief of Sta Secretary ofthe Army 0903504 By Order of the Secretary of the Air Force NORTON A SWARTZ rae General USAF Official Chief of Staff BRUCE CARLSON General USAF Command AFMC Army Distribution To be distributed in accordance with the initial distribution number IDN 256968 r
117. be performed on the item listed in column 2 For detailed explanation of these functions refer to Maintenance Functions outlined above Column 4 Maintenance Category Column 4 specifies each level of maintenance authorized to perform each function listed in column 3 by indicating work item required expressed as man hours in whole hours or decimals in the appropriate sub column This work time figure represents the active time required to perform that maintenance function at the indicated level of maintenance If the number or complexity of tasks within the listed maintenance function varies at different maintenance levels appropriate work time figures are 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 including any necessary disassembly assembly time troubleshooting fault location time and quality assurance 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 under the Two Level Maintenance concept are as follows Field C Operator or Crew maintenance O Service maintenance F Field maintenance Sustainment L Specialized Repair Activity H Below depot maintenance D Depot mainten
118. c AGOS IMEN oeste cete IRE 0010 00 4 V Belt Deflection Limits Table 1 0010 00 5 V Belt Tension Adjustment Figure 2 0010 00 4 V Belt Tension Check Figure 3 0010 00 5 Ad ie ee ei 0002 00 1 Inspection EE 0010 00 3 Installation E an Brill e 0010 00 3 Battery Charging Alternator 24 Figure 1 0010 00 2 Borezupn MEE 0002 00 1 Removal eee ace I ete Le 0010 00 2 Battery Charging Alternator 24 Figure 1 0010 00 2 Repalt 2 ii leitete ened eae ede eel 0010 00 3 Repair Pants List a A dd 0059 00 1 C D Compression Test dete e e E erede 0023 00 2 Compression Test Setup Figure 1 eee 0023 00 3 Crankcase Assembly and Dipstick Description DipStiCk ne En enm d e ae ae s 0002 00 1 reete tene eee A tede et mb Seat dele 0029 00 4 Crankcase Assembly and Dipstick Figure 1 0029 00 3 Installation E euius 0029 00 4 Crankcase Assembly and Dipstick Figure 1 0029 00 3 Location Dipstick cit een ud e tede terim udo 0002 00 1 Removal uec em nte am
119. can be corrected and improvements can be made to prevent the problem in future items Corrosion specifically occurs with metals It is an electrochemical process that causes the degradation of metals Itis commonly caused by exposure to moisture acids bases or salts An example is the rusting of iron Corrosion damage in metals can be seen depending onthe metal astarnishing pitting fogging surface residue and or cracking Plastics composites and rubbers can also degrade Degradation is caused by thermal heat oxidation oxygen solvation solvents or photolytic light typically ultraviolet UV processes The most common exposures are excessive heatorlight Damage from these processes will appear as cracking softening swelling and or breaking The form should be submitted to the address specified in DA PAM 738 750 Functional Users Manual for the Army Maintenance Management System TAMMS DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE Refer to TM 750 244 6 for demolition procedures when equipment destruction is required 0001 1 TM 9 2815 538 24 amp P 0001 00 PREPARATION FOR STORAGE OR SHIPMENT Refer to Preparation for Storage or Shipment work package WP 0031 00 WARRANTY INFORMATION Refer to Warranty Technical Bulletin TB 9 6115 643 24 for warranty information LIST OF ABBREVIATIONS ACRONYMS Abbreviation Acronym Definition A Ampere ATTN Attention AVIM Aviation Intermediate Maintenance AVUM Aviation Unit Main
120. charger forcing large amounts of clean air into the intake manifold After passing through the turbocharger the exhaust gases are channeled into a muffler to deaden the sound The exhaust gases should be vented away from the engine COMPRESSOR TURBINE SIDE SIDE INLET _ AIR AIR FILTER TURBOCHARGER EUBRICATI N SYSTEM AIR INLET HEATER INTAKE MANIFOLD EXHAUST GASES EXHAUST MANIFOLD Figure 4 Air Inlet and Exhaust System 0003 5 6 blank EXHAUST wrar GASES 15KW 2815 24M 108 TM 9 2815 538 24 amp P CHAPTER 2 TROUBLESHOOTING PROCEDURES FOR DIESEL ENGINE TM 9 2815 538 24 amp P CHAPTER 2 TROUBLESHOOTING PROCEDURES FOR DIESEL ENGINE WORK PACKAGE INDEX Title WP Sequence No TROUBLESHOOTING INDEX Enid rr rna d Er e ecd CK a D e Dn E E Eo Ra 0004 00 TROUBLESHOOTING liar 0005 00 TM 9 2815 538 24 amp P 0004 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 TROUBLESHOOTING INDEX TROUBLESHOOTING INDEX Malfunction Symptom Work Package and Page No 1 Engine does not start slow starter motor assembly rotation or no starter motor assembly rotation 0005 00 1 2 Engine does not start engine turns over at normal 3 Engine starts but soon stops with little or no exhaust smoke 4 Engine starts but soon stops
121. ckings figure 1 item 12 and fuel return hose assembly figure 1 item 13 from cylinder head assembly figure 1 item 14 6 Squeeze two spring clamps figure 1 item 15 and slide clamps up onto fuel return hose figure 1 item 16 7 Remove fuel return hose figure 1 item 16 from fuel injection pump assembly figure 1 item 10 and hose adapter figure 1 item 17 8 Remove hose adapter figure 1 item 17 and seal washer figure 1 item 18 only if damaged 0020 2 0020 00 TM 9 2815 538 24 amp P REMOVAL Continued 15KW 2815 24M 308A SEES m DOT Se RO ya wera e AV ENDE 3 MONA LEE Figure 1 Fuel Injection Lines and Return Hose 0020 3 TM 9 2815 538 24 amp P 0020 00 INSPECTION 1 2 3 Inspect all parts for wear cracks and corrosion Inspect all hardware for stripped or damaged threads Inspect for signs of leakage REPAIR Repair of this item is limited to removal and replacement INSTALLATION 1 Install seal washer figure 1 item 18 and hose adapter figure 1 item 17 2 Install fuel return hose figure 1 item 16 onto fuel injection pump assembly figure 1 item 10 and hose adapter figure 1 item 17 with two spring clamps figure 1 item 15 NOTE Rocker shaft assembly and intake and exhaust valve assemblies not shown for clarity 3 Install fuel return hose figure 1 item 13 five fuel return packings figure 1 item 12 and banjo b
122. clude ZIP Code Commander US Army CECOM LCMC Jane Q Doe SFC ATTN AMSEL LC LEO E ED 1234 Any Street Fort Monmouth NJ 07703 5006 Anytown AL 34565 PART ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE TITLE TM 11 1234 567 14 16 Sep 2001 Operator Field and Sustainment Support Maintenance Manual for Radio AN ABC 123 PARA FIGURE ITEM PAGE GRAPH LINE TABLE RECOMMENDED CHANGES AND REASON 1 WP0005 2 Test or Correctiive Action column should identify a different WP number PG 3 TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION Jane Q Doe SFC 123 4567 DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART Il REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION FORM NUMBER DATE TOTAL NO OF MAJOR PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM ITEMS RECOMMENDED ACTION NO NO NO NUMBER NO NO NO SUPPORTED PART REMARKS g amp remar kod RK S or suggestions for improvement of publications and ER bla or be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part Il reverse for Repair Parts and B
123. complete repair i e perform all authorized repair functions NOTE Some limited repair may be done on the item at a lower level of maintenance if authorized by the Maintenance Allocation Chart MAC and SMR codes Maintenance Code O Z B Application Explanation Unit AVUM is the lowest level that can do complete repair of the item Direct support AVIM is the lowest level that can do complete repair of the item General Support is the lowest level that can do complete repair of the item Specialized repair activity 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 Nonreparable No repair is authorized No repair is authorized No parts or special tools are authorized for maintenance of a B coded item However the item may be reconditioned by adjusting lubricating etc at the user level 0036 4 TM 9 2815 538 24 amp P 0036 00 EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES Continued Recoverability Code Recoverability codes are assigned to items to indicate the disposition action on unserviceable items The recoverability code is shown in the fifth position of the SMR code as follows Recoverability Code Application Explanation Z Nonreparable item When unserviceable condemn and dispose of the item at the level of maintenance shown in 3d position of SMR Code Reparab
124. configuration manual item 5 WP 0035 00 Equipment Conditions Personnel Required Coolant hoses removed end item One configuration manual WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0013 1 TM 9 2815 538 24 amp P 0013 00 REMOVAL 1 Remove two bolts figure 1 item 1 thermostat cover figure 1 item 2 gasket figure 1 item 3 thermostat figure 1 item 4 and O ring figure 1 item 5 from water pump assembly figure 1 item 6 2 Remove temperature switch figure 1 item 7 and gasket figure 1 item 8 from water pump assembly figure 1 item 6 15KW 2815 24M 304 Figure 1 Thermostat Cover and Temperature Switch INSPECTION 1 Inspect all parts for wear cracks
125. ction pump assembly and fuel injectors replace as required WP 0016 00 WP 0022 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual SYMPTOM Uneven engine speed hunting while under load MALFUNCTION Water in fuel system 27 Drain fuel tank and fuel lines hoses WP 0017 00 WP 0017 00 00 WP 0020 00 WP 0020 00 00 and end item configuration manual 2 Drain water from fuel filter end item configuration manual Fill fuel system with clean dry fuel end item configuration manual 0005 16 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Uneven engine speed hunting while under load Continued MALFUNCTION Defective governor CORRECTIVE ACTION Adjust replace governor as required end item configuration manual MALFUNCTION Poor spray pattern from fuel injection nozzle CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 MALFUNCTION Uneven volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injection pump assembly and fuel injectors replace as required WP 0016 00 WP 0022 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual SYMPTOM Excessive engine vibration MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual MALFUNCTION
126. d in the bulk material group work package of the RPSTL If the item is authorized to you by the 3rd 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 TM 9 2815 538 24 amp P 0036 00 EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES Continued Source Code Application Explanation AO Assembled by Items with these codes are not to be requested unit AVUM level requisitioned individually The parts that make up the AF Assembled by assembled item must be requisitioned or fabricated DS AVIM level and assembled at the level of maintenance indicated AH Assembled by GS by the source code If the 3rd position of the SMR level code authorizes you to replace the item but the AL Assembled by SRA Source code indicates the item is assembled at a AD Assembled by higher level order the item from the higher level of depot maintenance XA Do not requisition an 1 code item Order the next higher assembly Refer to the NOTE below XB If an item is not available from salvage order it using the CAGEC and P N XC Installation drawings diagrams instruction sheets field service drawings identified by manufacturer s P N XD 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 NOTE Cannibalization or controlled exchange whe
127. d item configuration manual MALFUNCTION Water in fuel system ee ACTION Drain fuel tank and fuel lines and hoses WP 0017 00 WP 0020 00 and end item configuration manual Drain water from fuel filter end item configuration manual Fill fuel system with clean dry fuel end item configuration manual MALFUNCTION Excessive slack in fan V belt CORRECTIVE ACTION Adjust fan V belt tension WP 0012 00 MALFUNCTION Clogged exhaust pipe CORRECTIVE ACTION Clean exhaust pipe end item configuration manual MALFUNCTION Engine used at high temperatures or at high altitude CORRECTIVE ACTION Check output drop and load matching requirements reduce load as required end item configuration manual 0005 10 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Excessive white smoke while under load Continued MALFUNCTION Clogged air filter CORRECTIVE ACTION Clean replace air filter end item configuration manual MALFUNCTION Defective thermostat CORRECTIVE ACTION Check thermostat replace as required WP 0013 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual MALFUNCTION Improper open or close timing of intake exhaust valves CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Worn turbocharger assembly bearing CORRECTIVE ACTION Inspect turbocharger assembly bearing replace as required
128. e item 5 WP 0035 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0018 1 TM 9 2815 538 24 amp P 0018 00 REMOVAL 1 Remove oil filter figure 1 item 1 2 Squeeze two spring clamps figure 1 item 2 and slide clamps up onto cooler out pipe figure 1 item 3 3 Remove cooler out pipe figure 1 item 3 from water pump assembly figure 1 item 4 and oil cooler assembly figure 1 item 5 4 Squeeze two spring clamps figure 1 item 6 and slide clamps up onto cooler in pipe figure 1 item 7 5 Remove cooler in pipe figure 1 item 7 from joint figure 1 item 8 and oil cooler assembly figure 1 item 5 6 Remove adapter figure 1 item 8 and drain plug figure 1 item
129. e 2 There will usually be two lines beginning with same size Under heading SIZE look down THREADS PER IN column to find numbers of threads per inch that match number of threads counted in step 2 Not required for metric screws NOTE Manufacturer s marks may vary Standard is all SAE Grade 5 3 line Metric screws are of three grades 8 8 10 9 and 12 9 Grades and manufacturer s marks appear on the screw head To find the grade screw being installed match markings on screw head to correct picture of CAPSCREW HEAD MARKINGS figure 2 or figure 3 CAPSCREW HEAD MARKINGS MANUFACTURER S MARKS MAY VARY SAE SAE SAE SAE GRADE 2 GRADE 5 GRADE 6 amp 7 GRADE 8 15KW 2815 24M 325 Figure 2 Capscrew Head Markings Standard 0032 2 TM 9 2815 538 24 amp P 0032 00 TORQUE TABLES Continued Table 1 Standard Dry Torque Limits SAE GRADE SAE GRADE SAE GRADE SAE GRADE NO 2 NO 5 NO 6 OR7 NO 8 DIA THREADS DIA IN PER IN MM LB FT LB FT LB FT LB FT 1 4 20 5 7 8 11 10 14 12 16 0032 3 TM 9 2815 538 24 amp P 0032 00 TORQUE TABLES Continued CAPSCREW HEAD MARKINGS MANUFACTURER S MARKS MAY VARY 15KW 2815 24M 326 Figure 3 Capscrew Head Markings Metric Table 2 Metric Dry Torque Limits METRIC GRADE 8 8 METRIC GRADE 10 9 METRIC GRADE 12 9 0032 4 TM 9 2815 538 24 amp P CHAPTER 4 SUPPORTING INFORMATION FOR DIESEL ENGINE TM 9 2815 538 24 amp P CHAPTER 4 SUPPORTING INFORMA
130. e NIIN consists of the last nine digits of the NSN NSN When using this column to locate an e g 5385 01 574 1476 item ignore the first four digits of NIIN 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 the repair parts list and special tools list work packages 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 2 Part Number P N Index Work Package P Ns in this index are listed in ascending alphanumeric sequence vertical arrangement of letter and number combinations which places the first letter or digit of each group in order A thru Z followed by the numbers 0 thru 9 and each following letter or digit in like order PART NUMBER Column Indicates the P N assigned to the item FIG Column This column lists the number of the figure where the item is identified located in the repair parts list and special tools list work packages ITEM Column The item number is the number assigned to the item as it appears in the figure referenced in the adjacent figure number column 0036 6 TM 9 2815 538 24 amp P 0036 00 HOW TO LOCATE REPAIR PARTS 1 When NSNs or P Ns Are Not Known First Using the table of contents determine the assembly gr
131. e ladies PMCS Introduction ita dele ev doen PMCS Including Lubrication INStrUCtIONS isc od heran end General Maintenance iei a eei sd ee td Pr and ee Uo ats ansehen Battery Charging Alternator 24 Vide icons AER ded doa SU osa daga tul does Fan V Belt 2 2 a p LR eet teg eat ala gd HIR gd Water Pump Assembly MD Thermostat Cover and Temperature Switch essen enemies Gear base Assembly PEOR A TP lde Gear Assembly 2 t ae Fuel Injection Pump Assembly 22 aid quiae tid Rada Rd I id d Win aan a aud Fuel Filter and Fuel a das llas Oil Cooler Assembly and Oil Pressure Starter Motor Assembly Fuel Injection Lines and Return Valve Cover ASS OMbIV PTOL aa la bb ii A Comipression Test 3 act iin Lee am desee nern lagen Cylinder Head Assembly ia did Valve Lash Adjustment 1 rci dot a is titan Intake Manifold Air Inlet Hose and Air Heaters tenens Nurboch rger Oil LIMOS ERR Turbocharger Assembly and Exhaust Manifold essere Crankcase Assembly and Flywheel As
132. e tee eal deen ne dde ae ed ne 0061 00 1 Camshaft Driving Gear and Idle Gear Assemblies 0043 00 1 Connecting Rod and Piston 0042 00 1 Cooling System eie e dd 0047 00 1 Crankcase Assembly sands Eis didattica acia caa 0055 00 1 tc eto a eio ket on nor RR dE MED Ea 0045 00 1 Cylinder Block Rene een 0038 00 1 Cylinder Head Assembly occiso bicis 0040 00 1 Engine Diesel 0037 00 1 Fan Assembly ir tein ete 0048 00 1 0044 00 1 Assembly ta lett abe edo bl E ips 0051 00 1 Fuel Injection Valve EEEE EA 0050 00 1 Fuel System c am 0049 00 1 Gear Case Assembly emn ipae bc dl iR ug 0046 00 1 Generator A 0059 00 1 Intake tidad 0056 00 1 0036 00 1 National Stock Number 0062 00 1 OIL Bypass 0053 00 1 Oil Filter and Oil 2 4 02 12 442 44 444111 nnne nrbs 0052 00 1 ASSEY
133. eath to personnel WARNING A qualified technician must make power connections and perform all continuity checks Power source may be a generator or commercial power Failure to comply with this warning may result in serious injury or death to personnel TM 9 2815 538 24 amp P WARNING SUMMARY Continued GENERAL SAFETY WARNINGS DESCRIPTION Continued WARNING Direct Current DC voltages are present at unit electrical components even with unit shut down Avoid shorting any positive with ground negative Failure to comply can cause injury to personnel and damage to equipment WARNING Ensure power is off before performing troubleshooting procedures Failure to comply may result in serious injury to personnel WARNING Ensure that engine cannot be started while maintenance is being performed Failure to comply may result in serious injury or death to personnel WARNING When running engine has hot metal surfaces that will burn flesh on contact Shut down unit and allow engine to cool before performing checks services and maintenance Wear gloves and additional protective clothing as required Failure to comply may result in serious injury or death to personnel WARNING When disconnecting or removing batteries disconnect negative lead that connects directly to grounding stud first disconnect negative end of interconnection cable next When installing batteries reverse connection sequence Failure to comply may result in s
134. ecessary Install new timing grid sticker part of new fuel injection pump assembly onto gear case plate with standard mark of sticker precisely in line with new mark on gear case plate figure 7 0016 7 TM 9 2815 538 24 amp P 0016 00 REMOVAL Continued MARK MADE ON GEAR CASE PLATE STANDARD MARK 15KW 2815 24M 359 Figure 7 Timing Grid Sticker Location 18 Remove three nuts figure 5 item 10 fuel injection pump assembly figure 5 item 11 and O ring figure 5 item 12 19 Record timing index number found in engraved mark position figure 8 on defective fuel injection pump assembly figure 5 item 11 0016 8 TM 9 2815 538 24 amp P 0016 00 REMOVAL Continued TIMING INDEX NUMBER 15KW 2815 24M 332A Figure 8 Timing Index Number INSPECTION 1 Inspect all parts for wear cracks and corrosion 2 Inspect all hardware for stripped or damaged threads 3 Inspect for signs of fuel leakage REPAIR 1 Repair of this item is limited to removal and replacement 2 Repair of fuel injection pump assembly figure 5 item 11 is not authorized INSTALLATION 1 Record timing index number found in engraved mark position figure 8 on new fuel injection pump assembly figure 2 item 11 2 Lubricate O ring figure 2 item 12 with petroleum jelly 3 Install O ring figure 2 item 12 fuel injection pump assembly figure 2 item 11 and three nuts figure 2 item 10 Tighten nuts j
135. ecoil mechanisms The following are examples of service functions a Unpack To remove from packing box for service or when required for the performance of maintenance operations b Repack To return item to packing box after service and other maintenance operations Clean rid the item of contamination d Touch up To spot paint scratched or blistered surfaces e Mark To restore obliterated identification 4 Adjust To maintain or regulate within prescribed limits by bringing into proper position by setting the operating characteristics to specified parameters 0034 1 TM 9 2815 538 24 amp P 0034 00 5 Align To adjust specified variable elements of an item to bring about optimum or desired performance 6 Calibrate To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipment used in precision measurement 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 7 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 into position a spare repair part or module component or assembly in a manner to allow the proper functioning of an equipment or system 8 Paint To prepare and spray color coats of paint
136. ection pump assembly provides increased control of timing and fuel air mixture The timing advance is achieved by precise control of the unit injector timing ENGINE STARTING AND BATTERY CHARGING COMPONENTS The engine has a starter motor assembly with integral starter solenoid which will engage the flywheel and rotate the engine so that it will start There is a set of two 12 volt 400 watt heaters which are wired in series and connected to an external 24 Vdc source in order to warm the inlet air just prior to entering the intake manifold in cold weather There is a 35 amp battery charging alternator 24 Vdc belt driven from pulleys on the front of the engine which can be used to recharge the batteries used to start the engine and used to run engine accessories after the engine is operating The battery charging alternator 24 Vdc requires batteries or equivalent for voltage regulation of the battery charging alternator 24 Vdc output 0003 1 TM 9 2815 538 24 amp P 0003 00 FUEL SYSTEM The fuel system figure 1 consists of a fuel tank or equivalent source of fuel piping fuel filter water separator electric fuel pump fuel filter injection pump and injectors Fuel is drawn from the fuel tank by the electric fuel pump Fuel then passes through the fuel water separator where water and small impurities are removed The fuel then passes through the fuel filter to the low pressure port of the gear driven fuel pump and to the accumulat
137. el injectors CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 SYMPTOM Exhaust temperature rises MALFUNCTION Insufficient coolant level CORRECTIVE ACTION 1 Check coolant level fill with correct coolant end item configuration manual 2 Check cooling system for leaks repair as required WP 0012 00 and end item configuration manual MALFUNCTION Excessive slack in fan V belt CORRECTIVE ACTION Adjust fan V belt tension WP 0010 00 MALFUNCTION Clogged exhaust pipe CORRECTIVE ACTION Clean exhaust pipe end item configuration manual MALFUNCTION Insufficient cooling effect of radiator CORRECTIVE ACTION 1 Check for defective thermostat replace as required WP 0013 00 2 Check for excessive slack in fan V belt adjust as required WP 0010 00 3 Check radiator for excessive debris on cooling fins clean as required end item configuration manual MALFUNCTION Too late timing of fuel injection pump assembly CORRECTIVE ACTION Check fuel injection pump assembly adjust timing WP 0016 00 0005 25 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Exhaust temperature rises Continued MALFUNCTION Uneven volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injection pump assembly and fuel injectors replace as required WP 0016 00 WP 0022 00 MALFUNCTION Excessive volume of fuel from fuel injectors CORRECTIVE ACT
138. em 2 10 Release three spring clamps figure 5 item 3 and remove three fuel hoses figure 5 item 4 0016 5 0016 00 TM 9 2815 538 24 amp P REMOVAL Continued 15KW 2815 24M 328B Figure 5 Fuel Injection Pump Assembly 0016 6 TM 9 2815 538 24 amp P 0016 00 REMOVAL Continued 11 12 13 14 15 16 17 Disconnect electrical connector figure 5 item 5 from engine harness end item configuration manual Remove two bolts figure 5 items 6 and 7 and bracket figure 5 item 8 Remove spacer figure 5 item 9 If original fuel injection pump assembly is to be re installed locate timing marks on figure 6 Use these original alignment marks to position fuel injection pump assembly set timing during assembly 2 Y ALIGNMENT MARKS 15 2815 24 358 Figure 6 Timing Mark Location If new fuel injection pump assembly is going to be installed and a timing grid sticker is not in place install new timing grid sticker part of new fuel injection pump assembly onto gear case plate with standard mark of sticker precisely in line with mark on gear case plate figure 7 If new fuel injection pump assembly is going to be installed and a timing grid sticker is in place remove this sticker Locate stamped mark on fuel injection pump assembly mounting flange Highlight this mark and make a new corresponding mark onto gear case plate Highlight this new mark also if n
139. emblies 0043 1 1 ITEM NO OOANDOARWN 2 SMR CODE PAHZZ PAHZZ PBHHH PAHZZ PAHZA PAHZZ PAFZZ PAHZZ PAHZZ PAFZZ PAFZZ PAFZZ PAFHH PAFZZ XBFZZ PAFZZ 3 NSN 2920 01 546 4582 2815 01 546 7688 2815 01 538 0974 3020 01 455 4443 2815 01 546 4309 5315 01 465 9931 5306 01 546 8929 5306 01 546 4266 5310 01 546 9272 5310 01 546 3576 3040 01 546 4092 3020 01 538 0777 5365 01 547 0544 5306 01 547 0081 4 CAGEC 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 0AK42 OAK42 0AK42 0AK42 0AK42 0AK42 0AK42 OAK42 0AK42 TM 9 2815 538 24 amp P 5 PART NUMBER 129150 14400 129150 14200 129508 14580 129150 14101 129150 02450 22512 070140 26106 080142 129150 25301 26776 140002 22217 140000 158552 51151 119802 25901 119802 25100 119802 25070 119802 25051 26106 080402 0043 2 6 DESCRIPTION AND USABLE ON CODE UOC GROUP 0105 IDLE GEAR ASSEMBLY FIG 7 CAMSHAFT DRIVING GEAR AND IDLE GEAR ASSEMBLIES CAMSHAFT ASSEMBLY GEAR HELICAL CAM CONTROL KEY MACHINE BOLT MACHINE BOLT MACHINE NUT SELF LOCKING GEAR PUMP GEAR ASSEMBLY IDLE BUSH IDLE GEAR SHAFT IDLE GEAR BOLT MACHINE END OF FIGURE 0043 00 8 8 1 1 1 1 2 4 1 1 1 1 1 1 1 3 TM 9 2815 538 24 amp P 0044 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FLYWHEEL ASSEMBLY REPAIR PARTS LIST Figure 8 Flywheel Assembly
140. embly figure 1 item 10 and install bolt figure 1 item 8 washer figure 1 item 6 and nut figure 1 item 3 Install bolt figure 1 item 3 and spacer figure 1 item 4 Do not tighten 4 Position V belt figure 1 item 7 over pulley of battery charging alternator 24 Vdc figure 1 item 2 Ensure V belt is properly positioned around other pulleys 5 Connect wire harness figure 1 item 1 to battery charging alternator 24 Vdc figure 1 item 2 Remove tags 6 Adjust V belt figure 1 item 7 tension per ADJUSTMENT procedure below 0010 3 TM 9 2815 538 24 amp P 0010 00 ADJUSTMENT 1 Loosen bolt figure 1 item 3 and nut figure 1 item 5 to adjust battery charging alternator 24 Vdc figure 1 item 2 2 Use pry bar figure 2 and pry battery charging alternator 24 Vdc figure 1 item 2 away from engine adjust V belt figure 1 item 7 tension and tighten hardware PRY BAR ADJUSTER GENERATOR 15KW 2815 24M 301 2A Figure 2 V Belt Tension Adjustment NOTE V belt tension can be checked at three different locations figure 3 Ensure V belt deflection limits for each V belt tension check location table 1 A B or C 3 Check V belt figure 1 item 7 tension figure 3 4 If V belt figure 1 item 7 tension is incorrect table 1 repeat steps 1 thru above 5 Runengine for at least 5 minutes end item configuration manual then check V belt tension figure 3 0010 4 TM 9 2815 538 24
141. ent INSTALLATION 1 Install four nozzle protectors figure 1 item 6 nozzle seats figure 1 item 5 and fuel injectors figure 1 item 4 into cylinder head assembly figure 1 item 3 NOTE Ensure bolt indentations on fuel injector retainers are positioned up when installing 2 Install four fuel injector valve retainers figure 1 item 2 and bolts figure 1 item 1 into cylinder head assembly figure 1 item 3 3 Install valve cover assembly WP 0021 00 Install fuel injection lines WP 0020 00 END OF WORK PACKAGE 0022 4 TM 9 2815 538 24 amp P 0023 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 COMPRESSION TEST INITIAL SETUP Tools and Special Tools Equipment Condition Shop equipment automotive supplemental Engine at operating temperature set no 2 item 1 WP 0035 00 end item configuration manual Fuel injection lines removed Personnel Required WP 0020 00 One Valve cover assembly removed WP 0021 00 References Fuel injectors removed WP 0022 00 WP 0005 00 WP 0020 OO thru WP 0022 00 End item configuration manual WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to pers
142. ent System TAMMS VG 38 3 2a Guide for Basic Military Preservation and Packing MILITARY STANDARDS AND SPECIFICATIONS 62624 Antifreeze MIL DTL 83133 Turbine Fuels Aviation Grades JP 4 JP 5 and JP 5 JP 8 ST MIL L 46167 Lubricating Oil Internal Combustion Engine Arctic MIL PRF 2104 Lubricating Oil Internal Combustion Engine Combat Tactical Service MIL STD 129 Markings for Shipment or Storage MIL STD 2073 1D Standard Practice for Military Packaging 0033 2 TM 9 2815 538 24 amp P 0034 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 MAINTENANCE ALLOCATION CHART MAC INTRODUCTION The Army Maintenance System Mac This introduction provides a general explanation of all maintenance and repair functions authorized at the two maintenance levels under the Two Level Maintenance System concept This MAC immediately following the introduction 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 shall be consistent with the capacities and capabilities of the designated maintenance levels which are shown on the MAC in column 4 as Field includes three subcolumns Operator Crew maintenance C
143. epair Activity TMDE Test Measurement and Diagnostic Equipment UOC Usable On Code 0036 7 8 blank TM 9 2815 538 24 amp P 0037 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 TURBOCHARGED DIESEL ENGINE REPAIR PARTS LIST 15KW 2815 24P 01 1A Figure 1 Turbocharged Diesel Engine 1 2 3 5 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN CAGEC NUMBER CODE UOC GROUP 00 ENGINE ASSEMBLY 15KW FIG 1 TURBOCHARGED DIESEL ENGINE 0AK42 4TNV84T DFM DIESEL ENGINE TURBOCHARGED 4 CYLINDER END OF FIGURE 0037 1 2 blank TM 9 2815 538 24 amp P 0038 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 CYLINDER BLOCK ASSEMBLY REPAIR PARTS LIST NS 4 5 A SD SS 0 2 4 S AW 224 OT T SEE ET Q 15KW 2815 24P 15 Figure 2 Cylinder Block Assembly 0038 1 TM 9 2815 538 24 amp P 0038 00 1 2 3 4 5 6 ITEM SMR PART DESCRIPTION AND USABLE ON NO CODE NSN _ NUMBER CODE UOC GROUP 01 ENGINE BLOCK ASSEMBLY FIG 2 CYLINDER BLOCK ASSEMBLY 0AK42 729508 01560 0AK42 27241 300000 0AK42 171051 01921 3120 99 549 3927 0AK42 129795 02411 0AK42 27241 120000 0AK42 124160 01910 3120 01 454 6117 0AK42 129150 02930 BEARING HALF SET SLEEVE 3120 01 546 8931 0AK42 129150 02940 BEARING HALF SET SLEEVE 3120 01 547 0495 0AK42 129001 02930 BEARING HALF SET SLEEVE 3120 01 546 848
144. equirements for TM 9 2815 538 248P THE METRIC SYSTEM AND EQUIVALENTS LINEAR MEASURE SQUARE MEASURE 1 Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches 1 Sq Centimeter 100 Sq Millimeters 0 155 Sq Inches 1 Meter 100 Centimeters 1000 Millimeters 39 37 Inches 1 Sq Meter 10 000 Sq Centimeters 10 76 Sq Feet 1 Kilometer 1000 Meters 0 621 Miles 1 Sq Kilometer 1 000 000 Sq Meters 0 386 Sq Miles WEIGHTS CUBIC MEASURE 1 Gram 0 001 Kilograms 1000 Milligrams 0 035 Ounces 1 Cu Centimeter 1000 Cu Millimeters 0 06 Cu Inches 1 Kilogram 1000 Grams 2 2 Lb 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet 1 Metric Ton 1000 Kilograms 1 Megagram 1 1 Short Tons TEMPERATURE LIQUID MEASURE RE eee 5 9 F 32 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces 212 Fahrenheit is equivalent to 100 Celsius 1 Liter 1000 Milliliters 33 82 Fluid Ounces 90 Fahrenheit is equivalent to 32 2 Celsius 32 Fahrenheit is equivalent to 0 Celsius 9 5 C 32 F APPROXIMATE CONVERSION FACTORS TO CHANGE TO MULTIPLY BY A Centimeters 2 540 Feet Meters Re pelo Tent 0 305 Yards Meters 0 914 mei Kilometers 1 609 Square Inches Square Centimeters 6 451 Square Feet Square Meters 0 093 Square Yards Square Meters 0 836 Square Miles Square Kilometers
145. er attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0026 1 TM 9 2815 538 24 amp P 0026 00 REMOVAL 1 Loosen clamps figure 1 items 1 and 2 2 Slide clamps figure 1 items 1 and 2 up onto air inlet hose figure 1 item 3 and remove hose 3 Tag and disconnect wires figure 1 item 4 from air heaters figure 1 item 5 See end item configuration manual for details 4 Remove four bolts figure 1 items 6 and 7 air intake bend figure 1 item 8 two gaskets figure 1 item 9 two air heaters figure 1 item 5 and gasket figure 1 item 10 5 Remove bolt figure 1 item 11 six bolts figure 1 item 12 in staggered pattern intake manifold figure 1 item 13 and manifold gasket figure 1 item 14 from cylinder head assembly figure 1 item 15 0026 2 TM 9 2815 538 24 amp P 0026 00 REMOVAL Continued TURBO CHARGER 15KW 2815 24M 312B Figure 1 Intake Manifold Air Inlet Hose and Air Heaters 0026 3 TM 9 2815 538 24 amp P 0026 00 INSPECTION 1 2 3 Inspect all parts for wear cracks and corrosion Inspect all hardware for stripped or damaged threads Inspect air heaters for signs of burning or damage REPAIR Repair of this item is limited to removal and replacement TESTING Air Heater Each air heater is rated 400 watts at 12 Vdc The two air heaters are connected in series with each ot
146. erious injury to personnel WARNING Engine housing panels can get very hot Allow panels to cool down before performing maintenance Failure to comply may result in serious injury or death to personnel WARNING Exhaust system can get very hot Shut down unit and allow system to cool before performing checks services and maintenance Failure to comply may result in severe burns and injury or death to personnel WARNING The oil system operates at high temperature and pressure Contact with hot oil can result in burns and scalding Shut down unit and allow system to cool before performing checks services and maintenance Wear heat resistant gloves and avoid contacting hot surfaces Do not allow hot oil or components to contact skin or hands Failure to comply may result in serious injury or death to personnel TM 9 2815 538 24 amp P WARNING SUMMARY Continued GENERAL SAFETY WARNINGS DESCRIPTION Continued WARNING Wear heat resistant gloves and avoid contacting hot metal surfaces with your hands after components have been heated Wear additional protective clothing as required Failure to comply may result in serious injury to personnel WARNING Cooling system operates at high temperature and pressure Contact with high pressure steam and or liquids can cause burns and scalding Shut down unit and allow system to cool before performing checks services and maintenance Failure to comply may result in injury or death to pe
147. erted into fuel injection pump assembly plunger port to determine when fuel injection pump assembly plunger is at bottom of its stroke Rotate crankshaft Clockwise CW until fuel injection pump assembly plunger is at bottom of its stroke This ensures fuel injection pump assembly shaft will not rotate from spring tension when drive gear is removed 3 Install fuel injection pump assembly plunger plug figure 1 4 Remove four bolts figure 2 item 1 and cover plate figure 2 item 2 from gear case assembly figure 2 item 3 15KW 2815 24M 355 Figure 2 Cover Plate 0016 3 TM 9 2815 538 24 amp P 0016 00 REMOVAL Continued WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated area only Failure to comply may result in serious injury or death to personnel 5 Clean drive gear and gear case assembly marking locations with breakthrough cleaning solvent and a wiping rag Mark drive gear and a matching mark on bore of gear case assembly opening figure 3 Do not remove these marks REFERENCE MARKS 15KW 2815 24M 356 Figure 3 Drive Gear Reference Marks CAUTION Do not loosen or remove four bolts on drive gear or internal fuel injection pump assembly timing will be lost and gear assembly must be replaced If nut or lockwasher is dropped into
148. es figure 1 items 10 and 9 onto baffle plate figure 1 item 8 2 Apply bead of gasket forming compound to surface of baffle plate figure 1 item 8 that contacts valve cover assembly figure 1 item 5 3 Install baffle plate figure 1 item 8 and four screws figure 1 item 7 INSTALLATION 1 Install valve cover gasket figure 1 item 6 onto valve cover assembly figure 1 item 5 2 Install valve cover assembly figure 1 item 5 three O rings figure 1 item 3 and knobs figure 1 item 2 3 Connect breather hose figure 1 item 1 to valve cover assembly figure 1 item 5 4 Install four seals figure 1 item 4 5 Install fuel injection lines WP 0020 00 END OF WORK PACKAGE 0021 3 4 blank TM 9 2815 538 24 amp P 0022 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FUEL INJECTORS REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Equipment Condition Shop equipment automotive supplemental Fuel injection lines removed set no 2 item 1 WP 0035 00 WP 0020 00 Valve cover assembly removed Personnel Required WP 0021 00 One References WP 0020 00 0021 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and mainte
149. ft bearings fuel injection pump assembly and turbocharger The fuel injection pump receives oil from the main gallery which it supplies to the turbocharger If oil pressure drops the oil pressure switch sends a signal to the control panel to indicate low oil pressure All oil eventually flows back into the oil pan for recirculation FILTER COOLER VALVE FUEL OIL PRESSURE TURBOCHARGER INJECTION CYLINDER BODY MAIN GALLERY CAMSHAFT CRANK SHAFT BEARING JOURNAL REGULATOR VALVE OIL PUMP OIL SUCTION PIPE STRAINER OIL PAN 15KW 2815 24M 107B Figure 3 Lubrication System 0003 4 TM 9 2815 538 24 amp P AIR INLET AND EXHAUST SYSTEM 0003 00 The air intake and exhaust system figure 4 consists of an air inlet heater intake manifold turbocharger and exhaust manifold An air filter assembly and a muffler as shown in the diagram are recommended for use with this engine Ambient air is drawn into the air filter assembly where airborne dirt is removed and trapped Filtered air is drawn through the air intake tubes to the turbocharger where it is pressurized In cold weather an air inlet heater is activated to warm the inlet air The pressurized inlet air enters the intake manifold to the combustion chambers and mixes with fuel from the fuel injectors The engine exhaust gases are released into the turbocharger which is mounted on the exhaust manifold The exhaust gases drive the turbo
150. g properly troubleshoot starter motor assembly circuitry end item configuration manual b Ifstarter motor assembly does not turn starter motor assembly is defective replace as required WP 0019 00 MALFUNCTION Incorrect oil grade type for ambient temperature range CORRECTIVE ACTION Drain oil fill with correct oil end item configuration manual SYMPTOM Engine does not start engine turns over at normal speed MALFUNCTION No fuel fuel tank empty CORRECTIVE ACTION Check fuel tank fill as required end item configuration manual MALFUNCTION No fuel insufficient fuel supply at fuel injection pump assembly CORRECTIVE ACTION 1 Check fuel water separator and filter replace as required end item configuration manual Check fuel filter clean as required WP 0017 00 Check fuel lines and hoses for clogs leaks repair as required WP 0017 00 and end item configuration manual MALFUNCTION No fuel fuel injection assembly failure CORRECTIVE ACTION Replace fuel injection pump assembly WP 0016 00 0005 2 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Engine does not start engine turns over at normal speed Continued MALFUNCTION No fuel clogged fuel filter CORRECTIVE ACTION 1 Check fuel filter clean as required WP 0017 00 2 Check fuel filter replace as required WP 0017 00 MALFUNCTION No fuel clogged or leaking fuel line CORRECTIVE ACTION Chec
151. general mechanic s item 5 WP 0035 00 End configuration manual Materials Parts Equipment Condition ae Pressure sensitive tape Turbocharger oil ia PARTS item 8 WP 0064 00 removed end item CONDITION configuration manual PERSONNEL Personnel Required REQUIRED One LEGEND TITLE The name of the procedure SUMMARY A listing of the general actions to be performed TOOLS AND SPECIAL TOOLS The tools and equipment needed to do the procedures MATERIALS PARTS The supplies and parts needed to do the procedures PERSONNEL REQUIRED The personnel needed to do the procedures REFERENCES Other work packages manuals and publications needed to do the procedure EQUIPMENT CONDITION The special condition s to be performed before starting the procedure v vi blank TM 9 2815 538 24 amp P CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION FOR DIESEL ENGINE TM 9 2815 538 24 amp P CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION FOR DIESEL ENGINE WORK PACKAGE INDEX Title WP Sequence No GENERAL INFORMAT ION niinc iio cr thun rrr e EL dr ee d DF DR Ki E EA d d E RR ad 0001 00 EQUIPMENT DESCRIPTION AND THEORY OF OPERATION sciosnmiccisnncondincancanenanpar ndcnnion in FOR 4 SEE EO RA RE ER ERR E ER AREA RA REFERRE EARS TM 9 2815 538 24 amp P 0001 00 FIELD
152. gs Supply Manuals SC SM TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER PARA FIGURE ITEM PAGE GRAPH LINE TABLE RECOMMENDED CHANGES AND REASON TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION FORM NUMBER DATE TITLE TOTAL NO OF MAJOR PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM ITEMS RECOMMENDED ACTION NO NO NO NUMBER NO NO NO SUPPORTED PART Ill REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 RECOMMENDED CHANGES TO PUBLICATIONS AND Use Part Il reverse for Repair Parts and BLANK FORMS Special Tool Lists RPSTL and Supply For use of this form see AR 25 30 the proponent agency is OAASA Catalogs Supply Manuals SC SM TO Forward to proponent of publication or form Include ZIP Code FROM Activity and loc
153. her Most failures will open the heating element and show an open circuit to a standard multimeter greater than 100 000 ohms To test the air heaters proceed as follows 1 Tag and disconnect wire harness from each air heater 2 Measure resistance between two terminals on each air heater 3 If open replace air heater 4 Measure resistance between each terminals and metal frame of air heater 5 If resistance is not greater than 1000 000 ohms replace air heater INSTALLATION 1 Install manifold gasket figure 1 item 14 manifold figure 1 item 13 six bolts figure 1 item 12 in staggered pattern and bolt figure 1 item 11 onto cylinder head assembly figure 1 item 15 Torque bolts to 16 7 to 21 0 Ib ft 22 6 to 28 4 Nm in same staggered pattern 2 Install gasket figure 1 item 10 two air heaters figure 1 item 5 two gaskets figure 1 item 9 air intake bend figure 1 item 8 and four bolts figure 1 items 7 and 6 Torque bolts to 16 7 to 21 0 Ib ft 22 6 to 28 4 Nm 3 Connect wires figure 1 item 4 to two air heaters figure 1 item 5 Remove tags See end item configuration manual for details 4 Install air inlet hose figure 1 item 3 and position and tighten clamps figure 1 items 2 and 1 END OF WORK PACKAGE 0026 4 TM 9 2815 538 24 amp P 0027 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 TURBOCHARGER OIL LINES REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP T
154. i e identified as maintenance significant Actions Welding grinding riveting straightening facing machining and or resurfacing 11 Overhaul That maintenance effort service action prescribed to restore an item to a completely serviceable operational condition as required by maintenance standards in appropriate technical publications Overhaul is normally the highest degree of maintenance performed by the Army Overhaul does not normally return an item to like new condition 12 Rebuild Consists of 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 material maintenance applied to Army equipment The rebuild operation includes the act of returning to zero those age measurements e g hours miles considered in classifying Army equipment components 0034 2 TM 9 2815 538 24 amp P 0034 00 Explanation of Columns in the MAC Section Column 1 Group Number Column 1 lists Functional Group Code FGC numbers the purpose of which is to identify maintenance significant components assemblies subassemblies and modules with the Next Higher Assembly NHA Column 2 Component Assembly Column 2 contains the item names of components assemblies subassemblies and modules for which a maintenance function is authorized Column 3 Maintenance Function Column 3 lists the functions to
155. ial tools are also listed in a separate work package Items listed are shown on the associated illustrations 2 Special Tools List Work Packages Work packages containing lists of special tools special TMDE and special support equipment authorized by this RPSTL as indicated by Basis of Issue BOI information in the DESCRIPTION AND USABLE ON CODE UOC column Tools that are components of common tool sets and or Class VII are not listed 3 Cross Reference Indexes Work Packages There are three cross reference indexes work packages in this RPSTL the National Stock Number NSN Index work package the Part Number P N Index work package and the Reference Designator Index work package The National Stock Number Index work package refers you to the figure and item number The Part Number Index work package refers you to the figure and item number The Reference Designator Index work package refers you to the figure and item number 0036 1 TM 9 2815 538 24 amp P 0036 00 EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES ITEM NO Column 1 Indicates the number used to identify items called out in the illustration SMR CODE Column 2 The SMR code containing supply requisitioning information maintenance level authorization criteria and disposition instruction as shown in the following breakout Source Code XX 1st two positions How to get an item Maintenance Code
156. ion is required Good general ventila tion is normally adequate Failure to comply may result in serious injury to personnel WARNING Chemical Agent Resistant Coating CARC paint is a health hazard and is irritating to eyes skin and respiratory system Wear protective eyewear mask and gloves when applying or removing CARC paint Failure to comply may result in serious injury to personnel WARNING Exhaust discharge contains deadly gases including carbon monoxide Do not operate unit in an enclosed area unless exhaust discharge is properly vented outside Failure to comply may result in serious injury or death to personnel Engine exhaust fumes contain deadly poisonous gases Severe exposure can cause death or permanent brain damage Exhaust gases are most dangerous in places with poor airflow Best defense against exhaust gas poisoning is very good airflow To protect yourself and your partners always obey the following rules e DO run engine indoors unless you have VERY GOOD AIRFLOW e DO NOT idle engine for a long time unless there is VERY GOOD AIRFLOW e Bealertatall times Check for smell of exhaust fumes e REMEMBER Best defense against exhaust gas poisoning is VERY GOOD AIRFLOW e Exhaust gas poisoning causes dizziness headache loss of muscle control sleepiness coma and death If anyone shows signs of exhaust gas poisoning get ALL PERSONNEL clear of unit Make sure they have lots of fresh air KEEP THEM WARM
157. ion manual MALFUNCTION Air in fuel system CORRECTIVE ACTION Bleed fuel system end item configuration manual MALFUNCTION Insufficient oil level low oil pressure shutdown CORRECTIVE ACTION Add oil to proper level end item configuration manual MALFUNCTION Incorrect oil grade type for ambient temperature range low oil pressure shutdown CORRECTIVE ACTION Drain oil fill with correct oil end item configuration manual MALFUNCTION Malfunctioning governor CORRECTIVE ACTION Adjust repair replace governor as required end item configuration manual 0005 4 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Engine starts but soon stops with little or no exhaust smoke Continued MALFUNCTION Insufficient fuel supply at fuel injection pump assembly CORRECTIVE ACTION 1 Check fuel water separator and filter replace as required end item configuration manual Check fuel filter replace as required WP 0017 00 Check fuel lines and hoses for clogs leaks repair as required WP 0017 00 WP 0020 00 and end item configuration manual MALFUNCTION Improper intake exhaust valve clearance CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual SYMPTOM Engine starts but soon stops with excessive exhaust smoke MALFUNCTION Clogged air filter CORRECTIVE ACTION C
158. ious injury or death to personnel 0010 1 TM 9 2815 538 24 amp P 0010 00 REMOVAL 1 Tag and disconnect wire harness figure 1 item 1 from battery charging alternator 24 figure 1 item 2 2 Remove bolt figure 1 item 3 spacer figure 1 item 4 nut figure 1 item 5 and washer figure 1 item 6 3 Push battery charging alternator 24 Vdc figure 1 item 2 toward engine to release and remove V belt figure 1 item 7 4 Support battery charging alternator 24 Vdc figure 1 item 2 and remove bolt figure 1 item 8 spacer figure 1 item 9 and battery charging alternator 24 Vdc from gear case assembly figure 1 item 10 5 Remove bolt figure 1 item 11 and bracket figure 1 item 12 only if damaged 3 12 15KW 2815 24M 301 1A Figure 1 Battery Charging Alternator 24 Vdc 0010 2 TM 9 2815 538 24 amp P 0010 00 INSPECTION 1 Inspect all parts for wear cracks corrosion and bent or broken terminals 2 Inspect all hardware for stripped or damaged threads 3 Inspect V belt for cracks oiliness or wear 4 Inspect wire harness for worn or missing insulation bent or damaged terminals and corrosion REPAIR Repair of this item is limited to removal and replacement INSTALLATION 1 Install bracket figure 1 item 12 and bolt figure 1 item 11 if previously removed 2 Position battery charging alternator 24 Vdc figure 1 item 2 and spacer figure 1 item 9 onto gear case ass
159. is used it shall have sufficient precision Use of a mercury column type manometer in combination is recommended for calibration and daily check Speed for increasing decreasing Control Pressure Pc shall be very slow near measuring point If mm position is exceeded restart from the beginning 1 Set manometer Pc applied to waste gate actuator to zero and set dial gage to zero 2 Gradually open pressure regulating valve and measure Pc value when actuator rod has traveled 2 mm Do not apply over 71 0 psi 0 49 MPa to actuator 3 For hysteresis let rod move to 3 mm first Then gradually close pressure regulating valve measure pressure when rod has moved 2 mm and obtain difference from pressure measured in step 2 above 0028 5 TM 9 2815 538 24 amp P 0028 00 INSPECTION Continued Waste Gate Actuator Leak Test 1 Prepare waste gate actuator for testing table 1 and figure 4 Table 1 Required Test Equipment EQUIPMENT REQUIREMENTS Dial gage Capable of measuring 0 to 0 39 inches 0 to 10 mm Flat head type recommended Manometer Mercury column or electrical type capable of measuring 0 0 to 29 0 psi 0 0 to 1 500 mmHg Pressure regulating Fine adjustment capability in range of 0 0 to 28 4 psi 0 0 to 0 196 MPa valve Pressure reducing Capable of reducing air supply pressure to 71 0 psi 0 49 MPa or less valve Pressure gage Bourdon tube pressure gage capable of measuring 0 0 to 142 0 0 0 to 0 98 MPa WASTE
160. k Forms located in the back of this manual directly to Commander U S Army CECOM Life Cycle Management Command LCMC and Fort Monmouth ATTN AMSEL LC LEO E ED Fort Monmouth NJ 07703 5006 You may also send in your recommended changes via electronic mail or by fax Our fax number is 732 532 1556 DSN 992 1556 Our e mail address is MONM AMSELLEOPUBSCHG conus army mil Our online web address for entering and submitting DA Form 2028s is http edm monmouth army mil pubs 2028 html b F Air Force By Air Force AFTO Form 22 Technical Manual TM Change Recommendation and Reply in accordance with paragraph 6 5 Section VI TO 00 5 1 directly to prime ALC MST A reply will be furnished to you CURRENT AS OF 15 FEBRUARY 2009 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TM 9 2815 538 24 amp P TABLE OF CONTENTS WP Sequence No WARNING SUMMARY HOW TO USE THIS MANUAL CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION FOR DIESEL ENGINE General Equipment Description and Data picta nen iie aen i qd ran leere ensure een Theory of Operation bc da a a TROUBLESHOOTING PROCEDURES FOR DIESEL ENGINE Troubleshooting Inden aii ee ee ee Troubleshooting Procedure idad a a ud CHAPTER 3 MAINTENANCE INSTRUCTIONS FOR DIESEL ENGINE Service DDOIPROOBIDIL e
161. k fuel lines and hoses for clogs leaks repair replace as required WP 0017 00 end item configuration manual MALFUNCTION Water in fuel system oe ACTION Drain fuel tank and fuel lines and hoses WP 0017 00 WP 0020 00 and end item configuration manual 2 Drain water from fuel filter WP 0017 00 Fill fuel system with clean dry fuel end item configuration manual MALFUNCTION Air in fuel system CORRECTIVE ACTION Bleed fuel system end item configuration manual MALFUNCTION Improper intake exhaust valve clearance CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Improper open or close timing of intake exhaust valves CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual 0005 3 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Engine starts but soon stops with little or no exhaust smoke MALFUNCTION No fuel fuel tank empty CORRECTIVE ACTION Check fuel tank fill as required end item configuration manual MALFUNCTION Clogged fuel filter CORRECTIVE ACTION 1 Check fuel filter clean as required WP 0017 00 2 Check fuel filter repair replace as required WP 0017 00 MALFUNCTION Clogged or leaking fuel line CORRECTIVE ACTION Check fuel lines and hoses for clogs leaks repair replace as required WP 0017 00 end item configurat
162. lace as required WP 0028 00 MALFUNCTION Defective thermostat CORRECTIVE ACTION Check thermostat replace as required WP 0013 00 MALFUNCTION Compression leakage from valve seat CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Improper open or close timing of intake exhaust valves CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Poor spray pattern from fuel injection nozzle CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 MALFUNCTION Uneven volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injection pump assembly and fuel injectors replace as required WP 0016 00 WP 0022 00 MALFUNCTION Incorrect oil grade type for ambient temperature range CORRECTIVE ACTION Drain oil fill with correct oil end item configuration manual 0005 9 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Insufficient engine output with black exhaust smoke Continued MALFUNCTION Too late timing of fuel injection pump assembly CORRECTIVE ACTION Check fuel injection pump assembly adjust timing WP 0016 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual SYMPTOM Excessive white smoke while under load MALFUNCTION Incorrect fuel grade type for ambient temperature range CORRECTIVE ACTION Drain fuel system fill with correct fuel en
163. le item When not uneconomically reparable condemn and dispose of the item at unit or AVUM level Reparable item When uneconomically reparable condemn and dispose of the item at the direct support or AVIM level H Reparable item When uneconomically reparable condemn and dispose of the item at the general support level D Reparable item When beyond lower level repair capability return to depot Condemnation and disposal of item not authorized below depot level L Reparable item Condemnation and disposal not authorized below specialized repair activity SRA A Item requires special handling or condemnation procedures because of specific reasons e g precious metal content high dollar value critical material or hazardous material Refer to appropriate manuals directives for specific instructions NSN Column 3 The NSN for the item is listed in this column CAGEC Column 4 The Commercial and Government Entity Code CAGEC is a five digit code which is used to identify the manufacturer distributor or Government agency activity that supplies the item PART NUMBER Column 5 Indicates the primary number used by the manufacturer individual company 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 0036 5 TM 9 2815 538
164. lean replace air filter end item configuration manual MALFUNCTION Water in fuel system CORRECTIVE ACTION 1 Drain fuel tank and fuel lines and hoses WP 0017 00 WP 0020 00 and end item configuration manual Drain water from fuel filter end item configuration manual Fill fuel system with clean dry fuel end item configuration manual MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual 0005 5 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Insufficient engine output with normal exhaust color MALFUNCTION Clogged fuel filter CORRECTIVE ACTION Replace fuel filter WP 0017 00 MALFUNCTION Air in fuel system CORRECTIVE ACTION Bleed air from fuel system end item configuration manual MALFUNCTION Clogged or leaking fuel line CORRECTIVE ACTION Check fuel lines and hoses for clogs leaks repair replace as required WP 0017 00 MALFUNCTION Incorrect oil grade type for ambient temperature range CORRECTIVE ACTION Drain oil fill with correct oil end item configuration manual MALFUNCTION Incorrect fuel grade type for ambient temperature range CORRECTIVE ACTION Drain fuel system fill with correct fuel end item configuration manual MALFUNCTION Insufficient fuel supply to fuel injectors d ACTION Check fuel water separator and filter replace as required end item configuration manual Check fuel filter
165. ll gasket figure 1 item 21 bolt figure 1 item 20 gasket figure 1 item 19 and plug figure 1 item 18 2 Install gasket figure 1 item 17 adapter figure 1 item 16 and three bolts figure 1 item 15 Torque bolts to 16 7 21 0 Ib ft 22 6 28 4 Nm 3 Install new O ring figure 1 item 14 gasket figure 1 item 13 water pump assembly figure 1 item 12 and three bolts figure 1 item 11 Torque bolts to 16 7 21 0 Ib ft 22 6 28 4 Nm 4 Install pipe assembly figure 1 item 9 onto nipple figure 1 item 10 with spring clamp figure 1 item 8 5 Install pipe assembly figure 1 item 6 onto nipple figure 1 item 7 with spring clamp figure 1 item 5 6 Install bolt figure 1 item 4 to secure pipe assembly figure 1 item 6 to water pump assembly figure 1 item 12 7 Install elbow figure 1 item 3 if previously removed 8 Install pipe assembly figure 1 item 2 onto elbow figure 1 item 3 with spring clamp figure 1 item 1 9 Install coolant hoses end item configuration manual 10 Install thermostat cover and temperature switch 0013 00 11 Install fan V pulley and V belt WP 0011 00 END OF WORK PACKAGE 0012 4 TM 9 2815 538 24 amp P 0013 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 THERMOSTAT COVER AND TEMPERATURE SWITCH REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools References Tool kit general mechanic s End item
166. mber or type number Explanation of Columns in the Remarks Section IV Column 1 Remarks Code The code recorded in column 6 of the MAC Column 2 Remarks This column lists information pertinent to the maintenance function being performed as indicated in the MAC 0034 4 MAC 1 GROUP NUMBER 00 01 0101 0102 0104 0105 0106 0107 0103 2 COMPONENT ASSEMBLY ENGINE ASSEMBLY ENGINE BLOCK ASSEMBLY ROCKER ARM ASSEMBLY CYLINDER HEAD ASSEMBLY VALVE COVER ASSEMBLY CONNECTING ROD AND PISTON ASSEMBLY IDLE GEAR ASSEMBLY CAMSHAFT ASSEMBLY FLYWHEEL HOUSING ASSEMBLY 0035 00 FIELD AND SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 MAINTENANCE ALLOCATION CHART MAC Table 1 Maintenance Allocation Chart 3 4 5 6 TOOLS AND MAINTENANCE MAINTENANCE EQUIPMENT REMARKS FUNCTION LEVEL REF CODE CODE rk mo neo CREW SERVICE FIELD DEPOT DEPOT ESTEE Inspect 0 2 0 5 0 5 Test 0 5 0 5 3 4 5 Service 0 3 0 5 1 5 Adjust 1 0 1 5 Replace 5 0 1 5 Repair 1 0 2 0 3 4 5 Overhaul 12 0 1 4 5 Inspect 0 5 0 5 Remove Install 2 0 1 5 Repair 3 0 1 4 5 Inspect 0 5 Adjust 1 0 5 Remove Install 1 0 45 Replace 1 0 4 5 Repair 1 5 4 5 Inspect 0 2 0 4 Test 0 3 3 4 5 Remove Install 2 0 1 5 Replace 2 0 1 5 Repair 3 0 3 4 5 Inspect 0 2 Remove Insta 0 5 5 Replace 0 5 5 Inspect 0 5 Test 0 3 3 4 5 Remove Install 40 1 3 5 Replace 4 0 1
167. n authorized may be used as a source of supply for items with the above source codes except for those source coded XA or those aircraft support items restricted by requirements of AR 750 1 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 Third Position 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 the following levels of maintenance 0036 3 TM 9 2815 538 24 amp P 0036 00 EXPLANATION OF COLUMNS IN THE REPAIR PARTS LIST AND SPECIAL TOOLS LIST WORK PACKAGES Continued Maintenance ____ C Application Explanation Crew or operator maintenance done within uni AVUM maintenance Unit level AVUM maintenance can remove replace and use the item Direct support AVIM maintenance can remove replace and use the item General support maintenance can remove replace and use the item Specialized repair activity can remove replace and use the item Depot can remove replace and use the item Fourth Position The maintenance code entered in the fourth position tells you whether or not the item is to be repaired and identifies the lowest maintenance level with the capability to do
168. nana n anna cana recorra nana CRANKCASE ASSEMBLY REPAIR PARTS INTAKE MANIFOLD REPAIR PARTS LIST 042422242 442 0 TURBOCHARGER ASSEMBLY REPAIR PARTS 118 44420 0 STARTER MOTOR ASSEMBLY REPAIR PARTS LIST 2 24 4 GENERATOR REPAIR PARTS LIST CRINES ERR SPECIAL TOOLS LIST n eb ecu EP GIRO EE Ep ec RELAX Am Ep BULK MATERIAL iia meto diia EAR NATIONAL STOCK NUMBER INDEX PART NUMBER INDEX O EXPENDABLE AND DURABLE ITEMS 118 4 01 WP Sequence Midi le AAPP E E E E MAINTENANCE ALLOCATION CHART MAC INTRODUCTION eene nnns MAINTENANCE ALLOCATION CHART REPAIR PARTS AND SPECIAL TOOLS LIST INTRODUCTION 0033 00 SCOPE 0033 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 REFERENCES This work package lists all field manuals forms technical bulletins technical manuals miscellaneous publications and military standards and specifications
169. nance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0022 1 TM 9 2815 538 24 amp P 0022 00 REMOVAL 1 Remove four bolts figure 1 item 1 and fuel injector valve retainers figure 1 item 2 from cylinder head assembly figure 1 item 3 2 Remove four fuel injectors figure 1 item 4 nozzle seats figure 1 item 5 and nozzle protectors figure 1 item 6 from cylinder head assembly figure 1 item 3 7 cc 15KW 2815 24M 309C Figure 1 Fuel Injectors 0022 2 TM 9 2815 538 24 amp P 0022 00 INSPECTION Fuel Injector Nozzle Pressure Test 1 Remove carbon deposits from nozzle hole thoroughly before testing WARNING Injection nozzle produces high pressure fuel spray User must wear protective goggles or face shield when using injection nozzle tester Do not direct spray toward bare skin Failure to comply may result in serious injury to personnel 2 Connect fuel injector to high pressure pipe of nozzle tester figure 2 15KW 2815 24M 314 Figure
170. nch 0 17 mm 2 If backlash exceeds limit replace idle gear as follows a Mark all gears at locations A B and C for proper orientation during assembly b Remove three bolts figure 1 item 1 idle gear shaft figure 1 item 2 idle gear bushing figure 1 item 3 and idle gear figure 1 item 4 FUEL INJECTION PUMP DRIVE GEAR CAMSHAFT GEAR DIRECTION OF ROTATION CRANKSHAFT GEAR 15KW 2815 24M 340A Figure 1 Idle Gear Assembly 0015 2 TM 9 2815 538 24 amp P 0015 00 INSPECTION 1 Measure outside diameter figure 2 of idle gear shaft figure 1 item 2 and inside diameter of idle gear bushing figure 1 item 3 2 If measurements or clearance limits are exceeded replace defective part 3 Inspect all parts for damage wear cracks and corrosion 4 Inspect all hardware for stripped or damaged threads 5 Check oil drain holes for obstructions SHAFT IDLE GEAR SHAFT DIAMETER INSIDE DIAMETER ITEM STANDARD LIMIT 1 8091 TO 1 8090 INCHES 1 8070 INCHES SHAFT OUTSIDE DIAMETER 45 950 TO 49 975 mm 45 900 mm 1 8110 TO 1 8120 INCHES 1 8139 INCHES BUSHING INSIDE DIAMETER 46 000 46 025 mm 46 075 mm 0 0009 TO 0 0029 INCHES 0 0068 INCHES CLEARANCE 0 025 TO 0 075 mm 0 175 mm 15KW 2815 24M 345 Figure 2 Idle Gear Shaft and Bushing REPAIR Repair of this item is limited to removal and replacement 0015 3 TM 9 2815 538 24 amp P 0015 00 INSTALLATION 5 6 Lub
171. nduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0020 1 TM 9 2815 538 24 amp P 0020 00 REMOVAL 1 Remove three bolts figure 1 item 1 and retainer figure 1 item 2 2 Remove bolt figure 1 item 3 and retainer figure 1 item 4 3 Disconnect four fuel injection lines figure 1 items 5 6 7 and 8 from four fuel injectors figure 1 item 9 and fuel injection pump assembly figure 1 item 10 Remove fuel injection lines and cover all fuel ports with pressure sensitive tape to prevent intrusion of foreign matter 4 Remove valve cover assembly WP 0021 00 NOTE Rocker arm shaft assembly and intake and exhaust valve assemblies not shown for clarity 5 Remove five banjo bolts figure 1 item 11 fuel return pa
172. nt pin figure 1 item 7 into flywheel housing figure 1 item 5 7 Install flywheel cover cap figure 1 item 6 into flywheel housing figure 1 item 5 8 Install flywheel housing figure 1 item 5 with four bolts figure 1 item 4 9 Install six bolts figure 1 item 3 WARNING Flywheel assembly is heavy and if dropped or mishandled may result in damage to equipment and injury to personnel 10 Install flywheel assembly figure 1 item 2 with six bolts figure 1 item 1 END OF WORK PACKAGE 0030 3 4 blank TM 9 2815 538 24 amp P 0031 00 SUSTAINMENT LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 PREPARATION FOR STORAGE OR SHIPMENT PRESERVATION There are no special preservation requirements The engine should be started and run until operating temperature is reached a minimum of every 60 days and ideally every 30 days If the engine is not going to be started for over 60 days recommend you contact the Army Material Command Major Subordinate Command responsible for engines to obtain special maintenance storage and preservation requirements and procedures PACKING Package per MIL STD 2073 1D as required MARKING Mark for shipment or storage per MIL STD 129 USE OF CORROSION PREVENTIVE COMPOUNDS MOISTURE BARRIERS AND DESICCANT MATERIALS Refer to Corrosion Prevention and Control TB 43 0213 SPECIAL INSTRUCTIONS FOR ADMINISTRATIVE STORAGE Placement of equipment in administrative storage should be for short
173. nten ance Failure to comply may result in damage to equipment and serious injury or death to person nel because of flames and explosion WARNING Connection of any electrical equipment and disconnection of any electrical equipment may cause an explosion hazard Do not connect or disconnect any electrical equipment in an explosive atmosphere Failure to comply may result in serious injury or death to personnel TM 9 2815 538 24 amp P WARNING SUMMARY Continued HAZARDOUS MATERIALS DESCRIPTION Continued WARNING Diesel fuel is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with diesel fuel Avoid repeated or prolonged contact Provide adequate ventilation Personnel are to wash exposed skin and change chemical soaked clothing promptly if exposed to fuel Failure to comply may result in serious injury or death to personnel WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin and eye protec tion are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated area only Failure to comply may result in serious injury or death to personnel WARNING Carbon removing compound is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with carbon removing compound Avoid repeated or prolonged contact Work in ventila
174. olts figure 1 item 11 onto four fuel injectors figure 1 item 9 Torque banjo bolts to 5 7 7 2 lb ft 7 8 9 8 Nm 4 Install valve cover assembly WP 0021 00 5 Install four fuel injection lines figure 1 items 8 7 6 and 5 onto fuel injection pump assembly figure 1 item 10 Do not tighten 6 Install four fuel injection lines figure 1 items 8 7 6 and 5 onto fuel injectors figure 1 item 9 7 Torque both ends of fuel injection lines figure 1 items 8 7 6 and 5 to 21 7 25 3 Ib ft 29 4 34 3 Nm 8 Install retainer figure 1 item 4 and bolt figure 1 item 3 9 Install retainer figure 1 item 2 and three bolts figure 1 item 1 END OF WORK PACKAGE 0020 4 TM 9 2815 538 24 amp P 0021 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 VALVE COVER ASSEMBLY REMOVAL DISASSEMBLY INSPECTION REPAIR ASSEMBLY INSTALLATION INITIAL SETUP Tools and Special Tools References Tool kit general mechanic s WP 0020 00 item 5 WP 0035 00 Equipment Condition Materials Parts Fuel injection lines removed Gasket forming compound WP 0020 00 item 2 WP 0064 00 Personnel Required One WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply
175. om fuel filter end item configuration manual Fill fuel system with clean dry fuel end item configuration manual MALFUNCTION Clogged exhaust pipe CORRECTIVE ACTION Clean exhaust pipe end item configuration manual MALFUNCTION Clogged air filter CORRECTIVE ACTION Clean replace air filter as required end item configuration manual MALFUNCTION Poor spray pattern from fuel injection nozzle CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 MALFUNCTION Uneven volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injection pump assembly and fuel injectors replace as 0016 00 WP 0022 00 0005 15 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Uneven engine speed hunting while idling MALFUNCTION Water in fuel system CORRECTIVE ACTION 1 Drain fuel tank and fuel lines and hoses WP 0017 00 WP 0020 00 and end item configuration manual Drain water from fuel filter end item configuration manual Fill fuel system with clean dry fuel end item configuration manual MALFUNCTION Defective governor CORRECTIVE ACTION Adjust replace governor as required end item configuration manual MALFUNCTION Poor spray pattern from fuel injection nozzle CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 MALFUNCTION Uneven volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel inje
176. onnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless itis properly grounded Failure to comply may result in serious injury or death to personnel 0023 1 TM 9 2815 538 24 amp P 0023 00 COMPRESSION TEST NOTE Procedures provide compression test for cylinder no 1 Other cylinders are typical 1 Crank engine end item configuration manual to make sure all internal components are lubricated 2 Install nozzle protector figure 1 item 1 nozzle seat figure 1 item 2 and adapter figure 1 item 3 into cylinder head assembly figure 1 item 4 and secure with fuel injector valve retainers figure 1 item 5 and bolt figure 1 item 6 3 Connect quick disconnect figure 1 item 7 of compression gage assembly figure 1 item 8 into adapter figure 1 item 2 4 Crank engine end item configuration manual until compression gage indication stabilizes 5 Engine compression must be 440 913 to 411 907 psi 3 04 to 2 84 MPa with minimum limit of 369 845 to 341 839 psi 2 55 to 2 35 MPa 6 If engine compression is not within tolerance refer to troubleshooting procedures to isolate malfunction WP 0005 00 7 Repeat steps 2 thru 6 above
177. ons REPAIR Repair of this item is limited to removal and replacement 0024 3 TM 9 2815 538 24 amp P 0024 00 INSTALLATION 1 Install new cylinder head gasket figure 1 item 5 onto cylinder block assembly figure 1 item 6 CAUTION If alignment pins do not align with cylinder block assembly correctly cylinder head gasket or cylinder block combustion surface may be damaged 2 Make sure alignment pins are aligned and carefully install cylinder head assembly figure 1 item 5 onto cylinder block assembly figure 1 item 6 3 Install 18 bolts figure 1 item 4 and torque to initial torque of 30 31 to 34 60 Ib ft 41 1 to 46 9 Nm per sequence in figure 2 Then torque bolts to 62 91 to 67 19 Ib ft 85 3 to 91 1 Nm using same sequence 4 Compress hose clamp figure 1 item 1 and install hose figure 1 item 2 onto cylinder head assembly figure 1 item 3 5 Install exhaust manifold WP 0028 00 6 Install intake manifold and air inlet hose WP 0026 00 7 Install water pump assembly WP 0012 00 8 Install valve cover assembly WP 0021 00 9 Install fuel injection lines WP 0020 00 END OF WORK PACKAGE 0024 4 TM 9 2815 538 24 amp P 0025 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 VALVE LASH ADJUSTMENT INITIAL SETUP Tools and Special Tools References Tool kit general mechanic s item 5 WP 0035 00 Equipment Condition Personnel Required Valve cover assembly removed One
178. ools and Special Tools Personnel Required Tool kit general mechanic s One item 5 WP 0035 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0027 1 TM 9 2815 538 24 amp P 0027 00 REMOVAL 1 Remove two bolts figure 1 item 1 oil return line figure 1 item 2 and O ring figure 1 item 3 from turbocharger figure 1 item 4 Discard O ring 2 Remove bolt figure 1 item 5 and retainer figure 1 item 6 from cylinder head assembly figure 1 item 7 3 Remove nut figure 1 item 8 from retainer figure 1 item 9 4 Remove banjo bolt figure 1 item 10 and two seal washers figure 1 items 11 and 12 from fuel injection pump assembly figure 1 item 13 Discard seal washers
179. or The accumulator is used to maintain constant fuel pump pressure by compensating for small fluctuations in fuel pressure The pressure control valve regulates fuel pump pressure Pressurized fuel from the fuel pump is applied to the gear driven fuel distributor which supplies fuel to the injection pump based on engine timing When a particular cylinder is near the end of a compression cycle the fuel distributor enables fuel flow to that cylinder s fuel injector nozzle Whenever the fuel distributor aligns with a cylinder the cam will actuate the plunger in the injection pump forcing high pressure fuel into that cylinder s fuel injector nozzle This cycle is repeated for each of the four cylinders The fuel that is not used is returned to the fuel tank via an excess fuel return line ORIFICE EXCESS FUEL RETURN INJECTION PUMP FUEL DISTRIBUTOR FUEL FUEL TIMER FILTER INJECTOR PISTON ACCUMULATOR ELECTRIC FUEL FEED PUMP OVERFLOW ORIFICE HIGH PRESSURE GALLERY FUEL TANK INJECTION ASSEMBLY HOUSING PRESSURE PRESSURE GALLERY CONTROL VALVE 15KW 2815 24M 105B Figure 1 Fuel System 0003 2 TM 9 2815 538 24 amp P 0003 00 ENGINE COOLING SYSTEM The engine cooling system figure 2 consists of a water pump thermostat belt driven fan and cooling jackets The water pump is located on the front of the cylinder block and is belt driven from the crankshaft pulley The water
180. oup to which the item belongs This is necessary since figures are prepared for assembly groups and subassembly groups and lists are divided into the same groups Second Find the figure covering the functional group or the subfunctional group to which the item belongs Third Identify the item on the figure and note the number s Fourth Look in the repair parts list work packages for the figure and item numbers The NSNs and part numbers are on the same line as the associated item numbers 2 When NSN is Known First If you have the NSN look in the STOCK NUMBER column of the NSN index work package The NSN is arranged in NIIN sequence Note the figure and item number next to the NSN Second Turn to the figure and locate the item number Verify that the item is the one you are looking for 3 When P Ns is Known First If you have the P N and not the NSN look in the PART NUMBER column of the P N index work package Identify the figure and item number Second Look up the item on the figure in the applicable repair parts list work package ABBREVIATIONS Abbreviation Explanation AVIM Aviation Intermediate Maintenance AVUM Aviation Unit Maintenance BOI Basis of Issue CAGEC Commercial and Government Entity Code EMP Electromagnetic Pulse KW Kilowatt MAC Maintenance Allocation Chart NIIN National Item Identification Number NSN National Stock Number OS Oversize SMR Source Maintenance and Recoverability SRA Specialized R
181. ous problem Keep the equipment clean Clean as you work and as needed Use breakthrough cleaning solvent and a wiping rag to clean metal surfaces Use soap and water to clean rubber or plastic material 2 Bolts clamps nuts and screws Continuously check for looseness Look for chipped paint bare metal rust or corrosion around bolt and screw heads and nuts Tighten them when you find them loose 3 Welds Many items on the engine are welded To check these welds look for chipped paint rust cor rosion or gaps When these conditions exist notify sustainment level maintenance on DA Form 5988 E 4 Electrical wires connectors and harnesses Tighten loose connectors Look for cracked or broken insulation bare wires and broken connectors 5 Hoses and fluid lines Check hoses and fluid lines for wear damage and leaks Ensure clamps and fittings are tight 6 Hinges Check hinges for security and operation 7 Data plates Check data caution and warning plates for security and legibility 0007 2 TM 9 2815 538 24 amp P 0007 00 PMCS COLUMN DESCRIPTIONS ITEM NO Lists order in which PMCS should be performed also used as a source of item numbers for the TM number column on DA Form 5988 E when recording results of PMCS INTERVAL Indicates when each check is to be performed MANHOUR Lists approximate time required to perform check ITEM TO BE CHECKED OR SERVICED Lists item to be checked or serviced PROCEDURE Pro
182. ov com
183. pletely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0028 1 TM 9 2815 538 24 amp P 0028 00 REMOVAL 1 Remove four bolts figure 1 item 1 turbocharger assembly figure 1 item 2 and gasket figure 1 item 3 from exhaust manifold figure 1 item 4 2 Remove turbocharger assembly gasket figure 1 item 5 and stud bolt figure 1 item 6 if required 3 Remove bolt figure 1 item 7 from exhaust manifold figure 1 item 4 4 Remove three bolts figure 1 item 8 from exhaust manifold figure 1 item 4 5 Remove four bolts figure 1 item 9 exhaust manifold figure 1 item 4 and exhaust manifold gasket figure 1 item 10 from cylinder head assembly figure 1 item 11 6 Cover oil ports with pressure sensitive tape to prevent contamination or debris from entering turbocharger assembly figure 1 item 2 0028 2 0028 00 TM 9 2815 538 24 amp P REMOVAL Continued 15KW 2815 24M 313 Figure 1 Turbocharger Assembly and Exhaust Manifold 0028 3 TM 9 2815 538 24 amp P 0028 00 INSPECTION Rotor Play 1 Inspect all parts for wear cracks and corrosion 2 Inspect all hardware for stripped or dam
184. pped in breakthrough cleaning solvent 3 Machined surfaces which are deeply nicked could affect assembly operation and should be replaced 4 Minor damage to threaded capscrew holes should be repaired with thread tap of same size to prevent cutting oversize END OF WORK PACKAGE 0009 3 4 blank TM 9 2815 538 24 amp P 0010 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 BATTERY CHARGING ALTERNATOR 24 VDC REMOVAL INSPECTION REPAIR INSTALLATION ADJUSTMENT INITIAL SETUP Tools and Special Tools Personnel Required Tool kit general mechanic s One item 5 WP 0035 00 References Materials Parts End item configuration manual Marker tags item 7j WP 0064 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when working on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless itis properly grounded Failure to comply may result in ser
185. r ambient temperature range CORRECTIVE ACTION Drain oil fill with correct oil end item configuration manual MALFUNCTION Leakage from oil lines CORRECTIVE ACTION Check oil lines repair as required WP 0018 00 and WP 0028 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual MALFUNCTION Clogged oil filter CORRECTIVE ACTION Replace oil filter end item configuration manual SYMPTOM Excessive blow by gas MALFUNCTION Incorrect oil grade type for ambient temperature range CORRECTIVE ACTION Drain oil system fill with correct oil end item configuration manual 0005 21 0005 00 TM 9 2815 538 24 amp P TROUBLESHOOTING Continued SYMPTOM Continued Excessive blow by gas Continued MALFUNCTION Clogged oil filter CORRECTIVE ACTION Replace oil filter end item configuration manual MALFUNCTION Compression leakage from valve seat CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Worn intake exhaust valve guides CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Excessive volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual SYMPTOM Engine overheats MALFUNCTION Excessive slack in fan V belt CORREC
186. r or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless it is properly grounded Failure to comply may result in serious injury or death to personnel 0024 1 0024 00 TM 9 2815 538 24 amp P REMOVAL Compress hose clamp figure 1 item 1 and remove hose figure 1 item 2 from cylinder head assembly figure 1 item 3 1 ERES ASS Ne AED QUAD Y RU NE 15 2815 24 511 Figure 1 Cylinder Head Assembly 0024 2 TM 9 2815 538 24 amp P 0024 00 REMOVAL Continued NOTE It may be necessary to free cylinder head assembly from cylinder block assembly by tapping with soft head hammer 2 Loosen 18 bolts figure 1 item 4 per sequence in figure 2 then remove bolts in same sequence CAMSHAFT SIDE FAN SIDE HEAD BOLT LOOSENING ORDER CAMSHAFT SIDE FAN SIDE HEAD BOLT TIGHTENING ORDER 15KW 2815 24M 353 Figure 2 Cylinder Head Bolts 3 Remove cylinder head assembly figure 1 item 3 and move to clean work location 4 Remove cylinder head gasket figure 1 item 5 from cylinder block assembly figure 1 item 6 Discard cylinder head gasket INSPECTION 1 Inspect all parts for damage wear cracks and corrosion 2 Inspect all hardware for stripped or damaged threads 3 Check oil drain holes for obstructi
187. r usual operating conditions PMCS intervals must be performed more frequently when operating under unusual conditions Always perform preventive maintenance in the same order so it gets to be a habit Once you have had some practice you will spot anything wrong in a hurry Tools included with the engine are to be used when doing the PMCS Wiping rags are needed to remove dirt or grease If you find something wrong when performing the PMCS fix it if you can using troubleshooting procedures WP 0005 maintenance procedures If something appears to be wrong and you cannot repair it write it down on your DA Form 5988 E If you find something seriously wrong report it to sustainment level maintenance as soon as possible Item numbers in column 1 of the PMCS table indicate the PMCS sequence Use these item numbers for the TM number column on DA Form 5988 E Information in column 6 of the PMCS table lists conditions that make the equipment not ready available Write up items not repaired on DA Form 5988 E for sustainment level maintenance For further information on how to use these forms see DA PAM 738 750 0007 1 TM 9 2815 538 24 amp P 0007 00 CORROSION PREVENTION AND CONTROL CPC CPC of materiel is a continuing concern It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future systems While corrosion
188. replace as required WP 0017 00 Check fuel injection pump assembly replace as required WP 0016 00 Check fuel lines and hoses for clogs leaks repair as required WP 0017 00 MALFUNCTION Clogged strainer at feed pump inlet CORRECTIVE ACTION Clean strainer end item configuration manual 0005 6 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Insufficient engine output with normal exhaust color Continued MALFUNCTION Improper intake exhaust valve clearance CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Compression leakage from valve seat CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Leaking cylinder head assembly gasket CORRECTIVE ACTION Replace cylinder head assembly gasket WP 0024 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual SYMPTOM Insufficient engine output with white exhaust smoke MALFUNCTION Incorrect fuel grade type for ambient temperature range CORRECTIVE ACTION Drain fuel system fill with correct fuel end item configuration manual MALFUNCTION Water in fuel system en ACTION Drain fuel tank and fuel lines and hoses WP 0017 00 WP 0020 00 and end item configuration manual 2 Drain water from fuel filter end item configuration manual Fill fuel system with clean dry fuel end item configuration manual 0005 7 TM 9 281
189. ricate idle gear bushing figure 1 item 3 and idle gear shaft figure 1 item 2 with engine lubricating oil Align all gears per marks A B and C and install idle gear figure 1 item 4 idle gear bushing figure 1 item 3 idle gear shaft figure 1 item 2 and three bolts figure 1 item 1 Install gear case assembly WP 0014 00 Install water pump assembly WP 0012 00 Install fan V pulley and V belt WP 0011 00 Install battery charging alternator 24 Vdc WP 0010 00 END OF WORK PACKAGE 0015 4 TM 9 2815 538 24 amp P 0016 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FUEL INJECTION PUMP ASSEMBLY REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools References Shop equipment automotive vehicle gear puller item 3 WP 0035 00 Tool kit general mechanic s item 54 WP 0035 00 End item configuration manual Materials Parts Breakthrough cleaning solvent Equipment Condition item 6 WP 0064 00 Fan V pulley and V belt removed Engine lubricating oil item 4 Gasket forming compound WP 0064 00 Fuel injection lines removed Petroleum jelly item 3 WP 0064 00 WP 0064 00 Wiping rag item 5 Intake manifold and air inlet hose removed WP 0026 00 Personnel Required Turbocharger oil line removed One WP 0027 00 WARNING Metal jewelry will conduct electricity All jewelry can become entangled in rotating components Remove all jewelry when
190. rking on unit Failure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless itis properly grounded Failure to comply may result in serious injury or death to personnel 0014 1 TM 9 2815 538 24 amp P 0014 00 REMOVAL 1 Remove bolt figure 1 item 1 washer figure 1 item 2 and pulley figure 1 item 3 2 Remove oil seal figure 1 item 4 Discard oil seal 3 Remove four bolts figure 1 item 5 4 Remove 12 bolts figure 1 item 6 5 Remove three bolts figure 1 item 7 and gear case assembly figure 1 item 8 6 Remove oil filler cap figure 1 item 9 and O ring figure 1 item 10 Discard O ring 7 Remove two bolts figure 1 item 11 cover figure 1 item 12 and O ring figure 1 item 13 0014 2 0014 00 TM 9 2815 538 24 amp P REMOVAL Continued 15KW 2815 24M 329C Figure 1 Gear Case Assembly Inspect all parts for damage wear cracks and corrosion INSPECTION 1 Inspect all hardware for s
191. rsonnel WARNING In extreme cold weather skin can stick to metal Avoid contacting metal items with bare skin in extreme cold weather Failure to comply may result in serious injury or death to personnel WARNING Operating unit exposes personnel to a high noise level Hearing protection must be worn when operating or working near unit when unit is running Failure to comply may result in serious hearing damage to personnel WARNING Many components require a two person lift Lifting heavy components can cause back strain Ensure proper lifting techniques are used when lifting heavy components Failure to comply may result in serious injury to personnel WARNING Each battery weighs more than 70 pounds 32 kg and requires a two person lift Lifting batteries can cause back strain Ensure proper lifting techniques are used when lifting batteries Failure to comply may result in serious injury to personnel WARNING Unit is extremely heavy and requires an assistant and a lifting device forklift overhead lifting device with sufficient capacity Failure to comply may result in serious injury or death to personnel WARNING Support components when removing attaching hardware or component may fall Failure to comply may damage equipment and result in serious injury to personnel TM 9 2815 538 24 amp P WARNING SUMMARY Continued GENERAL SAFETY WARNINGS DESCRIPTION Continued WARNING Retaining rings and springs are under
192. s 2 Inspect threaded areas for wear distortion stretching or evidence of cross threading 3 Mark all damaged areas for repair or replacement Castings Forgings and Machined Metal Parts 1 Inspect machined surfaces for nicks burrs raised metal wear or other damage 2 Check all inner and outer surfaces for breaks or cracks 3 Mark all damaged material for repair or replacement TAGGING INSTRUCTIONS When tagging is required during the removal procedure remove tags during the installation procedure REPAIR INSTRUCTIONS NOTE Refer to Source Maintenance and Recoverability SMR codes assigned to support items listed in the RPSTL work packages WP 0036 00 thru WP 0064 00 Any repair procedure peculiar to a specific part or component is covered in the work package relating to that item After repair clean all parts thoroughly to prevent dirt metal chips or other foreign material from entering working parts Castings Forgings and Machined Metal Parts 1 Minor cracked castings or forgings may possibly be repaired Refer to TC 9 237 WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated area only Failure to comply may result in serious injury or death to personnel 2 Repair minor damage to machined surfaces with fine tooth mil file or crocus cloth di
193. sed at high temperatures or at high altitude CORRECTIVE ACTION Check output drop and load matching requirements reduce load as required end item configuration manual 0005 12 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Excessive black smoke while under load Continued MALFUNCTION Turbocharger assembly waste gate malfunction CORRECTIVE ACTION Inspect turbocharger assembly replace as required WP 0028 00 MALFUNCTION Improper open or close timing of intake exhaust valves CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Compression leakage from valve seat CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Uneven excessive volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injectors replace as required WP 0022 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual MALFUNCTION Uneven volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injection pump assembly and fuel injectors replace as required WP 0016 00 WP 0022 00 MALFUNCTION Excessive volume of fuel from fuel injectors CORRECTIVE ACTION Check fuel injection pump assembly and fuel injectors replace as required WP 0016 00 WP 0022 00 MALFUNCTION Too late timing of fuel injection pump assembly CORRECTIVE ACTION Check fuel injection pump assembly adjust timing
194. sembly and Flywheel 0 Preparation for Storage or 4240101 01 1 PSI eal ect CHAPTER 4 SUPPORTING INFORMATION FOR DIESEL ENGINE een ran Maintenance Allocation Chart MAC Introduction ccccccccsssecscssscsescsesesesececscsesacsesesesececsesesacseseseeeeaes Maintenance Allocation Chart 2 1 4 2 000201 0 60000000000 000000000000 0000550 Repair Parts and Special Tools List Turbocharged Diesel Engine Repair Parts TM 9 2815 538 24 amp P TABLE OF CONTENTS Continued WP Sequence No CHAPTER 4 SUPPORTING INFORMATION FOR DIESEL ENGINE Continued Cylinder Block Assembly Repair Parts essent tent Rocker Arm Shaft Assembly Repair Parts 0039 0 Cylinder Head Assembly Repair Parts 0040 0 Valve Cover Assembly Repair Parts 0041 0 Connecting Rod and Piston Assembly Repair Parts 0042 0 Camshaft Driving Gear and Idle Gear Assemblies Repair Parts 0043 0 Flywheel Assembly Repair Parts Crankshaft Assembly Repair Parts 1181 0045 0 Gear Case Assembly Repair Parts 0046 0 Cooling System Repair Parts Llst
195. tarting aid Protection devices Low oil pressure switch Trip pressure Voltage rating Coolant high temperature switch Trip temperature Voltage rating 12 Vdc quantity 2 in series 24 Vac Yanmar 129612 7701 24 Vdc Direct Yanmar 129900 77240 24 Vdc Belt drive 35A at 24 24 Vdc 800W intake air preheater 11 4 psi 0 8 kg cm 24 225 F to 235 F 107 C to 112 C 24 0002 6 TM 9 2815 538 24 amp P 0003 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 THEORY OF OPERATION GENERAL This work package contains functional descriptions of the diesel engine and explains how engine functional systems interact with one another ENGINE OVERVIEW The engine is an in line four cylinder turbocharged diesel engine with a firing order of 1 3 4 2 cylinder number 1 is located at the flywheel end of the engine Each oylinder utilizes four non hydraulic adjustable valves two intake and two exhaust for a total of 16 valves The gear driven cam shaft operates push rods that operate the rocker arms to open each pair of valves Each valve pair operate together using a valve bridge The valve pairs allow greater air flow into and out of the cylinders to increase engine performance The engine rotation is CCW when viewed from the flywheel end The cylinder bore is 3 307 inches 84 mm and the stroke is 3 543 inches 90 mm providing a total displacement of 121 7 cubic inches 1 995L The fuel inj
196. ted area only Failure to comply may result in serious injury or death to personnel WARNING Fuels used in unit are flammable Do not smoke or use open flames when performing mainten ance Failure to comply may cause flames and possible explosion Failure to comply may result in damage to equipment and serious injury or death to personnel WARNING Fuels used in unit are flammable When filling fuel tank maintain metal to metal contact between filler nozzle and fuel tank opening to eliminate static electrical discharge Failure to comply may cause flames and possible explosion Failure to comply may result in damage to equipment and serious injury or death to personnel WARNING Hot exhaust gases can ignite flammable materials Allow room for safe discharge of hot gases and sparks Failure to comply may result in serious injury or death to personnel WARNING Eye protection is required when working with compressed air Compressed air can propel particles at high velocity and injure eyes Do not exceed 15 psi pressure when using compressed air Failure to comply may result in serious injury to personnel TM 9 2815 538 24 amp P WARNING SUMMARY Continued HAZARDOUS MATERIALS DESCRIPTION Continued WARNING Cleaning compound is toxic Avoid prolonged breathing of vapors Use in a ventilated area only Failure to comply may result in serious injury to personnel WARNING Avoid breathing fumes generated by soldering Eye protect
197. tem fill as required end item configuration manual 3 Flush lubricating system fill as required end item configuration manual 4 Operate engine and check for coolant in oil or oil in coolant end item configuration manual 0005 23 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Continued Engine overheats Continued MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual SYMPTOM Low coolant temperature MALFUNCTION Defective thermostat CORRECTIVE ACTION Check thermostat replace as required WP 0013 00 SYMPTOM Air intake pressure drops MALFUNCTION Engine used at high temperatures or at high altitude CORRECTIVE ACTION Check output drop and load matching requirements reduce load as required end item configuration manual MALFUNCTION Clogged air filter CORRECTIVE ACTION Clean replace air filter as required end item configuration manual MALFUNCTION Improper intake exhaust valve clearance CORRECTIVE ACTION Adjust valve lash WP 0025 00 MALFUNCTION Compression leakage from valve seat CORRECTIVE ACTION Replace cylinder head assembly WP 0024 00 MALFUNCTION Internal engine problem CORRECTIVE ACTION Replace engine end item configuration manual 0005 24 TM 9 2815 538 24 amp P 0005 00 TROUBLESHOOTING Continued SYMPTOM Air intake pressure rises MALFUNCTION Excessive volume of fuel from fu
198. tem 1 from starter motor terminals 2 Tagand disconnect wire harness figure 1 item 2 from starter motor assembly figure 1 item 3 3 Remove two bolts figure 1 item 4 and starter motor assembly figure 1 item 3 from flywheel housing figure 1 item 5 15KW 2815 24M 307A Figure 1 Starter Motor Assembly INSPECTION 1 Inspect all parts for wear cracks and corrosion 2 Inspect all hardware for stripped or damaged threads 3 Inspect starter motor assembly and wire harness for worn or missing insulation bent or damaged terminals and corrosion REPAIR Repair of this item is limited to removal and replacement INSTALLATION 1 Carefully position starter motor assembly figure 1 item 3 onto flywheel assembly housing figure 1 item 5 and install two bolts figure 1 item 4 Torque bolts to 57 8 to 72 2 Ib ft 78 8 to 98 0 Nm 2 Connect wire harness figure 1 item 2 to starter motor assembly figure 1 item 3 Remove tags 3 Position terminal covers figure 1 item 1 over starter motor terminals END OF WORK PACKAGE 0019 2 TM 9 2815 538 24 amp P 0020 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 FUEL INJECTION LINES AND RETURN HOSE REMOVAL INSPECTION REPAIR INSTALLATION INITIAL SETUP Tools and Special Tools Personnel Required Tool kit general mechanic s One item 5 WP 0035 00 References Materials Parts Pressure sensitive tape item 8 WP 0064 00 WARNING Metal jewelry will co
199. tenance BD Bundle bhp Brake horsepower BOI Basis of Issue BX Box CAGEC Commercial and Government Entity Code CARC Chemical Agent Resistant Coating CCW Counterclockwise Chp Chapter cm Centimeter CN Carton CPC Corrosion Prevention and Control CW Clockwise DC Direct Current DIA Diameter EIC End Item Code EIR Equipment Improvement Recommendations EMP Electromagnetic Pulse ESD Electrostatic Discharge FGC Functional Group Code FIG Figure gal Gallon gph Gallons Per Hour HCl Hardness Critical Item HZ Hertz 1 0 Identification IDN Initial Distribution Number in Inch ISO International Standards Organization kg Kilogram 0001 2 TM 9 2815 538 24 amp P 0001 00 LIST OF ABBREVIATIONS ACRONYMS Continued Abbreviation Acronym Definition kPa Kilopascal KW Kilowatt L Liter Ib Pound Ib ft Pound foot Iph Liters Per Hour m Meter MAC Maintenance Allocation Chart MI Modification Instructions mm Millimeter mmHz Millimeter Per Hertz MPa Megapascal MTOE Modified Table of Organization and Equipment MWO Modification Work Order N A Not Applicable NBC Nuclear Biological and Chemical NHA Next Higher Assembly NIIN National Item Identification Code Nm Newton Meter No Number NSN National Stock Number OS Oversize OSHA Occupational Safety and Health Act P N Part Number Pc Control Pressure PG Package PMCS Preventive Maintenance Checks and Services psi Pounds Per Square Inch qt Quart QTY Q
200. tension and can act as projectiles when being removed Use eye protection when removing retaining rings or springs Failure to comply may result in serious injury to personnel WARNING Oil filter base and housing springs are under tension and can act as projectiles when being removed Use eye protection when removing springs Failure to comply may result in serious injury to personnel WARNING Do not use engine starter to turn flywheel Failure to comply may result in serious injury to personnel WARNING Fan has sharp blades Use caution and wear gloves when removing or installing belts Failure to comply may result in serious injury to personnel TM 9 2815 538 24 amp P WARNING SUMMARY Continued EXPLANATION OF HAZARDOUS MATERIALS ICONS EYE PROTECTION human figure with goggles shows that material can cause injury to eyes CHEMICAL drops of liquid on hand shows that material can cause burns or irritation to human skin or tissue VAPOR human figure in a cloud shows that material vapors present danger to life or possible death FIRE flames show that material is flammable EXPLOSION flame and burst shows that material can explode if subjected to high temperatures sources of ignition or high pressure RADIATOR steam in face and body shows that escaping steam and hot water exist HAZARDOUS MATERIALS DESCRIPTION WARNING Batteries give off a flammable gas Do not smoke or use open flame when performing mai
201. tor assembly figure 1 sheet 1 item 3 is located on the left rear side of the engine The electric starter engages the flywheel mechanically to start the diesel engine Batter Charging Alternator 24 Vdc The battery charging alternator figure 1 sheet 1 item 4 is located on the left side of the engine The battery charging alternator provides 24 Vdc to maintain the starting batteries in a state of full charge and to power engine accessories Fuel Injection Pump Assembly The fuel injection pump assembly figure 1 sheet 2 item 5 provides high pressure fuel to the fuel injectors Oil Filter The oil filter figure 1 sheet 2 item 6 removes contaminants from the engine oil to maintain a clean supply of oil to lubricate the moving parts of the engine Oil Dipstick The oil dipstick figure 1 sheet 2 item 7 provides a means of checking the oil level of the engine Turbocharger Assembly The turbocharger assembly figure 1 sheet 2 item 8 is powered by engine exhaust gases It compresses and speeds up the airflow from the air filter to provide pressurized air to the engine for better combustion and more power without increased fuel consumption 0002 1 TM 9 2815 538 24 amp P 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS Continued Sensor Switches The primary sensor switches on the engine are the coolant temperature switch figure 1 sheet 3 item 9 and oil pressure switch figure 1 sheet 3 item 13 Water Pump
202. tract Skin and eye protection are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated area only Failure to comply may result in serious injury or death to personnel 1 Clean inner and outer surfaces with breakthrough cleaning solvent and a wiping rag 2 Remove grease and accumulated deposits with a stiff bristle brush WARNING Particles blown by compressed air are hazardous Make sure air stream is directed away from user and other personnel in area User must wear protective goggles or face shield when using compressed air Failure to comply may result in serious injury to personnel 3 Blow out all tapped threaded holes with compressed air to remove dirt and cleaning fluids Electrical Cables and Rubber Components CAUTION Do not wash rubber components and electrical cables with breakthrough cleaning solvents or mineral spirits Serious damage to or destruction of material may result Clean electrical cables and rubber components with water mild soap solution and wiping rag INSPECTION INSTRUCTIONS All components and parts must be carefully checked to determine the following 1 If they are serviceable for reuse 2 If they can be repaired 3 they must be replaced 0009 2 TM 9 2815 538 24 amp P 0009 00 INSPECTION INSTRUCTIONS Continued Drilled and Tapped Threaded Holes 1 Inspect for wear distortion cracks or any other damage in or around hole
203. tripped or damaged threads 2 3 Check oil drain holes for obstructions 0014 3 TM 9 2815 538 24 amp P 0014 00 REPAIR Repair of this item is limited to removal and replacement INSTALLATION 1 Install new O ring figure 1 item 13 cover figure 1 item 12 and two bolts figure 1 item 11 2 Install new O ring figure 1 item 10 and oil filler cap figure 1 item 9 WARNING Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin and eye protection are required when working in contact with cleaning solvent Avoid repeated or prolonged contact Work in ventilated area only Failure to comply may result in serious injury or death to personnel 3 Thoroughly clean mounting surface of gear case assembly figure 1 item 8 with breakthrough cleaning solvent and wiping rag 4 Apply gasket forming compound to mounting surface of gear case assembly figure 1 item 8 5 Install gear case assembly figure 1 item 8 and three bolts figure 1 item 7 6 Install 12 bolts figure 1 item 6 7 Install four bolts figure 1 item 5 8 Lubricate oil seal figure 1 item 4 with engine lubricating oil and install 9 Install pulley figure 1 item 3 using washer figure 1 item 2 and bolt figure 1 item 1 10 Install fan V pulley and V belt WP 0011 00 11 Install battery charging alternator 24 Vdc WP 0010 00 END OF WORK PACKAGE 0014 4 TM 9 2815 538 24 amp amp 0015 00
204. uality Deficiency Report or SF 361 Transportation Discrepancy Report Check equipment against packing slip to see if shipment is complete Report all differences using procedure given in DA PAM 738 750 Perform Preventive Maintenance Checks and Services PMCS WP 0008 00 Schedule next PMCS on DD Form 314 Preventive Maintenance Schedule and Record Report all deficiencies on DA Form 5988 E Equipment Inspection and Maintenance Worksheet automated or on DA Form 2404 Equipment Inspection and Maintenance Worksheet if deficiencies appear to involve unsatisfactory design END OF WORK PACKAGE 0006 2 INITIAL SETUP Tools and Special Tools Tool kit general mechanic s item 5 WP 0035 00 Materials Parts Breakthrough cleaning solvent item 6 WP 0064 00 Wiping rag item 5 WP 0064 00 INTRODUCTION TM 9 2815 538 24 amp P FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 PMCS INTRODUCTION 0007 00 Personnel Required One References DA Form 5988 E DA PAM 738 750 PMCS are performed to keep the engine in operating condition Inspect the engine within specified intervals so defects are found and corrected or problems are reported before any serious damage or failure occurs Do the PMCS as shown in the PMCS table WP 0008 00 Pay attention to WARNINGs and CAUTIONs WARNING means someone could be hurt A CAUTION means equipment could be damaged NOTE Designated intervals are performed unde
205. uantity REF Reference RL Roll rpm Revolutions Per Minute RPSTL Repair Parts and Special Tools List SAE Society of Automotive Engineers SMR Source Maintenance and Recoverability SRA Specialized Repair Activity TAMMS The Army Maintenance Management System 0001 3 TM 9 2815 538 24 amp P 0001 00 LIST OF ABBREVIATIONS ACRONYMS Continued Abbreviation Acronym Definition TB Technical Bulletin TDC Top Dead Center TM Technical Manual TMDE Test Measurement and Diagnostic Equipment TQ Tactical Quiet TU Tube Unit of Issue UOC Useable On Code USEPA U S Environmental Protection Agency UUT Unit Under Test UV Ultraviolet Vdc Volts Direct Current W Watt WP Work Package Degrees Celsius oF Degrees Fahrenheit QUALITY OF MATERIAL Material used for replacement repair or modification must meet the requirements of this TM If quality of material requirements are not stated in this manual the material must meet the requirements of the drawings standards specifications or approved engineering change proposals applicable to the subject equipment SAFETY CARE AND HANDLING The diesel engine contains no radioactive components or parts or radioactive material requiring special handling or consideration The diesel engine contains no electronic modules or components requiring special handling to protect them from Electrostatic Discharge ESD This manual describes physical and chemical processes that ma
206. ure to comply may result in serious injury or death to personnel DO NOT wear loose clothing when performing checks services and maintenance Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Make sure unit is completely shut down and free of any power source before attempting any repair or maintenance on unit Failure to comply may result in serious injury or death to personnel High voltage is produced when unit is in operation Never attempt to start or maintain unit unless itis properly grounded Failure to comply may result in serious injury or death to personnel 0030 1 TM 9 2815 538 24 amp P 0030 00 REMOVAL WARNING Flywheel assembly is heavy and if dropped or mishandled may result in damage to equipment and injury to personnel 1 Remove six bolts figure 1 item 1 and flywheel assembly figure 1 item 2 2 Remove six bolts figure 1 item 3 four bolts figure 1 item 4 and flywheel housing figure 1 item 5 3 Remove flywheel cover cap figure 1 item 6 4 Remove alignment pin figure 1 item 7 only if damaged NOTE An alternate procedure to remove oil seal is to wrap crankshaft end with masking tape to protect surface and gently pry out seal with a small screwdriver 5 Remove six bolts figure 1 item 8 three bolts figure 1 item 9 and oil seal case assembly figure 1 item 10 6 Remove and discard oil seal figure 1 item
207. ust enough to allow fuel injection pump assembly to rotate 4 Treat timing index numbers figure 8 recorded in step 1 above and REMOVAL step 19 above as if numbers have decimal points For example timing index number 68 would be 6 8 0016 9 TM 9 2815 538 24 amp P 0016 00 INSTALLATION Continued 5 Calculate difference between timing index numbers of old fuel injection pump assembly figure 5 item 11 and new fuel injection pump assembly figure 5 item 11 Always subtract smaller timing index number from larger timing index number NOTE Each mark on timing index sticker represents a 0 5 degree change in timing referenced from the standard mark 6 Iftiming index number of new fuel injection pump assembly figure 5 item 11 is larger than timing index number of old fuel injection pump assembly fuel injection pump assembly figure 5 item 11 timing must be advanced rotated away from engine figure 9 by amount determined from step 5 above figure 10 DELAYED ADVANCED o FUEL INJECTION PUMP ASSEMBLY INSTALLATION BOLTS 15KW 2815 24M 339B Figure 9 Timing Adjustment Example 24 STANDARD MARK 0 5 1 0 ADVANCE 15 2815 24 335 Figure 10 Timing Index Sticker 0016 10 TM 9 2815 538 24 amp P 0016 00 INSTALLATION Continued T 10 11 12 13 14 15 16 17 18 19 20 If timing index number of old fuel injection pump assembly figure 5 item
208. vides brief description of procedure as well as any information required to accomplish each check or service EQUIPMENT NOT READY AVAILABLE IF Lists condition in which engine should not be operated or accepted END OF WORK PACKAGE 0007 3 4 blank TM 9 2815 538 24 amp P 0008 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 PMCS INCLUDING LUBRICATION INSTRUCTIONS INITIAL SETUP Tools and Special Tools References Tool kit general mechanic s WP 0006 00 thru WP 0032 00 item 5 WP 0035 00 End item configuration manual Personnel Required One PMCS Table 1 Preventive Maintenance Checks and Services ITEM TO BE EQUIPMENT ITEM MAN CHECKED OR NOT READY NO INTERVAL HOUR SERVICED PROCEDURE AVAILABLE IF 1 First 50 0 5 Fan V belts 1 Check fan V belts for wear or Fan V belts worn hours cracks 0011 00 or cracked 2 Check fan V belt tension and Fan V belts out of adjust tension if required adjustment WP 0010 00 2 First 50 0 3 Engine oil and 1 Drain lubricating oil Fill with Lubricating oil not hours filter correct oil end item changed configuration manual 2 Replace oil filter when Oil filter not lubricating oil is changed end changed item configuration manual 3 300 hours 0 3 Engine oil and 1 Drain lubrication oil Fill with Lubricating oil not filter correct oil end item changed configuration manual 2 Replace oil filter when Oil filter not lubrication oil is changed end changed
209. y require the use of chemicals solvents paints or other commercially available material Users of the manual should obtain the material safety data sheets Occupational Safety and Health Act OSHA Form 20 or equivalent from the manufacturers or suppliers of materials to be used Users must be completely familiar with manufacturer supplier information and adhere to their procedures recommendations warnings and cautions for safe use storage and disposal of these materials COMMON TOOLS AND TEST EQUIPMENT For authorized common tools and equipment refer to the Modified Table of Organization and Equipment CTA 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items or CTA 8 100 Army Medical Department Expendable Durable Items as applicable to your unit SPECIAL TOOLS TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT TMDE AND SUPPORT EQUIPMENT Special tools TMDE and support equipment are needed for field level maintenance They are listed in the Repair Parts and Special Tools List RPSTL work packages WP 0036 00 WP 0063 00 and in the Maintenance Allocation Chart MAC work package 0035 00 0001 4 TM 9 2815 538 24 amp P 0001 00 REPAIR PARTS Repair parts are listed and illustrated in the RPSTL work packages WP 0036 00 thru WP 0063 00 0001 5 6 blank TM 9 2815 538 24 amp P 0002 00 FIELD LEVEL DIESEL ENGINE 4TNV84T DFM NSN 2815 01 538 4257 EQUIPMENT DESCR

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