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TM 9-2815-252-24 - Liberated Manuals

1. e Blue Exhaust Abnormal Engine Noise Detonation or Pre IgnitlOn end ae tva Engine Vibrating UM ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 2 Troubleshooting Malfunction Test or Inspection Corrective Action 1 ENGINE WILL NOT CRANK Step 1 Check for defective end item starting system Troubleshoot per end item maintenance manual If not defective do step 2 Step 2 Check for defective starter motor and solenoid a Test starter and solenoid refer to paragraph 3 24 3 1 b Repair replace defective starter and or solenoid refer td paragraph 3 24 2 STARTER OPERATES BUT WILL NOT TURN OVER Check for worn or broken starter pinion gear and or flywheel ring gear a Remove starter and inspect pinion gear and flywheel ring gear for damage refer to paragraph 3 24 2 b Replace defective clutch assembly and or flywheel ring gear refer td paragraph and or refer to end item maintenance manual 3 ENGINE HARD TO START OR WILL NOT START Step 1 Check for stop start lever in wrong position a Check position for lever If in proper position do step 2 b Adjust stop start lever refer paragraph 3 23 5 Step 2 Check for clogged fuel filter Refer to paragraph 3 16 for inspection If not clogged do step
2. 3 52 Cylinder Head Assembly 3 54 D C P EE 1 4 Description Detailed m e 1 2 Destruction of Army Materiel to Prevent Enemy Use sise 1 1 DEtaIlEG DESCHOUOM RE ne 1 2 Disassembly and Assembly Sequence for Overhaul iii 3 12 Door Oll Filter GrankCas6 mi a c teen anna dans CR t c or tan 3 36 Index 1 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 INDEX Continued PAGE E Electrical System cde ud 2 1 KETE T EEA A A E A O A A A 3 61 Engine Oill Pressur 3 40 Engine Inspecting And Servicing deretur eed oe pcou dd 1 5 Equipment BI 1 4 Equipment Improvement Recommendations EIR Reporting 1 1 Exhaust Man Od i 2 a US 3 16 Expendable Durable Supplies and Materials List C 1 F Filter D D OE MI EE 3 29 Oiband Grankcase dettes the re ree thee ttn estat 3 36 meniad c E 3 71 Forms Records and Reports Maintenance sise 1 1 Fuel injector Pipes and Fuel Return Line iii 3 33 Return Line Fuel Injector Pipes 3 33 Solenoid RE I EM EE 3 34 Fuel Eter SRE e PU 3 29 Euel Iniection P
3. 3 26 iudice 3 22 Injector c ant 3 30 Pipes and Fuel Return Line 2 1 11100000 eae eee aaa eee 3 33 Inspecting and Servicing Engine sisi 1 5 3 15 Introduction Principles of Operation 2 1 J K L lever ROCKS ciet tete uctus udo M 3 52 Line Fuel Injector Pipes and Fuel Return iii 3 33 Liri ss Fuel SUPPLY ARS or Ae M edd id Ad id 3 28 LUDrICAUON SVSIEITEO sS goods ea eM Ce eM dI ME 2 1 M Main Bearing HOUSING ARR 3 72 Maintenance Allocation B 1 Maintenance Forms Records and Reports 1 1 Maintenance Procedure and Authorized Level of D 1 Manifold AREE 3 16 lim 3 15 Materials List Expendable Durable Supplies ss C 1 N Oil Filter and Crankcase Door 04 110 eee eee eee 3 36 Oil Pressure Test ENGINE 3 40 Oil PUMp and Strainer e DEPT NE dat dida 3 38 Overhaul
4. Step 3 Check for air in fuel system lines ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 2 Troubleshooting Malfunction Test or Inspection Corrective Action Prime fuel system at fuel filter refer tolparagraph 3 14 If fuel system is free of air do step 4 Step 4 Check for fuel injector nozzles dirty or faulty a Remove and test fuel injectors refer td paragraph 3 17 If not defective do step 5 b Replace fuel injector s refer tolparagraph 3 17 Step 5 Check for improper fuel pump timing a Check fuel pump timing refer td paragraph 3 14 If fuel pump timing is correct do step 6 b Adjust fuel pump timing refer to paragraph 3 14 Step 6 Check for defective fuel injection pumps a Test fuel injection pumps refer to paragraph 3 13 3 b Replace defective fuel injection pumps refer to paragraph 3 13 4 ENGINE HARD TO START OR WILL NOT START IN COLD WEATHER Step 1 Check for faulty heater plugs a Test heater plugs refer to paragraph 3 6 2 If heater plugs not defective do step 2 b Replace defective heater plug s refer td paragraph 3 6 Step 2 Refer to Malfunction 3 and perform steps 1 through 6 5 ENGINE MISFIRES OR RUNS IRREGULARLY OR STALLS FREQUENTLY Step 1 Check for air in fuel system lines Prime fuel system at fuel filter refer to paragraph 3 12 If not air do step 2 3 4 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 2 Troubleshooting Malfunction Test or Inspection Malfunction
5. o c o 3 30 3 a b ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Install hand tighten a capscrew 1 into nearest connecting rod bearing cap bolt hole Using a suitable lever against crankcase and end of capscrew press down on end of lever until piston rings are clear of cylinder bore Lift out piston 5 and connecting rod 3 and tag with corresponding cylinder number Install bearing cap 2 onto connecting rod 3 Inspect and Measure Thoroughly clean cylinder barrel Check for scoring and wear Clean piston 5 FIGURE 3 36 by removing all traces of carbon from both upper and underside of crown and ring grooves Check for correct gap clearance refer lto TABLE 316 with piston rings 6 in an unworn section of cylinder barrel Clean connecting rod 3 Check bushing 9 for wear Replace if worn If big end has been disassembled because of metal failure oil passages in crankshaft must also be examined for obstruction and fragments of metal NOTE The maximum advisable piston to cylinder clearance given is the clearance between the bottom of the piston skirt across the faces and the cylinder bore measured in the region of travel of the piston skirt The clearance is not to be measured at the top of the bore When cylinders are rebored the lower skirt should be etched or painted with the amount of the oversize NOTE The ring gaps given in TABLE 3 6 bre those to be anticipated when checking rings a
6. ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 SAFETY SUMMARY For first aid refer to FM 21 11 Warning The noise level when operating could cause hearing damage Ear protection must be worn Warning Where applicable prior to performing engine maintenance ensure batteries are disconnected Warning Do not drain coolant until the coolant temperature is below operating temperature Always loosen cooling system filler cap radiator cap or drain cock slowly to relieve any excess pressure Warning Diesel fuel Is flammable and toxic to eyes skin and respiratory tract Skinleye protection required Avoid repeated prolonged contact Good general ventilation Is normally adequate Warning Cleaning solvent Is flammable and toxic to eyes skin and respiratory tract Skinleye protection required Avoid repeated prolonged contact Good general ventilation Is normally adequate Warning Compressed air used for cleaning can create airborne particles that may enter the eyes Pressure will not exceed 30 psig 207 kPa Eye protection required a b blank ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 TECHNICAL MANUAL HEADQUARTERS DEPARTMENTS OF THE ARMY AND THE AIR FORCE NO 9 2815 252 24 WASHINGTON D C 1 September 1993 TECHNICAL MANUAL Unit Direct Support and General Support Maintenance Instructions DIESEL ENGINE MODEL DN2M 2 CYLINDER 0 9 LITER NSN 2815 01350 2205 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS Yo
7. Crankshaft Pulley Water Pump Intake Manifold Cylinder Cover Coolant outlet and Thermostat Fan Drive Pulley Gear End Cover Starter Motor Starter Solenoid Cylinder Head ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 THT QD WD FIGURE 1 1 Engine Components 1 3 ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 1 9 EQUIPMENT DATA TABLE 1 1 Equipment Data Model issues DN2M IRR Two cylinder four cycle liquid cooled diesel Bore Stroke sisi 3 38 3 12 in 86 80 mm Displacement RM 56 7 Cu Jom ee ee EE II 0 9 liters Horsepower Rating iii 12 3 BHP 1800 rpm Compression 18 511 Length REM 22 5 571 5 mm Width RR 17 77 in 451 4 mm Height RM 57 in 522 5 mm Weight 183 lbs 83 kg Rotation looking at flywheel sis Counterclockwise Mean Piston Speed 1800 RPM 0 0 00004 954 ft min 288 m min Number of Flywheel Ring Gear nennen nennen nnne nnns nsns 96 Idle Speed it SE PSP SU 1745 RPM Firing Order e Re tate unte tut 1 2 Lubrication System 3 2 qts 3 0 liters Coolant System Capacity engine only 0 55 gal 2 08 liters Oil Pressure 1800 36 248 Oil Pressure Relief Valve Setting 222 00 45 59 psi 310 407 kPa Capacity Between
8. 3 10 3 op 1 Os EN oooopCO9mr o pen ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 Service coolant system refer to end item maintenance manual WATERPUMP Removal Drain coolant system refer to end item maintenance manual Relieve fan belt tension NOTE Nut 6 FIGURE 3 4 left hand threads Remove nut 6 washer fan and fan belt If installed tag and disconnect electrical leads to temperature sensors Loosen clamps and disconnect inlet and outlet hoses NOTE Identify location of two shorter capscrews 8 for use during installation Remove five capscrews 7 and 8 two nuts 10 and seven washers 9 Slide water pump 11 with thermostat b and housing 3 attached from mounting studs 17 Remove and discard gasket 12 Remove sleeve 13 and two preformed packings 14 Discard preformed packings Remove mounting plate 15 and gasket 16 Discard gasket If damaged remove two mounting studs 17 Cover all openings Inspection Inspect pump impeller for damage corrosion or missing blades Inspect pump rotation for abnormal noise binding and other abnormal conditions Inspect pump housing for cracks corrosion or any other damage Inspect sleeve for corrosion or any other damage Inspect mounting studs for damage Installation Remove all covers installed during removal Clean all mating surfaces of any traces of old gaskets Dry all surfaces CAUTION If two water
9. a Inspect pump for freedom of movement by turning gear b Check oil pressure relief valve setting using hydraulic test stand Valve should relieve at 47 to 59 psi 324 to 407 kPa Inspect strainer for blockage and clean as necessary d Inspect all parts for wear or damage and replace defective components FIGURE 3 17 Strainer and Oil Pump 3 21 3 Installation a Position oil pump bB FIGURE 3 17 crankcase with cutout section of pump behind gear facing top of crankcase Secure oil pump 5 with two capscrews 3 and washers 4 Tighten capscrews to 78 in Ibs 8 8 Nm Install oil strainer 2 in right pump port with strainer gauze parallel with sump base Tighten retaining nut Install relief valve 1 in left pump port and tighten retaining nut Install crankcase door refer to paragraph 3 20 2 4 Install camshaft refer to paragraph 3 29 3 3 39 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 9 Service lubrication system refer to end item lubrication order h Operate engine and check for proper operation and for leakage 3 22 ENGINE OIL PRESSURE TEST a Tag and disconnect electrical leads to oil pressure sender remove oil pressure sender and install test pressure gage 0 150 psi 01034 kPa refer to FIGURE 3 18 FIGURE 3 18 Oil Pressure Test Setup Start engine and check oil pressure Remove oil pressure gage and install oil pressure sender Install electrical conne
10. This copy is a reprint which includes current pages from Change 1 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TECHNICAL MANUAL UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS DIESEL ENGINE MODEL DN2M 2 CYLINDER 0 9 LITER NSN 2815 01 350 2205 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENTS OF THE ARMY AND AIR FORCE 1 SEPTEMBER 1993 ARMY TM 9 2815 252 24 AIR FOCE TO 38G1 92 2 C3 CHANGE HEADQUARTERS DEPARTMENTS OF THE ARMY AND THE AIR FORCE NO 3 WASHINGTON D C 30 October 1996 TECHNICAL MANUAL UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS DIESEL ENGINE MODEL DN2M 2 CYUNDER 0 9 LITER NSN 2815 01 350 2205 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TM 9 2815 252 24 TO 38G1 92 2 1 September 1993 is changed as follows Remove and insert pages as indicated below New changed text material is indicated by a vertical bar in the margin An illustration change is indicated by a miniature pointing hand Remove pages i and ii 3 1 and 3 2 3 15 and 3 16 3 33 and 3 34 2 Retain this sheet in front of manual for reference purposes By Order of the Secretaries of the Army and Air Force Official fret B ALL JOEL B HUDSON Administrative Assistant fo the Secretary of the Army 02952 HENRY VICCELLIO Jr General USAF Commander Air Force Material Command DI
11. Check for continuity between brushes with a multimeter 2 If there is no continuity indicated field coil is open and field coil frame must be replaced 8 Check for continuity between field coil frame and brushes 4 If continuity is indicated field coil is grounded and field coil frame must be replaced d Test solenoid 1 Check for continuity between solenoid terminals M and B with a multimeter refer to FIGURE 3 24 2 No continuity should be indicated when solenoid plunger is in normal out position 8 Push solenoid plunger in and observe multimeter Multimeter should indicate continuity If no continuity is indicated solenoid must be replaced 3 48 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TERMINAL B TERMINAL S TERMINAU FIGURE 3 24 Solenoid Terminals 3 24 4 Cleaning and Inspection Warning Cleaning solvent Is flammable and toxic to eyes skin and respiratory tract Skin eye protection required Avoid repeated prolonged contact Good general ventilation Is normally adequate CAUTION Do not clean overrunning clutch In solvent or other cleaning solution Washing clutch will remove grease which may result in damage to the clutch a Wipe all metallic parts with a cleaning cloth TX 1250 that has been slightly dampened with solvent P D 680 b Inspect all parts for damaged threads cracks distortion or other visible damage Warning Compressed air used for cleaning can create airborne particles
12. Using valve guide replacement tool 317 50033 refer to FIGURE 3 29 remove each valve guide as follows Place cylinder head on its side in a soft jawed vice Screw mandrel 1 into tool 2 Place sleeve 3 onto tool Fit bevelled adapter 4 into sleeve 3 and locate bevel into valve seat Locate mandrel 1 through guide from valve seat side Screw small threaded sleeve 5 onto mandrel 1 at valve rocker side Holding sliding handle firmly to prevent rotation turn double handled lever clockwise until guide is withdrawn through head 8 If itis found difficult to start moving guides a sharp tap with a copper hammer should break seal b Regrind valves and valve seats in cylinder head NOTE Valves seat grinding angles are 150 44 5 and 60 Valve angle is 45 c Using valve guide removal and replacement tool 317 50033 refer toL FIGURE 3 291 install each valve guide Install mandrel 1 into valve guide hole from valve rocker end Place valve guide over mandrel 1 with counterbored end of guide facing towards valve seats Place depth stop 317 50108 6 over mandrel 1 and screw on threaded sleeve 5 Fit tool complete with bevelled adapter 4 onto mandrel 1 at valve seat side Hold sliding handle firmly to prevent rotating Turn double handled lever clockwise until depth stop prevents further movement At this point guide will protrude 0 463 to 0 482 11 75 to 12 25 mm above cylinder head 3 27 5
13. remove capscrew 13 and washer 14 d Position head upright on bench and place a suitable block of wood under head of valve 15 or 16 Warning Do not stand in front of valve springs while compressing them Failure to follow this warning could result in personal Injury NOTE If valves are to be reused tag them with cylinder number from which they were removed Manufacturer recommends that all valves and springs be replaced during a major overhaul e Using standard valve spring compressor tool remove each valve as follows 1 Push down on tool until collets 17 can be removed 2 Gently release tool Remove carrier 18 spring 19 seal 20 and plate 21 Discard seal 3 Turn cylinder head 6 over and remove valve 15 or 6 f Insert hex key allen wrench into breather tube 23 to support bore of tube Using pliers remove breather tube s 23 FIGURE 3 29 Valve Guide Tool and Depth Stop 3 27 3 Inspect and Measure a Using appropriate measuring devices check components listed in TABLE 3 4 for wear Replace components that exceed maximum clearance 3 57 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 4 Cylinder Head Component Wear Limits Component Initial Maxims Dimension Clearance inches inches Hydraulic tappet diameter 0 842 21 386 0 843 21 405 0 11 Hydraulic tappet bore 0 8435 21 425 0 004 0 8445 21 450 Valve spring free length 1 72 43 7 See Note Below 1 79 45 5 V
14. 6 Install two capscrews 35 and 36 and nuts 37 on base plate 34 Position base plate 34 on crankcase and secure with capscrew 33 If removed install new bushing 32 From outside crankcase install new preformed packing 31 and speed quadrant 30 into crankcase hole From inside crankcase install lever 29 on speed quadrant 30 and secure with capscrew 27 and washer 28 From outside crankcase position bushing 23 new preformed packing 24 and lever 25 into crankcase hole aa Install trip lever spring 26 on lever assembly 22 ab From inside crankcase position lever assembly 22 bushing 21 and spring 20 on lever 25 and secure with capscrew 18 and washer 19 lt 2 3 43 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 ac Connect spring 15 to bushing and hole on governor lever 6 ad Install droop adjust screw 14 in governor lever 6 and install retainer 2 shim 13 and pin 12 Turn screw 24 fully counterclockwise ae Install two thrust washers 1 and 2 FIGURE 3 20 and sleeve 3 on camshaft 3 23 3 Inspection a Inspect all external components for corrosion b Inspect all threaded components for thread damage and rounded comers on hex heads c Inspect all springs for broken coils distortion or missing ends d Inspect area components for enlarged or worn holes e Inspect area bushings for scores or other damage 3 23 4 Installation a Carefully ins
15. 78 in Ibs 8 8 Nm Connect electrical leads to heater plugs Refer to end item maintenance manual Remove tags Install air intake piping Refer to end item maintenance manual D oogpwNoopgp o0oo00c0p t Change 3 3 15 3 7 3 7 1 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 2 Intake Manifold EXHAUST MANIFOLD Removal Remove exhaust piping Refer to end item maintenance manual Remove four nuts LEIGUBE 2 3 exhaust manifold 2 and two gaskets 3 from studs 4 Discard gaskets 3 If damaged remove four studs 4 Cover all openings Inspection Inspect manifold for cracks corrosion or other damage Replace if damaged Inspect attaching hardware studs and nuts for thread damage Replace if damaged 3 16 Change 3 3 7 3 ococmp 3 8 ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 3 Exhaust Manifold Installation Remove all covers installed during removal Clean exhaust manifold and cylinder head mating surfaces of any traces of old gasket If removed install four studs 4 FIGURE 3 3 in cylinder head Install two new gaskets 3 manifold 2 and four nuts 1 Tighten nuts to 78 in lbs 8 8 Nm Install exhaust piping refer to end item maintenance manual Section V COOLING SYSTEM MAINTENANCE GENERAL This section provides maintenance for cooling system components Components of cooling system not mentioned in this Section can be found in
16. Check gear end of shaft for nicks and burrs 3 64 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 5 Camshaft Component Wear Limits Component Initial Maximum Dimension Clearance Gear end camshaft bushing bore 0 007 0 17 Gear end camshaft journal diameter Center camshaft bushing bore 0 007 0 17 Center camshaft journal diameter Flywheel end camshaft bushing bore 0 007 0 17 Flywheel end camshaft journal diameter 3 29 3 Installation a Carefully install camshaft 3 FIGURE 3 34 into crankcase keeping it square at all times Take care to line up O timing marks on crankshaft and camshaft gears exactly b Rotate camshaft 3 until large holes in gear line up with bolt holes in thrust plate c Turn thrust plate as necessary to install two capscrews 1 and new lockwashers 2 Tighten capscrews 1 to 75 80 in Ibs 8 4 to 9 0 Nm d Check camshaft end play as follows 1 2 3 4 Push camshaft towards flywheel end Install a dial indicator in position against gear wheel Zero the dial indicator 1 2 S 4 Move camshaft as far as it will go towards gear end Movement recorded on the dial indicator should be 0 004 to 0 011 in 0 10 to 0 28 mm CAUTION Excessive camshaft end play affects governing and can cause uneven firing e Measure timing gear backlash FIGURE 3 35 as follows 1 Set a dial indicator on timing gear to be measured 2 Hold gear to be checked and adjoining gear
17. GS DEPOT D 6 NUMBER ASSEMBLY FUNCTION C O REMARKS 00 ENGINE ASSEMBLY INSPECT 2 5 A 5KW TEST 1 5 3 SERVICE 3 5 4 ADJUST 1 0 1 0 4 4 0 REPLACE 8 0 B REPAIR 1 0 20 20 01 INTAKE amp EXHAUST INSPECT 4 SYSTEM REPAIR 5 0101 INTAKE MANIFOLD INSPECT 2 0 1 4 REPLACE 2 0 1 4 C 0102 HEATER PLUG TEST 4 1 4 3 4 REPLACE 3 4 C 0103 EXHAUST INSPECT MANIFOLD Ril 2 0 1 4 REPLACE 2 0 1 4 C 02 COOLING SYSTEM INSPECT 4 4 REPAIR 5 0201 THERMOSTAT INSPECT 7 5 4 REPLACE 5 4 C 0202 WATER PUMP INSPECT 4 4 2 0 1 4 REPLACE 2 0 1 4 03 FUEL SYSTEM INSPECT 4 2 REPAIR 5 10 0301 PUMP FUEL INSPECT 4 5 1 0 ADJUST 2 0 2 4 10 2 0 1 4 REPLACE 2 0 1 4 C 0302 FUEL FILTER AS INSPECT 1 SEMBLY SERVICE 2 4 3 4 REPLACE 3 4 C REPAIR 3 4 0303 FUEL INJECTOR INSPECT 1 1 2 TEST 2 5 3 4 5 Ril 2 0 4 REPLACE 2 0 4 C B 4 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Section Il MAINTENANCE ALLOCATION CHART Continued FOR DIESEL ENGINE MODEL DN2M MAINTENANCE LEVEL COMPONENT MAINTENANCE UNIT DS GS DEPOT TOOLS AND ASSEMBLY FUNCION C o F H D EGQUP REMARKS 0304 FUEL SOLENOID INSPECT E INSTALLATION ADJUST 2 4 REPAIR 2 4 D 04 LUBRICATION SYS INSPECT 1 A TEM SERVICE 2 REPAIR 5 10 0401 OIL FILTER INSPECT 1 A REPLACE 2 1 4 0402 CRANKCASE DOOR INSPECT 4 1 Ril 1 5 1 4 REPLACE 1 5 1 4 C 0403 STRAINER INSPECT 1 Ril 2 4 REPLAC
18. Install flywheel refer to end item maintenance manual Install starter refer to paragraph 3 24 6 3 71 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 38 Flywheel Housing 3 32 MAIN BEARING HOUSING 3 32 1 Removal a Drain engine lubrication system refer to end item maintenance manual Remove flywheel housing refer 4 paragraph 3 31 1 c Remove crankcase door refer to paragraph 3 20 2 1 CAUTION Failure to remove a center bearing tube may result In distorting It making it difficult to remove at a later stage d Use an intake manifold bolt to remove center bearing tube refer td FIGURE 3 39 Leave bolt in tube until it is installed to ensure tube is installed correct way e Remove five capscrews 2 FIGURE 3 40 securing main bearing housing 3 3 72 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 CENTER BEARING TUBE FIGURE 3 39 Center Bearing Tube f Remove bearing housing 3 If it is tight use two recesses in 3 o clock and 9 o clock positions and pry it off with a suitable screwdriver Remove and discard shim 4 NOTE Thrust bearing 5 will come out with main bearing housing 0 Remove thrust bearing 5 Clean all traces of old shim and compound from housing and crankcase i Using suitable driver drive oil seal 6 from housing 3 taking care not to damage bearing 7 j Remove bearing 7 from housing 3 as follows Mount housing 3 in a soft jawed vice 1 2
19. Remove cylinder head assembly refer td paragraph 3 27 1 Remove gear end cover refer 10 paragraph 3 28 1 Remove flywheel housing refer td paragraph 3 31 1 3 76 m n ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Remove camshaft refer th paragraph 3 29 1 Remove crankcase door refer 19 paragraph 3 20 2 1 NOTE Oil pump does not need to be removed Remove oil pressure relief valve and strainer refer to paragraph 3 21 1 Remove pistons and connecting rods refer t paragraph 3 30 1 Using a suitable puller remove crankshaft pinion gear 8 FIGURE 3 40 Remove key 9 from crankshaft 10 NOTE Use two flywheel bolts in end of crankshaft and a bar to hold crankshaft Remove main bearing housing refer td paragraph 3 32 1 Gently withdraw crankshaft 10 through flywheel end of crankcase Remove two capscrews 11 securing center bearing upper housing 12 to lower housing 13 Remove both housings 2 and 13 and bearings 14 If necessary remove two dowel pins 15 from lower housing 13 Remove thrust bearings 16 from gear end of crankshaft 10 3 33 2 Inspect and Measure a Inspect all bearings for scoring or wear If connecting rod big end has been disassembled because of failure of bearing oil passages in crankshaft must be examined for obstruction and fragments of metal Replace thrust bearings if they are damaged or worn Check center bearing clearance using bearing gage PLASTIGAGEPR1 as follow
20. Solenoid Installation 3 35 Oil Filter and Crankcase Door Crankcase Door Fastener Tightening Sequence Strainer and Oil Pump rer Oil Pressure Test Setup iii Governor System nennen nnn Governor Weights 2 Starter Connection and Mounting Hardware Starter Assembly Starter Solenoid Test Circuit Solenoid Terminals 2 00 4 0 0 Overrunning CIUC RES Checking Pinion e NR 3 27 Cylinder Cover and Rocker Lever UV 3 53 Cylinder Head Assembly nnns Valve Guide Tool and Depth Stop Checking Cylinder Head Clearance Cylinder Head Bolt Tightening Gear End Cover 2 Gear End Cover Capscrew Tightening Sequence Camshaft Assembly Measuring Gear Backlash 2 ARMYARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 LIST OF ILLUSTRATIONS continued I1 c I m U gt O m 3 36 Piston and Connecting Rod Assemblies 3 68 3 37 Piston Ring and Gap Location sis 3 69 Flywheel POL SIN ees eei ciet nn nn a utens Center Bearing Tube 1 then nnn
21. Support Maintenance General Support Maintenance Depot Maintenance e Column 5 Tools and Equipment Column 5 specifies by code those common tool sets individual tools and special tools TMDE and support equipment required to perform the designated function f Column 6 Remarks This column shall when applicable contain a letter code in alphabetic order which shall be keyed to the remarks contained in section IV B 4 EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS SECTION lll a Column Reference Code The tool and test equipment reference code correlates with a code used in the MAC section Il column 5 b Column 2 Maintenance Category The lowest category of maintenance authorized to use the tool or test equipment c Column 3 Nomenclature Name or identification of the tool or test equipment d Column 4 National Stock Number The National stock number of the tool or test equipment e Column 5 Tool Number The manufacturer s part number B 5 EXPLANATION OF COLUMNS IN REMARKS SECTION IV a Column Reference Code The code recorded in column 6 section Il b Column 2 Remarks This column lists information pertinent to the maintenance function being performed as indicated in the MAC section Il B 3 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Section Il MAINTENANCE ALLOCATION CHART FOR DIESEL ENGINE MODEL DN2M MAINTENANCE LEVEL GROUP COMPONENT MAINTENANCE UNIT DS
22. Test or Inspection Corrective Action Step 2 Check for clogged fuel filter Refer to paragraph 3 16 for inspection If not clogged do step 3 Step 3 Check for defective governor system Adjust governor system refer to paragraph 3 23 5 If properly adjusted do step 4 Step 4 Check for low coolant temperature a If coolant temperature not low do step 5 b Replace defective thermostat refer td paragraph 3 9 Step 5 Check for fuel injector nozzles dirty defective or leaking a Remove and test fuel injectors refer td paragraph 3 11 If not defective do step 6 b Replace fuel injector nozzle s refer to paragraph 3 17 Step 6 Check for defective fuel injection pumps a Test fuel injection pumps refer paragraph 3 13 3 If not defective do step 7 b Replace fuel injection pump s refer to paragraph 3 13 Step 7 Check for improper fuel pump timing Adjust fuel pump timing refer to paragraph 3 14 If adjusted properly do step 8 Step 8 Weak or broken valve springs a Remove and check valve springs refer td paragraph 3 27 b Remove and check valve springs refer td paragraph 3 27 6 ENGINE DOES NOT DEVELOP FULL POWER ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 2 Troubleshooting Malfunction Test or Inspection Corrective Action Step 1 Check for blocked air intake system Remove blockege as found If no blockage is found do step 2 Step 2 Check for loss in vacuum a Perform vacuum check Refer td
23. and fuel pump tappet 7 and slowly turn crankshaft until fuel pump tappet is felt to be at its lowest position e Remove gear end cover refer paragraph 3 28 1 and remove rack spring 15 FIGURE 3 19 from governor lever f Using fuel pump rack setting gage 317 50114 clamp pump rack in shutdown position Screw on gage threads into end cover tapped hole refer to FIGURE 3 9 CC 29 55 5 mm FIGURE 3 9 Setting Pump Rack 3 25 ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 g If removed install stud 3 FIGURE 3 7 h Install correct original shim pack 6 on fuel pump 5 1 Do not remove or add to original shims installed between pump flange and steel plate 2 Use extreme care to ensure that individual shim packs are installed between each fuel pump plate an crankcase and that they are retained with their original respective cylinder 3 Shims are available in three sizes and are color coded refer td TABLE 3 3 TABLE 3 3 Color Coded Shim Packs for Fuel Pump 0 003 in 0 075 mm Slate Blue 0 005 in 0 125 mm 0 010 in 0 250 mm i If original shim thickness is not known or if fuel pump is being replaced fuel pump must be timed refer to paragraph 3 14 j Gently insert fuel pump and shims into crankcase Ensure that fuel pump rack engages with slot in governor rack CAUTION If fuel pump is not turned counterclockwise or moves before tightening it Is possible that engine will not stop when req
24. die to repair damaged threads which may impair the strength and closeness of the threads and is not recommended Do not allow grease or oil to enter a blind threaded hole as hydraulic action present when bolt or stud is screwed in could split or stress housing To check or re torque a bolt or nut item is slackened a quarter of a turn and then tightened to specified value A steel ISO metric bolt capscrew or nut can be identified by the letter M either on hem or one hexagon flat The strength grade will also be marked on top or one flat On nuts with identification marks on one face the frictional area of that surface will be reduced therefore nut should be installed with unmarked face towards component Service tools are designed to aid disassembly and assembly procedures and their use will prevent possible unnecessary damage to components It is recommended that service tools are always used some operations cannot be safely carried out without aid of relevant tool 3 11 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 o When removing disconnecting fuel or lubrication lines and coolant hoses cap coverall openings to prevent entry of foreign material 3 4 DISASSEMBLY AND ASSEMBLY SEQUENCE FOR OVERHAUL The following paragraphs provide the sequence of disassembly and assembly for complete overhaul of the engine Step by step procedures can be found in remaining sections off Chapter 3 3 4 1 Disassembly Every effort must be made to maint
25. e If water manometer is not available place a piece of thick paper over the oil fill opening If crankcase vacuum retains paper vacuum is good MUST BE ABOVE EXPECTEO LEVEL DIPSTICK HOLE DIPSTICK HOLE MEASURE AND MULTIPLY BY TWO AFTER START FIGURE 3 1 Locally Manufactured Water Manometer Section IV INTAKE AND EXHAUST SYSTEM MAINTENANCE 3 6 INTAKE MANIFOLD 3 6 1 Removal Remove air intake piping Refer to end item maintenance manual Tag and disconnect electrical leads from heater plugs 1 FIGURE 3 2 If damaged or defective remove heater plugs 1 from manifold Remove four bolts 2 four washers 3 intake manifold 4 and two gaskets 5 Discard gaskets 5 Cover all openings Inspect and Measure Inspect manifold for cracks corrosion or other damage Replace if damaged Inspect attaching hardware for damage Replace if damaged Inspect heater plugs for damage Set multimeter for ohms and test heater plugs Normal reading is 4 to 5 ohms Zero resistance indicates a shorted heater and a high reading indicates an open heater Installation Remove all covers installed during removal Install new or tested heater plugs 1 FIGURE 3 2 in manifold 4 Clean intake manifold 4 and cylinder head mating surfaces of any traces of old gasket Position two new gaskets 5 and intake manifold 4 on cylinder head Install four washers 3 and four bolts 2 Tighten bolts to
26. engage retaining ring when installed e Install lever 21 as noted during removal spring set 19 and packing 20 f Adjust pinion shaft end play as follows Gear 18 Armature shaft bearings Stopper 24 Sleeve bearing in front bracket 16 Pinion gear 25 gt TZ CTH Lever 21 sliding portion o eo 1 Place gear 18 on pinion shaft 2 Install center bracket 15 and secure with screw 14 3 Install new gasket 13 washer 12 and new retaining ring 11 4 Measure pinion shaft end play with a feeler gage between center bracket 15 and washer 12 3 50 g h i j k l m ARMY 9 2815 252 24 AIR FORCE TO 38G1 92 2 5 Adjust end play to between 0 0039 to 0 020 in 0 1 to 0 5 mm with adjustment washers 17 Install cover 10 and secure with two screws 9 Install armature 8 in center bracket 15 Install brushes in brush holder assembly 5 Position frame assembly 7 on center bracket 15 Tab on frame assembly 7 must fit in notch in center bracket Pull brushes upward and install brush holder assembly 5 on frame assembly 7 Ensure brushes in brush holders seat against commutator bars Position rear bracket 6 and secure brush holder assembly 5 to rear bracket 6 with two screws 4 Install two through bolts 3 NOTE Be sure that rectangular hole in solenoid 1 plunger shaft engages lever 21 in hous
27. f From inside crankcase remove capscrew 27 and washer 28 remove lever 29 9 From outside crankcase remove speed quadrant 30 and preformed packing 31 Discard preformed packing 31 h If damaged remove bushing 32 3 41 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 19 Governor System i Remove capscrew 33 securing base plate 34 to crankcase remove base plate 34 j Remove two capscrews 35 and 36 and nuts 37 from base plate 34 k Remove thrust collar 38 and two bushings 39 from governor lever 6 3 42 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Turn camshaft until a weight 4 FIGURE 3 20 is horizontal Remove capscrew 5 and lockwasher 6 securing each retainer plate 7 to camshaft gear Remove retainer plate 7 with weights Discard lockwasher Remove pin 8 shims 9 and weights 4 from retainer plate Repeat steps through n for other retainer plates and weights Lightly lubricate pins 8 with engine lubricating oil MIL L 2104 and install them and shims 9 in new weights 4 Install weights 4 and pins 8 with large section of weights facing out e 5 1 FIGURE 3 20 Governor Weights r Install retainer plates 7 and secure each with a capscrew 5 and new lockwasher 6 Tighten capscrews to 6 5 ft Ibs 8 8 Nm Ensure all weights 4 move freely Install two bushings 391 FIGURE 3 19 and thrust collar 38 on governor lever
28. gear 25 Remove retaining ring 23 Remove stopper 24 pinion gear 25 and spring 26 from overrunning clutch 22 n Remove overrunning clutch 22 from front bracket 16 FIGURE 3 22 Starter Assembly 3 24 3 Testing 3 24 3 1 Testing Starter Installed a Make sure batteries are fully charged and that all battery and starter cables are serviceable and properly installed 3 47 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 b Set multimeter for volts DC and connect as shown in FIGURE 3 23 Test A If voltage is indicated solenoid is defective c Momentarily connect a jumper as shown in FIGURE 3 23 Test B Multimeter should indicate battery voltage and starter should crank the engine If multimeter does not read battery voltage the solenoid is defective If multimeter indicates battery voltage but starter does not operate starter is defective ULTIMETER TESTB MULTIMETER __ TESTA M BATTERIES FIGURE 3 23 Starter Solenoid Test Circuit 3 24 3 2 Testing Starter Components a Test armature for grounds 1 Set multimeter for ohms and touch armature shaft and each commutator bar with multimeter leads 2 If multimeter indicates a low reading approximately zero ohms armature is grounded and requires replacing b Test armature for open circuits 1 Check for continuity between commutator segments with multimeter 2 If an open circuit is indicated armature must be replaced C Test field coil 1
29. paragraph 3 5 2 b If loss in vacuum do step Step 3 Engine overheated Refer to Engine Overheating Malfunction 7 If not a problem refer to Malfunction 5 7 ENGINE OVERHEATING Step 1 Inspect coolant level a Check engine for coolant leaks If engine has no leaks do step 2 b Repair coolant leaks refer to end item maintenance manual Step 2 Check for defective thermostat a If thermostat is suspected of being defective replace thermostat Refer td paragraph 3 9 b If engine continues to overheat do step 3 Step 3 Check for defective water pump a Remove and check water pump for damage Refer tb paragraph 3 10 If not defective do step 4 b Replace defective water pump Refer t paragraph 3 10 Step 4 Check improper fuel pump timing ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 2 Troubleshooting Malfunction Test or Inspection Corrective Action Adjust fuel pump timing Refer to paragraph 3 14 8 EXCESSIVE OIL CONSUMPTION Step 1 Check for oil leakage a Inspect engine for oil leaks If not leaks do step 2 b Repair or replace defective components Step 2 Check for blocked air intake system Remove blockage as found If no blockage do step 3 Step 3 Check for defective intake or exhaust valve seals or valve guides a M Repair or replace defective components Refer paragraph 3 27 b Disassemble and inspect valve seals and guides Refer paragraph 3 27 If not defective repl
30. psi 20 685 kPa Using end item controls crank engine and observe pressure gage Pressure gage should read approximately 3000 psi 20 685 kPa If reading is not as specified replace fuel pump Remove pressure gage and connect fuel injector pipe Tighten coupling nut to 21 0 ft Ibs 28 5 Nm Installation Remove all caps covers installed during removal Before installing fuel injection pump ensure governor is correctly adjusted refer td paragraph 3 23 5 Change 2 3 23 ARMY TM 9281 252 24 AIR FORCE TO 38G1 92 2 TO RETURN LINE NO 1 FUEL INJECTOR FIGURE 3 7 Fuel Injection Pump Fuel Filter and Supply Lines 70 5 GOVERNMENT PRINTING OFFICE 1996 755 025 40001 3 24 ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 CAUTION Under no circumstances must any attempt be made to remove fuel pump tappet stud from crankcase to prevent damage to engine block c If tappet 7 FIGURE 3 7 and thrust cup 8 were removed install them as follows 1 Tappet is installed in crankcase using long nosed pliers held open against top inside edge of tappet recess 2 Submerge tappet in clean engine lubricating oil MIL L 2104 3 Insert tappet in crankcase with longer slot facing outward to ensure it is correctly located over tappet stud refer to de thrust cup 8 FIGURE 3 7 TAPPET STUD TAPPET LONGER SLOT CY XT FIGURE 3 8 Fuel Pump Tappet and Stud d Press down on top of thrust cup 8
31. refer to paragraph 3 21 Remove connecting rod caps refer tb paragraph 3 30 Carefully remove carbon build up from the top of cylinder bore Turn crankshaft until piston is at Top Dead Center TDC Lift out pistons and connecting rods refer 19 paragraph 3 30 Insert common screwdriver in flywheel to lock flywheel Remove crankshaft pulley left hand thread Remove screwdriver Move engine control to stop position Remove each fuel injection pump Use care to retain shim pack with each pump refer td paragraph 3 13 Remove gear end cover refer Release speeder spring from governor lever assembly Remove governor lever assembly and governor rack refer to Remove governor sleeve refer tp paragraph 3 23 Remove governor weights refer to paragraph 3 23 Use a suitable magnet and remove hydraulic tappets and fuel pump tappets refer paragraphs 3 27 and 3 13 3 12 ad ae af ag ah ai aj ak al am an ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Rotate engine until governor weight slots in camshaft are vertical refer or Remove two camshaft thrust plate screws and control lever tension spring refer paragraphs 3 29 and 23 Carefully remove camshaft refer paragraph 3 29 Remove oil pump refer 10 paragraph 3 21 Remove crankshaft pinion refer to paragraph 3 33 Remove flywheel housing refer to paragraph 3 31 Remove flywheel end main bearing housing refer
32. seven capscrews 4 washers 5 end cover 6 and gasket 7 Discard gasket g If damaged use suitable driver and drive oil seal 8 from end cover 6 Discard seal 8 h If damaged remove two dowels 9 from crankcase 3 28 2 Inspection a Inspect crankshaft front oil seal 8 FIGURE 3 32 for excessive wear damage or signs of leakage b Inspect crankshaft pulley 2 for cracks and wear Inspect end cover 6 for cracks or other physical damage 3 28 3 Installation a If removed install two dowels 9 FIGURE 3 32 flat end first into crankcase fully b Install new seal 8 as follows 1 Lightly grease sealing lip of new seal 8 with general purpose grease 630 2 Position new seal 8 into outside neck of end cover 6 lip side first and position it squarely on shoulder of seal boss 3 Using suitable driver drive seal into position in end cover 6 Clean all traces of old gasket from crankcase and end cover mating surfaces Install new gasket 7 dry over two dowels 9 and onto crankcase Install oil seal tool into outside face of oil seal 8 f Install end cover 6 taking care to ensure new gasket 7 is not damaged and cover is correctly installed over dowels 9 g Install seven capscrews 4 and washers 5 securing end cover 6 to crankcase Tighten capscrews to 78 in Ibs 8 8 Nm in sequence shown in FIGURE 3 33 Install plug 3 i Insert common screwdriver through flywheel housi
33. specific operating temperature of 170 to 220 F 77 to 1040C for the engine 1 8 2 Lubrication System The lubrication system consists of the oil sump a gear type oil pump pressure relief valve spin on type oil filter and internal passages within the engine 1 8 3 Fuel System The function of the fuel system is to inject a metered quantity of clean atomized fuel into the engine cylinders at a precise time near the end of the compression stroke of each piston The fuel system consists of the fuel tank electrically driven transfer pump fuel filter water separator fuel filter and a fuel injection pump and fuel injector for each cylinder The fuel tank transfer pump and fuel filter water separator are not mounted on engine 1 8 4 Electrical System electrical system is 24 VDC operation and consists of a battery charging alternator starter externally mounted battery and other items as required The battery charging alternator is mounted on front of engine and is belt driven When the engine is operating the battery charging alternator supplies 24 VDC to recharge the battery and maintain it at a full state of charge The starter is mounted on the flywheel housing and when energized engages the ring gear of the flywheel to rotate the engine Coolant Inlet Exhaust Manifold Fuel Injection Pumps Fuel Supply Connection Fuel Filter Flywheel Housing Dipstick Oil Filler Crankcase Cil Filter
34. stress locations in particular nuts and or bolts from connecting rods and cylinder heads should be replaced When assembling an engine it is always advisable to apply a small quantity of new lubricating oil to all moving parts After any maintenance work on engine has been completed lubricating oil and fuel levels must be checked and all safety guards installed before operating When a new fan drive belt has been installed check belt tension after first 20 hours of operation Wear protective overalls and keep items of loose clothing clear of all hot and moving parts Whenever possible clean components and surrounding area before removing or disassembling Take care to exclude all dirt and debris from fuel injection equipment while it is being serviced Some parts are cemented with gasket compound with others being dry Before assembly remove all traces of old gasket and compound Take extreme care to exclude dirt from all gasket surfaces and gasket compound from all tapped holes unless otherwise specified It is recommended that all oil seals are replaced once they have been removed from their original position Seals must be installed square in housing and all lip seals must be installed with lip facing lubricant to be retained A service tool should be used to install all oil seals and care must be taken to prevent damaging new seal when it passes over shafts Replace all nuts bolts capscrews and studs with damaged threads Do not use a tap or
35. tb paragraph 3 32 Use a manifold bolt to remove center main bearing locating dowel Gently withdraw crankshaft refer ATEEK Remove all main and camshaft bearing shells refer t paragraph 3 34 Cap or cover all openings to prevent entry of foreign material 3 4 2 Assembly NOTE When assembling engine use normal engine lubricating oil MIL L 2104 to spray all moving parts during assembly and all bearings and bushings must be well lubricated during assembly Replace all gaskets or Oreo OS gre op Remove all caps covers installed during disassembly Install main bearing shells refer to paragraph 3 34 Install gear end thrust bearings refer t paragraph 3 34 Install crankshaft Ensure that center bearing dowel hole is correctly aligned refer td paragraph 3 33 Install flywheel end thrust bearings Install main bearing housing refer to paragraph 3 32 Check crankshaft end play Normal end play should be 0 007 to 0 015 in 0 18 to 0 38 mm Install center main bearing locating dowel Install flywheel housing refer to paragraph 3 31 Install flywheel Heat crankshaft pinion and install it with timing marks outward refer to paragraph 3 33 Install oil pump refer to paragraph 3 21 Install engine control and speeder spring refer 19 paragraph 3 23 Install camshaft aligning timing marks and ensure thrust plate is located correctly refer to paragraph 3 29 Install fuel pump tappets Install hyd
36. that may enter the eyes Pressure will not exceed 30 psig 207 kPa Eye protection required Inspect armature commutator If commutator is dirty or discolored clean with abrasive paper 400 Use compressed air to blow sand out from between commutator segments d Clean around brushes and holders by wiping off all brush dust and dirt If brushes are shorter than 0 433 in 11 0 mm they should be replaced e Check for free movement of brushes Brushes should move freely when placed in brush holders Replace brush springs if weak or worn 3 49 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 NOTE If pinion gear is worn or damaged inspect flywheel ring gear also f Inspect armature shaft gear bearings reduction gear and pinion gear for wear or damage Replace any part that is damaged g When pinion gear Is placed upon overrunning clutch pinion gear should turn freely in one direction and lock when turned in opposite direction refer to FIGURE 3 25 3 24 5 Assembly a Apply a light coating of general purpose grease 630AA to following starter components before assembling 1 Armature 8 FIGURE 3 22 shaft gear FIGURE 3 25 Overrunning Clutch 2 3 4 5 6 7 8 Solenoid 1 plunger Position overrunning clutch 22 into front bracket 16 Install spring 26 and pinion gear 25 on overrunning clutch shaft Slide stopper 24 onto shaft and install new retaining ring 23 in groove Stopper 24 must fully
37. the end item maintenance manual 3 17 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Warning If the engine has been operating and coolant is hot allow engine to cool before you slowly loosen filler cap and relieve pressure from cooling system Failure to follow this procedure could result In personal Injury THERMOSTAT Removal Remove negative battery cable Drain coolant system refer to end item maintenance manual Loosen hose clamp and disconnect outlet hose from thermostat housing 3 FIGURE 3 4 Remove two capscrews 1 washers 2 thermostat housing 3 and gasket 4 Discard gasket 4 Remove thermostat 5 from water pump NOTE If thermostat is suspected of being defective replace thermostat Inspection Inspect thermostat for excessive wear or damage Inspect housing for cracks corrosion or other damage 3 18 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 4 Cooling System Replacement Replace thermostat if worn or damaged Replace housing if badly corroded or damaged Installation Remove all covers installed during removal Clean any debris and traces of old gasket from thermostat housing 3 FIGURE 3 4 and water pump 11 mating surfaces Dry all surfaces Install thermostat b in water pump Install new gasket 4 thermostat housing 3 two washers 2 and capscrews 1 Connect outlet hose to thermostat housing 3 and secure with hose clamp 3 19 3 10 3 10 1
38. with oil feed hole in crankcase Using camshaft bushing tool 317 50106 install camshaft bushing 4 as follows NOTE When bushing 4 is replaced split in it must be positioned at top of bushing bore 1 Install new bushing 4 over guide threads 2 Screw on depth plate 3 Install slide hammer onto guide threads 4 Place assembly squarely into crankcase bushing bore from outside of crankcase 5 Use slide hammer to install bushing If necessary install two pivot supports 3 If necessary install two capscrews 1 and copper washers 2 Inspection WARNING Cleaning solvent Is flammable and toxic to eyes skin and respiratory tract Avoid repeated prolonged contact Good general ventilation Is normally adequate WARNING Compressed air used for cleaning can create airborne particles that may enter the eyes Pressure will not exceed 30 psig 207 kPa Eye protection required NOTE All components must be removed from engine block for inspection and cleaning Clean block 12 FIGURE 3 48 thoroughly using dry cleaning solvent P D 680 pressure steam or a hot tank CAUTION If engine block is cleaned in a hot tank be sure to remove any aluminum parts 3 81 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 such as nameplates Aluminum parts can be damaged or destroyed by hot tank solutions Make sure all passages and crevices are cleared of sludge and grease All coolant passages must be cleared of any lime deposi
39. 017 0 0019 0 05 24 9925 24 9975 86 000 86 025 0 006 0 40 85 891 0 006 0 15 0 006 0 15 0 005 0 12 NOTE Torque connecting rod bolts refer tg paragraph 3 30 4 3 70 3 31 3 31 1 3 31 2 ARMY 9 2815 252 24 AIR FORCE TO 38G1 92 2 Submerge piston and piston rings in clean engine lubricating oil MIL L 2104 Fit piston and rod into cylinder while compressing piston rings using a suitable piston ring compressor Push down on piston crown and turn crankshaft counterclockwise until big end is almost at Bottom Dead Center BDC Ensure identification marks on the cap and rod are identical and on the camshaft side of the engine and replace cap Install two bolts 1 and tighten them to 222 in lbs 25 Nm If removed attach oil pressure relief valve and oil strainer to oil pump Install cylinder head refer paragraph 3 27 6 Install crankcase door refer td paragraph 3 20 2 4 FLYWHEEL HOUSING Removal Remove starter refer to paragraph 3 24 1 Remove flywheel refer to end item maintenance manual Scribe a mark on flywheel housing 1 FIGURE 3 38 and crankcase Support weight of flywheel housing 1 and remove four capscrews 2 securing flywheel housing remove housing Installation Position flywheel housing 1 FIGURE 3 38 on crankcase aligning scribe marks made during removal and secure with four capscrews 2 Tighten capscrews to 58 ft lbs 78 6 Nm
40. 1 sq meter centare 100 sq decimeters 10 76 sq feet 1 sq dekameter are 100 sq meters 1 076 4 sq feet 1 sq hectometer hectare 100 sq dekameters 2 47 acres 1 sq kilometer 100 sq hectometers 386 sq mile 1 centigram z 10 milligrams z 15 grain 1 decigram z 10 centigrams z 1 54 grains 1 gram 10 decigram 035 ounce 1 decagram 10 grams 35 ounce 1 hectogram 10 decagrams 3 52 ounces 1 kilogram z 10 hectograms 2 2 pounds 1 quintal 100 kilograms 220 46 pounds 1 metric ton 10 quintals 1 1 short tons Cubic Measure 1 centimeter 1000 cu millimeters 06 cu inch 1 cu decimeter 1000 cu centimeters 61 02 cu inches 1 cu meter 1000 cu decimeters 35 31 cu feet Approximate Conversion Factors To change To Multiply by To change To Multiply by inches centimeters 2 540 ounce inches Newton meters 007062 feet meters 305 centimeters inches 394 yards meters 914 meters feet 3 280 miles kilometers 1 609 meters yards 1 094 square inches square centimeters 6 451 kilometers miles 621 square feet square meters 093 square centimeters square inches 155 square yards square meters 836 square meters square feet 10 764 square miles square kilometers 2 590 square meters square yards 1 196 acres square hectometers 405 square kilometers square miles 386 cubic feet cubic meters 028 square hectometers acres 2 471 cubic yards cubic meters 765 cubic meters cubic feet 35 315 fluid ounces m
41. 13 11 BLACK OR GRAY SMOKE Step 1 Check for defective fuel injectors ARMY TM 9 281 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 2 Troubleshooting Malfunction Test or Inspection Corrective Action a Remove and test fuel injectors Refer to paragraph 3 17 If not defective do step 2 b Replace fuel injector s Refer td paragraph 3 17 Step 2 Check for improper fuel pump timing a Adjust fuel pump timing Refer to paragraph 3 14 b If timing is correct repair or replace defective engine 12 BLUE EXHAUST SMOKE Step 1 Check for blocked air intake system Remove blockage as found If no blockage is found do step 2 Step 2 Check for loss in vacuum a Perform vacuum check Refer to paragraph 3 5 2 b If vacuum is correct do step C If vacuum is not correct repair or replace engine Step 3 Check for defective intake or exhaust valve seals or valve guides a Repair or replace defective components Refer tp paragraph 3 27 b Disassemble and inspect valve seals and guides Refer to paragraph 3 27 If not defective repair or replace defective engine 13 ABNORMAL ENGINE NOISE Step 1 Check for worn tappets a Inspect tappets for wear Refer to paragraph 3 27 If not worn do step 2 b Replace worn tappets Refer to paragraph 3 27 3 9 ARMY TM 9 281 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 2 Troubleshooting Malfunction Test or Inspection Corrective Action Step 2 Check for bent pushrods a Replace
42. 3 Figure 7 24 Table 8 25 Item 9 26 Total 123 27 Text This is the text for the problem below line 27 0 090 BR RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT QUT FOLD IT AND DROP IT IN THE MAIL Poet SENT mI m IN THIS SPACE TELL WHAT IS WRONG AND WHAT SHOULD BE DONE ABOUT IT PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER SIGN HERE DA M 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR JUL 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS Linear Measure 1 centimeter 10 millimeters 39 inch 1 decimeter 10 centimeters 3 94 inches 1 meter 10 decimeters 39 37 inches 1 dekameter 10 meters 32 8 feet 1 hectometer 10 dekameters 328 08 feet The Metric System and Equivalents Liquid Measure 1 centiliter 10 milliters 34 fl ounce 1 deciliter 10 centiliters 3 38 fl ounces 1 liter 10 deciliters 2 33 81 fl ounces 1 dekaliter 10 liters 2 64 gallons 1 hectoliter 10 dekaliters 26 42 gallons 1 kiloliter 10 hectoliters 264 18 gallons 1 kilometer 10 hectometers 3 280 8 feet Square Measure Weights 1 sq centimeter 100 sq millimeters 155 sq inch 1 sq decimeter 100 sq centimeters 15 5 sq inches
43. 3 17 1 3 26 g ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 Turn engine over manually to establish TDC between compression and power strokes for cylinder being timed Normal engine direction of rotation is clockwise as viewed from the fan end Correct top center occurs approximately 140 degrees of crankshaft rotation after intake valve closes h Remove intake valve rocker lever nut and rocker lever refer to paragraph 3 26 1 Warning Do not stand over valve springs when depressing valves Failure to observe this warning could result In personal injury Using valve spring tool depress intake valve until it contacts the piston crown approximately 0 051 to 0 059 inches 1 3 to 1 5 mm Then remove collets carrier and spring from intake valve NOTE If valve can be depressed more than approximately 0 25 in 6 35 mm piston is not in correct position Engine should be rotated to correct position to avoid possibility of dropping valve into cylinder once carrier and spring are removed Valve can now be depressed until head of valve rests on top of piston refer to FIGURE 3 10 Mount a dial indicator refer to FIGURE 3 10 to cylinder head to check intake valve drop Carefully turn engine a small amount either side of TDC and dial indicator can be zeroed at TDC FIGURE 3 10 Checking Piston Drop Measure piston drop Engine should then be rotated opposite normal crankshaft rotation counterclockwise as viewed from fan end to
44. 3558 E 1 E 2 blank ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 INDEX PAGE A Allocation Chart Maintenance 2 1 400 nnnnn nn nnns nan hired setis eae n asi s sss B 1 Army Materiel to Prevent Enemy Use Destruction 1 1 Assemblies Piston and Connecting 3 66 Assembly GIE TA RE 3 79 Cylinder Headsin tenete tiia Ra rata na ata Eia aa an 3 54 a s Dl s D s D 3 45 Assembly GCamishaft tob AAA A AAA AA RAA A A A 3 64 B Bearing Housing Main ss 3 72 Bleeding and Priming Fuel System iii 3 21 CamshattASSe 3 64 Chart Maintenance rhe a B 1 Ghare Torge pr Cd E 1 Gonnecting Rod ASsembli s Pistoniand coiere oleate au ae 3 66 COOIINO SYSTEME RAR cT 2 1 Cover Cylinder iene ana a RS NA 3 52 Gear ml alo hese oc ree ec er Per ese merrier PKT 3 61 Grankcase Assembly xe es net a Pe NEED IU LU atin ADU 3 79 Grankcase Door Oil Filter atnd pc Y E e I n ead etd Dots 3 36 Branka SEN ACUT MEE 3 14 QE VS rapa 3 76 Cylinder
45. 41 2 Install bolt and dolly into bearing 5 FIGURE 3 43 from oil seal side crankcase outside face 3 79 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 3 Install bridge over bolt threads until two legs are against crankcase 4 Install spacer onto bolt 5 Use a suitable wrench to tighten nut until bearing shells are withdrawn e If damaged remove pipe plugs 6 7 and 8 and expansion plugs 9 10 and 11 FIGURE 3 43 Crankcase Assembly 3 80 f g 3 34 3 ARMY 9 2815 252 24 AIR FORCE TO 38G1 92 2 If removed install pipe plugs 6 7 and 8 and expansion plugs 9 10 and 11 Using main bearing tool 317 50111 install crankshaft main bearing 5 as follows 1 Place large tapered collar on a bench with pilot pin facing up refer to FIGURE 3 41 2 Place new bearing shells b FIGURE 3 43 into collar ensuring that one oil feed hole is in line with pilot pin and end of shell is in line with mark on collar face 3 Place driver onto collar with cutout on driver located over collar pilot pin 4 Push driver sufficiently until bearings come out other side of collar to provide a lead in 5 Install assembly into crankcase from gear end with pilot pin in line with the oil feed hole in crankcase 6 Place bolt through assembly 7 Install bridge spacer and nut onto bolt 8 Tighten nut until driver is against face of collar 9 Remove tool 10 that oil hole in bearing shell 5 is correctly aligned
46. 66 S Scope G neral Informati n 1 1 Sequence for Overhaul Disassembly and Assembly 3 12 Servicing Engine Inspecting and iii 1 5 Shipment Preparation for Storage and iii 1 1 Solenoid F elita 3 34 Starter Assembly tete tete ates ete tos etta ete tena 3 45 Storage and Shipment Preparation for 1 1 3 38 Supplies and Materials Expendable Durable is C 1 Supply Lines etie eels 3 28 Index 4 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 INDEX Continued PAGE S Continued System edm Sete t a 2 1 Electrical ana ORT 2 1 gdill U UO ele 2 1 GOVEMMNON D EUIS 3 40 MEE 2 1 Tes Engine Gana aa Raa eee net 3 40 m S 3 18 TORQUES aman Gi 1 Troubleshooting Procedures e tet eo eeu 3 2 0 Vacuum EGTANKC ASE te Mere ecd eer 3 14 Wea rainy iL EE 1 1 Water LEE 3 20 X 2 Index 51 Ind
47. Assembly 3 59 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 a Using standard valve spring compressor tool install each valve 15 or 16 FIGURE 3 28 as follows 1 Lightly lubricate valve stem with engine lubricating oil MIL L 2104 and insert valve 15 or 16 2 3 4 Lay head 6 upright bench and place a block of wood under head of valve being replaced Place valve spring plate 21 in position valve guide and is not distorted 9 Install valve spring 19 and spring carrier 18 9 carrier 18 7 Gently release tool and check that collets 17 are correctly located b If removed install capscrew 13 washer 14 and breather tubes 23 3 27 6 Installation When installing cylinder head valve to piston contact can be avoided by waiting for up to 45 minutes for lubricating oil to bleed down CAUTION Removal of any part of the valve gear will allow the hydraulic tappet to extend and hydraulically lock CAUTION Ensure that no piston is at TDC when replacing head Failure to follow this procedure could cause misalignment of the head NOTE When new tappets have been installed the engine must be cranked for at least 15 seconds before attempting to start it a Ensure cylinder head 6 FIGURE 3 28 and crankcase mating surfaces are clean and dry b f Install hydraulic tappets 11 solid end first and new washers 10 in crankcase Install new pushrod sea
48. Destruction of Material sise TM 750 244 3 Repair Part and Special Tools List Diesel Engine DNPM TS amino 5 MISCELLANEOUS PUBLICATIONS Maintenance Management Policy 0 0 n einn AFR 66 1 Preservation of USAMECOM Mechanical Equipment for Shipment and Storage iii TB 740 97 2 5 AFR 900 4 The Army Maintenance Management System 5 DA PAM 738 750 USAF Material Deficiency Reporting sis TO 00 35D54 A 1 A 2 blank ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 APPENDIX B MAINTENANCE ALLOCATION CHART Section INTRODUCTION B 1 THE ARMY MAINTENANCE SYSTEM MAC a This introduction section 1 provides a general explanation of all maintenance and repair functions authorized at various maintenance levels under the standard Army Maintenance System concept b The Maintenance Allocation Chart MAC in section Il designates overall authority and responsibility for the performance of maintenance functions on the identified end item or component The application of the maintenance functions to the end item or component will be constant with the capacities and capabilities of the designated maintenance levels which are shown in the MAC in column 4 as Unit includes two subcolumns C operator crew and O unit maintenance Direct Support includes an F sub
49. Dipstick Marks ss 27 oz 0 8 liters Oil Eilter Capacity ee A tes A 8 5 oz 0 25 liters Alternator 24 VDC 18 amp Starter EAE SNA A SEA A AU AStA RD UN Ult Lr 24 VDC 3 2 kw ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Section Ill PREPARATION FOR USE 1 10 INSPECTING AND SERVICING ENGINE This section provides information and guidance for inspecting servicing and installing the engine 1 10 1 Inspection Check that all packing materials have been removed Check engine identification plate for positive identification Inspect engine exterior for shipping damage Check fan belt drive for proper tension Inspect engine for loose or missing mounting hardware or damaged or missing parts ococmp 1 10 2 Service Except for servicing the lubrication system all other servicing must be accomplished after engine is mounted in the end item refer to end item lubrication order LO 1 5 1 6 blank ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 CHAPTER 2 OPERATION Section PRINCIPLES OF OPERATION 2 1 INTRODUCTION This section contains functional descriptions of the engine systems and how they are connected to the end item 2 2 COOLING SYSTEM The cooling system consists of a radiator hoses thermostat belt driven fan water pump and cooling jackets within the engine The water pump forces coolant through passages coolant jackets in the engine block and cylinder head where coolant absorbs hea
50. Disassembly and Assembly Sequence nnn 3 12 Operating Barreto RR 2 2 Index 3 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 INDEX Continued PAGE P Pipes and Fuel Return Line Fuel Injector iii 3 33 Piston and Connecting Rod nnns nnn ntes snnt nnne nnn nnns nnns 3 66 PMES Proc dures anaic rider tnt 3 1 Preparation for Storage and Shipment iii 1 1 Pressures est ERRORES 3 40 Prevent Enemy Use Destruction of Army Materiel sis 1 1 Priming Fuel System Bleeding and iii 3 21 Procedures 3 1 Tro bleshootirig Lada uu 3 2 Pump Fuel IN CtION nct Rep 3 22 Oil and Strainers a a ede deu 3 38 Timing Fuel Injection es ata iran udin dud did dida 3 26 Wat deat e ud 3 20 0 Recommendations EIR Reporting Equipment Improvement 2 00 nennen nnns 1 1 Records and Reports Maintenance Forms iii iini 1 1 References M CP Pp RU ci D NU D oo Die A 1 Reporting Equipment Improvement Recommendations 1 1 Reports Maintenance Forms Records 41 1 4 4 0 44 0 annii 1 1 Return Line Fuel Injector Pipes and 3 33 into MESURES 3 52 Rod Assemblies Piston and Connecting 3
51. E 317 50033 MENT TOOL MAIN BEARING 317 50111 TOOL FUEL PUMP RACK 317 50114 GAGE GOVERNOR RACK 317 50115 Section IV REMARKS FOR DIESEL ENGINE MODEL DN2M REFERENCE REMARKS CODE A Refer to end item operator s manual Refer to end item maintenance manual B C Replace function is identical to remove install function D Repair is limited to replacement of damaged parts refer to remove install function B 8 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 APPENDIX C EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST Section INTRODUCTION C 1 SCOPE This appendix lists expendable durable supplies and materials you will need to operate and maintain the engine These items are authorized to you by CTA 50 970 Expendable Durable Items except medical class V repair parts and heraldic items 2 EXPLANATION OF COLUMNS a Column 1 ltem number This number is assigned to the entry in the listing and is referenced in the narrative instructions to identify the item e g Use cleaning compound item 5 Appendix b Column 2 Level This column identifies the lowest level of maintenance that requires the item C Operator crew O Unit maintenance F Direct support maintenance H General support maintenance C Column 3 National stock number This is the national stock number assigned to the item which you can use to requisition it d Column 4 Item name description Commercial and Governme
52. E 2 4 0404 OIL PUMP AS INSPECT A SEMBLY Ril 5 2 4 REPLACE 5 2 4 05 GOVERNOR SYS INSPECT 2 TEM ADJUST 5 15 4 11 REPAIR 5 10 0501 GOVERNOR LEVER INSPECT 2 amp RACK ASSEMBLY 5 4 REPLACE 5 4 REPAIR 5 5 4 06 STARTER INSPECT 1 ASSEMBLY TEST 5 10 1 4 Ril 1 0 4 REPLACE 1 0 4 C REPAIR 5 10 4 07 ENGINE SUB INSPECT 1 A ASSEMBLY REPAIR 5 25 0701 ROCKER LEVER INSPECT 4 Ril 1 0 1 4 REPLACE 1 0 1 4 C 0702 CYLINDER HEAD INSPECT 2 ASSEMBLY R I 4 0 2 4 REPLACE 4 0 2 4 C REPAIR 2 0 070201 VALVE SPRING INSPECT 3 TEST 2 4 Ril 1 0 2 3 REPLACE 1 0 2 3 5 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Section Il MAINTENANCE ALLOCATION CHART Continued FOR DIESEL ENGINE MODEL DN2M MAINTENANCE LEVEL COMPONENT MAINTENANCE UNIT DS GS DEPOT TOOLS AND ASSEMBLY FUNCTION C O F H D REMARKS 070202 EXHAUST amp INTAKE INSPECT 5 VALVES TEST 4 1 0 2 3 REPLACE 1 0 2 3 070203 CYLINDER HEAD INSPECT TEST REPAIR 2 oun m 0703 GEAR END COVER INSPECT 4 ASSEMBLY 1 REPLACE 1 0704 CAMSHAFT 5 INSPECT 5 SEMBLY TEST 5 2 4 0 2 REPLACE 4 0 2 0705 CONNECTING ROD INSPECT amp PISTON AS SEMBLY REPAIR oo N e 070501 CONNECTING ROD INSPECT ASSEMBLY TEST REPLACE REPAIR 070502 PISTON ASSEMBLY INSPECT TEST REPLACE REPAIR 0706 MAIN BEARI
53. E 3 36 Piston and Connecting Rod Assemblies f Use a piston ring expander and install piston rings 6 with word TOP facing up as follows refer to FIGURE 3 37 1 Lower groove oil control ring 2 Middle groove compression ring 3 Top groove firing ring 3 30 4 Installation a Turn crankshaft journal to TDC 3 68 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 NOTE If necessary separate each bearing cap 2 FIGURE 3 36 and connecting rod 3 as it is installed Do not mix bearing caps and connecting rods If damaged Install new connecting rod big end bearing shells 4 FIGURE 3 38 ensuring they are correctly located in both connecting rod and cap Stagger piston ring 6 gaps so each ring gap is set at 90 degrees to adjacent rings and 45 degrees from piston pin 8 axis FIGURE 3 37 Piston Ring and Gap Location 3 69 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 6 Piston and Connecting Rod Component Wear Limits Component Initial Maximum Dimension Clearance Connecting rod small end bushing Piston pin diameter Cylinder bore Piston diameter bottom of skirt across thrust face Piston ring gaps Top piston ring width Top piston ring groove width 2nd piston ring width 2nd piston ring groove width Oil piston ring width Oil piston ring groove width Connecting rod big end bore See Note Bearing shell thickness Crankpin diameter inches inches 25 005 25
54. EMY USE Refer to TM 750 244 3 for procedures to destroy equipment to prevent enemy use 1 5 PREPARATION FOR STORAGE OR SHIPMENT Refer to TB 740 97 2 for procedures to place the equipment into storage 1 6 WARRANTY The engine is warranted for a specific period of time Refer to the end item warranty technical bulletin The warranty starts on the date found in block 23 DA Form 2408 9 in the equipment log book Report all defects in material or workmanship to your supervisor who will take appropriate action 1 1 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Section Il EQUIPMENT DESCRIPTION AND DATA 1 7 GENERAL The diesel engine FIGURE 1 1 is two cylinder four cycle fuel injected naturally aspirated and liquid cooled The firing order is 1 2 The number one cylinder is toward the fan end of the engine serial number is found on right side of the cylinder body at number one cylinder location Rotation of engine is counterclockwise as viewed from flywheel NOTE All locations referenced herein are given facing the flywheel end rear of the engine 1 8 DETAILED DESCRIPTION 1 8 1 Cooling System The cooling system consists of a radiator water pump cooling fan thermostat and connecting hoses The fan is mounted on shaft of water pump and both are belt driven from the crankshaft pulley The thermostat controls engine temperature and is installed in the top of engine The function of the cooling system is to maintain a
55. ENANCE LEVEL Paragraph Maintenance Level __ 53 96 3 3 26 3 4 5 6 7 8 9 13 25 29 Change 1 D 1 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Section PARAGRAPH TO MAINTENANCE LEVEL Cont Paragraph Maintenance Level Maintenance Level Paragraphs 3 17 3 18 3 19 3 20 3 22 3 23 3 24 3 28 3 23 3 24 3 25 3 26 3 27 3 28 F 3 29 3 30 3 31 3 32 3 33 3 34 Change 1 D 2 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 APPENDIX E TORQUE CHART Torques are given as wet torques hardware should be lightly oiled before installing To ensure the component is pulled down correctly the sequences shown throughout this manual must be followed TABLE E 1 SPECIFICATIONS Description Stop run control assembly screw Crankcase door bolts End cover bolts Manifold bolts or nuts Oil pump bolts Camshaft thrust plate screws Governor weight plate screws Rocker cover nut Connecting rod bolts Fuel swivel union plug Fuel lift pump blanking plate Injector clamp bolt Fuel line bracket bolt Water pump bolts Center bearing housing bolts Flywheel end bearing housing bolts Injector pipe nuts Radiator fan nut left hand thread Fuel pump clamp nut Valve rocker nut Starter motor screw Fuel Pump delivery valve holder Injector nozzle nut Flywheel bolts Flywheel housing screws Oylinder head bolts stage one stage two stage three Metric Conversion Nm ft lbs x 1
56. NGS INSPECT TEST REPLACE Vd 0101 0707 CRANKSHAFT INSPECT 3 TEST 3 2 2 0 REPLACE 1 0 0708 CRANKCASE INSPECT 5 ASSEMBLY TEST 5 8 0 2 REPLACE 8 0 2 REPAIR 1 0 2 RRA O 070801 CAMSHAFT BEAR INSPECT 5 INGS TEST 5 2 REPLACE 1 0 4 6 B 6 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Section Il MAINTENANCE ALLOCATION CHART Continued FOR DIESEL ENGINE MODEL DN2M MAINTENANCE LEVEL COMPONENT MAINTENANCE LAE DESEE ND DEPOT TOOLS AND ASSEMBLY FUNCTION EQUIP REMARKS 070802 CRANKCASE INSPECT TEST B 7 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Section TOOLS AND TEST EQUIPMENT REQUIREMENTS FOR DIESEL ENGINE MODEL DN2M TOOL OR TEST EQUIPMENT MAINTENANCE NATION NATO TOOL REF CODE CATEGORY NOMENCLATURE STOCK NUMBER NUMBER SHOP EQUIPMENT AUTOMOTIVE 4910 00 754 0654 SC4910 95 CL A74 MAINTENANCE AND REPAIR OR GANIZATIONAL MAINTENANCE COMMON NO 1 LESS POWER TOOL SET BASIC FIELD MAINTE 4910 00 754 0705 SC4910 95 CL A31 NANCE SHOP EQUIPMENT AUTOMOTIVE 4910 00 754 0707 SC4910 95 CL A63 MAINTENANCE AND REPAIR FIELD MAINTENANCE SUPPLE MENTAL SET NO 2 LESS POWER TOOL KIT GENERAL MECHANIC S 5180 00 177 7033 SC5180 90 CL N26 SHOP EQUIPMENT FUEL AND 4940 00 754 0714 SC4940 95 CL B20 ELECTRICAL SYSTEM ENGINE FIELD MAINTENANCE BASIC LESS POWER TOOL BUSHING CAMSHAFT 317 50106 STOP VALVE GUIDE DEPTH 317 50108 TOOL VALVE GUIDE REPLAC
57. PME Thermostat MEE Water EE Fuel System Maintenance iii C uc Bleeding and Priming Fuel System Fuel Injection nnm nnn nnn nennen Fuel Injection Pump Timing ss Fuel Supply Lines Fuel Filter 9 Fuel Be Teo Fuel Injector Pipes and Fuel Return Fuel Solenoid Lubrication System Maintenance 2 Oil Filter and Crankcase Door Oil Pump and Strainer ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 Engine Oil Pressure Test 3 40 Governor System Maintenance nennen nnne nnns 3 40 Governor SY SIN Ls Re DEED S E DUE Electrical System Maintenance ccccccccsccsecsecsecsecsecseesecsecsessesaesaecaesesaeeaeeaesaseaeeaees Starter Assembly Engine Subassembly Maintenance sse nnne 3 52 CYLINDER COVER ROCKER LEVER CYLINDER HEAD 5 GEAR END COVER uiia nere dh chet te E e e E e Dee RR 3 61 CAMSHAFT ASSEMBLY eene PISTON AND CONNECTING ROD ASSEMBLIES FLYWHEEL HOUSING 3 rnnt e
58. Place bolt of main bearing tool 317 50111 through plain dolly refer to FIGURE 3 41 3 Install bolt and dolly into bearing 7 FIGURE 3 40 from oil seal side crankcase outside face 4 Install bridge over bolt threads until two legs are against housing face 3 73 S 6 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 41 Main Bearing Tool Install spacer and nut onto bolt Use a suitable wrench to tighten nut until bearing shells 7 are withdrawn 3 32 2 Installation a Install bearing 7 FIGURE 3 40 in main bearing housing 3 as follows 11 Mount housing 3 in a soft jawed vice with small oil feed hole facing up Place large tapered collar of main bearing tool 317 50111 on a bench with pilot facing up Place new bearing shells 7 into collar ensuring one oil feed hole is in line with pilot pin of collar and end of shell is in line with the mark on collar face Place driver onto collar with cutout on driver located over collar pilot pin Push driver sufficiently until bearings 7 come out other side of collar to provide a lead in Install assembly into housing 3 from oil seal side crankcase outside face with pilot pin in line with oil feed hole in housing Place bolt through assembly Install bridge spacer and nut onto bolt Tighten nut until driver is against face of collar Remove tool that oil hole in bearing shell 7 is correctly aligned with oil feed hole in housing 3
59. REPORTS 1 2 1 Reports of Maintenance and Unsatisfactory Equipment Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738 750 the Army Maintenance Management System TAMMS Air Force personnel will use AFR 66 1 Maintenance Management Policy for maintenance reporting and TO 00 35D54 for unsatisfactory equipment reporting 1 2 2 Reporting of Item and Packaging Discrepancies Fill out and forward SF 364 Report of Discrepancy ROD as prescribed in AR 735 11 2 DLAR 414 55 SECNAVINST 4355 1 8 AFR 400 54 MCO 4430 3J 1 2 3 Transportation Discrepancy Report TDR SF 361 Fill out and forward Transportation Discrepancy Report TDR SF 361 as prescribed in AR 55 38 NAVSUPINST 4610 33C AFR 75 18 MCO P4610 19D DLAR 4500 15 1 3 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS FIR 1 3 1 Army If your Military Standard Engine 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 Put it on an SF 368 Product Quality Deficiency Report Mail it to us at Commander U S Army Aviation and Troop Command ATTN AMSAT I MDO 4300 Goodfellow Boulevard St Louis Missouri 63120 1798 We will send you a reply 1 3 2 Air Force Air Force personnel are encouraged to submit EIR s in accordance with AFR 900 4 1 4 DESTRUCTION OF ARMY MATERIEL TO PREVENT EN
60. STRIBUTION To be distributed in accordance with DA Form 12 25 E ARMY TM 3 2815 252 24 AIR FORCE TO 3861 92 2 c2 DENNIS J REIMER General United States Army Chief of Staff RONALD R FOGELMAN General USAF Chief of Staff block no 5141 requirements for TM 9 2815 252 24 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 C2 CHANGE HEADQUARTERS DEPARTMENTS OF THE ARMY AND THE AIR FORCE NO 2 WASHINGTON D C 31 October 1995 TECHNICAL MANUAL UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS DIESEL ENGINE MODEL DN2M 2 CYLINDER 0 9 LITER NSN 2815 01 350 2205 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TM 9 2815 252 24 TO 38G1 92 2 1 September 1993 is changed as follows 1 Remove and insert pages as indicated below New or changed text material is indicated by a vertical bar in the margin An illustration change is indicated by a miniature pointing hand Remove pages Insert pages 3 15 and 3 16 3 15 and 3 16 3 23 and 3 24 3 23 and 3 24 2 Retain this sheet in front of manual for references purposes By Order of the Secretaries of the Army and Air Force gt a Official Hans YVONNE M HARRISON Administrative Assistant to the Secretary of the Army 00998 HENRY VICCELLIO Jr General USAF Commander Air Force Material Command DISTRIBUTION ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 C2 DENNIS J REIMER General United States Army Chief of
61. Staff RONALD R FOGELMAN General USAF Chief of Staff To be distributed in accordance with DA Form 12 25 E block no 5141 requirements for TM 9 2815 252 24 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 C1 CHANGE HEADQUARTERS DEPARTMENTS OF THE ARMY AND AIR FORCE NO 1 WASHINGTON D C 15 DECEMBER 1993 TECHNICAL MANUAL UNIT DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS DIESEL ENGINE MODEL DN2M 2 CYLINDER 0 9 LITER NSN 2815 01 350 2205 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TM 9 2815 252 24 TO 38G1 92 2 1 SEPTEMBER 1993 is changed as follows 1 Remove and insert pages as indicated below New or changed text material is indicated by a vertical bar in the margin An illustration change is indicated by a miniature pointing hand Remove pages Insert pages D 1 D 2 blank D 1 and D 2 2 Retain this sheet in front of manual for reference purposes ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 By Order of the Secretaries of the Army and Air Force GORDON R SULLIVAN General United States Army Z2 A bor Chief of Staff MILTON H HAMILTON Administrative Assistant to the Secretary of the Army 05821 MERRILL A McPEAK General USAF Chief of Staff Official RONALD W YATES General USAF Commander Air Force Materiel Command DISTRIBUTION To be distributed in accordance with DA Form 12 25 E block no 5141 requirements for TM 9 2815 252 24
62. Ulip o c cv ROT QI DUE Roe Den UE NE en 3 22 Euel Injection Pu rmp5sbimibig s oett cete ctv tameu Dc OUT DIE 3 26 Euel SUupply Eines exon eee e cM A IND MM PM MD aac IL DM LM pe EM LUUD LER RP this 3 28 Fuel SYST ME PR UIN ML DM ats UD ae A EE RD E 2 1 Bleeding and Priming oett tette ep oe re e eee nt neon Dee ees 3 21 Mj CCUM emt MM DE 3 30 G Eig lo CPDCC 3 61 General Cooling System nnn nnns 3 17 Equipment Description and Data 1 2 Fuel System Maintenance 3 21 Maintenance 3 11 Governor System 3 40 Head Assembly Cylinder 3 54 Housing 53225555585 Eure dan MEE M MEE NE e ME Ue e eM MR E mee EUR EE 3 71 Main Bearings desse ennt eterne d e etus ere e e tue er a e e tre eMe e e EUER 3 72 Index 2 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 INDEX Continued PAGE Improvement Recommendations EIR Reporting Equipment 1 1 Injection TIMING FUEN rs
63. ace defective engine 9 LOW OIL PRESSURE Step 1 Check for improper grade of oil a Refer to end item lubrication order If proper grade of oil do step 2 b If improper grade of oil refer paragraph 3 20 and change oil and filter Step 2 Check for engine running hot a Refer to Engine Overheating malfunction 7 in this table b If not running hot repair or replace defective engine 10 EXCESSIVE FUEL CONSUMPTION Step 1 Check for leak in fuel system Malfunction ARMY TM 9 281 252 24 AIR FORCE TO 38G1 92 2 TABLE 3 2 Troubleshooting Test or Inspection Step 2 Step 3 Step 4 Step 5 Step 6 Corrective Action a Check fuel system for leaks If not leaks do step 2 b Repair fuel system Check for blocked air intake system Remove blockage as found If no blockage is found do step 3 refer to end item technical manual Check for defective fuel injectors a Remove and test fuel injectors Refer to paragraph 3 17 If not defective do step 4 b Replace fuel injector s Refer to paragraph 3 17 Check for loss in vacuum a Perform vacuum check Refer td paragraph 3 5 2 b If not loss in vacuum do step 5 Check for improper fuel pump timing a If timing is correct do step 6 b Adjust fuel pump timing Refer paragraph 3 14 Defective fuel injection pumps a Test fuel injection pumps Refer tb paragraph 3 13 3 b Replace fuel injection pump s Refer to paragraph 3
64. acket refer td paragraph 3 19 1 Remove seven bolts 3 FIGURE 3 15 two nuts 5 two stand off studs 6 and eleven washers 4 securing crankcase door 7 to crankcase remove door 7 and gasket 8 Discard gasket If damaged remove studs 9 from engine 3 36 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 15 Oil Filter and Crankcase Door 3 20 2 2 Replace a Remove crankcase door refer to paragraph 320 2 1 b Remove adapter ol FIGURE 3 15 c Remove oil filler cap 10 and preformed packing 11 Discard preformed packing d Remove dipstick 12 and remove preformed packing 13 from dipstick Discard preformed packing e Remove two nuts 14 and lockwashers 15 securing plate 16 remove plate 16 and gasket 17 Discard lockwasher 15 and gasket 17 3 37 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 f Remove two studs 18 g Install two studs 18 h Position new gasket 17 and plate 16 on studs 18 and secure with two nuts 14 and new lockwashers 15 i Install new preformed packing 13 on dipstick 12 and install dipstick j Install new preformed packing 11 on oil filler cap 10 and install cap k Install adapter 2 1 Install crankcase door refer to paragraph 3 20 2 4 3 20 2 3 Inspection a Inspect dipstick 12 FIGURE 3 15 for legibility Replace if damaged b Inspect preformed packings 13 and 11 for deterioration and replace as necessary c Inspect crankc
65. ain engine in a clean condition and repair oil leaks With a new or overhauled engine parts settle during first few hours running and their tightness must be subsequently checked When engine is being disassembled all items must be identified retained in their respective cylinder orientation and all related components must be treated similarly The instructions given deal with individual components and it may be necessary to remove other components prior to performing certain procedures lt BE Drain engine coolant fuel and lubrication systems refer to end item maintenance manual Remove fan drive belt refer to end item maintenance manual Remove battery charging alternator refer to end item maintenance manual Remove fan refer to end item maintenance manual Remove intake and exhaust manifolds refer paraaraphs 2 8 and 3 7 Remove fuel pump to injector pipes refer t paragraph 3 18 Remove injectors refer tb paragraph 3 17 Remove head covers refer paragrap Remove valve rockers and pushrods refer to paragraph 3 26 Remove water pump refer paragraph 3 10 Remove cylinder head refer 10 paragraph 3 27 Lift out pushrod tubes rubber seals and washers refer t paragraph 3 27 Remove remaining fuel pipes and fuel filter refer to and Remove dipstick and crankcase door refer tb paragraph 3 20 Remove oil pressure relief valve and the oil strainer
66. alve guide bore 0 283 7 195 installed 0 285 7 250 Valve stem diameter 0 2817 7 155 0 0065 0 165 0 2823 7 170 NOTE Replace the spring if the length is 1 67 in 42 5 mm or less b Check that intake valve seat is sunk 0 037 to 0 05 in 0 95 to 1 26 mm and exhaust valve seat is sunk 0 052 to 0 065 in 1 33 to 1 64 mm below combustion surface If not regrind valve seats refer to paragraph 3 c Check cylinder head clearance as follows NOTE This procedure is used to determine what size head gasket is required Start with medium size gasket 1 Place head gasket onto crankcase Align holes in gasket with those in crankcase Rotate engine so pistons are below cylinder head deck 2 Using a very small amount of general purpose grease 630AA place four pieces of solder SN60WRAP2 size 0 062 1 58 mm thick on pistons as shown in FIGURE 3 80 Space solder on outer edge and as near as possible in line with piston pin Care must be taken to ensure that solder will be clear of valve recesses 3 Install cylinder head and torque bolts refer to paragraph 3 27 6 4 Manually rotate engine through two complete revolutions 3 58 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 SOLDER FIGURE 3 30 Checking Cylinder Head Clearance 5 Remove cylinder head and measure the thickness of solder This should be 0 0276 to 0 0354 in 0 7 to 3 27 4 Repair 0 9 mm and is obtained by a single gasket under head a
67. 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 g 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 h Replace To remove an unserviceable item and install a serviceable counterpart in its place Replace is authorized by the MAC and is shown as the 3rd position code of the SMR code B 1 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 i Repair The application of maintenance services including fault location troubleshooting removal installation and disassembly assembly procedures and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage fault malfunction or failure in a part subassembly module component or assembly and item or system j 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 i e DMWR Overhaul in normally the highest degree of maintenance performed by the Ar
68. approximately 0 01 in 0 2544 mm drop beyond specified piston drop of 0 99 in 2 519 mm Then rotate in direction of normal crankshaft rotation until specified piston drop is reached It is important that specified piston drop be approached in direction of normal crankshaft rotation NOTE It may be necessary to push down on valve stem to overcome friction of stem seal and maintain contact of valve head to piston crown 3 27 ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 NOTE Ensure top face of crankcase is clean m Using a depth gage measure distance X from top face of crankcase to top of fuel pump tappet cap refer to FIGURE 3 11 Subtract dimension X from dimension 2 02 in 51 196 mm to obtain required thickness of shim pack to be installed between fuel injection pump plate and crankcase n Install intake valve spring carrier and collets refer tol paragraph 3 27 5 o Install rocker lever and rocker lever nut refer to paragraph 3 26 3 FIGURE 3 11 FUEL INJECTOR Pump Dimensions NOTE Hydraulic tappet bleed down must be verified before proceeding refer to paragraph p Install fuel injection pump refer td paragraph 3 13 4 q Install fuel injector and fuel injector pipe refer to and 3 18 3 r Install cylinder head cover refer td paragraph 3 25 3 3 15 FUEL SUPPLY LINES 3 15 1 Removal a Loosen clamps 4 FIGURE 3 7 and disconnect supply hoses of fuel line 11 from fuel injection pumps 5 b Discon
69. ase door 7 for cracks dents or other damage Replace if damaged d Inspect adapter 2 for thread damage and replace as necessary 3 20 2 4 Installation a Ensure crankcase door and crankcase mating surfaces are clean and dry b If removed install tappet studs 9 FIGURE 3 15 in engine block Refer td FIGURE 3 8 for proper alignment with tappet slot and tappet movement c Position new gasket 8 and crankcase door 7 on crankcase and secure with seven bolts 3 two nuts 5 and two standoff studs 6 with eleven washers 4 Tighten bolts 3 to 78 in lbs 8 8 Nm in sequence shown in FIGURE 3 16 d Install fuel solenoid and bracket refer to 3 13 4 e Install oil filter cartridge refer to f Service lubrication system refer to end item lubrication order 9 Operate engine and check for leakage S wo o ORMOND FIGURE 3 16 Crankcase Door Fastener Tightening Sequence 3 21 OIL PUMP AND STRAINER 3 21 1 Removal a Drain lubrication system refer to end item maintenance manual b Remove camshaft refer td paragraph 3 29 1 c Remove crankcase door refer td paragraph 3 20 2 1 3 38 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 d From inside crankcase unscrew oil pressure relief valve 1 FIGURE 3 17 oil pump 5 e Unscrew strainer 2 coupling nut from oil pump 5 f Remove two capscrews 3 and washers 4 securing oil pump 5 remove oil pump 3 21 2 Inspect and Test
70. b Lightly grease steel back of thrust bearing 5 with general purpose grease 630AA and position it in housing 3 Ensure that tab is correctly located and copper face will be toward crankshaft Coat both sides of a new main bearing housing shim 4 with sealing compound MIL R 46082 Install it to housing 3 with flat side towards crankcase 3 75 3 33 3 33 1 ARMY 9 2815 252 24 AIR FORCE TO 38G1 92 2 NOTE Two sizes of shim 4 are available 0 015 and 0 020 0 38 and 0 5 Start with smaller shim and check end play Position housing 3 with shim 4 on crankcase and secure with five capscrews 2 Tighten capscrews to 240 in 16 27 2 Nm in sequence shown in FIGURE 3 42 FIGURE 3 42 Bearing Housing Capscrew Tightening Sequence CAUTION Striking crankshaft may displace thrust bearings 5 and damage bearing locating tube if It has not been removed Check crankshaft end play refer td paragraph 3 33 2 Install oil seal 6 as follows 1 Place new oil seal 6 squarely into housing 3 Do not use any compound on seal 2 Using a suitable driver against outside face of seal 6 drive seal into bearing housing 3 Install center bearing locating tube 1 with tapped end facing outward Install crankcase door refer td paragraph 3 20 2 4 Install flywheel housing refer to paragraph 3 31 2 CRANKSHAFT Removal Drain lubrication system refer to end item maintenance manual
71. bent pushrods Referlto paragraph 3 26 b Inspect pushrods for straightness Refer td paragraph 3 26 If straight repair or replace defective engine 14 DETONATION OR PRE IGNITION Step 1 Check for defective fuel injectors a Remove and test fuel injectors Refer paragraph 3 17 If not defective do step 2 b Replace fuel injectors Refer t paragraph 3 17 Step 2 Check for improper fuel pump timing Adjust fuel pump timing Refer tolparagraph 3 14 If timing is correct do step 3 Step 3 Check for carbon build up in compression chambers a Remove cylinder head and inspect for carbon build up Refer td paragraph 3 27 b Remove carbon and or replace components as necessary 3 10 3 3 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Section Ill GENERAL MAINTENANCE GENERAL This section provides general maintenance not found in other sections Chapter 3 3 1 General Instructions Warning Where applicable prior to performing engine maintenance ensure batteries are disconnected Failure to observe this warning could result in personal injury NOTE Refer to end item maintenance manual for removal of any components necessary to gain access to engine It is strongly recommended that bolts or nuts securing cylinder heads covers and doors be tightened in proper sequence When assembling an engine it is always advisable to replace nuts bolts and lockwashers that have been removed from high
72. column General Support includes an H subcolumn Depot includes an D subcolumn c Section Ill lists the tools and test equipment both special tools and common tools sets required for each maintenance function as referenced from section II d Section IV contains supplemental instructions and explanatory notes for a particular maintenance function B 2 MAINTENANCE FUNCTIONS MAINTENANCE FUNCTIONS WILL BE LIMITED TO AND DEFINED AS FOLLOWS a Inspect To determine the serviceability of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination i e by sight sound or feel b Test To verify serviceability by measuring the mechanical or electrical characteristics of an item and comparing those characteristics with prescribed standards Service Operations required periodically to keep an item in proper operating condition i e to clean includes decontamination when required to preserve to drain to paint or to replenish fuel lubricants chemical fluids or gases d Adjust To maintain or regulate within prescribed limits by bringing into proper or exact position or by setting the operating characteristics to specified parameters e Align To adjust specified variable elements of an item to bring about optimum or desired performance f Calibrate To determine and cause corrections to be made or to be adjusted on instruments or test measuring
73. cription And Data 232 Gerieral ee on er n d di d diu d o qu d o qu d i d o d o d Detailed DescriptiOnissi oorr re Equipment Change 3 i ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 TABLE OF CONTENTS continued PAGE Section Ill Preparation For Use 5 1 10 Inspecting and Servicing Engine 1 5 CHAPTER 2 edi Principles ANG PRENNE Introduction Goolitig 4c 2 1 Lubrication System cccccccccssssesscsscsessesscsscsecsecsessassecsscsessassessacsassassassassasasaseaees Fuel System iii Electrical System sien Operating Instructions AMMESSI OC Preventive Maintenance Checks and Services PMCS PMCS Procedures Troubleshooting sise Troubleshooting Procedures ssssssssssssseseseeeeeennn nennen General Maintenance 2 000000 Disassembly and Assembly Sequence for Overhaul Crankcase Intake And Exhaust System Maintenance 2 22 4 Intake Manifold iii Exhaust Cooling System Maintenance General
74. ctors Remove tags Engine oil pressure should be 36 psi 248 kPa at 1800 rpm popop Section VIII GOVERNOR SYSTEM MAINTENANCE 3 23 GOVERNOR SYSTEM 3 23 1 Removal a Remove fuel injection pumps refer to paragraph 3 13 11 b Remove gear end cover refer td paragraph 3 28 11 c Unhook speeder spring 1 FIGURE 3 19 from retainer 2 and lever 29 remove spring d Unhook spring 3 from pivot pin 4 e Remove lower pivot pin 4 from lower pivot support 5 and governor lever 6 Remove pivot retainer 7 Remove spring 3 from lower pivot support 5 f Remove upper pivot pin 8 from upper pivot support 9 and governor lever 6 Remove pivot retainer 10 Use care to retain all end play shims 11 that are installed 3 40 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 9 Carefully remove governor lever assembly and fuel pump rack 6 from crankcase 3 23 2 Repair a Remove two thrust washers 1 and 2 FIGURE 3 20 and sleeve 3 from camshaft b Remove pin 12 shim 13 and retainer 2 from droop adjust screw 14 remove screw 14 c Disconnect spring 15 from governor lever 6 bushing d Remove two nuts 16 and capscrews 17 from end cover e Remove capscrew 18 and washer 19 from inside crankcase remove spring 20 bushing 21 and lever assembly 22 From outside crankcase remove bushing 23 preformed packing 24 and lever 26 Discard preformed packing 24 Remove trip lever spring 26
75. ctrical leads Discard lockwashers b Support weight of starter and remove two capscrews 5 and washers 6 securing starter Remove starter c Cover opening in flywheel housing 3 24 2 Disassembly a Tag and disconnect wire from solenoid 1 FIGURE 3 22 b Remove two screws 2 securing solenoid 1 remove solenoid 3 45 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 21 Starter Connection and Mounting Hardware Remove two through bolts 3 Remove screws 4 securing brush holder assembly 5 to rear bracket 6 and remove rear bracket Remove brush holder assembly 5 and frame assembly 7 Using a screwdriver pull brushes upward and remove brush holder assembly 5 from frame assembly 7 Remove armature 8 Remove screws 9 and cover 10 Remove retaining ring 11 washer 12 and gasket 13 from shaft CAUTION Center bracket 15 has spring tension Use care when removing screw 14 to avoid damaging parts j Remove screw 14 and center bracket 15 from front bracket 16 NOTE Count washers 17 They are used to adjust shaft end play k Remove washer s 17 NOTE Note direction that lever assembly is installed before removing it This will aid in reassembly 3 46 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Remove gear 18 spring set 19 packing 20 and lever assembly 21 from overrunning clutch 22 m Push down on stopper 24 and pinion
76. d screw linkage 5 into solenoid 8 leaving number of threads exposed as noted during removal Tighten linkage locknut Position solenoid 8 with linkage 5 on bracket 11 and secure with two capscrews 6 and washers 7 Connect linkage 5 to lever 13 using capscrew 1 knob 2 washer 3 and retaining nut 4 3 35 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Connect electrical leads to solenoid 8 as tagged during removal Remove tags Adjust fuel solenoid installation refer to end item maintenance manual Section VII LUBRICATION SYSTEM MAINTENANCE Oil FILTER AND CRANKCASE DOOR Oil Filter Cartridge Replacement Drain lubrication system refer to end item maintenance manual Loosen cartridge 1 by turning counterclockwise with a filter wrench Discard used cartridge Wipe filter mating surface with a clean rag Apply light coat of engine lubricating oil MIL L 2104 to new cartridge 1 gasket Place cartridge on adapter 2 and turn clockwise until cartridge is hand tight Using filter wrench turn cartridge an additional 1 2 to 3 4 turn Service lubrication system refer to end item lubrication order Operate engine and check for leakage 3 20 2 Crankcase Door g 3 20 3 20 1 a b f g 3 20 2 1 a b Removal Drain lubrication system refer to end item maintenance manual Remove oil filter cartridge refer tolparagraph 3 20 11 Remove fuel solenoid and br
77. e nnn nnne nnns US LES AL LA EL E Main Bearing Tool 1 nna Bearing Housing Capscrew Tightening Sequence 2 3 43 Crankcase Assembly uU HR ce es 3 80 TABLE PAGE 1 1 Equipment Data 1 4 Preventive Maintenance Checks and Services PMCS Ire use RT 3 3 Color Coded Shim Packs for Fuel Pump 0222 3 26 3 4 Cylinder Head Component Wear Limits 3 58 3 5 Camshaft Component Wear Limits 3 65 Piston and Connecting Rod Component Wear Limits Crankshaft Component Wear Limits E 1 SPOCHICA ONG ds 1 v vi blank ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 CHAPTER 1 INTRODUCTION Section GENERAL INFORMATION 1 1 SCOPE 1 1 1 Type of Manual This manual contains unit direct support and general support maintenance instructions for the Model DN2M Diesel Engine hereafter referred to as engine Also included are descriptions of major systems components and their functions in relation to other systems components 1 1 2 Purpose of Equipment The engine provides a driving force for generators or other equipment requiring this size 12 HP and compatibility 1 2 MAINTENANCE FORMS RECORDS AND
78. e this warning could result in severe personal injury or death NOTE Catch fuel in suitable container Disconnect end Hem fuel supply line from fuel filter 15 FIGURE 3 7 If damaged or if replacing filter assembly remove f sting 12 from filter 15 Remove swivel union plug 9 securing fuel line 11 to fuel filter 15 remove fuel line 11 and two seals 10 card seals 10 Remove two capscrews 13 and lockwashers 14 securing filter 15 to mounting bracket 18 remove filter Discard lockwashers 14 e If damaged remove capscrew 16 and lockwasher 17 securing bracket 18 to flywheel housing Discard lockwasher 17 f 3 1 6 3 a b Cap all openings Installation Remove all caps installed during removal If removed position bracket 18 FIGURE 3 7 on flywheel housing and secure with capscrew 16 and new lockwasher 17 Tighten capscrew to 58 fl Ibs 78 6 Nm Position fuel filter 15 on bracket 18 and secure with two capscrews 13 and new lockwashers 14 Connect fuel supply line 11 to fuel filter 15 using two new seals 10 and swivel union plug 9 If removed or replaced install fitting 12 in filter 15 If required connect end item fuel supply line to fuel filter 15 FUEL INJECTOR Removal Warning Fuel is flammable Keep fuel away from heat and open flame Failure to observe this warning could result in severe personal injury or death CAUTION Do not apply e
79. eal 6 refer to paragraph 3 32 2 Check that crankshaft 10 is free to rotate Install key 9 on gear end of crankshaft WARNING Use care to prevent serious burns when handling pinion gear 8 CAUTION Insufficient heat or delay in Installation could well cause pinion to become Jammed on crankshaft whereas overheating may cause softening of pinion Heat crankshaft pinion gear 8 to a straw yellow color 460 F 238 C and install it on crankshaft ensuring that O mark is facing outward Install pistons and connecting rods refer to paragraph 3 30 4 Install camshaft refer to paragraph 3 29 3 Install flywheel housing refer to paragraph 3 31 2 Install gear end cover refer to paragraph 3 28 3 CRANKCASE ASSEMBLY 3 34 1 Removal Remove crankshaft refer to paragraph 3 33 1 3 34 2 Repair a d If damaged remove two capscrews 1 FIGURE 3 43 and copper washers 2 If damaged remove two pivot supports 3 Using camshaft bushing tool 317 50106 remove camshaft bushing 4 as follows 1 Install guide into bushing 4 from inside crankcase 2 Install slide hammer onto guide threads WARNING Care must be taken to ensure that any part of hand Is not likely to become trapped between two parts of slide hammer while it Is being used 3 Use slide hammer to remove bushing 4 Using main bearing tool 317 50111 remove crankshaft main bearing 5 as follows 1 Place bolt through plain dolly refer to FIGURE 3
80. em maintenance manual ak Install fuel filter and all other fuel pipes refer to and al Service engine coolant fuel and lubrication systems refer to end item maintenance manual and lubrication order 3 5 CRANKCASE VACUUM 3 5 1 General The value depends to some extent on the type and size of air cleaner installed on the engine Regardless of type air cleaner used vacuum with a clean air cleaner must not be less than a minimum of 0 79 in 20 mm water gage WG The vacuum is measured with a manometer at the lubricating oil dipstick hole with the engine running In engines in good condition vacuum increases slightly with engine speed but not proportionally A fluctuating vacuum may indicate faulty oil seals valves or piston blow by troubles Crankcase pressure can cause serious oil leaks and often occurs in engines which need overhauling 3 5 2 Measure Vacuum a Remove lubricating oil dipstick b If water manometer is available connect one end of a 0 374 in 9 5 mm OD plastic tube to a water manometer Insert other end of tube into dipstick hole refer to NOTE Average vacuum should be 1 37 in 34 8 mm WG Minimum allowed is 0 79 in 20 mm WG Warning The noise level when operating could cause hearing damage Ear protection must be worn 3 14 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Start engine and record reading on manometer d Stop engine disconnect manometer and install oil dipstick
81. ex 6 blank TM 9 2815 252 24 TO 38G1 92 2 By Order of the Secretaries of the Army and Air Force GORDON R SULLIVAN General United States Army Official y ex Los Chief of Staff MILION H HAMIL Administrative Assistant to the Secretary of the Army 05276 MERRILL A McPEAK General USAF Chief of Staff Official RONALD W YATES General USAF Commander Air Force Materiel Command DISTRIBUTION To be distributed in accordance with DA Form 12 25 E block no 5141 requirements for TM 9 2815 252 24 U S GOVERNMENT PRINTIING OFFICE 1995 393 393 20352 These are the instructions for sending an electronic 2028 The following format must be used if submitting an electronic 2028 The subject line must be exactly the same and all fields must be included however only the following fields are mandatory 1 3 4 5 6 7 8 9 10 13 15 16 17 and 27 From Whomever lt whomever avma27 army mil To mpmt avma28 st louis emh7 army mil Subject DA Form 2028 From Joe Smith Unit home Address 4300 Park City Hometown St MO Zip 77777 Date Sent 19 OCT 93 Pub no 55 2840 229 23 Pub Title TM 10 Publication Date 04 JUL 85 11 Change Number 7 12 Submitter Rank MSG 13 Submitter F Name Joe 14 Submitter M Name T 15 Submitter L Name Smith 16 Submitter Phone 123 123 1234 17 Problem 1 18 Page 2 19 Paragraph 3 20 Line 4 21 NSN 5 22 Reference 6 2
82. illiliters 29 573 cubic meters cubic yards 1 308 pints liters 473 milliliters fluid ounces 034 quarts liters 946 liters pints 2 113 gallons liters 3 785 liters quarts 1 057 ounces grams 28 349 liters gallons 264 pounds kilograms 454 grams ounces 035 short tons metric tons 907 kilograms pounds 2 205 pound feet Newton meters 1 356 metric tons short tons 1 102 pound inches Newton meters 11296 Temperature Exact Fahrenheit 5 9 after Celsius C temperature subtracting 32 temperature PIN 071745 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines A HREFzhttp www liberatedmanuals com Free Military and Government Manua
83. ing NOTE Apply sealing compound MIL R 46082 to screws 2 before assembly Install solenoid 1 and secure with screws 2 Reconnect wire to solenoid Remove tag Check pinion gap as follows 1 Connect a 24 VDC power source positive lead toterminal S on solenoid and negative lead to starter frame 2 Apply power to solenoid and pinion gear will shift 3 Disconnect terminal M wire to stop pinion from rotating 4 Gently push pinion shaft towards solenoid and measure amount of travel refer to FIGURE 3 26 Pinion gap should be 0 0118 to 0 787 in 0 3 to 2 0 mm 5 Adjust gap by increasing or decreasing number of fiber washers between solenoid and front bracket Increasing number of washers decreases gap and decreasing number of washers increase gap 3 24 6 Installation a Remove cover in flywheel housing b Position starter in flywheel housing and secure with two capscrews 5 FIGURE 3 21 and washers 6 Tighten capscrews to 30 ft Ibs 40 7 Nm c Connect wires to starter as tagged during removal using capscrew 3 new lockwasher 4 nuts 1 and new lockwashers 2 Remove tags 3 51 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 PINION PINION GAP FIGURE 3 26 Checking Pinion Gap Section X ENGINE SUBASSEMBLY MAINTENANCE 3 25 CYLINDER COVER 3 25 1 Removal Remove two nuts 1 FIGURE 3 27 and preformed packings 2 securing each valve cover 3 to cylinder head remove cove
84. l 12 in cylinder head 6 and new pushrod seal 9 in crankcase NOTE Seal 12 has a lip on one side and seal 9 has no lip Lightly coat bore of seals 9 and 12 with general purpose grease 630AA CAUTION Use extreme care to ensure pushrod tubes 8 are centered and fully installed in seals 9 Misalignment of pushrod tubes can cause serious damage to seals Install pushrod tubes 8 into crankcase Install cylinder head guide studs in opposite corners of engine block deck NOTE If old head gasket size is not known perform Check Cylinder Head Clearance refer to 3 27 3 3 60 Install a new valve stem seal 20 to valve guide 22 taking care to ensure it is correctly located over Push down on tool until collets 17 can be installed in position with their tops slightly sunk in valve spring ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 9 Three head gaskets 7 are available Check old gasket for number of identification holes in one corner of gasket One hole 0 053 in 1 35 mm 2 holes 0 058 in 1 47 mm and 3 holes 0 063 in 1 60 mm h Install a new gasket 7 and cylinder head 6 over guide studs Ensure that pushrod tubes 8 are properly aligned with head i Remove cylinder head guide studs NOTE There are three types of cylinder head bolts used Install them in their proper locations as noted during removal j Install two bolts 3 two bolts 4 and four washers 5 Refer tq FIGURE 3 27 and insta
85. l of its least component that is assigned as SMR code for the level of maintenance under consideration i e identification as maintenance significant Actions W elding grinding riveting straightening facing machining and or resurfacing B 2 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 d Column 4 Maintenance Category Column 4 specifies by the listing of a work time figure in the appropriate subcolumn s the category of maintenance authorized to perform the function listed in Column 3 This figure represents the active time required to perform that maintenance function at the indicated category of maintenance If the number or complexity of the tasks within the listed maintenance function varies at different maintenance categories appropriate work time figures will be shown for each category 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 quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the maintenance allocation chart The symbol designations for the various maintenance categories are as follows Operator or Crew Unit Maintenance Direct
86. ll four bolts 7 and spacers 8 Tighten all bolts finger tight k Tighten all eight bolts in three stages and in sequence shown in FIGURE 3 31 1 First tighten to 6 2 ft Ibs 8 4 Nm FIGURE 3 31 Cylinder Head Bolt Tightening Sequence 2 Second tighten to 38 5 ft Ibs 52 2 Nm 3 Final tighten to 66 6 ft lbs 90 3 Nm Install rocker levers and Pushrods refer to paragraph 3 26 3 m Install cylinder covers refer to paragraph 3 25 3 n Position lifting eye 2 on bolts 4 and secure with two nuts 1 Install fuel injectors refer to p Install fuel injector pipes refer to paragraph 3 18 3 Install exhaust manifold refer to paragraph 3 7 3 r Install intake manifold refer to 3 28 GEAR FND COVFR 3 28 1 Removal Insert common screwdriver through flywheel housing into flywheel gear ring Ensure that it is in position by attempting to turn flywheel a b Remove fan belt refer to end item maintenance manual NOTE Bolt 1 FIGURE 3 32 has left hand threads 3 61 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 c Remove bolt 1 securing crankshaft pulley 2 to crankshaft remove pulley 2 d Remove screwdriver CAUTION To avoid possible damage do not use a screwdriver on cover or crankcase mating faces to remove gasket e Remove plug 3 FIGURE 3 32 Gear End Cover 3 62 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 f Supporting weight of end cover 6 remove
87. ls lt A gt Sincerely Igor Chudov http igor chudov com
88. lywheel causing the engine to turn over When engine start is complete the starter is deenergized and disengages from the flywheel 2 1 ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 Section Il OPERATING INSTRUCTIONS NOTE Refer to end Item operator s manual ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 CHAPTER 3 MAINTENANCE SECTION PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS 3 1 PMCS PROCEDURES 3 1 1 General To ensure that engine is ready for operation at all times it must be inspected so defects can be discovered and corrected before they result in serious damage or failure Perform operators PMCS prior to or in conjunction with performance of engine PMCS For engine PMCS Refer ta TABLE 3 1 TABLE 3 1 Preventive Maintenance Checks and Services PMCS Interval Procedures Check Equipment is Item for and have Not Ready to be repaired or adjusted Available Inspected as necessar If 250 Filter Refer td paragraph 3 20 1 500 Fuel Filter Replace fuel filter element Refer to paragrap 1000 Fuel Injectors Remove inspect and test Refer to 1500 Engine Vacuum Check engine vacuum Refer t 1500 Engine Oil Check engine oil Pressure pressure Refer to Change 3 3 1 ARMY TM 9 2815 252 24 AIR FORCE TO 38 1 92 2 SECTION Il TROUBLESHOOTING 3 2 TROUBLESHOOTING PROCEDURES 3 2 1 Purpose of Troubleshooting Table This section contains troubleshooting information for locating and correcting o
89. my Overhaul does not normally return an item to like new condition k Rebuild Consists of those service 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 hours miles etc considered in classifying Army equipment and components B 3 EXPLANATION OF COLUMNS IN THE MAC SECTION Il a Column 1 Group Number Column 1 lists functional group code numbers the purpose of which is to identify maintenance significant components assemblies subassemblies and modules with the next higher assembly b Column 2 Component Assembly Column 2 contains the names of components assemblies subassemblies and modules for which maintenance is authorized c Column 3 Maintenance Function Column 3 lists the functions to be performed on the item listed in column 2 For detailed explanation of these functions see paragraph B 2 Service Inspect test service adjust align calibrate and or replace Fault location troubleshooting The process of investigating and detecting the cause 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 leve
90. n unworn part of the bore For every 0 01 mm 0 0004 in by which the actual bore size exceeds the initial dimension the ring gap will increase by approximately 0 03 mm 0 0012 in The firing ring side clearance is measured with a new ring flush with the top piston land NOTE Oversize pistons and piston rings and under size big end and main bearing shells are available Nonstandard sizes are marked by the amount they are under or oversize as a suffix to the part numbers which can be found in the following locations e Piston Rings stamped on the face of the ring Pistons stamped on the top surface e Bearings stamped on the steel outside surface of the bearing Using appropriate measuring devices check components listed in TABLE 3 6 for wear Replace components that exceed maximum clearance Repair NOTE Lay piston rings 6 FIGURE 3 36 out in order of removal to aid in installation Use a standard ring expander to remove piston rings 6 Remove retaining rings 7 and push pin 8 out of connecting rod 3 and piston 5 Separate piston 5 from connecting rod 3 3 67 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 C If necessary replace bushing 9 from connecting rod 3 d Install piston 5 to connecting rod 3 with wording CAMSHAFT SIDE on top of piston to same side as identification marks on connecting rod big end and cap e Insert piston pin 8 and secure with two retaining rings 7 FIGUR
91. nect fuel return hose from fuel supply line 11 c Remove swivel union plug 9 securing fuel line 11 to fuel filter 15 remove fuel line 11 and two seals 10 Discard seals 10 d Capall openings 3 15 2 Inspection a Inspect metal portions of fuel line for dents or deformations b Inspect hoses of fuel line for cracks deterioration or any other damage 3 28 3 15 3 PPaovp ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 Installation Remove all caps installed during removal Connect fuel line 11 to fuel filter 15 using two new seals 10 and swivel union plug 9 Connect supply line 11 hoses to fuel injection pumps 5 and secure with clamps 4 Connect fuel return line to supply line 11 FUEL FILTER Service Warning Fuel Is flammable Keep fuel away from heat and open name Failure to observe this warning could result In severe personal injury or death NOTE Catch fuel in suitable container Remove through bolt 11 FIGURE 3 12 and cannister 2 Remove and discard fuel filter 3 and gaskets Fill cannister 2 with clean fuel Install cannister 2 with bolt 1 a b c Install new filter 3 and gaskets d e f Prime fuel system refer 10 paragraph 3 12 FIGURE 3 12 Fuel Filter 3 29 3 1 6 2 a b C Dis d ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 Removal Warning Fuel Is flammable Keep fuel away from heat and open name Failure to observ
92. ng to lock flywheel 2 NOTE Bolt 1 is left hand thread j Install crankshaft pulley 2 on crankshaft and secure with bolt 1 Tighten bolt 1 to 221 ft Ibs 300 Nm FIGURE 3 33 Gear End Cover Capscrew Tightening Sequence k Remove screwdriver Install fan belt refer to end item maintenance manual 3 63 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 3 29 CAMSHAFT ASSFMBLY 3 29 1 Removal a Remove end cover refer b Remove cylinder head refer tq C d Remove governor system refer 4 paragraph 3 23 1 e Rotate camshaft until large holes in gear line up with two capscrews 1 FIGURE 3 34 paragraph 3 28 1 paragraph 3 27 1 Remove fuel injection pumps refer to paragraph 3 13 1 f Remove two capscrews 1 and lockwashers 2 securing thrust plate to crankcase remove camshaft 3 from crankcase keeping it square at all times Discard lockwashers FIGURE 3 34 Camshaft Assembly CAUTION No attempt must be made to remove pinion gear from camshaft Camshaft and gear are supplied as an assembly 3 29 2 Inspect and Measure a b Examine camshaft bushing for scars wear Check camshaft gearwheel and crankshaft pinion teeth for wear Ensure cams are not chipped or damaged Check tappets for damage to contact face e Using appropriate measuring devices check components listed in TABLE 3 5 for wear Replace components that exceed maximum clearance f
93. nt Entity Code CAGEC and part number This provides the other information you need to identify the item e Column 5 Unit of measure This code shows the physical measurement or count of an item such as gallon dozen gross etc Section EXPENDABLE DURABLE SUPPLIES LIST ITEM NO NATIONAL STOCK DESCRIPTION U M NUMBER 1 Unit DS GS 7920 01 338 3329 Cloth Cleaning TX 1250 2 DS GS 5210 00 640 6178 Gage Bearing Clear BX PLASTIGAGEPR1 3 Unit DS GS 9150 00 663 1770 General Purpose Grease 630AA TU 4 Unit DS GS 9150 00 152 4117 Lubricating Oil Eng 15 40W QT MIL L 2104 5 Unit DS GS 5350 00 224 7201 Paper Abrasive 400 SHT 6 DS GS 8030 00 891 8358 Sealing Compound LOCTITE 609 TU MIL R 46082 7 DS GS 3439 00 974 1873 Solder Tin Alloy Compound OZ SN60WRAP2 8 Unit DS GS 6850 00 264 9038 Solvent Dry Cleaning P D 680 5 Gal GL Can C 1 C 2 blank ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Appendix D MAINTENANCE PROCEDURE AND AUTHORIZED LEVEL OF MAINTENANCE Section INTRODUCTION SCOPE This appendix shall be used when a Commercial Off The Shelf COTS manual is used by the Military services This appendix is divided into three sections Section gives a brief description of the sections within this appendix Section II list the paragraphs to the associated maintenance level Section list the maintenance level to the associated paragraphs Section PARAGRAPH TO MAINT
94. om tee fitting 13 Remove tiedown straps 14 and remove hose 10 Discard tiedown straps Remove two hoses 5 from fuel injectors 8 and tee fittings 13 Remove tee fittings 13 from hose 15 remove hose 15 Disconnect hose 16 from tee fitting 13 remove hose 16 Loosen nuts on fuel injector pipes 3 and 4 at fuel injection pump and fuel injector 8 Remove cylinder head cover nuts 1 securing fuel injector pipes 3 and 4 clips remove pipes 3 and 4 If damaged replace preformed packing 2 Cap all openings Change 3 3 33 3 18 2 a b 3 18 3 op 0 1 3 19 1 ARMY 92815 252 24 AIR FORCE 38G1 92 2 Inspection Inspect fuel injector pipes for wear kinks or fitting damage Replace as necessary Inspect hoses for cracks deterioration or any other damage Installation Remove all caps installed during removal Connect fuel injector pipes 3 and 4 FIGURE 3 13 to fuel injectors 8 and fuel injection pumps Tighten nuts finger tight Secure fuel injector pipe clips using cylinder head cover nuts 1 Tighten nuts to 78 in lbs 8 8 Nm Starting at fuel injector 8 tighten fuel injector pipes 3 and 4 nuts to 21 0 ft lbs 28 5 Nm Install tee fitting 13 into hose 16 Install tee fittings 13 in hose 15 Connect hoses 5 to tee fittings 13 and to fuel injectors 8 Connect hose 10 to tee fitting 13 and secure hose 10 with new tied
95. own straps 14 Install union 11 and washer 12 to end of fuel supply hose Connect hose 10 to union 11 FUEL SOLENOID Removal Tag and disconnect electrical leads from solenoid 8 FIGURE 3 14 Remove capscrew 1 knob 2 washer 3 and retaining nut 4 securing linkage 5 to lever 13 Remove two capscrews 6 and washers 7 securing solenoid 8 to bracket 11 remove solenoid 8 with linkage 5 Count number of threads exposed prior to unscrewing linkage 5 This will aid installation and adjustment If damaged or if replacing solenoid loosen locknut on linkage 5 and unscrew linkage from solenoid 8 If damaged remove two nuts 9 and washers 10 securing bracket 11 to engine remove bracket 11 If damaged remove two studs 12 and washers 10 from engine block 3 34 3 1 9 2 a b 3 19 3 3 19 4 b c d e ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 6 13 5 3 2 1 FIGURE 3 14 Fuel Solenoid Installation Inspection Inspect linkage for bends or any other damage Inspect threaded components for thread damage Refer to end item maintenance manual for inspection of solenoid Adjustment For adjustment of fuel solenoid installation refer to end item maintenance manual Installation If removed install two studs 12 FIGURE 3 14 and washers 10 in engine block If removed position bracket 11 on studs 12 and secure with two nuts 9 and washers 10 If remove
96. perate properly CAUTION To retain governor setting leave one fuel pump in position NOTE Catch fuel in a suitable container a Loosen clamp FIGURE 347 and disconnect fuel supply line 11 from fuel injector pump 5 b Position engine speed control counterclockwise to stop position and hold in this position with a plastic tie wrap refer to FIGURE 3 6 3 22 3 13 2 op 3 13 3 3 13 4 op ARMY TM 9281 252 24 AIR FORCE TO 38G1 92 2 Remove fuel injector pipe between pump 5 FIGURE 3 7 and fuel injector refer paragraph 3 18 paragraph 3 15 Remove fuel supply lines refer to Remove nut 1 and damp 2 securing fuel injection pump 5 NOTE Care must be taken to avoid dropping items into crankcase Lift fuel injection pump 5 out of crankcase and remove shim pack 6 Tag them as to which cylinder they came from If necessary remove thrust cup 8 and tappet 7 from crankcase using magnetic pick up Tag them as to which cylinder they came from If damaged remove stud 3 Cap cover all openings Inspection Inspect pump housing for cracks corrosion or any other damage Inspect shim pack for corrosion or damage Inspect tappet for cracks corrosion or any other damage Test NOTE This test must be performed with engine installed in end item Disconnect fuel injector pipe from top of pump to be tested Connect a fuel pressure gage capable of displaying 3000
97. perating troubles which may develop in the engine Each malfunction for an individual component unit or system is followed by a list of tests or inspections which will help you to determine probable causes and corrective action to take You should perform tests inspections and corrective actions in order listed This table cannot list all malfunctions that may occur nor all tests or inspections and corrective actions If a malfunction is not listed or cannot be corrected by listed corrective actions notify your supervisor NOTE Before you use this table be sure you have performed your PMCS Prior to performing troubleshooting procedures within this manual perform your operator s troubleshooting and the end item maintenance manual troubleshooting procedures SYMPTOM INDEX Malfunction Troubleshooting Procedures Page Engine Will Not Crank s t te rece e e ee ave pete de ee Ue veu Ure vv Starter Operates But Will Not Turn Engine Hard to Start Will Not Start Engine Hard to Start or Will Not Start In Cold Weather cient mete e e EE eee Ee EE ED ee E ee eene oia Engine Misfires or Runs Irregularly or Stalls Frequently 9 Engine Does Not Develop Full Power iii Engine Overheating ENTM Excessive Oil ierdie ein ee ae ene a ee Ne MET Excessive Fuel Consumption iii Bl ck or Gray Smoke
98. pump studs 17 FIGURE 3 4 been removed they must be Installed and finger tightened Do not overtighten as this will cause thread damage preventing a fiat sealing surface If removed install two mounting studs 17 finger tight Install two new preformed packings 14 and sleeve 13 Install new gasket 16 mounting plate 15 new gasket 12 and water pump 11 Secure pump to crankcase with seven washers 9 two nuts 10 and five capscrews 8 and 7 Install two shorter capscrews 8 as noted during removal Tighten hardware to 186 in Ibs 21 0 Nm 3 20 i j k 3 11 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 Connect inlet and outlet hoses to water pump and tighten hose clamps If removed install temperature sensors in water pump and connect electrical leads Remove tags NOTE Nut 6 has left hand threads Install fan belt fan washer and nut 6 Tighten nut 6 to 20 to 24 ft lbs 27 to 32 Nm Tighten fan belt Service coolant system refer to end item maintenance manual Section VI FUEL SYSTEM MAINTENANCE GENERAL This section provides maintenance for fuel system components Components of the fuel system not mentioned in this section can be found in end item maintenance manual Observe the following precautions a b C d e 3 12 Always cap fuel connections after removal to prevent contamination When priming or checking fuel pump timing care must be taken to wipe spilled fuel from ou
99. r 3 and gasket 4 Discard gasket 4 and preformed packings 2 3 25 2 Inspection a Inspect cover for cracks dents or any other damage b Inspect nuts for rounded hex corners or thread damage 3 25 3 Installation a Remove any traces of old gasket from cylinder head and valve covers 3 FIGURE 3 27 mating surfaces b Ensure mating surfaces are clean and dry c Position each valve cover 3 with new gasket 4 on cylinder head and secure with two nuts 1 and new preformed packings 2 Tighten nuts 1 to 78 in Ibs 8 8 Nm 3 23 ROCKER LEVER 3 26 1 Removal a Remove cylinder covers refer td paragraph 3 25 1 b Remove nut 4 FIGURE 3 21 securing rocker lever 6 to cylinder head bolt 7 remove rocker lever c Remove pushrod 9 d Repeat steps b and c for remaining rocker levers and pushrods e Do not remove cylinder head bolt 7 and spacer 8 unless damaged or cylinder head is being removed 3 26 2 Inspect and Measure a Check pushrod 9 FIGURE 3 27 as follows 1 Lay pushrod on a surface plate 3 52 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 27 Cylinder Cover and Rocker Lever 3 53 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 2 Roll pushrod along surface plate checking for curvature with a feeler gage Normal reading should be 0 008 in 0 2 mm or less 3 Inspect both ends of pushrod for excessive wear or damage If excessive wear or damage is found replace p
100. rankshaft 10 Secure with two capscrews 11 and tighten to 186 in Ibs 21 0 Nm c Install crankshaft 10 Into crankcase from flywheel end Ensure that center bearing locating tube hole is aligned with hole in crankcase d Apply a small amount of general purpose grease 630AA to steel side of thrust bearings 16 and place them gear end of crankcase with tab correctly located and copper face toward crankshaft 10 TABLE 3 7 Crankshaft Component Wear Limits Component Initial Maximum Dimension Clearance inches inches Flywheel end main bearing housing bore Bearing shell thickness Crankshaft journal diameter Gear end main bearing housing bore Bearing shell thickness Crankshaft journal diameter Center main bearing housing bore Bearing shell thickness Crankshaft journal diameter Thrust bearing thickness NOTE Replace thrust bearing if thickness is less than 0 0394 in 2 20 mm CAUTION Take special care when passing crankshaft 10 through gear end bearing as it is quite easy to score bearing shell with crankshaft 3 78 m n 3 34 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 NOTE Ensure tube is fully seated and not in housing capscrew head recess With an inlet manifold bolt inserted in center bearing locating tube 1 insert tube through crankcase wall and into center bearing housing 13 Remove bolt from tube Install rear main bearing housing 3 and oil s
101. raulic tappets Install governor weights and governor sleeve refer td paragraph 3 23 Install governor lever assembly and springs Set governor Install fuel injection pumps refer to paragraph 3 13 Install gear end cover refer t Adjust engine control refer tb paragraph 3 23 5 3 13 ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 Install crankshaft pulley refer to paragraph 3 28 NOTE The pistons with rings and connecting rods assembled must be submerged in engine lubricating oil MIL 2104 just before installing into cylinder Drain after submersion so that no oil is left in combustion chamber or inside the piston x Install pistons and connecting rods refer td paragraph 3 30 y Install oil pressure relief valve and strainer refer to z Install crankcase door and dipstick refer td paragraph 3 20 aa Install pushrod rubber seals washers and pushrod tubes refer to paragraph 3 27 ab Install cylinder head refer to paragraph 3 27 ac Install pushrods and valve rockers refer to paragraph 3 26 ad Install cylinder head covers refer to paragraph 3 25 ae Install fuel injectors and fuel injector pipes refer to and 3 18 af Install water pump refer RE ER ag Install intake and exhaust manifolds refer to and 3 7 ah Install fan refer to end item maintenance manual ai Install battery charging alternator refer to end item maintenance manual aj Install fan drive belt and tension it refer to end it
102. rt at 3480 psi 23 995 kPa for used injector and 3552 to 3697 psi 24 491 to 25 491 kPa for new injector and a well atomized spray pattern should be visible Injector leakoff rate is 10 to 40 seconds between 2205 and 1470 psi 15 203 and 10 136 kPa Installation Remove all covers installed during removal Ensure seating in cylinder head is clean and smooth NOTE If injector sealing washer 9 FIGURE 3 13 has been used more than once it will become compressed and may adversely affect combustion It is recommended that new injector sealing washers are installed on assembly Ensure that two washers are not installed to an injector Lightly smear a very small amount of general purpose grease 630AA to one side of new injector sealing washer 9 Place one washer only over each injector nozzle greased side first Install injector 8 Install clamp 7 and finger tighten bolt 6 Install a new preformed packing 2 into recess on cylinder head cover Install injector pipe 3 or 4 and finger tighten nuts Install cylinder head cover nut retaining injector pipe clip and tighten to 78 in Ibs 8 8 Nm Tighten injector clamp bolt 6 to 186 in Ibs 21 0 Nm Tighten injector pipe 3 or 4 nuts to 21 0 in Ibs 28 5 Nm Install injector fuel return hose 5 FUEL INJECTOR PIPES AND FUEL RETURN LINE Removal Disconnect hose 1D FIGURE 3 1 from union 11 Remove union 11 and washer 12 from end of fuel supply hose Disconnect hose 10 fr
103. s 1 Place a piece of correct size bearing gage approximately 0 25 in 6 35 mm off center across full width of one bearing shell 2 Install bearing and torque bolts CAUTION Ensure crankshaft Is not turned when bearing gage is In place and all traces of It must be removed before final assembly of bearings to prevent damage to crankshaft and bearings 3 Remove bearing shell Compare width of bearing gage against scale printed on bearing gage container Compare with values found in TABLE 3 7 Using appropriate measuring devices check components listed in TABLE 3 7 for wear Replace components that exceed maximum clearance Check crankshaft end play as follows 1 Set a dial indicator so that actuating plunger makes contact with flywheel end face of crankshaft 2 Push crankshaft firmly towards gear end of engine and zero indicator 3 Push crankshaft firmly towards flywheel end of engine and check end play This should be 0 0071 to 0 0149 in 0 18 to 0 38 mm End play is maintained by installing a single 0 0149 or 0 0197 in 0 38 or 0 50 mm aluminum shim behind bearing housing flange 3 77 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 3 33 3 Installation a Install new bearing in gear end of crankcase refer to paragraph 3 34 4 Position new center bearing shells 14 FIGURE 3 40 on upper and lower housing Install upper housing 12 and lower housing 13 ensuring words FLYWHEEL END are facing flywheel end of c
104. spective valve has closed 3 27 CYLINDER HEAD ASSEMBLY 3 27 1 Removal a Remove intake manifold refer to paragraph 36 1 b Remove exhaust manifold refer td paragraph 3 7 1 NOTE Cap all fuel line connections that have been opened to prevent contamination of fuel system Remove fuel injector pipes refer to paragraph 3 18 1 Remove fuel injectors refer tol paragraph 3 17 1 e Remove two nuts 1 FIGURE 3 28 securing lifting eye 2 remove lifting eye 2 eo 3 54 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 f Remove cylinder covers refer td paragraph 3 25 1 g Remove rocker levers and pushrods refer td paragraph 3 26 1 NOTE There are three types of cylinder head bolts used Note location of these for proper location during installation h Remove two bolts 3 two bolts 4 and four washers 5 Refer t FIGURE 3 27 and remove four bolts 7 and spacers 8 NOTE check old gasket for number of identification holes i e one two or three this will aid installation 3 55 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 28 Cylinder Head Assembly 3 56 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 i Lift off cylinder head 6 FIGURE 3 28 and gasket 7 Discard gasket 3 27 2 Disassembly a Remove pushrod tubes 8 FIGURE 3 28 seals 9 washers 10 and tappets 11 from crankcase b Remove seals 12 from cylinder head 6 Discard seals 12 C If necessary
105. stationary 3 Move gear tooth side to side in backlash Record indicated backlash Total Indicator Reading TIR Standard TIR is 0 004 0 007 in 0 10 to 0 17 mm with a limit of 0 012 in 0 30 mm 4 If TIR exceeds limit replace gear 3 65 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 f Install governor system refer to paragraph 3 23 4 g Install fuel injection pumps refer to paragraph 3 13 4 h Install cylinder head refer to paragraph 3 27 6 i Install end cover refer to paragraph 3 28 3 FIGURE 3 35 Measuring Gear Backlash and End Play 3 30 PISTON AND CONNECTING ROD ASSEMBLIES 3 30 1 Removal a Remove crankcase door refer td paragraph 3 20 2 1 b Remove cylinder head refer td paragraph 3 27 1 If number one piston is to be removed unscrew oil pressure relief valve and oil strainer from oil pump d Rotate crankshaft as necessary to gain access to connecting rod bearing cap capscrews 1 FIGURE 3 36 Warning To avoid possible Injury due to sharp edges of machined crankcase face use a drive socket and not a wrench CAUTION Number stamped on connecting rod must correspond with number stamped on end cap Damage to crankshaft can occur e Remove two capscrews 1 connecting rod 3 and bearing cap 2 f If damaged or worn remove bearing halves 4 9 Carefully scrape any build up of carbon from top of cylinder bore h Rotate crankshaft until piston is at TDC 3 66 3 30 2
106. stop position 2 Adjust upper capscrew 17 until it just touches curved part of lever 25 and lock it in this position with nut 16 3 Move lever 25 clockwise to run position and make appropriate G setting c Make governor G setting as follows NOTE 3 44 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 The G setting is made to ensure that fuel pumps deliver correct amount of fuel for desired engine speed NOTE This adjustment requires use of governor setting gage 317 50115 1 Move lever 25 clockwise to run position 2 Insert 26 5 part of setting gage between head of upper capscrew 17 and top of curved part of lever 25 3 Adjust lower capscrew 17 until lever 25 just touches setting gage 4 Tighten lower capscrew locknut 16 5 Remove gage NOTE Speed adjustment must be made with engine installed refer to end item maintenance manual NOTE Speed adjustments are made after governor has been correctly set Capscrews 35 and 36 are used to adjust speed control NOTE Engine speed is controlled by speeder spring 1 inside crankcase d Adjust speed in accordance with end item maintenance manual Section IX ELECTRICAL SYSTEM MAINTENANCE 3 24 STARTFR ASSFNBI Y 3 24 1 Removal NOTE Perform testing on starter motor before removal from engine assembly refer to paragraph 3 24 3 1 a Remove nuts 1 FIGURE 3 21 lockwashers 2 capscrew 3 and lockwasher 4 Tag and disconnect all ele
107. t from the engine When the coolant temperature is below operating temperature the thermostat is closed and coolant is bypassed to the water pump inlet coolant temperature increases to 160 F 71 C the thermostat starts to open restricting bypass flow and opening flow to the radiator As coolant temperature continues to increase to 1850F 85 the thermostat is fully opened shutting off all bypass flow and providing full flow through the radiator Air forced through the fins of the radiator by the fan cools the coolant pumped through the radiator Items are added to the engine to monitor coolant temperature and to warn if temperature exceeds a predetermined value 2 3 LUBRICATION SYSTEM The lubrication system consists of an oil sump dipstick pump relief valve and filter The oil sump is a reservoir for lubricating oil The dipstick indicates oil level in sump The pump draws oil from the sump through a screen which removes large impurities The oil then passes through a relief valve preset to limit oil pressure to 47 to 59 psi 324 to 407 kPa The oil then passes through a spin on type filter where small impurities are removed From the filter oil enters the cylinder head oil gallery and flows to the crankshaft and bearings The connecting rod bearings are pressure fed through internal drillings in the crankshaft from the supply to the main bearings Splash oil lubricates the gears and the underside of the pistons The governor camshaf
108. t is lubricated by a drilled bolt oil jet An internal crankcase drilling provides an oil feed to the hydraulic tappets After passing through the block the oil returns to the oil sump Items are added to monitor oil pressure and to warn stop engine if pressure drops to a dangerously low value 2 4 FUEL SYSTEM 2 4 1 The fuel system consists of an external fuel tank electrically driven transfer pump fuel filter water separator fuel filter fuel injection pump and fuel injector for each cylinder and piping Fuel from an external source is supplied to the fuel injection pumps The injection pumps provide a pressurized metered quantity of clean atomized fuel through the injector nozzles into the cylinders at a precise time near the end of the compression stroke of each piston The fuel that is not used by the injectors is returned to the fuel tank via an excess fuel return line 2 4 2 Extremely cold outside temperatures make starting the engine difficult To improve engine starting a cold weather starting aid has been provided that features two heater plugs in the intake manifold The heater plugs are energized during engine preheat starting cycle 2 5 ELECTRICAL SYSTEM The electrical system consists of external mounted batteries starter battery charging alternator and related relays and switches for control of the system Battery power supplied to the starter during the start cycle energizes the starter which engages the ring gear of the f
109. tall governor lever 6 assembly onto camshaft and use care to ensure that flywheel end of fuel pump rack is located in its housing b If removed install pivot retainer 7 and 10 on upper and lower pivot pins 4 and 8 Secure governor lever 6 to lower pivot support 5 using pivot pin 4 Connect spring 3 to pivot pin 4 Install top pivot pin 8 through upper pivot support 9 and into governor lever 6 Be sure to use original end play shims 11 Long loop of speeder spring 1 connects to retainer 2 e Connect speeder spring 1 to retainer 2 and lever 29 f Check governor end play refer to paragraph 3 23 5 step a g Install gear end cover refer to paragraph 3 28 3 h i Install fuel injection pumps refer to paragraph 3 13 4 Perform governor system adjustments refer td paragraph 3 23 5 steps b c and d 3 23 5 Adjustment a Adjust govemor lever 6 FIGURE 3 19 assembly end play as follows 1 Move lever assembly 6 until it abuts against top pivot support 9 Check that it falls freely under its own weight 2 Check governor lever 6 assembly end play Add or remove 0 0098 in 0 25 mm shims 11 at top pivot support 9 to obtain an end play of 0 0039 to 0 0118 in 0 1 to 0 33 mm NOTE Adjustments in steps b thru d must be done with gear end cover installed b Adjust control lever 25 setting as follows 1 Turn control lever 25 counterclockwise into
110. teet eite ee eee e e ots MAIN BEARING 220 0000 2 tire hee eet eere Pe eu eU eu e ad Re TN 6 CRANKCASE 5 REFERENCES t epo ute MAINTENANCE ALLOCATION CHART EXPENDABLE DURABLE SUPPLIES AND MATERIALS LIST MAINTENANCE PROCEDURE AND AUTHORIZED LEVEL OF MAINTENANCE D 1 at i M tee ET ET Index 1 TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 LIST OF ILLUSTRATIONS FIGURE PAGE 1 1 Engine Components Locally Manufactured Water Manometer Manoir uad ld auda nda haut aatia xcd C oling CL EP TET Priming Fuel System 2 nennen nennen nsns nnns Engine Speed Fuel Injection Pump Fuel Filter and Supply Lines Fuel Pump Tappet and Stud Setting Pump nnn Checking Piston Drop iii Fuel Injector Pump Dimensions Fuel Filter Fuel Injectors Fuel Injector Pipes and Fuel Return Line 3 14 Fuel
111. ts and scale Carefully inspect block for cracks or damage Replace block if there is evidence of physical damage ooo o When determined that engine block is serviceable clean out threads for cylinder head capscrews in top deck of engine block using a M10 x 1 25 sized tap Use compressed air to remove any debris or fluid which may be present in tapped holes after cleaning 3 34 4 Installation Install crankshaft refer to paragraph 3 33 3 3 82 ARMY TM 9 2815 252 24 AIR FORCE TO 38G1 92 2 APPENDIX A REFERENCES A 1 SCOPE This appendix lists all forms field manuals technical manuals and miscellaneous publications references in this manual A 2 FORMS Air Force Reporting of Errors AFTO Form 22 Product Quality Deficiency nnne nennen nsns SF 368 Recommended Changes to DA Publications DA Form 2028 2 Recommended Changes to Publications and Blank Forms 9 n DA Form 2028 Report of Discrepancy ROD m SF 364 Reporting of Item and Packaging 2 AR 735 11 2 Reporting of Transportation Discrepancies in AR 55 38 Transportation Discrepancy sise SF 361 Equipment Control records n DA Form 2408 9 A 3 FIELD MANUALS FES Ald SOldIers a Lc FM 21 11 A 4 TECHNICAL MANUALS
112. tside of engine Special care must be taken to see that no leakage exists from fuel pipe connections on pump When tightening or loosening fuel pump delivery connections use two wrenches to prevent pump from twisting on its seating and causing misalignment of pump calibration When installing fuel pipe from pump to injector fuel pipe must be correctly aligned and line up freely at both ends Do not pry on pipe to install or leakage may result BLEEDING AND PRIMING FUEL SYSTEM The following procedure is performed with engine cranking or running a b C d e Loosen two screws 1 FIGURE 3 5 on fuel filter to allow air to escape Tighten screws Loosen injector fuel pipe 2 at fuel injection pumps Loosen delivery valve holder 3 on fuel injection pumps up to a quarter of a turn until no air bubbles are expelled Tighten delivery valve holder 3 using 17 mm crowsfoot wrench to 35 ft lbs 47 5 Nm Tighten injector pipe nut 2 to 21 ft lbs 28 5 Nm 3 21 3 13 3 13 1 ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 FIGURE 3 5 Priming Fuel System FUEL INJECTION PUMP Removal Warning Fuel is flammable Keep fuel away from heat and open flame Failure to follow this warning could result In personal injury or death CAUTION If more than one fuel pump is being removed extreme care must be taken to ensure that shim pack Is replaced to Its original cylinder otherwise when Installed fuel pumps may not o
113. u can help improve this manual If you find any mistakes or if you know of a way to improve these procedures please let us know A Mail your letter or DA Form 2028 Recommended Changes to Publications and Blank Forms or DA Form 2028 2 located in the back of this manual directly to Commander US Army Aviation and Troop Command ATTN AMSAT I MP 4300 Goodfellow Blvd St Louis MO 63120 1798 You may also submit your recommended changes by E mail directly to lt mpmt avma28 st louisemh7 army mil gt Instructions for sending an electronic 2028 may be found at the back of this publication immediately preceding the hard copy 2028 F Air Force AFTO Form 22 Directly to Commander Sacramento Air Logistics Center ATTN TILBA McClellan AFB CA 95652 5990 AFMC A reply will be furnished directly to you DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited TABLE OF CONTENTS INTRODUCTION mE Secti General Informatio sinoni Mt SCOPES PUE Maintenance Forms Records and Reports Reporting Equipment Improvement Recommendations Eir Destruction Of Army Materiel To Prevent Enemy Use Preparation For Storage Or 2 Equipment Des
114. uired k Carefully turn fuel pump counterclockwise until pump rack is felt against stop l Holding pump in this position install clamp 2 and secure with nut 1 beveled face towards clamp finger tight m Tighten nut to 25 ft lbs 33 9 Nm n Install fuel injector pipe between pump 5 and fuel injector refer to paragraph 3 18 Connect fuel supply line 11 to fuel injection pump using clamp 4 p Remove rack setting gage q Connect governor fever to rack spring 15 FIGURE 3 19 r Install end cover refer td paragraph 3 28 3 3 14 FUEL INJECTION PUMP TIMING Warning Cleaning solvent is flammable and toxic to eyes skin and respiratory tract Skin eye protection required Avoid repeated prolonged contact Good general ventilation IA is normally adequate Each fuel injection pump is timed individually during assembly at factory and when an existing or new fuel injection pump is installed it is only necessary to reinstall existing shim pack or a new pack of same thickness as original This procedure is necessary only if original shims have been lost or mixed with those of another pump Use care to avoid dirt entering into engine during fuel injection pump timing procedure If practical start with a thorough cleaning Use dry cleaning solvent P D 680 to remove all external dirt For each fuel injection pump to be timed repeat following procedure f Remove cylinder head cover and fuel injector refer td paragraphs 3 25 1 and
115. ushrod b Inspect rocker lever valve stem contact surface for step wear and scoring If contact surfaces have light step wear or scoring they may be honed with an oil stone If step wear or scoring is severe rocker lever must bereplaced 3 26 3 Installation CAUTION Ensure that no piston Is at TDC when Installing pushrods Failure to follow this caution could damage equipment a Lightly oil pushrod 9 FIGURE 327 with engine lubricating oil MIL L 2104 and install it in cylinder head Ensure pushrod does not interfere with cylinder head clearance hole b Lightly oil rocker lever 6 and install it on cylinder head bolt 7 Secure with nut 5 finger tight c Gradually tighten nut 5 until heel of rocker lever 6 makes contact with ball end of pushrod 9 Ensure rocker lever is centered over valve stem d Tighten nut 5 to 25 ft lbs 33 9 Nm e Repeat above steps a thru d for remaining pushrods and rocker levers f Wait for up to 90 seconds on a new tappet or up to 45 minutes on a used engine for the hydraulic tappet to bleed down CAUTION Do not force crankshaft to rotate If rotation is not free easy movement This will prevent engine damage if a piston comes in contact with valve NOTE Check for bleed down by rotating pushrods If a pushrod rotates after the respective valve has closed that hydraulic tappet has bled down g Manually turn the crankshaft very slowly checking that all pushrods will rotate after their re
116. xcessive force to Injection fuel pipes Failure to observe this caution could result in damage to fuel pipes NOTE Catch fuel in suitable container Disconnect and remove fuel injector pipe 3 3 or 4 FIGURE 3 13 refer to paragraph 3 18 1 3 30 ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 Disconnect fuel return hose 5 from injector 8 Remove bolt 6 securing clamp 7 remove clamp Remove fuel injector 8 from cylinder head Remove injector copper sealing washer 9 from cylinder head taking care not to damage seating area Cover all openings 3 1 7 2 Inspection a Check nozzle body and nozzle needle for damage or deformation If damaged or deformed replace fuel injector roago nozzle b Inspect threaded components for thread damage and replace as necessary 3 17 3 Test a Attach fuel injector to a fuel injector tester Point fuel injector into a clear container 3 31 ARMY TM 92815 252 24 AIR FORCE TO 38G1 92 2 TO FITTING ON NO 1 INJECTION PUMP LB PS 47 8 V QV 9 ss FUEL TANK FIGURE 3 13 Fuel Infectors Fuel Injector Pipes and Fuel Return Line 3 32 o 3 18 3 18 1 ARMY 92815 252 24 AIR FORCE TO 38G1 92 2 Warning Keep body clear of test spray Fluid can be injected into blood stream causing blood poisoning possible death Open valve on fuel injector tester and operate lever at one stroke per second Spray should sta

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