null  null
TM 9-2815-202-34
TECHNICAL MANUAL
DIRECT SUPPORT AND
GENERAL
SUPPORT
MAINTENANCE
ENGINE,
MODEL
DIESEL
W/CONTAINER:
7083-7395
(2815-01-043-7092)
(2815-01-260-0211)
ENGINE,
MODEL
DIESEL
7083-7396
W/CONTAINER
(2815-01-040-3120)
(2815-01-260-0212)
ENGINE,
MODEL
7083-7398
ENGINE,
MODEL
DIESEL
(2815-00-936-7659)
DIESEL
7083-7399
W/CONTAINER
W/CONTAINER
(2815-00-134-4845)
DISTRIBUTION STATEMENT: Approved for
public release. Distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
20 FEBRUARY 1990
TM 9-2815-202-34
WARNING SUMMARY
The following is a list of warnings that appear in this manual. Mechanics must
become familiar with all warnings. Severe injury or death can be avoided by
mechanics who understand the vehicle and are alert to possible dangers.
WARNING
Fuel spraying on hot components is a extreme fire hazard. Control leakage
immediately to prevent injury.
WARNING
Protective fan screens must be installed prior to doing maintenance in the
engine compartment when engine is running or when engine is in ground hop
mode. Contact with rotating fan can cause injury (FM 21-11).
WARNING
When inspecting a blower on a engine with the engine running, keep fingers,
equipment, and clothing away from moving parts of the blower. Run engine at
low speeds only.
WARNING
Compressed air used for cleaning purposes will not exceed 30 PSI. Use only
with effective chip guarding and personal protective equipment (goggles/shieid,
gloves, etc).
WARNiNG
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles
and gloves and use only in a well-ventilated area. Avoid contact with skin,
eyes, and clothes and don’t breathe vapors.
Do noto use near
open frames or
o
o
excessive heat. The flash point is 100 F-138°F (38 C-50 C). If you become
dizzy while using cleaning solvent, get fresh air immediately and get medical
aid. If contact with eyes is made, wash your eyes with water and get medical aid
immediately.
WARNING
Wear safety glasses and stand clear of air release ports when purging air from
a pressurized container. Make certain air pressure is fully vented before
disassembly. Injury to eyes and inner ears can result from failure to properly
vent containers before disassembly.
TM 9-2815-202-34
WARNING
Never crawl under equipment when performing maintenance unless equipment
is securely blocked. Keep clear of equipment when it Is being raised or
lowered. Do not allow heavy components to swing while suspended by lifting
device. Exercise extreme caution when working near a cable or chain under
tension. Equipment may drop or shift and injury to personnel may result.
WARNING
Do not touch ignition coil or air heater assembly while performing tests. High
voltage is present. Personal injury may result.
WARNING
Firmly secure spring-loaded mechanisms during disassembly. The spring can
eject parts at high speed If released in an uncontrolled manner. Personal injury
may result.
WARNING
Use goggles, rubber gloves, and rubber apron when cleaning parts in carbonremoving compound. Provide adequate ventilation. Avoid inhaling fumes and
skin contact. If compound Is splashed on skin, flush with fresh water and wash
with alcohol. Alcohol containing 2 to 3 percent camphor Is preferable.
WARNING
Do not grasp or graze sharp edges of oil control rings with bare hands. Rings
are extremely sharp and can cut personnel when mishandled.
WARNING
Coolant system cleaning solution Is an acid. Wear protective goggles and
equipment. Avoid contact with skin, eyes, and clothing. If contact is made, flush
area with water and seek medical aid immediately or injury may result.
TM 9-2815-202-34
WARNING
Fuel injector may contain residual fuel oil and can emit a high pressure jet of
fuel from spray tip when bumped. Always hold injector so that tip will spray
away from skin. Fuel oil which enters blood stream may cause serious infection.
WARNING
Use heat-resistant gloves when handling heated parts. Metal components will
dissipate heat quickly. Burns to personnel will result.
WARNING
Wear proper ear protection when running engine. Noise volume of engine can
cause hearing loss or injury.
WARNING
Protective turbocharger air inlet shield must be installed prior to doing
maintenance when engine is running and air inlet has been removed. Contact
with rotating blades will cause injury to personnel.
WARNING
Mercury is a toxic material. Avoid contact with skin. Avoid breathing mercury
vapor over prolonged periods of time. Clean up spilled mercury immediately.
Dispose of small amounts of mercury by wiping with aluminum foil.
TM
CHANGE
9-2815-202-34
C1
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington D. C., 9 October 1992
NO. 1
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
ENGINE, DIESEL W/CONTAINER: MODEL 7083-7391
(2815-01-335-4579)
ENGINE, DIESEL W/CONTAINER: MODEL 7083-7395
(2815-01-043-7092) (2815-01-260-0211)
ENGINE, DIESEL W/CONTAINER: MODEL 7083-7396
(2815-01-040-3120) (2815-01-260-0212)
ENGINE, DIESEL W/CONTAINER: MODEL 7083-7398
(2815-00-936-7659)
ENGINE, DIESEL W/CONTAINER: MODEL 7083-7399
(2815-00-134-4845)
TM 9-2815-202-34, 20 February 1990, is changed as follows:
1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the margin of the page.
Remove Pages
Insert Pages
i and ii . . . . . . . . . . . . . . . . . . . . . . .i and ii
v thru xi/xii Blank . . . . . . . . . . . . . .v thru xii
1-1 thru 1-11/1-12 Blank . . . . . . . . 1-1 thru 1-12
2-1 thru 2-6. . . . . . . . . . . . . . . . . . . 2-1 thru 2-6
2-9 and 2-10 . . . . . . . . . . . . . . . . .2-9 and 2-10
2-15 and 2-16 . . . . . . . . . . . . . . . . . 2-15 thru 2-16
None . . . . . . . . . . . . . . . . . . . . . . . . 2-19/2-20 Blank
3-1 and 3-2. . . . . . . . . . . . . . . . . . . 3-1 and 3-2
3-7 thru 3-14 . . . . . . . . . . . . . . . . . .3-7 thru 3-14
3-17 thru 3-20 . . . . . . . . . . . . . . . . .3-17 thru 3-20
3-23 and 3-24 . . . . . . . . . . . . . . . . .3-23 and 3-24
3-27 thru 3-43/3-44 Blank . . . . . . . 3-27 thru 3-43/3-44 Blank
4-1 and 4-2. . . . . . . . . . . . . . . . . . 4-1and 4-2
4-35 thru 4-42 . . . . . . . . . . . . . . . . .4-35 thru 4-42
4-45 thru 4-52 . . . . . . . . . . . . . . . . .4-45 thru 4-52
4-55 thru 4-62 . . . . . . . . . . . . . . . . .4-55 thru 4-62
4-65 thru 4-70 . . . . . . . . . . . . . . . . .4-65 thru 4-70
4-77 thru 4-88 . . . . . . . . . . . . . . . . .4-77 thru 4-88
4-93 and4-94 . . . . . . . . . . . . . . . . .4-93 and 4-94
4-97 thru 4-100 . . . . . . . . . . . . . . . .4-97 thru 4-100
4-103 thru 4-106 . . . . . . . . . . . . . . . 4-103 thru 4-106
Approved for public release; distribution unlimited.
Remove Pages
Insert Pages
4-113 thru 4-116 . . . . . . . . . . . . . . 4-113 thru 4-116
4-119 thru 4-124 . . . . . . . . . . . . . 4-119 thru 4-124
4-131 and 4-132 . . . . . . . . . . . . . . 4-131 and 4-132
4-137 thru 4-146 . . . . . . . . . . . . . . 4-137 thru 4-146
4-149 thru 4-152 . . . . . . . . . . . . . . 4-149 thru 4-152
4-161 thru 4-178 . . . . . . . . . . . . . . 4-161 thru 4-178
4-183 and 4-184 . . . . . . . . . . . . . . 4-183 and 4-184
4-187 thru 4-194 . . . . . . . . . . . . . . 4-187 thru 4-194
4-203 thru 4-206 . . . . . . . . . . . . . . 4-203 thru 4-206
4-213 and 4-214 . . . . . . . . . . . . . . 4-213 and 4-214
4-221 and 4-222 . . . . . . . . . . . . . . 4-221 and 4-222
4-227 thru 4-236 . . . . . . . . . . . . . . 4-227 thru 4-236
4-261 and 4-262 . . . . . . . . . . . . . . 4-261 and 4-262
4-265 and 4-266 . . . . . . . . . . . . . . . . 4-265 and 4-266
5-1 thru 5-16 . . . . . . . . . . . . . 5-1 thru 5-16
5-23 and 5-24 . . . . . . . . . . . . . . . . 5-23 and 5-24
5-27 and 5-28 . . . . . . . . . . . . . . . . 5-27 and 5-28
5-31 thru 5-64 . . . . . . . . . . . . . . . . 5-31 thru 5-64.2
5-67 thru 5-72.. . . . . . . . . . 5-67 thru 5-72
None
5-75 thru 5-102
6-1 and 6-2 . . . . . . . . . . . . . . . . . . 6-1 and 6-2
6-43 thru 6-46 . . . . . . . . . . . . . . . . 6-43 thru 6-46
7-1 and 7-2 . . . . . . . . . . . . . . . . . . 7-1 and 7-2
7-7 thru 7-10 . . . . . . . . . . . . . . . . . 7-7 thru 7-10
8-1 and 8-2 . . . . . . . . . . . . . . . . . . 8-1 and 8-2
8-5 thru 8-16 . . . . . . . . . . . . . . . . . 8-5 thru 8-16
8-19 thru 8-26 . . . . . . . . . . . . . . . . 8-19 thru 8-26
8-29 thru 8-34 . . . . . . . . . . . . . . . . 8-29 thru 8-34
8-37 thru 8-54. . . . .. . . . . .8-37 thru 8-54
A-1 and A-2. . . . . . . . . . .A-1 and A-2
B-1 thru B-3/B-4 Blank. . . . . . . . . . . B-1 thru B-3/B-4 Blank
C-1 thru C-3/C-4 Blank. . . . . .. . . . .C-1 thru C-3/C-4 Blank
D-1 and D-2 . .. . . . . . . .D-1 and D-2
D-13/D-14 Blank. . . . . . . . . . . . D-13 thru D-15/D-16 Blank
E-1/E-2Blank . . . . . . . . . . . . . . . . E-1/E-2 Blank
F-1 and F-2 . . . . . . . . . . . . . . . . . . F-1and F-2
F-5/F-6 Blank . . . . . . . . . . . F-5
. and F-6
G-1 and G-2 . . . . . . . . . . . G-1 and G-2
G-5 and G-6 . . . . . . . . . . . . . . . . . G-5 and G-6
Glossary-1 and Glossary-2 . . . . . . Glossary-1 and Glossary-2
lNDEX-1thru lNDEX-6 . . . . . . . . . lNDEX-1thru lNDEX-8
Cover . . . . . . . . . . . . . . . . . . . . . . . Cover
File this change sheet in front of the publication for reference purposes.
3. The purpose of this change is to add coverage for the Model 7083-7391 Low Heat Rejection
Engine.
By Order of the Secretary of the Army:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
Official:
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
03055
Distribution:
To be distributed in accordance with DA Form 12-37-E (Block 2072) Direct Support and General
Support maintenance requirements for TM 9–2815-202-34.
TM 9-2815-202-34
Technical Manual
No. 9-2815-202-34
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C. 20 February 1990
TECHNICAL MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE
ENGINE, DIESEL W/CONTAINER:
MODEL 7083-7391 (2815-01-335-4579)
ENGINE, DIESEL W/CONTAINER:
MODEL 7083-7395 (2815-01-043-7092)
(2815-01 -260-021 1)
ENGINE, DIESEL W/CONTAINER:
MODEL 7083-7396 (2815-01-040-3120)
(2815-01-260-0212)
ENGINE, DIESEL W/CONTAINER:
MODEL 7083-7398 (2815-00-196-7659)
ENGINE, DIESEL W/CONTAINER:
MODEL 7083-7399 (2815-00-134-4845)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual by calling attention to errors and by recommending
improvements and stating your reasons for the recommendations. Your letter or DA Form 2028
(Recommended Changes to Publications) should be mailed directly to: Commander, U.S. Army
Tank-Automotive Command, ATTN: AMSTA-MB, Warren, Ml 48397-5000. A reply will be
furnished to you.
DISTRIBUTION STATEMENT: Approved for public release. Distribution is unlimited.
TABLE OF CONTENTS
Para. No
Page No.
How to Use This Manual . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
CHAPTER 1
Section I General
1-1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2
Maintenance Forms, Records, and Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3
Destruction of Army Material to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4
Preparation for Storage or Shipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-5
Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . 1-1
1-6
Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Change 1
i
TM 9-2815-202-34
Para. No.
Page No.
Section II Equipment Information
1-7
Equipment Description . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 1-2
1-8
Location and Description of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-9
Differences between Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-10 Equipment Data. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Section III Principles of Operation
1-11 Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Chapter 2
2-1
2-2
2-3
2-4
2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
.
Preliminary Inspection . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Malfunction, Test or Inspection, and Corrective Action . . . . . . . . .. . . . . . . . . . . 2-1
Symptom Index . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Malfunction, Test or Inspection, and Corrective Action Procedures . . . . . . . . . . . 2-3
Chapter 3
Section I Introduction
3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Section II General Cleaning and Maintenance Instructions
3-2
Cleaning and General Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Section Ill Removal and Installation of Engine
3-3
Engine From/To Container-12268285 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Engine From/To Container-10909159/10923108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-4
Preparation of Engine Prior to Removal of Engine Accessories and
3-5
Installation on Maintenance Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Section IV Removal/lnstallation of Engine Accessories Prior to Installation on
Maintenance Stand
3-6
Oil Cooler Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-7
Oil Level Gage Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3-8
Starter Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Air Box Drains Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-9
3-10 Turbocharger Oil Return Line Removal/installation
(Models 7083-7391,7083-7396, and 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-11 Turbocharger Oil Supply Line Removal/lnstallation
(Models 7083-7395 and 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-12 Turbocharger Oil Supply Line Removal/lnstallation
(Models 7083-7391 and 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3-13 Turbocharger Oil Supply Line RemovaI/Installation
(Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3-14 Air Inlet Manifold to Turbocharger Removal/lnstallation
(Models 7083-7391 and 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3-15 Air Inlet Manifold to Turbocharger Removal/lnstallation
(Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Section V Engine installation/Removal onto Maintenance Stand
3-16 Engine On Maintenance Stand Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
ii
Change 1
TM 9-2815-202-34
Page No.
Para. No.
Chapter 4
.
Repair Procedures For Major Components For
Engine Model 7083-7395
Section l Introduction
4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 4-2
Section II General Engine Maintenance
Turbocharger Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-2
Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. -6
4-3
Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-4
Fuel Strainer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-5
Fuel Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-6
Engine Lifting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
4-7
Thermostat, Thermostat Housing and Crossover Tubes Replacement . . . . . . . . . . . . . . . . . . .4-1 6
4-8
Water Pump Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-9
..
4-10 Air Box Heater Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-11 Engine Rocker Arm Cover and Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
...
4-12 Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40
4-13 Air Inlet Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4-14 Tachometer Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
4-15 Block Mounted Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49
4-16 Blower Drive Shaft and Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52
4-17 Governor Cover and Throttle Control Rods Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
4-18 Governor and Blower Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
4-19 Blower Drive Gear and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
.
4-20 Oil Pan Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-66
4-21 Camshaft Front Gear Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. -68
4-22 Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
.
4-23 Rear Oil Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-77
4-24 Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. -80
..
4-25 idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
4-26 Injector Control Tube and Throttle Delay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
4-27 Cylinder Head Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. -98
4-28 Engine Lower Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. -101
4-29 Camshaft and Gear Assemblies Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
4-30 Cylinder Block End Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-116
4-31 Oil Pressure Regulator and Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121
.
4-32 Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-124
Section Ill Engine Disassembly/Assembly
4-33 Piston and Connecting Rod Maintenance (Cross-head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-132
4-34 Cylinder Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-144
4-35 Crankshaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-152
4-36 Cylinder Block Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-162
Section IV Component Repair
..
4-37 Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-175
4-38 Cylinder Head Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4-184
4-39 Oil Cooler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-214
4-40 Fuel Injector Assembly Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-222
...
4-41 Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-235
4-42 Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-248
4-43 Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-262
iii
TM 9-2815-202-34
Page No.
Para. No.
Chapter 5
Repair Procedures for Major Components for
Engine Model 7083-7396
Section I Introduction
..
5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Section II General Engine Maintenance
Turbocharger Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-2
Exhaust Manifold and Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-3
Fuel Lines Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-4
.
5-5
Engine Lifting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Water Manifolds Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-6
Water Pump Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-7
Air Box Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-8
Engine Rocker Arm Cover and Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-9
.
5-10 Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5-11 Air Inlet Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-12 Tachometer Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-13 Block Mounted Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5-14 Accessory Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-15 Blower Drive Shaft and Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5-16 Governor Cover and Throttle Control Rod Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-17 Governor and Blower Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
5-18 Blower Drive Gear and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
..
5-19 Oil Pan Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-20 Camshaft Front Gear Cover and Damper Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-21
Flywheel Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-22 Rear Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
5-23 Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. -27
..
5-24 Idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-25 Injector Control Tube and Throttle Delay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27
. -27
5-26 Cylinder Head Assembly Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5-27 Engine Lower Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-28 Camshaft and Gear Assemblies Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-29 Cylinder Block End Plates Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-30 Oil Pressure Regulator and Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33
.
5-31
Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33
Section III Engine Disassembly/Assembly
5-32 Piston and Connecting Rod Maintenance (Cross-head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-33 Cylinder Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-34 Crankshaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33
.
.
5-35 Cylinder Block Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33
Section IV Component Repair
.
5-36 Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33
..
5-37 Cylinder Head Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
.
5-38 Oil Cooler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-63
..
5-39 Fuel Injector Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
5-40 Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
..
5-41 Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-64
..
..
5-42 Water Pump Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
iv
TM 9-2815-202-34
Para. No.
Page No.
Chapter 5.1
Section I Introduction
5.1-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
Section II General Engine Maintenance
5.1-2 Turbocharger Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
5.1-3 Exhaust Manifold and Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-77
5.1-4 Fuel Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
5.1-5 Engine Lifting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
5.1-6 Engine Water Manifolds Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5.1-7 Water Pump Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5-83
5.1-8 Glow Plug Controller and Harnesses Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
5.1-9 Engine Rocker Arm Cover and Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . ...5-86
5.1-10 Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
5.1-11 Air Inlet Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
5.1-12 Tachometer Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-13 Block Mounted Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-14 Accessory Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-15 Blower Drive Shaft and Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-16 Governor Cover and Throttle Control Rod Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-17 Governor and Blower Assembly Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-92 Blower Drive Gear and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-19 Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-20 Camshaft Front Gear Cover and Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-21 Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-22 Rear Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-23 Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-24 Idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-25 Injector Control Tube and Throttle Delay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-26 Cylinder Head Assembly Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-27 Engine Lower Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-28 Camshaft and Gear Assemblies Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-29 Cylinder Block End Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-30 Oil Pressure Regulator and Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
5.1-31 Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Section Ill Engine Disassembly/Assembly
5.1-32 Piston and Connecting Rod Maintenance (Cross-Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
5.1-33 Cylinder Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
5.1-34 Crankshaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
5.1-35 Cylinder Block Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
Section IV Component Repair/Assembly
5.1-36 Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5.94
5.1-37 Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-102
5.1-38 Oil Cooler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5.1-39 Fuel Injector Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5.1-40 Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-102
5.1-41 Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5.1-42 Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-102
Change 1
v
TM 9-2815-202-34
Page No.
Para. No.
Chapter 6
r
Repair Procedures For Major Components For
Engine Model 7083-7398
Section I Introduction
6-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 6-2
Section II General Engine Maintenance
Turbochanger Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-2
Turbocharger Removal/lnstaIlation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-3
Exhaust Manifold and Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-4
Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-5
Fuel Strainer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
...
6-6
Fuel Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-7
6-8
Engine Lifting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Thermostat, Thermostat Housing and Crossover Tubes Replacement . . . . . . . . . . . . . . . . . . 6-13
6-9
6-10 Water Pump Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-11 Air Box Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-12 Engine Rocker Arm Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-13 Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-14 Air Inlet Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-15 Tachometer Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6-16 Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-17 Blower Drive Shaft and Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-18 Governor Cover and Throttle Control Rod Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-19 Governor and Blower Assembly Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-20 Blower Drive Gear and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-21 Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-22 Camshaft Front Gear Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-23 Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-24 Rear Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-25 Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-26 Idler Gear Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-27 Injector Control Tube Replacement...: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-28 Cylinder Head Assembly Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-29 Engine Lower Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-30 Camshaft and Gear Assemblies Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-31 Cylinder Block End Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-32 Oil Pressure Regulator and Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-33 Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Section Ill Engine Disassembly/Assembly
6-34 Piston and Connecting Rod Maintenance (Trunk Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6-35 Cylinder Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6-36 Crankshaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6-37 Cylinder Block Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Section IV Component Repair
6-38 Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
6-39 Cylinder Head Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6-40 Oil Cooler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6-41 Fuel Injector. Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6-42 Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6-43 Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
6-44 Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
vi
Change 1
TM 9-2815-202-34
Page No.
Para. No.
Chapter 7
Repair Procedures For Major Components For
Engine Model 7083-7399
Section I I n t r o d u c t i o n
7-1
General . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Section II General Engine Maintenance
7-2
Turbocharger Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Turbocharger Removal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-3
Exhaust Manifold and Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-4
Fuel Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-5
Engine Lifting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-6
Water Manifolds Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-7
Water Pump Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-8
Air Box Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-9
7-10 Engine Rocker Arm Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-11
Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-12 Air Inlet Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-13 Tachometer Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-14 Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-15 Accessory Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-16 Blower Drive Shaft and Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-17 Governor Cover and Throttle Control Rod Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-18 Governor and Blower Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-19 Blower Drive Gear and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-20 Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-21 Camshaft Front Gear Cover and Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-22 Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-23 Rear Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-24 Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-25 Idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-26 Injector Control Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-27 Cylinder Head Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-28 Engine Lower Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-29 Camshaft and Gear Assemblies Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-30 Cylinder Block End Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-31 Oil Pressure Regulator and Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-32 Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Section Ill Engine Disassembly/Assembly
7-33 Piston and Connecting Rod Maintenance (Trunk Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-34 Cylinder Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-35 Crankshaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-36 Cylinder Block Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Section IV Component Repair
7-37 Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-38 Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7-16
7-39 Oil Cooler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-40 Fuel Injector Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-41 Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-42 Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7-43 Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 7-16
Change 1 vii
TM 9-2815-202-34
Para. No.
Page N o .
Chapter 8
Section I Introduction
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-1
Section II Engine Preparation and Adjustment
Engine Preparation for Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
8-2
Interval and Adjustment Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8-3
Exhaust Valve Clearance Adjustment (Hot or Cold Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8-4
Fuel Injector Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8-5
Governor
Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8-6
Fuel Injector Control Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8-7
Throttle Delay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8-8
Starting Aid Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8-9
8-10 Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8-11 Maximum No-Load Speed Adjustment (Dual Range Limiting Speed Governor).. 8-26
8-12 Maximum No-Load Speed Adjustment (Limiting Speed Governor) . . . . . . . . . . . . . . . . . . . . . . . . 8-30
8-13 Governor Buffer Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
8-14 Cylinder Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8-15 Fuel Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8-16 Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
8-17 Crankcase Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
8-18 Air Box Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
8-19 Preparation for Run-ln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
8-20 Engine Run-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
Appendix A
Appendix B
Appendix C
Expendable/Durable Supplies and Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Appendix D
Illustrated List of Manufactured items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Appendix E
General Torque Limits Required For Fasteners In Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Appendix F
F-1
Appendix G
Glossary
Alphabetical Index
viii
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....................................................... . . . . . . . . . . . . . .A-1
Tools and Test Equipment - Special Tools and Common Tool Sets . . . . . . . . . . . . . . . . . . . . . . B-1
Change 1
Engine Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Glossary-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .lndex-1
TM 9-2815-202-34
HOW TO USE THIS MANUAL
Before starting a procedure, read HOW TO USE THIS MANUAL and Para 3-2, CLEANING
AND GENERAL REPAIR INSTRUCTIONS.
WHAT IS IN THE MANUAL - FRONT TO BACK
SUMMARY OF WARNINGS AND FIRST AID lists the warnings and first aid information in this
manual. These warnings contain additional information about hazards that could hurt or kill
personnel.
TABLE OF CONTENTS lists the chapters, sections, and appendixes in this manual. It also lists
the pages where chapters, sections, and appendixes can be found.
CHAPTER 1 covers general information and gives a quick review of major engine components
and features.
CHAPTER 2 covers the instruction for direct support and general support (DS/GS) level
troubleshooting of the engines in the vehicle
CHAPTER 3 tells how to remove/install the engine from the container and install/remove the
engine from the maintenance stand. Chapter 3 also includes the cleaning and general repair
instructions to use with every procedure.
CHAPTER 4 contains repair procedures to be performed on engine model 7083-7395.
CHAPTER 5 contains repair procedures to be performed on engine model 7083-7396. If a
procedure is the same as for model 7083-7395, Chapter 5 will refer to the appropriate
paragraph in Chapter 4.
CHAPTER 5.1 contains repair procedures to be performed on engine model 7083-7391. If a procedure
is the same as for model 7083-7395 or 7083-7396, Chapter 5.1 will refer to the appropriate paragraph
in Chapter 4 or 5.
CHAPTER 6 contains repair procedures to be performed on engine model 7083-7398. If a
procedure is the same as for model 7083-7395 or 7083-7396, Chapter 6 will refer to the
appropriate paragraph in Chapter 4 or 5.
CHAPTER 7 contains repair procedures to be performed on engine model 7083-7399. If a
procedure is the same as for model 7083-7395, 7083-7396, or 7083-7398, Chapter 7 will refer
to the appropriate paragraph in Chapter 4, 5, or 6.
CHAPTER 8 tells how to adjust, prepare, and test the engine for operation after the engine has
undergone repair.
APPENDIX A lists references, such as technical manuals and other publications, to be used by
personnel.
APPENDIX B lists the tools used in the procedures, their part numbers, and the correct catalog
or tool list where each tool may be found.
APPENDIX C lists expendable/durable supplies and materials used to maintain or repair the
engine.
Change 1 i x
TM 9-2815-202-34
APPENDIX D lists manufactured items that are used to support the procedures.
APPENDIX E gives the general torque limits required for standard fasteners on the engine.
APPENDIX F lists the mandatory replacement parts used to maintain or repair the engine.
APPENDIX G lists the engine repair specifications for repairing the engine.
GLOSSARY gives the meaning of unusual terms found in the procedures.
ALPHABETICAL INDEX lists the major engine parts that can be repaired or replaced at the DS
or GS level. Each entry in the index includes the procedure paragraph number.
DA FORM 2028-2 is used to report an error found in this manual.
METRIC CONVERSION CHART converts U.S. measurements to their metric equivalents.
Measurements in the procedures are given in both U.S. and metric units.
HOW TO USE YOUR MANUAL ON THE JOB
The best way to Iearn about this manual is to practice using it. Knowing how to use this
manual will save time and effort.
Where do you start?
Entry to a repair procedure in this manual may come from observation, troubleshooting, or the
Army Oil Analysis Program (AOAP). The problem will help identify the item that needs repair or
replacement.
How do you fix the problem?
x
1.
Find the correct repair procedure in the manual. Pick a key word from the item to be
repaired or replaced. Look up the word in the Alphabetical Index, which gives the
paragraph number of the procedure.
2.
Turn to the procedure and read it carefully before starting. Pay attention to warnings
and cautions. Get the equipment, supplies, and any other personnel needed. Parts
which will be destroyed or should not be reused are listed in the setup as Mandatory
Replacement Parts.
3.
Start with step a in the procedure and do each step in order. In some referenced
procedures, one or more steps may have been completed. If so, proceed to the next
step. If a part fails inspection and requires replacement, refer to the Repair Parts and
Special Tools List (RPSTL) TM 9-2815-202-24P.
Change 1
TM 9-2815-202-34
HOW TO USE THIS MANUAL (cont)
HOW TO USE A MAINTENANCE PROCEDURE
The first page of a repair procedure lists everything needed to perform that procedure. The
following paragraphs describe all the blocks of information found there.
APPLICABILITY. The data under this heading identifies those specific models to the procedure
applies.
TOOLS AND SPECIAL TOOLS. Individual tools from your mechanic’s tool kit are not listed
under this heading. If any tools from this kit are required, the tool kit itself is listed as the first
item. Special tools, manufactured tools, and tools from any other source are listed with a
reference to a specific item number and appendix letter. The referenced appendix provides
the necessary information to find or make the tool. App B lists all special tools, tools from
supply catalog sets, kits and outfits, and tools which must be acquired through the GSA
catalog. App D lists the manufactured tools with complete fabricating instructions.
MANDATORY REPLACEMENT PARTS. Any repair parts that are destroyed in disassembly or
not normally reused are listed under this heading with reference to App F and specific item
number. App F gives the detailed information necessary to requisition the parts if they are not
on hand. This heading will appear only if new parts are always required for the procedure.
EXPENDABLE/DURABLE SUPPLIES. Any expendable or consumable supplies needed to
perform the procedure are listed under this heading with reference to App C and specific item
number. App C gives the detailed information necessary to requisition the parts if they are not
on hand. This heading will appear only if such supplies are required for the procedure.
PERSONNEL REQUIRED. The number of personnel required to perform the procedure are
listed here. This heading only appears in procedures that require more than one person.
EQUIPMENT CONDITION. This heading describes the condition the equipment must be in
before starting the procedure. The paragraph for each conditions is listed followed by a
description of the part removed, repaired, or adjusted.
FEATURES OF THE NEW PROCEDURE FORMAT
WARNINGS. General warnings are placed both within the procedure right before the step
where they apply and in the list of WARNINGS found on the inside of the front cover of this TM.
They call attention to hazards that could kill or injure personnel.
CAUTIONS. Cautions are found within the procedure immediately before the step where they
apply. They call attention to hazards or actions that could damage equipment.
Change 1
xi
TM 9-2815-202-34
NOTES. Notes are found within a procedure immediately before the appropriate step. They contain
important facts or instructions to make the procedure easier or to modify the procedure for a similar
model.
USE OF TOOLS AND PERSONNEL. Each procedure lists the tool kits and tools that are needed for
the procedure. The procedure steps tell how and where to use special tools. However, the procedure
steps do not tell which persons do which steps in the procedures needing more than one person. The
mechanic responsible for the procedure should direct the rest of the personnel on what to do.
REFERENCES. References from one procedure to another within the TM are by paragraph number.
References to other Technical Manuals are by the TM number only and the user needs to use the
Alphabetical Index of that TM to find the information needed.
PROCEDURE ORGANIZATION. Most procedures in this TM fall into the category of
removal /Installation, replacement, repair, or adjustment. Replacement can contain removal,
disassembly, inspection, assembly, and installation in the same procedure. Repair generally contains
disassembly, inspection, and assembly in the same procedure.
HOW TO USE THE REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) WITH THIS MANUAL
The RPSTL gives the National Stock Number (NSN) required to order parts which fail inspection in the
repair procedures. To use the RPSTL to identify and order a part, do the following:
1.
In this manual, turn to the page of the procedure where the part is installed.
2.
Go to the RPSTL and find the same illustrated part. That part will have an item number
assigned to it. Find the SMR code for the item.
3.
If the SMR code does not authorize your level to repair the item, reassemble it and send it to
the authorized level of maintenance.
4.
If the SMR code does authorized your level to repair the item, look this figure and item number
up in the figure and item number cross-reference index in the back of the RPSTL to find the
NSN of the item to be ordered.
xii Change 1
TM 9-2815-202-34
CHAPTER 1
INTRODUCTION
Contents
Para
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Destruction of Army Material to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Location and Description of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Differences between Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Page
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-5
1-9
1-10
1-11
Section I. GENERAL
1-1. SCOPE
a. Type of Manual: Direct Support and GeneraI Support Maintenance.
b. Model Number and Equipment Name. Series 8V71T diesel engine, models 7083-7391,
7083-7395, 7083-7396, 7083-7398, and 7083-7399.
c. Purpose of Equipment: Powers the M109/M992 and M110/M578 Family of Vehicles (FOV).
1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS. Department of the Army forms
and procedures used for equipment maintenance will be those prescribed by DA PAM 738-750.
1-3. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE. For general
destruction procedures, refer to TM 750-244-6.
1-4. PREPARATION FOR STORAGE OR SHIPMENT. Preparation for storage or shipment is
provided in Paragraph 3-3 or 3-4.
1-5. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR). If any
M109/M992 or M110/M578 FOV diesel engine needs improvement, let us know. Send us an EIR. The
user is the only one who can tell us how the equipment might be improved. Let us know why you don’t
like the design. Put it on an SF 368 (Quality Deficiency Report). Mail it to us at: Commander, U.S.
Army Tank-Automotive Command, ATTN: AMSTA-QRT, Warren, Michigan 48397-5000. We’ll send a
reply.
Change 1 1-1
■
TM 9-2815-202-34
1 - 6 . WARRANTY INFORMATION. The Series 8V71T diesel engine is warranted for 12 months.
Report all defects in material or workmanship in accordance with TB 9-2815-202-34.
Section Il. EQUIPMENT INFORMATION
1-7.
EQUIPMENT DESCRIPTION. All the engine models are two cycle, fuel injected, V-type, liquid
cooled, and eight cylinder diesel engine with dry cylinder liners. The cylinders are numbered one, two,
three, and four on the left and right starting from the front of the engine. The terms “right”, “left”, “front”,
and “rear” are defined as viewed from the rear or flywheel end of the engine. The engine serial number
and model are stamped on the right side, upper front corner of the cylinder block. On model
7083-7391, an option label is affixed to one valve rocker arm cover which carries the engine serial
number, model number, tune-up specifications, and a list of optional equipment used on the engine.
1-2
Change 1
TM 9-2815-202-34
1-3
TM 9-2815-202-34
1-7. EQUIPMENT DESCRIPTION (Cont)
RIGHT FRONT VIEW
LEFT REAR VIEW
■ MODEL 7083-7399
RIGHT FRONT VIEW
LEFT REAR VIEW
MODEL 7083-7391
1-4 Change 1
TM 9-2815-202-34
1-8.
LOCATION AND DESCRIPTION OF COMPONENTS
a. Water Pump. Mounted on the front
engine cover and driven by a right camshaft gear.
It circulates coolant through the cylinder block,
cylinder heads, and oil cooler.
b. Governor. Mounted on the front end of the
blower and driven by a blower rotor. It is used to
control the idle and maximum engine operating
speeds.
c. Oil Pan. Mounted on the bottom of the
cylinder block. It provides a reservoir for engine oil.
d. Valve Rocker Covers. Encloses the
valve and injector rocker arm mechanisms located
on top of cylinder heads.
e. Starter. Mounted on left side of flywheel
housing. It is an electric starter and engages the
flywheel ring gear.
f. Flywheel. Mounted on the rear of the
crankshaft. It is used to provide true alinement of
transmission flex plate.
g. Oil Cooler. Mounted on lower right side of
engine block. It uses engine coolant to cool engine
and transmission oil.
Change 1
1-5
TM 9-2815-202-34
1-8.
LOCATION AND DESCRIPTION OF COMPONENTS (Cont)
h. Exhaust Manifolds. Attached directly to
cylinder heads. They route exhaust gases through
attached exhaust piping to the turbocharger.
i. Liquid Level Gage (Oil). Mounted on the
lower left front cylinder block (models 7083-7395
and 7083-7398) or right rear oil pan (models
■ 7083-7391, 7083-7396, and 7083-7399). It
measures the liquid level in the oil pan.
j. Thermostats and Housing Assembly.
Mounted on the front of the left cylinder head and
connected to the right cylinder head with crossover
tubes (models 7083-7395 and 7083-7398). They
control coolant temperature by restricting coolant
flow to the radiator.
k. Fuel Strainer. Mounted on the left front
corner of the cylinder block (models 7083-7395
and 7083-7398). It filters fuel to fuel pump.
l. Fuel Filter. Mounted on the right front
corner of the cylinder block (models 7083-7395
and 7083-7398). It filters fuel to fuel inlet manifold.
m. Water Manifolds. Mounted on top of cylinder heads (models 7083-7391, 7083-7396, and
7083-7399). They collect coolant as it leaves the cylinder heads.
n. Crankshaft Vibration Damper. Mounted on a hub on the front of the crankshaft (models
■ 7083-7391, 7083-7396, and 7083-7399). It reduces torsional vibration in the crankshaft.
1-6 Change 1
TM 9-2815-202-34
o. Turbocharger. Mounted on the rear of
the engine (models 7083-7395 and 7083-7398)
or on the left exhaust manifold (models
97083-7391,7083-7396, and 7083-7399). It
increases engine efficiency by delivering high
pressure air to the blower using exhaust gas
energy.
p. Turbocharger Regulator. Mounted on
the outlet of the left exhaust manifold (models
7083-7398 and 7083-7399). It bypasses excessive
exhaust gas flow to the turbocharger.
q. Fuel Pump. Attached to the governor
housing and driven off the right side blower rotor. It
supplies low pressure fuel to fuel inlet manifolds in
cylinder heads.
r. Blower. Mounted on top of the cylinder
block. It supplies a constant volume of fresh air per
revolution to the cylinders.
Change 1
1-7
TM 9-2815-202-34
1-8. LOCATION AND DESCRIPTION OF COMPONENTS (Cont)
s. Cylinder Heads. Mounted on the top of each cylinder bank. They contain fuel manifolds,
exhaust valves, injectors, injector and valve operating mechanisms, and glow plugs (model
7083-7391 ). Special Low Heat Rejection (LHR) cylinder heads are used on model 7083-7391. These
heads reject less heat to the coolant; therefore, more heat energy in the exhaust gases is available for
use by the turbocharger. Built in heat shields in the exhaust ports, which insulate hot exhaust gas from
the engine coolant, are the main feature of the LHR cylinder head.
t. Camshafts. Located on top of each cylinder bank. They actuate injector and exhaust valve
operating mechanisms.
u. Cylinder Block. Being the main structural part. It provides rigidity and ensures alinement of all
load bearing assemblies.
v. Crankshaft. Attached to the bottom of the cylinder block. It transfers the engine load through the
flywheel and supplies oil to piston assemblies.
w. Piston and Connecting Rod Assemblies. Four assemblies are located in each bank. Pistons
are cooled and lubricated by oil pressure fed up through drilled connecting rods.
x. Oil Pump. Mounted on the bottom of the cylinder block. It pumps oil throughout the engine for
lubrication and cooling.
1 - 8 Change 1
TM
9-2815-202-34
y. Bypass Blower System. The bypass feature increases fuel efficiency by reducing the
amount of engine power required to operate the blower. The bypass feature allows the air in the
blower to be bypassed when sufficient airflow from the turbocharger is available to sustain an
adequate air/fuel ratio for combustion for model 7083-7391.
z. Glow Plugs. They improve cold weather startability by heating the combustion chamber of
each cylinder. The plugs screw into the cylinder head and protrude into the combustion chamber for
model 7083-7391.
aa. Glow Plug Controller. Attached to the rear of the air inlet housing, it is a control module used
to regulate the glow plug duty cycle for cold starting applications for model 7083-7391.
Change 1
1-8.1/1-8.2 Blank
TM 9-2815-202-34
1-9.
DIFFERENCES BETWEEN MODELS
7083-7391 7083-7395 7083-7396 7083-7398 7083-7399
COMPONENT
Rear mounted turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . —
Side mounted turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Model T18A90 turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . —
Model T3030 turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . —
Model TV8405 turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Turbocharger regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . —
Bypass blower system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Dual range limiting speed governor . . . . . . . . . . . . . . . . . —
Crankshaft and camshaft dampers . . . . . . . . . . . . . . . . . . X
Crosshead piston and connecting rod
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Trunk piston and connecting rod assembly . . . . . —
Crankcase breather on flywheel housing . . . . . . . . . —
Accessory drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Throttle delay assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . —
Front mounted fuel filter and fuel strainer . . . . . . . . —
Remote mounted fuel filter and fuel strainer . . . . X
Air box heater air pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . —
Air box heater fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . —
Thermostat, housing, and water crossover
tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . —
Water manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Low heat rejection cylinder heads . . . . . . . . . . . . . . . . . . . . . X
Insulated turbocharger turbine housing . . . . . . . . . . . X
Insulated exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Glow plug controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* Effective
x
x
—
x
—
—
—
—
x
—
x
—
—
—
x
x
—
x
_
x
—
—
—
—
—
—
—
x
x
—
—
—
—
—
x
x
—
—
x
x
—
x
x
_
—
x
—
—
—
—
—
x
—
—
—
x
—
x
—
x
—
x
—
x
—
—
x
X
x
—
_
x
x **
x
—
—
x
—
■
x
x
x
—
—
x
—
x
x
x
—
—
—
—
—
—
—
x
—
—
—
—
—
from serial number 8VA-294357 and above.
Effective through serial number 8VA-294356.
Change 1
1-9
TM 9-2815-202-34
1-10. EQUIPMENT DATA
GENERAL SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel, two-cycle
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detroit Diesel Corporation
■ Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7083-7391, 7083-7395, 7083-7396, 7083-7398, 7083-7399
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-type
Crankshaft Rotation (from Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L,3R,3L, 4R,4L, 2R,2L, 1R
Total Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568 cu.in.(9.32L)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
. .... in. (108 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0
..... in. (127 mm)
Number of Main Beatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17:1
Minimum Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 PSl(3068 kPa)@600 RPM
Maximum Brake Horsepower(at 2300 RPM)(All Models Except 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 HP
Maximum Brake Horsepower (at 2300 RPM) (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 HP
ENGINE SPEED RATINGS
Maximum Governed Speed, Full-Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 RPM
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-650 RPM
Low Maximum No-Load Speed (M578 Vehicle Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1350-1375 RPM
Maximum No-Load Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2450-2500 RPM
ENGINE LUBRICATION SYSTEM
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sump, pressure
Total Capacity (with Filters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 qt (38 L)
Operating Pressure (at 2300 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70 PSI (345-483 kPa)
Minimum operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 PSl (207 kPa)
Idle Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PSl (34 kPa)
Normal Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-250°F (93-121°C)
type
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
...
FUEL SYSTEM
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear type
Fuel Injectors (All Models Except 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model N80 unit Injector
Fuel Injectors (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model 7590 unit injector
o
below -20°F (-29 C)
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DF2-DF1
..
..
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VV-F-800
Supply pressure (to injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70 PSI (345-483 kPa)
EXHAUST SYSTEM
Exhaust Manifolds (All Models Except 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air cooled
Exhaust Manifolds (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulated
Exhaust Valves per Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
0.015 in. (0.381 mm)
Cold Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013 in. (0.330 mm)
* Formerly Detroit Diesel Allison Division of GMC
1-10
Change 1
TM 9-2815-202-34
COOLING SYSTEM
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 qts. (29.3 L)
Normal Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160-185°F (71-85°C)
Maximum Top Tank Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230°F (110°C)
Coolant Flow (at 2300 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
..
GPM (541 L/min)
Thermostats (Models 7083-7395 and 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Blocking Type
Thermostats (Models 7083-7391, 7083-7396, and 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote mounted
DRIVE RATIOS AND ROTATION
Right Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1 CCLW
Left Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1 CLW
Blower Drive (Models 7083-7391,7083-7395, and 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.95:1 CLW
Blower Drive (Models 7083-7398 and 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.05:1 CLW
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27:1 CLW
Fuel Pump (Models 7083-7391, 7083-7395, and 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.95:1 CLW
Fuel Pump (Models 7083-7398 and 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.05:1 CLW
WaterPump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
..
CCLW
Table 1-1 Engine Physical Data
Model
7083-7391
7083-7395
7083-7396
7083-7398
Length - in.
(cm.)
42.4
(108)
5.35
(136)
42.4
(108)
55.5
(141)
42.4
(108)
Width - in.
(cm.)
54.9
(139)
40.7
(103)
54.9
(139)
41.2
(105)
57.8
(147)
Height - in.
(cm.)
41.6
(106)
40.8
(104)
41.6
40.8
41.6
(106)
(104)
(106)
Weight - lb.
(Kg.)
2495
(1132)
2495
(1132)
2495
(1132)
2617
(1187)
2602
(1180)
7083-7399
Section Ill. PRINCIPLES OF OPERATION
1-11. PRINCIPLES OF OPERATION. The diesel engine is an internal combustion power unit where
the heat energy of fuel is converted into work energy inside the cylinder. This particular engine has a
two stroke cycle (sometimes called a two cycle). A two stroke engine completes one cycle (intake,
compression, power, and exhaust) every time the piston goes up and down - up being one stroke and
down being the return stroke. The air intake and exhaust functions are accomplished during the
compression and power strokes.
Change 1
1-11
TM 9-2815-202-34
1-11. PRINCIPLES OF OPERATION (Cont)
The engine has a turbocharger and a blower to force air into the cylinders (called supercharging) for
both the intake and the exhaust functions. When the piston is halfway down, the exhaust valves open.
Shortly thereafter, the piston drops below a row of inlet ports in the cylinder liner wall. Pressurized air
is then forced through the cylinder. During this process, all of the exhaust gases are removed (or
scavenged) from the cylinder. When the exhaust valves close, during the pistons upward stroke, fresh
air is trapped in the cylinder for compression.
Fuel injection into the cylinder begins with the piston near its highest point and continues into the
power stroke. The intense heat created by the high compression of the air immediately ignites the fine
fuel spray. The combustion continues until the injected fuel has burned. The resulting pressure forces
the piston downward on its power stroke. When the piston is about halfway down, the exhaust valves
open. Shortly thereafter, the piston drops below the ports, and the cylinder is again swept with clean
scavenging air. This entire combustion cycle is completed in each cylinder for each revolution of the
crankshaft.
1-12
Change 1
TM 9-2815-202-34
CHAPTER 2
TROUBLESHOOTING PROCEDURES
Para
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preliminary inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Malfunction, Test or Inspection, and Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
..
Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Malfunction, Test or Inspection, and Corrective Action Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Page
2-1
2-1
2-2
2-2
2-3
2-1. GENERAL. Troubleshooting is a logical, systematic search for the cause(s) of malfunction(s).
Direct Support troubleshooting of the engine can be performed with the engine installed in the
vehicle.
NOTE
When troubleshooting is performed with the engine in a vehicle,
the information in this manual will be used in conjunction with the
information contained in the applicable vehicle type-20
maintenance manual.
The purpose of troubleshooting is to establish the nature and extent of repair required to return the
engine to serviceable condition. Thorough troubleshooting before the engine is removed from the
vehicle may reveal malfunctions external to the engine. Correction of such external malfunctions may
prevent the unnecessary effort of removing the engine.
Troubleshooting by a Direct Support shop is necessary to verify the diagnosis made before the
engine is removed. Such troubleshooting may be the only means of uncovering all defects in an
engine received in an unserviceable condition from another activity.
Troubleshooting may be necessary to determine the cause when a repaired engine fails to perform
properly.
2-2. PRELIMINARY INSPECTION
CAUTION
Maintenance personnel must have a thorough knowledge of
vehicle operation before attempting to troubleshoot an installed
engine. The purpose and use of all operator controls must be
thoroughly understood. Refer to applicable vehicle operators
manual for procedures concerning operation of vehicle.
Verification of all preliminary checks at crew and unit level should be made.
If preliminary troubleshooting of the vehicle is not conclusive, refer to vehicle TM’s listed in App A for
preliminary inspections.
2-1
TM 9-2815-202-34
2-3. MALFUNCTION, TEST OR INSPECTION, AND CORRECTIVE ACTION
Troubleshooting procedures are provided in Malfunction, Test or lnspection, and Corrective Action.
The most likely malfunction symptoms to be encountered have been listed followed by tests and
inspections to determine the probable cause and the recommended corrective action.
To use this information, first find the malfunction symptom that best describes the actual condition.
Perform the tests or inspections to determine the probable cause and make the corrections indicated.
If no cause is found or corrective action does not resolve the problem, proceed to the malfunction
symptom that next best describes the condition.
2-4. SYMPTOM INDEX
SYMPTOM
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
2-2
DESCRIPTION OF MALFUNCTION
PAGE
Engine Will Not Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Engine Cranks Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Engine Rotates But Fails To Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Uneven Running Or Stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Engine Will Not Deliver Rated Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Excessive Engine Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Blue Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Excessive Black Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
White Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Engine Coolant Operating Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Excessive Turbocharger Noise Or Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Bypass Valve Fails To Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Excessive Exhaust Pressure At Turbocharged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Inoperative Air Heater At low Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Inoperative Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Change 1
TM 9-2815-202-34
2-5.
MALFUNCTION, TEST OR INSPECTION, AND CORRECTIVE ACTION
PROCEDURES
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HARD STARTING OF ENGINE
1.
ENGINE WILL NOT ROTATE
Step l. Inspect starter and battery connections for loose, corroded, or broken cables.
a. Tighten Ioose connections.
b. Clean corroded cables and terminals.
c. Replace broken or frayed cables.
Step 2. Check batteries for low or no voltage (Refer to applicable vehicle type-20
maintenance manual for tests and services).
CAUTION
Do not rotate engine in a counterclockwise direction to avoid
loosening the crankshaft bolt.
Step 3. Check for internal seizure by slowly turning engine clockwise with wrench on
crankshaft bolt at front of engine. If engine cannot be rotated one complete
revolution, internal damage is indicated.
Remove engine from vehicle to determine cause.
END OF TEST
2.
ENGINE CRANKS SLOWLY
Step 1. Check batteries (For low or no voltage, refer to vehicle type-20 maintenance
manual for test and services).
Step 2. Check starter electrical circuits (Refer to vehicle type-20 maintenance manual for
starter operational tests).
Step 3. Check for proper grade of oil for temperature conditions (Refer to applicable vehicle
LO for proper grade of oil).
END OF TEST
2-3
TM 9-2815-202-34
MALFUNCTION, TEST OR INSPECTION, AND CORRECTIVE ACTION
PROCEDURES (Cont)
2-5.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3.
ENGINE ROTATES BUT FAILS TO START
Step 1. Check main fuel supply line valves are open and fuel supply level inadequate.
Step 2. Check fuel pump for damaged drive shaft or drive coupling. insert end of 1/8 inch
diameter wire through one of the pump flange drain holes. Crank engine
momentarily ;note if slight vibration is felt in wire.
If wire vibrates, drive shaft is all right. If no vibration is felt, replace fuel pump.
WARNING
Fuel spraying on hot components is an extreme fire
hazard. Control leakage immediately to prevent injury.
Step 3. Check for air in fuel system.
a. Disconnect fuel return line and drain into a bucket.
WARNING
Protective fan screens must be installed prior to doing
maintenance in the engine compartment when engine
is running or when engine is in ground hop mode.
Contact with rotating fan can cause injury (reference
FM 21-11).
b. Crank engine momentarily. Observe fuel return flow. Uneven flow or bubbles
in fuel indicate air in fuel system.
Step 4. Check for contaminated fuel (water in fuel).
a. Drain and clean fuel strainer and filter.
b. Replace with new element as required (Refer to vehicle type-20 maintenance
manual).
2-4
Change 1
TM 9-2815-202-34
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3.
ENGINE ROTATES BUT FAILS TO START (Cont)
Step 5. Check fuel grade.
a. Check source of supply to determine fuel being used.
b. Refer to applicable vehicle LO for proper grade of fuel.
Step 6. Check fuel lines, fittings, and fuel filters for leaks, loose connections, bends, dents,
or kinks.
a. Tighten loose connections and fittings.
b. Repair or replace damaged fuel lines and filters as required.
Step 7. Check for binding of governor to injector linkage that would prevent positioning of
injector racks to FULL FUEL position.
a. Correct binding linkage.
b. Readjust governor and injector controls (Refer to Para 8-7).
Step 8. Check condition of blower drive shaft and coupling.
Replace damaged parts (Refer to Paragraphs 4-16, 5-15, or 5.1-15 for
appropriate engine model).
END OF TEST
Change 1
2-5
TM 9-2815-202-34
MALFUNCTION, TEST OR INSPECTION, AND CORRECTIVE ACTION
PROCEDURES (Cont)
2-5.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ABNORMAL ENGINE OPERATION
4.
UNEVEN RUNNING OR STALLING
Step 1. Check fuel supply level.
Step 2. Check fuel strainer and fuel filter for Ieaking gaskets, clogged filters, or loose
connections.
Step 3. Check fuel lines for loose connections, damage, twists, and bends.
Step 4. Check fuel spill back for air in fuel system.
a. Disconnect fuel return line from fitting at fuel tank. Hold end of fuel line in a
container.
WARNING
Protective fan screens must be installed prior to doing
maintenance in the engine compartment when engine
is running or when engine is in ground hop mode.
Contact with rotating fan can cause injury (reference
FM 21-11).
b. Start engine and run at 1200 RPM.
NOTE
Air bubbles rising to surface indicate air being drawn into fuel
system.
c. Measure fuel; 0.8 GPM is required.
Step 5. Check engine tune up adjustments (Refer to Para 8-5).
WARNING
Protective fan screens must be installed prior to doing
maintenance in the engine compartment when engine
is running or when engine is in ground hop mode.
Contact with rotating fan can cause injury (reference
FM 21-11).
Step 6. Check for faulty injectors.
a. Remove rocker arm cover.
b. Start engine.
2-6
TM 9-2815-202-34
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
4.
UNEVEN RUNNING OR STALLING (Cont)
NOTE
If injector is malfunctioning, there will be no noticeable difference
in sound and operation of engine.
c. Hold injector follower down with a screwdriver with engine idling to prevent
operation of injector.
d. Replace faulty injector.
e. Check injector timing (Refer to Para 8-5).
f. Install rocker arm cover.
Step 7. Check for low compression (Refer to Para 8-14).
Step 8. Check for misfiring cylinders.
a. Remove rocker arm covers.
b. Remove cam follower assemblies.
c. Check for worn cam rollers, camshaft, bent push rods, or worn rocker arm
bushings.
d. Replace damaged parts.
e. Install cam follower assemblies.
f. Install rocker arm covers.
Step 9. Check for a clogged or missing restricted fitting on the fuel return line.
END OF TEST
2-7
TM 9-2815-202-34
2-5.
MALFUNCTION, TEST OR INSPECTION, AND CORRECTIVE ACTION
PROCEDURES (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5.
ENGINE WILL NOT DELIVER RATED POWER
Step 1. Check crankcase oil level.
Fill as required.
Step 2. Check for cIogged/dirty air cleaner system.
Clean, repair, or replace as required.
Step3. Check for improper engine adjustments (Refer to Paragraphs 8-4 thru 8-14).
Step 4. Check governor linkage from governor to fuel rack for binding or damage (Refer to
Para 8-7).
Step 5. Check for low cylinder compression (Refer to Para 8-14).
NOTE
● Return
o
fuel temperature must be less than 150 F (66°C) or loss of horsepower will
occur.
●A
power
decrease
of 0.6 to 4.0 horsepower for each 10° temperature rise above
o
o
90 F (32 C) will occur.
Step 6. Check for high return fuel temperature.
Step 7. Inspect turbocharger for damage.
CAUTION
Do not attempt to remove carbon build up on turbine wheel
without removing turbocharger from engine. Blades of wheel
must be thoroughly cleaned. Chunks of carbon left on blades
could cause bearing failure. However, it is not necessary to
disassemble turbocharger to remove dirt and dust build up.
a. Remove turbocharger exhaust pipe.
2-8
TM 9-2815-202-34
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5.
ENGINE WILL NOT DELIVER RATED POWER (Cont)
b. Check that turbine wheel rotates freely. If turbine does not rotate, then
turbocharger bearings have seized.
c. Inspect turbine wheel for nicks, cracks, or contact.
d. Install turbocharger exhaust.
e. Remove vehicle air inlet hose and pipe.
f. Inspect compressor wheel and housing for contact.
g. Inspect compressor wheel for nicks, cracks, or other damage.
WARNING
Dry cleaning solvent P-D-680 is toxic and flammable.
Wear protective goggles and gloves and use only in a
well-ventilated area. Avoid contact with skin, eyes, and
clothes and don’t breathe vapors. Do not use near
open
flames or excessive
heat. The flash point is
o
o
o
100 F-138°F (38 C-50 C). If you become dizzy while
using cleaning solvent, get fresh air immediately and
get medical aid. If contact with eyes is made, wash
your eyes with water and get medical aid immediately.
h. Inspect compressor for excessive dirt or foreign material. If necessary, remove
compressor housing, clean compressor wheel and housing with dry cleaning
solvent, and install compressor housing.
i. Replace turbocharger assembly if damaged (Refer to Paragraphs 4-2, 5-2,
5.1-2, 6-3, or 7-3 for appropriate engine model).
■
j. Install vehicle air inlet hose and pipe.
Step 8. Check for leaks in engine air intake or exhaust manifold.
END OF TEST
Change 1
2-9
TM 9-2815-202-34
MALFUNCTION, TEST OR INSPECTION, AND CORRECTIVE ACTION
PROCEDURES (Cont)
2-5.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
LUBRICATING SYSTEM
6.
EXCESSIVE ENGINE OIL CONSUMPTION
Step 1. Check oil lines and connections for leaks.
Step 2. Clean and inspect crankcase breathers (Refer to Paragraphs 4-11, 4-15, 6-16, or
7-14 for appropriate engine model).
Step 3. Check blower oil seals for leaks.
a. Remove air inlet housing.
WARNING
When Inspecting a biower on a engine with the engine running, keep
fingers, equipment and ciothing away from moving parts of the biower.
Run engine at iow speeds oniy.
Protective fan screens must be installed prior to doing maintenance in
the engine compartment when engine is running or when engine is in
ground hop mode. Contact with rotating fan can cause injury (reference
FM 21-11).
b. Operate engine fluctuating between 650-1200 RPM and inspect blower end
plates for evidence of oil leakage past seals.
c. If leakage is detected, replace blower (Refer to Para 4-18).
Step 4. Check for blue smoke. Inspect exhaust manifolds and stacks for wetness or oil
discharge.
NOTE
If wetness or oil discharge is present in exhaust manifolds, it is usually an indication
of worn valve guides.
Low compression readings will indicate worn out cylinders.
Step 5. Check vehicle for leaks in air cleaner system which would allow contaminated air to
enter engine. Perform cylinder compression test (Refer to Para 8-14).
Step 6. Check turbocharger oil drain and supply lines for leakage.
END OF TEST
2-10
TM 9-2815-202-34
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. LOW OIL PRESSURE
NOTE
Make oil pressure checks with minimum water outlet temperature
o
of 160°F(710 C).
Step 1. Check oil level.
Step 2. Check operation of oil pressure gage (Refer to vehicle type-20 maintenance
manual).
Step 3. Check for diluted oil using fuel dilution test set.
a. Replace defective injector fuel tube assemblies.
b. Drain contaminated oil.
END OF TEST
2-11
TM 9-2815-202-34
MALFUNCTION, TEST OR INSPECTION, AND CORRECTIVE ACTION
PROCEDURES (Cont)
2-5.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8. BLUE EXHAUST SMOKE
Step 1. Check blower oil seals for leaks.
a. Remove air inlet housing.
WARNING
●
When Inspecting a blower on a engine with engine running, keep
fingers, equipment and clothing away from moving parts of blower. Run
engine at low speeds only.
●
Protective fan screens must be installed prior to doing maintenance In
the engine compartment when engine Is running or when engine is in
ground hop mode. Contact with rotating fan can cause injury (reference
FM 21-11).
b. Operate engine, fluctuating between 650-1200 RPM and inspect blower end
plates for evidence of oil leakage past seals.
c. If leakage is detected, replace blower (Refer to Para 4-18).
Step 2. Check turbocharger for defective oil seals.
a. Remove air intake hose and tube and exhaust pipe.
b. Check for evidence of oil on compressor or turbine.
c. If oil is present, replace turbocharger assembly.
d. Install air intake hose and tube and exhaust pipe.
Step 3. Perform oil analysis for coolant in engine oil. (Refer to DA PAM 738-750)
END OF TEST
2-12
TM 9-2815-202-34
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
9.
EXCESSIVE BLACK EXHAUST SMOKE
Step 1. Check for excessive fuel or irregular fuel distribution.
a. Check fuel injector timing (Refer to Para 8-5).
b. Check injector rack linkage adjustment (Refer to Para 8-7).
c.
If necessary, perform complete engine tune up (Refer to Para 8-4 thru
8-13).
d. Replace faulty injectors if this condition persists after performing steps a, b,
and c above (Refer to Para 4-38).
Step 2. Check air inlet for restrictions.
a. Clean air cleaner elements.
b. Clean blower housing screen.
Step 3. Check for proper grade of fuel (Refer to appropriate vehicle LO).
END OF TEST
2-13
TM 9-2815-202-34
MALFUNCTION, TEST OR INSPECTION, AND CORRECTIVE ACTION
PROCEDURES (Cont)
2-5.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10.
WHITE EXHAUST SMOKE
Step 1. Check for malfunctioning injectors.
a. Remove rocker arm covers.
WARNING
Protective fan screens must be Installed prior to doing
maintenance In the engine compartment when engine
is running or when engine is in ground hop mode.
Contact with rotating fan can cause injury (reference
FM 21-11).
b. Start engine.
NOTE
if injector is malfunctioning ,there will be no noticeable
difference in sound and operation of engine.
c. Hold fuel injector follower down with a screwdriver with engine idling to
prevent operation of injector. lf necessary, replace faulty injector (Refer to
Para 4-38).
d. Install rocker arm covers.
Step 2. Check for low cylinder compression (Refer to Para 8-14).
Step 3. Check for sticking exhaust valves.
a. Remove rocker arm cover and check for damaged or sticking exhaust valves.
b. Check for correct exhaust valve clearance (Refer to Para 8-4).
END OF TEST
2-14
TM 9-2815-202-34
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
COOLING SYSTEM
11.
ENGINE COOLANT OPERATING TEMPERATURE ABOVE NORMAL
Step 1. Check coolant level.
Step 2. Check operation of vehicle cooling system (Refer to appropriate vehicle type-20
maintenance manual).
Step 3. Check for collapsed, cracked, or disintegrated hoses.
Step 4. Check thermostats for operation. Remove thermostat and test (Refer to Para 4-8).
Step 5. Check for combustion gases in the cooling system.
a. Remove radiator filler cap.
WARNING
Protective fan screens must be Installed prior to doing
maintenance In the engine compartment when engine
is running or when engine is in ground hop mode.
Contact with rotating
. - (reference
.
— fan can cause injury
FM 21-11).
b. Operate engine at idle.
c. Check radiator for bubbles in coolant which indicates a damaged cylinder
head.
d.
Install radiator cap.
END OF TEST
2-15
TM 9-2815-202-34
MALFUNCTION, TEST OR INSPECTION, AND CORRECTIVE A C T I O N
PROCEDURES (Cont)
2-5.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AIR INTAKE SYSTEM
(TURBOCHARGER)
12.
EXCESSIVE TURBOCHARGER NOISE OR VIBRATION
Step 1. Check for improper clearance between turbine wheel and housing.
a. Remove vehicle exhaust pipe.
b. Inspect turbine wheel and housing for nicks, cracks, or contact between
wheel and housing.
c. Replace turbocharger assembly if damaged (Refer to Paragraphs 4-2,5-2,
5.1-2,6-3, or 7-3 for appropriate engine model).
d. Install vehicle exhaust pipe.
Step 2. Check for leaks in air intake or exhaust manifold.
a. Tighten loose connections.
b. Replace leaking gaskets.
END OF TEST
2-16 C h a n g e
1
TM 9-2815-202-34
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AIR INTAKE SYSTEM
(TURBOCHARGER REGULATOR - ENGINE)
(MODELS 7083-7398 AND 7083-7399 ONLY)
13.
BYPASS VALVE FAILS TO CLOSE
Step 1. Remove turbocharger regulator and check for carbon build-up on bypass valve.
Remove carbon as required.
Step 2. Check for broken bypass valve spring.
Replace turbocharger regulator if spring is broken (Refer to Para 6-2).
END OF TEST
14.
EXCESSIVE EXHAUST PRESSURE AT TURBOCHARGER
Step 1. Remove turbocharger regulator and check for carbon build upon bypass valve.
Remove carbon as required.
Step 2. Check for damaged air pressure lines.
Replace air pressure lines.
Step 3. Check turbocharger regulator calibration.
a. Remove air inlet line to turbocharger regulator.
NOTE
If regulator valve moves with 13.0 PSI (90.0 kPa) air pressure at
inlet, regulator is within limits.
b. Hookup air supply to regulator inlet port. Slowly apply air pressure and
record when valve movement occurs.
c. If regulator is out of limits, replace unit.
d. Install air inlet line to regulator.
END OF TEST
2-17
TM 9-2815-202-34
MALFUNCTION, TEST OR INSPECTION, AND CORRECTIVE ACTION
PROCEDURES (Cont)
2-5.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
COLD STARTING OPERATION
15.
INOPERATIVE AIR BOX HEATER AT LOW AMBlENT TEMPERATURE
Step1. Check spark at air box heater.
a. Using aglow test light, test for spark at electrode. (Refer to Para4-1 or 6-11
for appropriate engine model.)
b. inspect for electrical shorts, defective ignition coil, and cracked electrode
porcelain.
c. If necessary, replace faulty parts. (Refer to Para 4-10 or 6-11 for appropriate
engine model)
Step 2. Check fuel at air box heater.
a. Replace fuel filter and strainer elements.
b. Clean fuel nozzle.
Step 3. Check solenoid valve using a multimeter.
Replace if faulty (Refer to Para 4-10 or 6-11 for appropriate engine model).
Step 4. Check air pump for air flow.
Replace pump if faulty (Refer to Para 4-10).
Step 5. Check ignition coil for spark at electrode.
Replace coil if faulty (Refer to Para 4-10 or 6-11 for appropriate engine
model).
Step 6. Check pump and motor assembly for fuel flow.
Replace assembly if faulty (Refer to Para 6-11 ).
END OF TEST
2-18
TM 9-2815-202-34
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
16. INOPERATIVE GLOW PLUG SYSTEM AT LOW AMBIENT TEMPERATURE
(MODEL 7063-7391 )
Step 1. Check batteries for low or no voltage (Refer to applicable vehicle type-20
maintenance manual for test and services).
Step 2. Glow plug wait/pilot lamp does not light.
o
a. Ambient temperature above 50 F.
b. Check wait/pilot lamp bulb (Refer to applicable vehicle type-20 maintenance
manual for test and services).
c. All four paired glow plug connector pins short circuited (Refer to applicable
vehicle type-20 maintenance manual for test and services).
d. Controller switching device is open (Refer to Para 5.1-8 to remove and replace
glow plug controller).
Step 3. Glow plug wait/pilot lamp stays lit.
Fault in glow plug controller (Refer to Para 5.1-8 to remove and replace glow plug
controller).
Step 4. Glow plug wait/pilot lamp flashes during preglow and afterglow periods.
Glow plug controller short circuit protection fuse(s) failed. (Refer to applicable
vehicle type-20 maintenance manual for test and services).
END OF TEST
Change 1
2-19/2-20 Blank
TM 9-2815-202-34
CHAPTER 3
GENERAL REPAIR PROCEDURES AND ENGINE PREPARATION
Contents
Para
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Cleaning and General Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Engine From /To Container -12268285 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine From/To Container - 10909159/10923208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
Preparation of Engine Prior to Removal of Engine Accessories and
Installation on Maintenance Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...3-5
Oil Cooler Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Oil Level Gage Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Starter Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Air Box Drains Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Turbocharger Oil Return Line Removal/lnstallation
(Models 7083-7391,7083-7396, and 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Turbocharger Oil Supply Line Removal/installation
(Models 7083-7395 and 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Turbocharger Oil Supply Line Removal/installation
(Models 7083-7391 and 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Turbocharger 011 Supply Line Removal/installation
(Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Air inlet Manifold to Turbocharger Removal/installation
(Models 7083-7391 and 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Air Inlet Manifold to Turbocharger Removal/installation
(Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Engine on Maintenance Stand Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Page
3-1
3-2
3-8
3-17
3-27
3-30
3-32.2
3-33
3-34
3-35
3-36
3-37
3-38
3-39
3-40
3-42
Section I. INTRODUCTION
3-1. GENERAL. This chapter provides general maintenance practices of engine repair, removal and
installation of the engine from container, removal and installation of engine accessories required to
install the engine on the maintenance stand, and installation and removal of the engine onto the
maintenance stand.
Change 1 3 - 1
TM 9-2815-202-34
Section Il. GENERAL MAINTENANCE PRACTICES
3-2. CLEANING AND GENERAL REPAIR INSTRUCTIONS
a. Cleaning
(1) General. Procedures for cleaning will be the same for a great percentage of parts and
components. To avoid repetition of instructions, the general procedures for cleaning are
detailed in paragraphs 2 through 5 below. See TM 9-247 for additional information
pertaining to cleaning.
(a) Clean all parts before inspection, after repair, and before assembly.
(b) Hands should be kept free of grease which can collect dust and dirt.
(c) After cleaning, all parts should be covered or wrapped in plastic to protect them from
dust and dirt.
(2) Castings.
(a) Clean inner and outer surfaces of casting and all areas subject to oil and grease with
cleaning solvent.
(b)
Remove sludge and gum deposits from castings with a stiff brush.
WARNING
Compressed air used for cleaning purposes will not exceed 30 PSI. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(c) Use filtered compressed air to blow out and dry all tapped holes in castings.
(3) Oil Passages.
(a) Clean passages with wire or suitable probe to break up any sludge or gum deposits.
WARNING
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid contact
with skin, eyes, and clothes and don’t breathe vapors. Do not use near
o
open flames
or excessive heat. The flash point Is 100°F-138 F
o
(38°C-50 C). If you become dizzy while using cleaning solvent, get fresh
air immediately and get medical aid. If contact with eyes is made, wash
your eyes with water and get medical aid immediately.
3-2
TM 9-2815-202-34
(b) Wash passages by flushing with dry cleaning solvent.
(c) Dry passages by blowing them out with compressed air.
CAUTION
Do not allow cleaning solvent to be in contact with seals, cables, and flexible hoses.
Cleaning solvent will cause leather, rubber, and synthetic materials to dry out, rot, and
become stiff.
(4) Oil Seals, Cables, and Flexible Hoses.
Clean oil seals, cables, and flexible hoses with soap, water, and a stiff brush.
(5) Ball Bearings.
o
(a) After removing surface oil and gum deposits, place bearings in hot oil (140 F) to loosen
congealed oil and grease.
(b) Wipe bearing dry; do not use compressed air.
(c) After cleaning, coat bearings with a light film of oil and wrap in paper until parts are
inspected and assembled.
(d) See TM 9-214 for information on care and maintenance of bearings.
b. Inspection
(1) General. Procedures for inspection will be the same for a great percentage of the parts and
components. To avoid repetition of instructions, the general procedures for inspection are
detailed in paragraphs below. The engines are precision built and repair standards found in
App G for the component parts have been fixed at extremely close tolerances. Be sure to use
prescribed inspection equipment for inspecting component parts having extremely close
tolerances where cracks and other damage cannot be spotted visually. Replace parts or
components that fail to meet inspection criteria.
(2) Castings.
(a) Inspect all ferrous and nonferrous castings for cracks using a magnifying glass and a
strong light.
(b) Check particularly, areas adjacent to studs, pipe plugs, threaded inserts and in sharp
corners and fillets.
(c)
Inspect machined surfaces of castings for nicks, burrs or raised metal.
3-3
TM 9-2815-202-34
3-2. CLEANING AND GENERAL REPAIR INSTRUCTIONS (Cont)
(d) Mark damaged areas for repair with chalk or lumber crayon.
(e) Check all mating flanges on housings and supports for warpage with a straight edge or
a surface plate.
(f) Check all mating flanges for discoloration which may indicate persistent leakage.
(9) Inspect all pipe plug and capscrew tapped openings for damaged or stripped threads.
(h) Check all castings for conformance to applicable repair standards in App G.
(3) Ball Bearings. See TM 9-214 for inspection of bearings. Check all bearings for conformance
to applicable repair standards in App G.
(4) Studs. Inspect all studs for stripped or damaged threads, bent or loose condition, and
evidence of stretching.
(5) Gears.
(a) Inspect all gears for cracks using a magnifying glass and a strong light.
(b) Inspect all gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces.
(c) Check all gears for conformance to applicable repair standards in App G.
(6) Bushing and Bushing Type Bearings.
(a) Check all bushings and bushing type bearings for secure fit in their respective casting or
mating part and for evidence of heating which may be indicated by discoloration of
bushing or bearing surface.
(b) Inspect bushing and bushing type bearings for wear, burrs, nicks, or out-of-round
condition.
(c) Check for dirt in lubrication holes or grooves of bushings or bushing type bearings.
(d) Holes and grooves must be clean and free from damage to insure proper lubrication.
(e) Check all bushings and bushing type bearings for conformance to applicable repair
standards in App G.
(7) 011 Seals. Metal encased oil seals should not be replaced unless inspection indicates
damage.
(1) Inspect feather edge of oil seal for damage.
(2) Check seal for loss of softness and spring,
(8) Core Hole Plugs.
(1) Inspect core hole plugs for evidence of leakage.
(2) Replace seals if leaking or damaged.
3-4
TM 9-2815-202-34
c. Repair
(1) General. Procedures for repair will be the same for a great percentage of parts and
components. To avoid repetition of instructions, general procedures for repair are detailed in
paragraphs below. After repair, clean all parts thoroughly to prevent metal chips from repair
operations, or abrasives used in repair operations from entering working parts of the engine.
CAUTION
Avoid damage to casting while using welding equipment. Refer to TM 9-237 for
welding instructions.
(2) Castings.
(a) Replace all castings that are cracked or do not conform to tolerances specified in App G.
(b) Repair minor damage to machined surfaces with a fine file, emery cloth, or crocus cloth
dipped in cleaning solvent.
(c) Replace all castings on which machined surfaces are burred or nicked to the point of
impairing subsequent assembly or operation.
(d) Repair minor warpage of mounting flanges and gasket surfaces by working surfaces
across a sheet of emery cloth held tightly on a surface plate or a flat surface. Finish
similarly using crocus cloth.
(e) Replace castings having flanges which are warped to the point of impairing assembly or
operation.
(9)
Repair damaged pipe or cap screw threads in tapped holes with a thread tap.
NOTE
Pipe-plug threads in castings must be in good condition to prevent oil or water leakage.
(3) Ball Bearings.
(a) Replace all galled, pitted, or damaged ball bearings and any that do not conform to
tolerances specified in App G.
(b) See TM 9-214 for maintenance of bearings.
(4) Studs.
(a) Replace all bent or loose studs or studs showing evidence of stretching.
(b) Repair minor thread damage with a thread chaser.
3-5
TM 9-2815-202-34
3-2. CLEANING AND GENERAL REPAIR INSTRUCTIONS (Cont)
(c) Remove and replace studs as outlined in (d and e) below.
(d) Removal.
1. Using stud extractor, back studs out slowly to avoid heating and possible seizure.
2. When studs are broken off too short to use stud extractor, drill stud and extract with
an easy out remover.
3. Short studs may also be removed by welding a bar or nut to stud and removing with
a wrench.
(e) Replacement.
1. Only standard studs are supplied for replacement in steel or cast iron castings.
2. Unless threads in casting are damaged beyond repair, use standard studs.
3. If threaded openings are damaged and retapping will not clean up threads, drill and
tap opening in casting and install a threaded insert.
NOTE
Studs may have a coarse thread on one end and a fine thread on the other end. The
coarse threads on both ends are used in particular applications and normally the short
threaded end is in the aluminum casting. All replacement studs have a special coating
and must have a small amount of mica-base antiseize compound (MIL-A-13881)
applied on the threads before the studs are installed in casting. Thread replacement
stud into opening slowly to prevent overheating.
(5) Gears.
(a) Replace all gears that are cracked, worn, pitted, galled or do not conform to tolerances
specified in repair standards in App G.
(b) Remove sharp fins and burrs from gear teeth with crocus cloth dipped in cleaning
(6) Bushing and Bushing Type Bearings. When bushings and bushing type bearings are
damaged or worn beyond specified limits (App G), generally associated parts must also be
replaced. Reference to (a) and (b) below will be made in Chapters 4 thru 7 for the particular
part in which replacement of bushings and bushing type bearings is required.
(a) Removal. Remove bushing and bushing type bearings by pressing out with a suitable
arbor press or with special tools provided. (Refer to App B for listing of special tools and
equipment).
(b) Installation.
1. Aline bushings or bushing type bearings in casting or retaining cage.
2. Press into place with arbor press or with the special tools provided.
3. Clean repaired parts thoroughly before assembly or installation.
3-6
TM
9-2815-202-34
4. Bushing type bearings are machined for proper clearance and need no reaming.
(7) Oil Seals. Oil seals must be replaced when thin feather edge is damaged or when seal
material has become hard or brittle.
(a) Removal. Press or pry damaged oil seal from casting or adapter being careful not to
damage bore in casting or adapter.
(b) Repair.
1. When oil seal bore in casting or adapter is burred or damaged to a point where an
oil tight seal is impossible, replace casting or adapter.
2. Remove slight nicks, burrs and scratches from bore in casting or adapter with
crocus cloth dipped in cleaning solvent.
(c) Installation. Install new oil seal in bore of casting or adapter using proper oil seal
replacer tool.
d. Disassembly/Assembly Instructions
(1) General. Extreme care must be exercised in all component assembly operations to insure
satisfactory engine performance. Precautionary rules for assembly are outlined below.
(2) Precautionary Rules.
(a) Cleanliness is essential in all component assembly operations.
(b)
Dirt and dust, even in minute quantities, are abrasive.
(c)
Parts must be cleaned as specified and kept clean.
(d) Wrap or cover parts and components when assembly procedures are not immediately
completed.
(e) Coat all bearings and all contact surfaces with engine oil (App C, Item 16) to insure
lubrication of parts during initial engine starting.
(f)
Replace all gaskets and preformed packings removed in disassembly. Clean and
remove all traces of gasket material from surfaces.
(9) Store all fastening hardware (nuts, bolts, screws, and flat washers) in or with the related
component to assist in reassembly.
3-7
TM 9-2815-202-34
Section III. REMOVAL AND INSTALLATION OF ENGINE FROM CONTAINER
3-3. ENGINE FROM/TO CONTAINER - 12268285
This task covers:
a. Removal
b. Preservation
c. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7391 7083-7395 7083-7396
37 Lockwashers (App F, Item 95)
4 Lockwashers (App F, Item 94)
TOOLS AND SPECIAL TOOLS
EXPENDABLE/DURABLE SUPPLIES
General mechanics tool kit (App B, Item 96)
Three-legged sling (App B, Item 84)
Four-legged sling (App B, Item 82)
Torque wrench (App B, Item 101)
a. Removal
WARNING
Wear safety glasses and stand
clear of air release ports when
purging air from reusable
metal container. Make certain
air pressure is fully vented
before disassembly. Injury to
eyes and inner ears can result
from failure to properly vent
containers before
disassembly.
(1) Release pressure in container by
pressing air release button located at
center of breather valve (1).
(2) Remove twenty-eight bolts (2), twentyeight Iockwashers (3), and twentyeight nuts (4), from container. Discard
Iockwashers.
3-8 C h a n g e
1
Desiccant bags (App C, Item 14)
Seal (App C, [tern 35)
Sealant (App C, Item 39)
Preservation oil (App C, Item 31)
Tape (App C, Item 27)
Engine oil (App C, Item 16)
Grease (App C, Item 22)
TM 9-2815-202-34
WARNING
Never crawl under equipment
when performing maintenance
unless equipment is securely
blocked. Keep clear of
equipment when it is being
raised or lowered. Do not
allow heavy components to
swing while suspended by
lifting device. Exercise
extreme caution when working
near a cable or chain under
tension. Equipment may drop
or shift and injury to personnel
may result.
(3) Using a four hook chain (5), remove
top section of container (6).
(4) Inspect container seal (7), for cuts,
tears, or other damage. Discard seal if
unserviceable.
(5) Remove two bolts (8), two bevel
washers (9), two Iockwashers (10),
and two nuts (11 ) securing front Ushaped bracket (12) to container rail
(13). Discard Iockwashers.
(6) Remove three bolts (14), three bevel
washers (15), three Iockwashers (16),
and three nuts (17) securing rear
mounting bracket (18), to container
rail (19). Discard Iockwashers.
NOTE
•
•
In cases where engine has been
returned for repair, forward all
engine parts previously removed
and stored in container to proper
reconditioning aread.
For models 7083-7391 and
7083-7396, engine crankshaft
damper is secured inside shipping
container. If engine is to be made
operational, install damper (Refer
to Para 5-27).
Change
3-9
TM 9-2815-202-34
3-3. ENGINE FROM/TO CONTAINER - 12268285 (Cont)
NOTE
•
Use the three-legged sling to lift
engine models 7083-7395.
•
Use four-legged sling to lift
engine models 7083-7391
and 7083-7396.
(7) Remove engine from container (20),
using a multi-leg sling (21).
NOTE
●
Always install upper section of
the container on the bottom
section and seal container with
bolts, washers, and nuts after the
engine has been removed. This
action is necessary to avoid
weather damage to interior of
container.
●
Only model 7083-7395 requires
removal of fuel strainer in order to
remove front U-shaped bracket.
●
After removing four bolts and
Iockwashers to four U-shaped
brackets, install four bolts
(1/2-13x4) and four Iockwashers,
located in mailbag, in front
engine cover. Place removed
bolts (1/2-13x3-3/4) in mailbag.
Discard used Iockwashers.
(8) Remove bolt (22) securing fuel
strainer shell assembly (23) from
adapter (24). Remove shell assembly.
(9) With engine supported by sling,
remove four bolts (25), four flat
washers (26), and four Iockwashers
(27) securing U-shaped bracket (12)
to front of engine. Discard
Iockwashers.
(10) Remove two bolts (28 and 29), six flat
washers (30), four Iockwashers (31),
and two nuts (32) securing rear
mounting bracket (18) to flywheel
housing. Discard lockwashers.
3-10
Change 1
TM
9-2815-202-34
b. Engine Preservation
NOTE
All openings such as exhaust manifolds, air intakes, breathers etc. should not be
sealed. The engine does not require any special depreservation procedures to be
made serviceable.
(1) Preservation of the fuel system.
(a) Equip an auxiliary fuel container with a fuel line and fill container with a sufficient
amount of presentation oil.
(b) Locate the auxiliary fuel container so as to provide adequate pressure to assure proper
supply of preservation oil to the fuel system.
(c)
Disconnect the fuel line at the fuel pump inlet connection of the engine and connect the
line from the auxiliary fuel container to this point.
(d)
Disconnect the engine fuel return at the quick disconnect coupling and connect a
transparent plastic line at this point and insert opposite end into a recovery container to
collect return fuel.
(e) Turn fuel valve of the auxiliary container to the ON position. Start and run engine no
faster than 1200 revolutions per minute (RPM) until undiluted preservation oil is flowing
from the fuel return line.
3-11
TM 9-2815-202-34
3-3. ENGINE FROM/TO CONTAINER - 12268285 (Cont)
(2) Protection of Unserviceable
Assemblies. The following methods
should be used in protecting any
unserviceable engine assembly.
(a) Loosen clamp (33) securing hose
(34) to left rocker arm cover
breather (35). Remove hose.
NOTE
For models 7083-7391 and
7083-7396, removal of left rocker
arm cover requires removal of
turbocharger air outlet tube.
(b) Loosen four clamps (39)
connecting air outlet tube (40) to
turbocharger and air inlet. Slide
two hoses (41 ) onto outlet tube
and remove tube.
(c)
Remove two rocker arm cover
bolts (36), two flat washers (37),
and two rubber isolators (38).
Remove left rocker arm cover
(42).
(d) Remove rocker arm covers (42).
Slowly pour one-half gallon of
engine oil over valves and valve
train components of cylinder
head.
(e) Reinstall rocker arm cover (42).
(f)
Install two bolts (36), two flat
washers (37), and two rubber
isolators (38). Torque bolts to
15-20 Ib-ft (20-27 N-m).
(9) Repeat steps (a), (c), (d), (e), and
(f) for right rocker arm cover.
(h) Install hose (34) and clamp (33)
on rocker cover arm breather inlet
(35). Tighten clamp.
(i)
3-12
Install air outlet tube (40) with two
hoses (41 ) and four clamps (39)
between air inlet and
turbocharger. Slide hoses onto
air inlet and turbocharger
connections. Tighten clamps.
Change 1
TM 9-2815-202-34
(j)
Install oil filler cap or tape opening.
(k) Tape air inlet and exhaust openings closed.
(1)
Fill the crankcase with oil to a point approximately 15 inches below the top of the oil
gage rod tube. (Used oil can be used for this purpose).
(m) Manually turn engine over at least one complete revolution.
(n) Remove oil pan drain plug and drain oil.
(o) Reinstall oil pan drain plug.
(P) Install the oil gage rod (if missing, tape the tube opening closed).
(q) Apply a light coat of grease to front and rear exposed portions of the crankshaft and any
other exposed machined surface.
c. Installation
NOTE
• Do not
forward an unserviceable engine missing components or down parts.
• For
models 7083-7391 and 7083-7396, if installed, crankshaft damper must be
removed from engine and secured in container prior to engine installation in
container (Refer to Para 5-27 for damper removal). Crankshaft damper must be
protected and secured on shelf in container during shipment.
(1) Remove four bolts (25) securing front cover to engine. Store bolts in cloth mailbag in
container.
(2) Attach U-shaped bracket (12), to front of engine using four (1/2-13x4) bolts (25) (located in
mailbag in engine container), four flat washers (26), and four Iockwashers (27).
NOTE
●
Only model 7083-7395 will
require installation of fuel strainer
after front U-shaped bracket has
been installed.
●
Allow brackets to fit loosely so
adjustment is possible.
(3) Secure fuel strainer shell assembly (23) to
adapter (24) with bolt (22). Tighten bolt.
C h a n g e
1 3-13
TM 9-2815-202-34
3-3. ENGINE FROM/TO CONTAINER - 12268285 (Cont)
(4) Attach rear mounting bracket (18)
(with the 2 inch radius cutout on
starter side of engine) to flywheel end
using two bolts (28), and two bolts
(29), six flat washers (30), four
Iockwashers (31), and two nuts (32).
WARNING
Never crawl under equipment
when performing maintenance
unless equipment is securely
blocked. Keep clear of
equipment when it is being
raised or lowered. Do not
allow heavy components to
swing while suspended by
lifting device. Exercise
extreme caution when working
near a cable or chain under
tension. Equipment may drop
or shift and injury to personnel
may result.
NOTE
Use three-legged sling to lift engine
model 7083-7395. Use four-legged
sling to lift engine models
7083-7391 and 7083-7396.
(5) Lower engine into container (20)
using a multi-leg sling (21).
(6) Aline mounting brackets with holes in
the container rails.
NOTE
•
•
On model 7083-7395, aline
mounting brackets with holes on
left and right container rails (front
of container has nameplate.
On models 7083-7391 and
7083-7396, aline mounting
brackets with holes on front.
(7) Fasten front U-shaped bracket (12) to
container rail (13), underside with two
bolts (8) and two bevel washers (9).
On upper side, secure with two
Iockwashers (10), and two nuts (1 1).
3-14
Change 1
TM
9-2815-202-34
(8) Fasten rear mounting bracket (18) to
underside of container rail (19) with
three bolts (14) and three bevel
washers (15). On upper side, secure
with three Iockwashers (16), and
three nuts (17).
(9) Torque all bolts and nuts on brackets
to engine and container rail.
(10) Fill desiccant basket, mounted on
side wall of container, with 128 units
of class 1 desiccant.
CAUTION
Insure seal is properly sealed in
track on lower flange of container
(11) If removed, install seaI (7) in container
bottom.
(12) Apply sealant to container seal and
position seal.
(13) Assemble top section of container (6)
to bottom section of container (20) by
matching alinement dowels (43) on
bottom flange with mating holes on
top section.
(14) Install twenty-eight bolts (2), twentyeight Iockwashers (3), and twentyeight nuts (4). Torque bolts to
31-37 Ib-ft (43-52 N-m).
3-15
TM 9-2815-202-34
3-3. ENGINE FROM/TO CONTAINER - 12268285 (Cont)
(15) Allow container to stand for a
minimum of twelve hours; then check
and verify condition of humidity
indicator (44).
NOTE
Under moisture-free conditions, the
container humidity indicator will
show blue in color. Pink indicates
excessive moisture in container.
(16) If indicator is pink, disassemble
container and represerve engine.
Replace all desiccant bags and
replace container sealing gasket.
Reassemble and test container as
indicated in steps (9) thru (14).
END OF TASK
3-16
TM
9-2815-202-34
3-4. ENGINE FROM/TO CONTAINER - 10909159/10923108
This task covers:
a. Removal
b. Preservation
c. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395 7083-7396*
7083-7398 7083-7399*
46 Lockwashers (App F, Item
12 Lockwashers (App F, Item
8 Lockwashers (App F, Item
8 Lockwashers (App F,ltem
97)
95)
94)
93)*
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Three-legged sling (App B, Item 84)
Four-legged sling (App B, Item 82)
Torque wrench (App B, Item 101)
●
Applies to 10923108 container
EXPENDABLE/DURABLE SUPPLIES
Desiccant bags (App C, Item 14)
Seal (App C, item 36)
Sealant (App C, Item 39)
Seal (App C, Item 37)
Tape (App C, Item 27)
Engine oil (App C, Item 16)
Grease (App C, Item 22)
Preservation oil (App C, Item 31)
a. Removal
WARNING
Be sure to release the
pressure in the container
before opening to avoid injury
to personnel.
(1) Release pressure in container by
removing insert from pressure valve
(1). After pressure is released,
reinstall insert.
NOTE
For container 10923108, flat
washers are used in place of
Iockwashers to secure upper and
lower sections of container.
(2) Remove forty-six bolts (2), forty-six
Iockwashers (3), and forty-six nuts (4),
from container. Discard Iockwashers.
3-17
TM 9-2815-202-34
3-4. ENGINE FROM/TO CONTAINER (10909159/10923108*) (Cont)
WARNING
Never crawl under equipment
when performing maintenance
unless equipment is securely
blocked. Keep clear of
equipment when it is being
raised or lowered. Do not
allow heavy components to
swing while suspended by
lifting device. Exercise
extreme caution when working near a cable or chain under
tension. Equipment may drop
or shift and injury to personnel
may result.
(3) Using a four hook chain (5), remove
top section of container (6).
(4) Inspect container seal (7) for cuts,
cracks, or other damage. Discard seal
if unserviceable.
(5) Remove two bolts (8), two bevel
washers (9), two flat washers (1 O),
two Iockwashers (11), and two nuts
(12) securing front U-shaped bracket
(13) to container rail (14). Discard
Iockwashers.
(6) Remove four bolts (15), four bevel
washers (1 6), four flat washers (17),
four Iockwashers (18), and four nuts
(19) securing rear mounting bracket
(20), to container rail (21). Discard
Iockwashers.
(7) On models 7083-7396 and 70837399 only, remove two bolts (22), two
flat washers (23), two bevel washers
(24), two Iockwashers (25), and two
nuts (26) securing engine side
support bracket (27), to container rail
(28). Discard Iockwashers.
3-18 C h a n g e
1
TM 9-2815-202-34
NOTE
•
For models 7083-7396 and
7083-7399, engine crankshaft
damper is secured inside shipping
container. If engine is to be made
operational, install damper (Refer
to Para 5-27).
•
In cases where engine has been
returned for overhaul, forward all
engine parts previously removed
and stored in container to proper
reconditioning area.
•
Use the three-legged sling to lift
engine models 7083-7395 and
7083-7398.
•
Use the four-legged sling to lift
engine models 7083-7396 and
7083-7399.
(8)
Remove engine from container using
a multi-leg sling (29).
NOTE
Always install upper section of the
container on the bottom section and
seal container with bolts, washers,
and nuts after the engine has been
removed. This action is necessary to
avoid weather damage to interior of
container.
(9) With engine supported by sling,
remove three bolts (30), three flat
washers (31 ), and three Iockwashers
(32). Loosen bolt (30) at position (A)
and remove U-shaped bracket (13),
from front of engine. Discard
Iockwashers.
(10) Remove six bolts (33), two bolts (34),
ten flat washers (35), eight
Iockwashers (36), and two nuts (37)
securing rear mounting bracket (20)
to flywheel housing. Discard
Iockwashers.
Change 1 3-19
TM 9-2815-202-34
3-4. ENGINE FROM/TO CONTAINER - 10909159/10923108* (Cont)
(11) On models 7083-7396 and 70837399 only, remove two bolts (38), two
Iockwashers (39), and two flat
washers (40) securing bracket (41) to
left side of engine. Discard
Iockwashers.
b. Engine Preservation
NOTE
All openings such as exhaust
manifolds, air intakes, breathers etc.
shall not be sealed. The engine
does not require any special
depreservation procedures to be
made serviceable.
(1) Preservation through the fuel system.
(a) Equip an auxiliary fuel container
with a fuel line and fill container
with a sufficient amount of
preservation oil.
(b) Locate the auxiliary fuel container
to provide adequate pressure to
assure proper supply of
preservation oil to the fuel
system.
(c) Disconnect the fuel line at the fuel
pump inlet connection of the
engine and connect the line from
the auxiliary fuel container to this
point.
(d) Disconnect the engine fuel return
at the quick disconnect coupling
and connect a transparent plastic
line at this point and insert
opposite end into a recovery
container to collect the returned
fuel.
(e) Turn the fuel valve of the auxiliary
container to the ON position. Start
and run engine no faster than
1200 revolutions per minute
(RPM) until undiluted
preservation oil is flowing from
the fuel return line.
3-20
TM
9-2815-202-34
(2) Protection of Unserviceable
Assemblies.
The following methods should be
used in protecting any unserviceable
engine assembly.
(a) Loosen clamp (42) securing hose
(43) to left rocker arm cover
breather (44). Remove hose.
NOTE
For models 7083-7396 and 70837399, removal of left rocker arm
cover requires removing
turbocharger air outlet tube.
(b) For model 7083-7396 only,
loosen four clamps (49)
connecting air outlet tube (50) to
turbocharger and air inlet. Slides
hoses (51 ), and clamps onto
outlet tube and remove tube.
(c) For model 7083-7399 only,
disconnect hose assembly (52),
at air inlet housing (54). Loosen
two clamps (53) connecting air
inlet housing to turbocharger.
Slide hose (59) and clamps onto
housing. Remove three bolts (55
and 56), six Iockwashers (57) and
six flat washers (58) securing air
inlet housing. Remove housing.
(d) Remove two left rocker arm cover
bolts (45), two flat washers (46),
and two rubber isolators (47).
Remove left rocker arm
cover(48).
(e) Slowly pour one-half gallon of
engine oil over valves and valve
train components of cylinder
head.
3-21
TM 9-2815-202-34
3-4. ENGINE FROM/TO CONTAINER - 10909159/09231080* (Cont)
(f)
Reinstall rocker arm covers (48).
(9) Install two bolts (45), two flat
washers (46), and two rubber
isolators (47). Torque to
15-20 Ib-ft (20-27 N-m),
(h) Repeat steps (a), (d), (e), (f), and
(g) for right rocker arm cover.
(i)
Install hose (43) and clamp (42)
on rocker arm cover breather
inlets (44). Tighten clamp.
(j)
For model 7083-7396, position
air outlet tube (50) between
turbocharger and air inlet. Slide
hoses (51 ) and clamps (49) onto
turbocharger and air inlet.
Tighten clamps.
(k) For model 7083-7399, install air
inlet housing (54), three bolts (55
and 56), six Iockwashers (57) and
six flat washers (58). Torque bolts
(55 and 56) to 16-20 Ib-ft
(22-27 N-m). Slide hose (59) onto
turbocharger and tighten clamps
(53). Connect line (52) from
turbocharger waste gate valve
(61 ) to air inlet housing (54).
(1)
Install oil filler cap or tape
opening.
(m) Tape air inlet and exhaust
openings closed.
(n) Fill the crankcase with oil to a
point approximately 15 inches
below the top of the oil gage rod
tube, (used oil can be used for
this purpose).
(o) Manually turn engine over at
least one complete revolution.
(P) Remove oil drain plug and drain
oil.
(q) Reinstall oil drain plug.
3-22
TM 9-2815-202-34
(r) Install oil gage rod (if missing, tape the tube opening closed).
(s) Apply a light coat of grease to front and rear exposed portions of the crankshaft and any
other exposed machined surface.
c. Installation
NOTE
Do not forward an unserviceable
engine missing components or
down parts.
.For models 7083-7396 and
7083-7399, if installed, crankshaft
damper must be removed from
engine and secured in container
prior to engine installation in
container (Refer to Para 5-27 for
damper removal). Crankshaft
damper must be protected and
secured in container during
shipment.
(1) Attach U-shaped bracket (13), to front
of engine using four existing (on
engine) bolts (30), four flat washers
(31), and four Iockwashers (32).
NOTE
Allow brackets to fit loosely so
adjustment is possible.
(2) Attach rear mounting bracket (20),
(with the 2 inch radius cutout on
starter side of engine) to flywheel end
using six bolts (33), two bolts (34), ten
flat washers (35), eight Iockwashers
(36), and two nuts (37).
(3) On models 7083-7396 and 70837399 only, secure bracket (41 ) to
turbocharger side of engine with two
bolts (38), two flat washers (40), and
two Iockvvashers (39).
Change
1
3-23
TM
9-2815-202-34
3-4. ENGINE FROM/TO CONTAINER - 10909159/109231080*
WARNING
Never crawl under equipment
when performing maintenance
unless equipment is securely
blocked. Keep clear of
equipment when it is being
raised or lowered. Do not
allow heavy components to
swing while suspended by
lifting device. Exercise
extreme caution when working
near a cable or chain under
tension. Equipment may drop
or shift and injury to personnel
may result.
NOTE
Use the three-legged sling to lift
engine models 7083-7395 and
7083-7398. Use the four-legged
sling to lift engine models 70837396 and 7083-7399
(4) Lower engine into container, using a
multi-leg sling (29).
(5) Aline the mounting brackets with the
holes in the container rail.
(6) Fasten the rear mounting bracket
(20), to underside of container rail
(21 ) with four bolts(15) and four bevel
washers (16). On upper side, secure
with four flat washers (17), four
Iockwashers (18), and four nuts (19).
(7) Fasten the front U-shaped mounting
bracket (13), to underside of container
rail (14) with two bolts (8), and two
bevel washers (9). On upper side,
secure with two flat washers (10), two
Iockwashers(11), and two nuts (12).
(8) On models 7083-7396 and 70837399 only, secure side mounting
bracket (27), to container rail (28),
with two bolts (22), two flat washers
(23), two bevel washers (24) two
Iockwashers (25), and two nuts (26).
3-24
(Cont)
TM
9-2815-202-34
(9) Torque all bolts and nuts on brackets
to engine and container rail.
NOTE
Container 10909159 requires 80
units of desiccant, and container
10923108 requires 112 units.
(10) Fill desiccant basket, mounted on wall
of container, with desiccant.
CAUTION
Insure seal is properly seated in
track on lower container flange.
(11) If removed, install seal (7) in track on
container bottom.
(12) Apply sealant to container seal (7),
and position container seal on
container flange.
(13) Assemble top section of container (6)
to bottom section of container (62) by
matching alinement dowel on bottom
section flange with mating hole on top
section.
NOTE
● For
container 10923108, flat
washers are used in place of
Iockwashers to secure upper and
lower sections of container.
● For
container 10909159, torque
container bolts to 40-50 Ib-ft
(56-70 N-m).
● For
container 10923108, torque
container bolts to 88-105 Ib-ft
(123-147 N-m).
(14) Install forty-six bolts (2), forty-six
Iockwashers (3) and forty-six nuts (4),
Torque bolts.
(15) Pressurize the container to 5 psi (34
kPa) of dehydrated air and allow
container to stand for a minimum of
twelve hours, then check and verify
that air pressure is maintained.
3-25
TM 9-2815-202-34
3-4. ENGINE FROM/TO CONTAINER - 10909159/109231080* (Cont)
NOTE
Under moisture-free conditions, the container humidity indicator will show blue in color.
Pink indicates excessive moisture in container.
(16) If indicator (63) is pink, disassemble container and represeve engine. Replace all desiccant
bags and replace container sealing gasket. Reassemble and test container as indicated in
steps 11 thru 15.
END OF TASK
3-26
TM 9-2815-202-34
3-5.
PREPARATION OF ENGINE PRIOR TO REMOVAL OF ENGINE
ACCESSORIES AND INSTALLATION ON MAINTENANCE STAND
This task covers:
a. Preparation
b. Inspection
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
All
Tape (App C, Item 27)
Cleaning solvent (App C, Item 10)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Three-legged sling (App B, Item 84)
Four-legged sling (App B, Item 82)
a. Preparation for Removal of Accessories
WARNING
Never crawl under equipment
when performing maintenance
unless equipment is securely
blocked. Keep clear of
equipment when it is being
raised or lowered. Do not
allow heavy components to
swing while suspended by
lifting device. Exercise
extreme caution when working
near a cable or chain under
tension. Equipment may drop
or shift and injury to personnel
may result.
NOTE
(1)
●
Use the three-legged sling to lift
engine models 7083-7395 and
7083-7398.
●
Use four-legged sling to lift engine
models 7083-7391, 7083-7396, and
7083-7399.
Lift engine assembly for cleaning, draining,
and installation on maintenance stand by
using multi-leg sling (1) attached to engine
lifting brackets (2). Use a hoist having a
minimum lifting capacity of 1.5 tons (1.36
metric tons).
Change 1 3 - 2 7
TM 9-2815-202-34
3-5.
PREPARATION OF ENGINE PRIOR TO REMOVAL OF ENGINE
ACCESSORIES AND INSTALLATION ON MAINTENANCE STAND (Cont)
(2) Draining and Cleaning.
(a) Drain engine coolant from cylinder
block into a suitable container, by
opening two drain cocks(3) located
at rear of block on both sides.
(b) Drain coolant from oil cooler (4) by
opening drain cock (5) on rear of
cooler.
(c) After coolant has been drained, close
drain cocks (3 and 5).
(d) Using a separate container, drain
engine oil by removing drain plug (6)
in bottom of oil pan (7).
(e) Drain oil from oil cooler (4) by
removing two plugs (8) in bottom of
oil cooler.
(f)
Reinstall oil pan drain plug (6) and
two plugs (8) in bottom of oil cooler
(4).
(9) Using a separate container, drain
fuel oil from fuel filter (9) and fuel
strainer (10) by opening drain cocks
(11) in bottom of filters.
(h) Close drain cocks (11).
(i)
3-28
Seal all openings on the engine and
accessories with waterproof tape or
suitable plugs (Use extreme caution
to keep foreign material out of
working parts of engine assembly).
TM9-2815-202-34
(j) Wash exterior of engine using water under pressure to remove dirt and mud.
WARNING
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid contact
with skin, eyes, and clothes and do not breathe vapors. Do not use near
open
flame
or excessive heat. The flash point is 100°F-138°F
o
o
(38 C-50 C). If you become dizzy while using cleaning solvent, get fresh
air immediately and get medical aid. If contact with eyes is made, wash
your eyes with water and get medical aid immediately.
(k) Remove oil and grease by using a stiff brush and cleaning solvent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 PSI. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.)
(l) Remove moisture from engine by blowing off with compressed air.
b. Preliminary Inspection
(a) After engine has been thoroughly drained and cleaned, inspect external areas of engine
to determine leaks, broken or cracked areas and missing parts.
(b) Visually inspect external components for bent, broken or other damaged conditions.
(c) Mark faulty areas with chalk or crayon to serve as a guide in repair or replacement of
parts.
END OF TASK
3-29
TM 9-2815-202-34
Section IV. REMOVAL/lNSTALLATION OF ENGINE ACCESSORIES
PRIOR TO INSTALLATION OF ENGINE ONTO MAINTENANCE STAND
3-6. OIL COOLER REMOVAL/lNSTALLATION
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
■ All
MANDATORY REPLACEMENT PARTS
1 Gasket (App F ltem 53)
2 Gasket (App F, ltem 35)
12 Lockwashers (App F, ltem 93)
TOOLS AND SPECIAL TOOLS
PERSONNEL REQUIRED: 2
General mechanics tool kit (App B, Item 96)
Guide studs (App D, Item 3)
Torque wrench (App B, Item 101)
a. Removal
(1) Loosen two clamps (1)securing hose (2)to tube (3)and water pump outlet.
(2) Remove four bolts (4) and four lockwashers (5)securing tube (3)to oil cooler (6). Discard
Iockwashers.
(3) Remove tube (3), hose (2), and gasket (7). Discard gasket.
(4) Clean and remove all traces of gasket material from tube and oil cooler.
3-30 Change 1
TM9-2815-202-34
(5) Loosen clamp (8) on water outlet flange seal (9) between elbow (10) and flange (11) on
cylinder block.
WARNING
Support oil cooler to prevent cooler from slipping or falling. injury to
personnel can occur if oil cooler should fall during removal.
(6)
Remove one upper bolt (12) and second bolt from top (13). install guide studs in holes at
positions A and B to support oil cooler (6).
(7)
Remove remaining six bolts (12 and 13) and six Iockwashers (14) securing oil cooler to
cylinder block. Discard lockwashers.
(8)
Using second person, remove oil cooler (6), clamp (8), and flange seal (9).
(9)
Remove two guide studs from cylinder block.
(10)
Remove and discard two gaskets (15) from engine block and oil cooler.
(11) Clean and remove all traces of gasket material.
b. installation
(1)
install two guide studs, one in each hole at positions A and B, on cylinder block for mounting
oil cooler.
(2)
Position one gasket (15) over guide stud at position (B).
(3)
install bolt (13) and Iockwasher (14) at position (C) on oil cooler (6).
(4)
Position gasket (15) on back of oil cooler at bolt (13) position (C).
(5)
Position seal (9) and clamp (8) over water outlet flange (11).
(6)
Position oil cooler (6) over guide studs and install bolt (13) and lockwasher (14) at position
(c).
(7)
install three bolts (12), two bolts (13), and five Iockwashers (14).
(8) Remove two guide studs from cylinder block.
(9)
install remaining two bolts (12 and 13) and two lockwashers (14). Torque all bolts (12 and
13) to 30-35 lb-ft (41 -47 N-m).
(10) Position gasket (7) between oil cooler tube (3) and oil cooler (6).
(11) Secure tube (3) with four bolts (4) and four lockwashers (5). Torque bolts to 30-35 lb-ft
(41-47 N-m).
(12) Slide hose connection (2) upward onto water pump connection.
(13) Tighten hose clamps (1).
END OF TASK
3-31
TM 9-2815-202-34
3-7. OIL LEVEL GAGE REMOVAL/lNSTALLATION
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
TOOLS AND SPECIAL TOOLS
All
General mechanics tool kit (App B, Item 101)
a. Removal
NOTE
on models 7083-7391, 7083-7396, and 7083-7399, the liquid level gage attaches on
the right rear of oil pan.
On models 7083-7391, 7083-7396, and 7083-7399, secure liquid level gage to right
water manifold outlet for storage.
(1)
Remove nut (1) securing clip (2) to exhaust manifold stud (3).
(2)
Remove clip (2) from stud (3).
(3)
Unscrew connector (4) from adapter (5).
(4)
Remove oil level gauge tube and rod assembly (6).
b. Installation
(1) Install oil level gauge tube and rod
assembly (6) into adapter (5).
(2) Install clip (2) over exhaust manifold
stud (3), and secure with nut (1).
(3) Tighten connector (4) into adapter (5)
END OF TASK
3-32
Change 1
TM
9-2815-202-34
3-8. STARTER REMOVAL/INSTALLATION
This task covers: a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
All
2
3
1
1
TOOLS AND SPECIAL TOOLS
Lockwashers (App F, Item 98)
Lockwashers (App F, Item 97)
Lockwasher (App F, Item 99)
Gasket (App F, Item 63)
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
a. Removal
(1) Remove bolt (1) and two Iockwashers (2) securing ground strap (3) to side of engine block.
Discard Iockwashers.
(2) Remove nut (4), Iockwasher (5), and starter ground strap (6). Discard Iockwasher.
(2.1)
For model 7083-7391 only, disconnect glow plug power harness (10) by removing nut (11) and
Iockwasher (12) securing red power lead connection (13) at battery terminal (14) on solenoid
(15). Remove lead and reinstall nut and Iockwasher.
(2.2) Remove nut (16) and Iockwasher (17) securing orange switch lead connection (18) at switch
terminal (19) on solenoid (15). Remove lead and reinstall nut and Iockwasher.
(2.3) Remove nut (20) and Iockwasher (21) securing black ground lead connection (22) to ground
terminal (23) on solenoid (15). Remove lead and reinstall nut and Iockwasher.
WARNING
Block or secure starter before removing the three bolts and Iockwashers that
secure starter to engine flywheel housing. Component is heavy and dropping may
result in injury to personnel.
(3) Support starter (6), and remove three bolts (7), three Iockwashers (8), and gasket (9) securing
starter to flywheel housing. Discard Iockwashers.
(4) Remove starter (6) and discard gasket (9).
b. Installation
(1) Position gasket (9) and starter (6) on flywheel housing and secure using three bolts (7) and
three Iockwashers (8). Torque bolts to 95-105 Ib-ft (129-143 N-m).
(2) Install starter ground strap (3) to cylinder block using bolt(1) and two Iockwashers (2) (one
washer on each side of ground strap). Torque bolt to 23-26 Ib-ft (31-35 N-m).
(3) Install starter ground strap (3), nut (4) and Iockwasher (5) on starter. Torque nut to 20-25 Ib-ft
(27-34 N-m).
3-32.1 Blank/3-32.2
Change 1
TM 9-2815-202-34
3-8. STARTER REMOVAL/INSTALLATION
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
All
2
3
1
1
TOOLS AND SPECIAL TOOLS
Lockwashers (App F, Item 98)
Lockwashers (App F,ltem 97)
Lockwasher(App F, Item 99)
Gasket (App F, ltem 63)
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
a. Removal
(1) Remove bolt (1) and two Iockwashers (2) securing ground strap (3) to side of engine block.
Discard Iockwashers.
(2) Remove nut (4), Iockwasher (5), and starter ground strap (6). Discard Iockwasher.
I
(2.1)
For model 7083-7391 only, disconnect glow plug power harness (1 O) by removing nut (11) and
Iockwasher (12) securing red power lead connection (13) at battery terminal (14) on solenoid
(15). Remove lead and reinstall nut and Iockwasher.
(2.2) Remove nut (16) and Iockwasher(17) securing orange switch lead connection (18) at switch
terminal (19) on solenoid (15). Remove lead and reinstall nut and Iockwasher.
(2.3) Remove nut (20) and Iockwasher (21) securing black ground lead connection (22) to ground
terminal (23) on solenoid (15). Remove lead and reinstall nut and Iockwasher.
WARNING
Block or secure starter before removing the three bolts and Iockwashers that
secure starter to engine flywheel housing. Component is heavy and dropping may
result in injury to personnel.
(3) Support starter (6), and remove three bolts (7), three Iockwashers (8), and gasket (9) securing
starter to flywheel housing. Discard Iockwashers.
(4) Remove starter (6) and discard gasket (9).
b. Installation
(1) Position gasket (9) and starter (6) on flywheel housing and secure using three bolts (7) and
three Iockwashers (8). Torque bolts to 95-105 Ib-ft (129-143 N-m).
(2) Install starter ground strap (3) to cylinder block using bolt (1) and two Iockwashers (2) (one
washer on each side of ground strap). Torque bolt to 23-26 Ib-ft (31-35 N-m).
(3) Install starter ground strap (3), nut (4) and Iockwasher (5) on starter. Torque nut to 20-25 Ib-ft
(27-34 N-m).
3-32.1 Blank/3-32.2 Change 1
TM 9-2815-202-34
(4) For model 7083-7391 only, connect glow plug power harness (10) by removing nut (20) and
Iockwasher (21) from ground terminal (23) on solenoid (15). Attach black ground lead
connection (22) and secure with nut and Iockwasher. Tighten connection.
(5) Remove nut (16) and Iockwasher (17) from switch terminal (19) on solenoid (15). Attach orange
switch lead connection (18) and secure with nut and Iockwasher. Tighten connection.
(6) Remove nut (11 ) and Iockwasher (12) from battery terminal (14) on solenoid (15). Attach red
double lead power connection (13) and secure with nut and Iockwasher. Tighten connection.
END OF TASK
Change 1
3-33
TM9-2815-202-34
3-9. AIRBOX DRAINS REMOVAL/lNSTALLATION
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
TOOLS AND SPECIAL TOOLS
All
General mechanics tool kit (App B, Item 96)
a. Removal
NOTE
Airbox drains are located on both sides of the cylinder block below the air box covers.
(1) Unscrew connector (1) from 90 degree elbow (2) securing air box drain tubes (3) to side of
block.
(2) Remove air box drain tubes.
b. Installation
(1) Install air box drain tubes (3) in 90 degree elbow (2) located on both sides of the engine.
(2) Tighten connector (1).
END OF TASK
3-34
Change 1
TM 9-2815-202-34
3-10. TURBOCHARGER OIL RETURN LINE REMOVAL/lNSTALLATION
(MODELS 7083-7391,7083-7396, AND 7083-7399)
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
TOOLS AND SPECIAL TOOLS
17083-7391 7083-7396 7083-7399
General mechanics tool kit (App B, item 96)
a. Removal
(1) Loosen two clamps (1) located at
each end of turbocharger oil return
line (2).
(2) Remove oil return line (2).
b. Installation
(1) Install one end of turbocharger oil
return line (2) over elbow (3) at oil
pan connection. Install other end of oil
return line over oil outlet tube (4) at
turbocharger.
(2) Install two clamps (1) onto oil return
line (2) and tighten clamps.
END OF TASK
Change 1
3-35
TM 9-2815-202-34
3-11. TURBOCHARGER OIL SUPPLY, LINE REMOVAL/lNSTALLATION
(MODELS 7083-7395 AND 7083-7398)
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
TOOLS AND SPECIAL TOOLS
7083-7395 7083-7398
General mechanics tool kit (App B, Item 96)
a. Removal
(1) Disconnect turbocharger oil supply line (1) at turbocharger connector (2) and at elbow
connector (3) on left rear of engine block.
NOTE
Model 7083-7398 does not have clips securing turbocharger oil supply line.
(2) Remove two bolts (4) and two Iockwashers (5) securing oil supply line clips (6) to engine.
Reinstall two bolts and two Iockwashers that secure clips.
(3) Remove turbocharger oil supply line (1) with clips attached.
b. Installation
NOTE
On model 7083-7395, the end of the
oil supply with the 90 degree fitting
is connected at the turbocharger.
(1) Connect turbocharger oil supply line
(1) to turbocharger connector (2) and
engine block connector (3).
(2) Secure oil supply line (1) to engine
using two bolts (4) and two
Iockwashers (5) to fasten clips (6).
(3) Tighten oil supply line (1) pipe fittings
at connectors (2 and 3).
END OF TASK
3-36
TM 9-2815-202-34
■
3-12. TURBOCHARGER OIL SUPPLY LINE REMOVAL/lNSTALLATION
(MODELS 7083-7391 AND 7083-7396)
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7391 7083-7396
1 Lockwasher (App F,ltem 92)
TOOLS AND SPECIAL TOOLS
General mechanics tool set (App B, Item 96)
Torque wrench (App B, Item 101)
a. Removal
(1) Disconnect turbocharger oil supply line (1) at turbocharger connector (2) and at elbow
■
connector (3) on left front of engine block.
(2) Remove bolt (4), flat washer (5), Iockwasher (6), and nut (7) securing oil supply line clamp (8)
to angle bracket (9). Discard Iockwasher.
(3) Remove bolt (10) securing clamp (11) to airbox cover (12). Reinstall bolt in airbox cover.
(4) Remove turbocharger oil supply line (1) with clamps attached.
b. Installation
NOTE
The end of the oil supply line with the 90 degree fitting is connected at the turbocharger.
(1) Connect turbocharger oil supply line
(1) to turbocharger connector (2)
and elbow connector (3), at left front
of block.
(2) Secure oil supply line clamp (8) to
angle bracket (9) with bolt (4), flat
washer (5), Iockwasher (6), and nut
(7). Tighten bolt and nut.
(3) Remove bolt (10) from airbox cover
(12) and secure oil supply line clamp
(11) to cover. Torque airbox cover bolt to
8-12 Ib-ft (11-17 N-m).
(4) Tighten oil supply line (1) pipe fittings at
connectors (2 and 3).
END OF TASK
Change 1 3-37
TM 9-2815-202-34
3-13. TURBOCHARGER OIL SUPPLY LINE REMOVAL/lNSTALLATION
(MODEL 7083-7399)
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7399
3 Lockwashers (App F, Item 93)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
a. Removal
(1) Disconnect turbocharger oil supply line (1) at turbocharger connector (2) and at elbow
connector (3) on left rear of engine block.
(2) Remove two bolts (4) and two Iockwashers (5) securing oil supply line clips (6) to
turbocharger housing. Discard Iockwashers. Reinstall two bolts and two Iockwashers.
(3) Remove bolt (7), Iockwasher (8), and flat washer (9), securing oil supply line clip (10) to left
side of engine block. Discard Iockwasher.
(4) Remove turbocharger oil supply line (1) with clips attached.
b. Installation
(1) Connect turbocharger oil supply line
(1) to turbocharger connector (2) and
engine block connector (3).
(2) Secure oil supply line clip (10) to left
side of engine block with bolt (7),
Iockwasher (8), and flat washer (9).
Tighten bolt.
(3) Remove two bolts (4) and two
Iockwashers (5) from turbocharger
housing and secure oil supply line
clips (6) with two bolts and two
Iockwashers. Torque bolts to 150-200
lb-in (17-22.6 N-m).
(4) Tighten hose fittings at connectors
(2 and 3).
END OF TASK
3-38
TM 9-2815-202-34
3-14. AIR INLET MANIFOLD TO TURBOCHARGER REMOVAL/lNSTALLATION
(MODELS 7083-7391 AND 7083-7396)
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
TOOLS AND SPECIAL TOOLS
7083-7391 7083-7396
General mechanics tool kit (App B, Item 96)
a. Removal
(1) Loosen two hose clamps (1).
(2) Remove air inlet manifold (2).
(3) Remove two hose clamps (1) and
rubber hose connector (3).
b. Installation
(1) Install rubber hose connector (3) on
turbocharger air inlet end.
(2) install two hose clamps (1) over hose
connector (3).
(3) Tighten hose clamp (1) closest to
turbocharger.
(4) Install air inlet manifold (2) into hose
connector (3).
(5) Tighten remaining clamp (1) over air
inlet manifold.
END OF T A S K
Change 1
3-39
TM 9-2815-202-34
3-15. AIR INLET MANIFOLD TO TURBOCHARGER REMOVAL/INSTALLATION
(MODEL 7083-7399)
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY Replacement PARTS
7083-7399
8 Lockwashers (App F, Item 91 )
4 Lockwashers (App F, ltem 93)
1 Gasket (App F,ltem 58)
1 Gasket (App F,ltem 59)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
a. Removal
(1) Remove eight screws (1) and eight Iockwashers (2) securing air inlet manifold cover (3) to air
inlet manifold (4). Discard Iockwashers.
(2) Remove air inlet manifold cover (3) and gasket (5). Discard gasket.
(3) Remove four bolts (6), four Iockwashers (7) , and four flat washers (8) securing air inlet
manifold (4) to turbocharger. Discard Iockwashers.
3-40
TM 9-2815-202-34
NOTE
Support air inlet manifold prior to removing bolts that secure it to the turbocharger.
(4) Remove air inlet manifold (4) and gasket (9). Discard gasket.
b. Installation
(1) Position air inlet manifold gasket (9) on turbocharger at air inlet.
(2) Position air inlet manifold (4) on turbocharger.
(3) Install four bolts (6), four Iockwashers (7) , and four flat washers (8) securing air inlet
manifold to turbocharger. Torque bolts to 30-35 Ib-ft (41-47 N-m).
(4) Position cover (3) and gasket (5) on air inlet manifold (4).
(5) Install eight bolts (1) and eight Iockwashers (2) securing cover to air inlet manifold. Torque
bolts to 7-9Ib-ft(10-12 N-m).
END OF TASK
3-41
TM 9-2815-202-34
Section V. ENGINE lNSTALLATION/REMOVAL ONTO MAINTENANCE STAND
3-16. ENGINE ON MAINTENANCE STAND INSTALLATION/REMOVlAL
This task covers:
a. Stand Preparation
b. Installation
c. Removal
INITIAL SETUP
MODELS
All
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Three-legged sling (App B, Item 84)
Four-legged sling (App B, Item 82)
Maintenance stand (App B, Item 85)
Cradle (App B, Item 14)
Drain unit (App B, Item 15)
Brackets (App B, Item 8)
a. Maintenance Stand Preparation
(1) Attach engine cradle assembly (1) to engine maintenance stand (2) at hole location number
5.
(2) Install four mounting brackets (3) to side of engine block using two bolts (4), two flat washers
(5), and two Iockwashers (6) per bracket. Leave brackets loose for flexibility.
3-42 Change 1
TM 9-2815-202-34
b. Installation
NOTE
Use the three-legged sling to lift engine models 7083-7395 and 7083-7398.
● Use
four-legged sling to lift engine models 7083-7391, 7083-7396, and 7083-7399.
(1) Using a multi-leg sling, position engine assembly with four engine mounting brackets
attached on engine maintenance stand (2).
(2) Secure brackets (3) to stand cradle (1) side rails with four bolts (7), four lockwashers (8),
eight flat washers (9), and four nuts (10). Tighten bolts.
c. Removal
NOTE
● Use
the three-legged sling to lift engine models 7083-7395 and 7083-7398.
● Use
four-legged sling to lift engine models 7083-7391, 7083-7396, and 7083-7399.
(1) Attach a multi-leg sling to engine lifting brackets prior to removing engine from maintenance
stand (2).
(2) Remove four bolts (7), four Iockwashers (8), eight flat washers (9), and four nuts (10)
securing engine mounting brackets (3) to cradle assembly (1) side rails. Discard
Iockwashers.
(3) Remove eight bolts (4), eight flat washers (5), and eight Iockwashers (6) securing engine
mounting brackets (3) to sides of engine block. Remove brackets. Discard Iockwashers.
END OF TASK
Change 1
3-43/3-44 Blank
■
TM 9-2815-202-34
CHAPTER 4
REPAIR PROCEDURES FOR MAJOR COMPONENTS OF
ENGINE MODEL 7083-7395
Contents
Para
4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......
Turbocharger Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Fuel Strainer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Fuel Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Engine Lifting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Thermostat Housing and Crossover Tubes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Water Pump Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-9
Air Box Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Engine Rocker Arm Cover and Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 1
Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4-1 2
Air Inlet Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Tachometer Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4-14
.
Block Mounted Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Blower Drive Shaft and Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 6
Governor Cover and Throttle Control Rod Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 7
Governor and Blower Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Blower Drive Gear and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
..
Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
Camshaft Front Gear Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
..
Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Rear Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
..
Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Injector Control Tube and Throttle Delay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Cylinder Head Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Engine Lower Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
Camshaft and Gear Assemblies Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. -29
Cylinder Block End Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
Oil Pressure Regulator and Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
011 pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Piston and Connecting Rod Maintenance (Cross-head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Cylinder Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Crankshaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Cylinder Block Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
..
Turbocharger Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
..
Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38
Oil Cooler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Fuel Injector Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
..
Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41
Governor Repair (Dual-range Limiting Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
..
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Page
4-2
4-3
4-6
4-8
4-10
4-12
4-14
4-16
4-20
4-22
4-36
4-40
4-46
4-48
4-49
4-52
4-56
4-58
4-62
4-66
4-68
4-70
4-77
4-80
4-87
4-93
4-98
4-101
4-104
4-116
4-121
4-124
4-132
4-144
4-152
4-162
4-175
4-184
4-214
4-222
4-235
4-248
4-262
4-1
TM 9-2815-202-34
Section I. INTRODUCTION
4-1. GENERAL. This chapter provides the repair procedures performed on engine model 7083-
7396 after the engine has been installed on the maintenance stand. Component replacement
typically consists of removal, disassembly, cleaning/inspection, repair, assembly, and installation of
the component. Next, the engine block maintenance consists of disassembly, inspection, repair, and
assembly of the block components. For major components, the repair is handled separately from
removal and installation. Component repair usually consists of disassembly, cleaning/inspection, and
assembly. Although this chapter deals with model 7083-7395; when other models have identical or
nearly identical components, those models will also be covered in the same task.
4-2
TM 9-2815-202-34
Section Il. GENERAL ENGINE MAINTENANCE
4-2. TURBOCHARGER REMOVAL/INSTALLATION
This task covers:
a. Removal
b. Cleaning/Inspection
c. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395
TOOLS AND SPECIAL TOOLS
4 Locking nuts (App F, Item 105)
1 Gasket (App F, Item 79)
3 Lockwashers (App F, Item 93)
4 Lockwashers (App F, Item 95)
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
EQUIPMENT CONDITION
Para Description
3-11 Turbocharger oil supply line removed
a. Removal
(1) Loosen four clamps (1) and two
rubber connectors (2) securing
turbocharger oil drain tube (3).
Remove tube, hoses, and clamps.
(2) Loosen four clamps (4) and two hose
connectors (5) connecting air inlet
tube (6) to turbocharger (7) and air
inlet housing (8).
(3) Slide hoses (5) and clamps (4) onto
air inlet tube (6) and remove tube.
Remove hoses and clamps from tube.
(4) Remove four locking nuts (9) and four
flat washers (10) securing
turbocharger to exhaust tee (11).
Discard locking nuts.
CAUTION
Tape all openings of turbocharger after
removal to keep foreign particles from
entering and damaging turbocharger
blades.
(5) Remove turbocharger (7) and gasket
(12). Discard gasket.
4-3
TM 9-2815-202-34
4-2. TURBOCHARGER REMOVAL/lNSTALLATION (Cont)
(7) Remove four clamps (13) securing exhaust tubes (14 and 15), to exhaust tee (11) and
exhaust manifolds (16).
(8) Loosen three bolts (17) on exhaust tee (11) to aid in removal of exhaust tubes (14 and 15).
(9) Remove exhaust tubes (14 and 15) and clamps (13).
(lo) Remove three bolts (17) and three Iockwashers (18) securing exhaust tee (11) to mounting
bracket (19). Discard Iockwashers.
(11) Remove four bolts (20) and four lockwashers (21) securing mounting bracket (19) to flywheel
housing. Discard Iockwashers.
(12) Remove turbocharger mounting bracket (19).
b. Cleaning/inspection
(1) Clean all parts. Refer to para 3-2a.
(2) Inspect all parts. Refer to para 3-2b.
(3) Replace all parts failing inspection.
4-4
TM
9-2815-202-34
c. Installation
NOTE
Four bolts (22) and two bolts (23) were
installed in Para 4-24.
(1) Torque four bolts (22) and two bolts
(23) to 30-35 Ib-ft (41 -47 N-m).
(2) Install four bolts (20) and four
Iockwashers (21), fastening mounting
bracket (19) to flywheel housing.
Torque four bolts to 30-35 Ib-ft
(41-47 N-m).
(2) Start three bolts (17) and three
Iockwashers (18) securing exhaust
tee (11 ) to mounting bracket (19).
(3) Install exhaust tubes (14 and 15) and
four clamps (13) between exhaust tee
(11) and exhaust manifolds (16).
Tighten four clamps then torque three
bolts (17) to 30-35 Ib-ft (41-47 N-m).
(4) Position a gasket (12) on exhaust tee
(11),
(5) Remove protective covering from
bottom of turbocharger (7) and
position on exhaust tee (11).
(6) Install four locking nuts (9) and four
flat washers (10) securing
turbocharger (7) to exhaust tee (11).
Torque nuts to 35-39 Ib-ft (47-53
N-m).
(7) Slide two hose connectors (5) and
four clamps (4) onto air inlet tube (6).
(8) Install air inlet tube (6) between
turbocharger (7) and air inlet housing
(8). Tighten hose clamps (4).
(9) Install two hoses (2) and four clamps
(1) onto turbocharger oil drain tube
(3). Connect end of oil drain tube to
turbocharger drain and other end to
left side outboard flywheel housing
cover. Tighten four clamps (1).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
3-11 Install turbocharger oil supply line
4-5
TM 9-2815-202-34
4-3. EXHAUST MANIFOLD REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395
4 Gaskets (App F,ltem 41)
TOOLS AND SPECIAL TOOLS
EQUIPMENTCONDITION
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Para Description
Turbocharger removed
4-2
a. Removal
(1) Loosen five nuts(1 ) securing exhaust manifold (2) to cylinder head.
(2) SIide exhaust manifold (2) up and off cylinder head.
(3) Remove five nuts (1), three center retainers (3), and two end retainers (4).
(4) Remove two exhaust manifold gaskets (5). Discard gaskets.
(5) Repeat steps 1 thru 4 above for opposite side exhaust manifold.
b. Installation
NOTE
When installing metal clad exhaust manifold gaskets, insure crimped side of gasket is
facing cylinder head.
(1) Position two gaskets (5) over exhaust manifold studs (6).
NOTE
Position the bevel washers so outer diameter will rest on manifold and crown at center
is next to nut.
(2) Install three center retainers (3), two end retainers (4), and five nuts (1).
4-6
TM 9-2815-202-34
NOTE
Insure locating pads on exhaust manifold rest on cylinder block locating pads.
(3) Install exhaust manifold (2) to cylinder head by sliding downward between gaskets and
retainers.
(4) Torque five nuts (1) to 30-35 Ib-ft (41 -47 N-m) starting from center outward and alternating
toward either end.
(5) Repeat steps 1-4 above for opposite side exhaust manifold.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-2
Install turbocharger
4-7
TM 9-2815-202-34
4-4. FUEL FILTER REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395 7083-7398
4 Lockwashers (App F, Item 93)
1 Flat washer (App F, Item 17)
1 Filter element (App F, Item 15)
1 Seal (App F, Item 154)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
a. Removal
(1) Remove bolt (1) and flat washer (2) securing fuel filter canister (3) to filter head (4). Discard
flat washer.
(2) Remove filter element (5) from canister and remove seal (6) from filter head. Discard
element and seal.
(3) Disconnect fuel inlet line (7) at elbow connection (8) on fuel pump and at elbow connection
(9) on filter head (4). Remove line.
(4) Disconnect fuel line (10) at fuel filter connection (11) and front of right bank cylinder head.
Remove line.
(5) Remove two bolts (13), Iockwashers (14), and nuts (15) securing filter head (4) to mounting
bracket (16). Discard Iockwashers. Remove fuel filter head (4).
(6) Remove two bolts (17) and Iockwashers (18) securing mounting bracket (16) to water pump
(19). Remove mounting bracket and discard Iockwashers.
b. Installation
(1) Install two bolts (17) and two Iockwashers (18) securing mounting bracket (16) to water
pump (19).
(2) Install two bolts (13), two Iockwashers (1 4), and two nuts (15) securing filter head (4) to
mounting bracket (16).
(3) Connect fuel inlet line (7) to inlet side of fuel filter at elbow (9). Connect other end to fuel
pump at elbow connection (8).
(4) Connect fuel outlet line (10) to lower hole in front of right bank cylinder head. Connect other
end to connector (11) on outlet side of fuel filter.
4-8
TM 9-2815-202-34
(5) Install seal (6) in filter head (4).
(6) lnstall fuel filter element (5) in canister (3).
(7) lnstall (1) and flat washer (2) securing canister with filter to filter head (4). Tighten bolt
enough to prevent fuel leakage.
END OF TASK
4-9
TM 9-2815-202-34
4-5. FUEL STRAINER REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395 7083-7398
4 Lockwashers (App F, ltem 93)
1 Filter element Kit (App F, Item 16)
1 Flat washer
1 Filter element
1 Seal
TOOLS AND SPECIAL TOOLS
General mechanics tooI kit (App B, Item 96)
a. Removal
(1) Remove bolt (1) and flat washer (2) securing fuel strainer canister (3) to strainer head (4).
Remove canister and discard flat washer.
(2)
Remove strainer element (5) from canister and remove seal (6) from strainer head. Discard
element and seal.
(3) Remove bolt (7) and flat washer (8) from clip (9) and reinstall in water pump (10).
(4)
Disconnect fuel supply line (11 ) at elbow connection (12) on fuel pump (13) and at tee fitting
(14) on fuel strainer head (4). Remove fuel supply line (11).
(5) On model 7083-7398 only, disconnect air heater fuel supply line (15) at elbow on tee fitting
(14).
(6)
Remove two bolts (16), two Iockwashers (17), and two nuts (18) securing fuel strainer head
(4) to mounting bracket (19). Remove fuel strainer head and discard Iockwashers.
(7) Remove two bolts (20), two Iockwashers (21), bolt (22), flat washer (23), and spacer (24)
securing mounting bracket (19) to front of engine. Discard Iockwashers.
(8) Remove mounting bracket (19).
b. Installation
(1) Install bolt (22), flat washer (23), spacer (24), two bolts (20), and two Iockwashers (21)
securing mounting bracket (19) to front of engine.
(2) Install two bolts (16), two Iockwashers (17), and two nuts(18) securing fuel strainer head (4)
to mounting bracket (19).
4-10
TM 9-2815-202-34
(3) Connect fuel supply line (11) at tee fitting (14) on fuel strainer head (4) and elbow
connection (12) on fuel pump (13).
(4) Install bolt (7) and flat washer (8) securing fuel line clip (9) to water pump (10).
(5) On model 7083-7398 only, install air heater fuel supply line (15) at tee fitting (14) of fuel
strainer head (4).
(6) Install seal (6) in strainer head (4).
(7) Install fuel strainer element (5) in canister (3).
(8) Install bolt (1) and flat washer (2) securing canister (3) (with element) to strainer head (4)
Tighten bolt just enough to prevent fuel leakage.
END OF TASK
4-11
TM 9-2815-202-34
4-6. FUEL LINES REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395 7083-7398
3 Lockwashers (App F, Item 91 )
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
a. Removal
(1) Remove bolt (1), Iockwasher (2), and flat washer (3) securing angle bracket (4) to governor
cover (5). Reinstall bolt, Iockwasher, and flat washer in governor cover.
(2) Remove bolt (6), two flat washers (7), Iockwasher (8) and nut (9) attaching fuel line clip (10)
to angle bracket (4).
(3) Remove clip (10) from fuel crossover line (11 ).
(4) Disconnect fuel crossover line (11 ) from front of engine at elbow connectors (12) and remove
line.
(5) Disconnect fuel return crossover line (13) at connectors (14) located on inside rails at rear of
cylinder heads.
(6) Remove fuel return crossover line (13).
b. Installation
(1) Connect fuel return crossover line (13) to elbow connectors (14) on inside rails at rear of
cylinder heads.
(2) Install fuel line clip (10) on fuel crossover line (11).
(3) Install bolt (6), two flat washers (7), Iockwasher (8) and nut (9) securing angle bracket (4) to
clip (10). Torque nut to 15-19 Ib-ft (20-26 N-m).
(4) Connect fuel crossover line (11) at elbow connectors (12) at front of cylinder heads.
(5) Use bolt (1), Iockwasher (2), and flat washer (3) to secure angle bracket (4) to governor
cover (5). Torque bolt to 7-9 Ib-ft (10-12 N-m).
4-12
TM 9-2815-202-34
4-13
TM 9-2815-202-34
4-7. ENGINE LIFTING BRACKETS REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395
7083-7398
1 Lockwasher (App F,ltem 92)
4 Lockwashers (App F,ltem 94)
1 Lockwasher (App F, Item 95)
1 Lockwasher (App F, Item 96)
2 Gaskets (App F, Item 34)
TOOLSANDSPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
a . Removal
(1) Remove bolt (1), flat washer (2), lockwasher (3), and nut (4) securing angle bracket (5) to
front engine lifting bracket (6). Discard lockwasher.
(2) Remove bolt (7), Iockwasher (8), and nut (9) securing engine front lifting bracket (6), to
engine front cover (10). Discard Iockwasher.
(3) Remove bolt (11), Iockwasher (12), and spacer (13) securing engine front lifting bracket (6)
to engine front cover (10). Remove lifting bracket. Discard Iockwasher.
(4) Remove two bolts (14) and two Iockwashers (15) securing rear engine lifting bracket (16) to
back of cylinder head (17). Remove bracket and discard Iockwashers.
(5) Remove gasket (18) from back of cylinder head. Discard gasket.
(6) Repeat steps (3) and (4) for removal of opposite bank rear lifting bracket.
b. Installation
(1) Install two bolts (14), two Iockwashers (15), and gasket (18) securing rear engine lifting
bracket (16) to cylinder head (17). Torque bolts to 46-50 Ib-ft (62-68 N-m).
(2) Repeat step (1) for installation of opposite bank rear engine lifting bracket.
(3) Install bolt (11), Iockwasher (12), and spacer (13) securing engine front lifting bracket (6) to
engine front cover (10). Torque bolt to 71-75 Ib-ft (96-102 N-m).
(4) Install bolt (7), lockwasher (8), and nut (9) securing front engine lifting bracket (6) to engine
front cover (10). Torque nut to 107-117 Ib-ft (145-159 N-m).
(5) Install bolt (1), flat washer (2), Iockwasher (3), and nut (4) securing angle bracket (5) to front
engine lifting bracket (10). Torque nut to 13-17 Ib-ft (18-23 N-m).
4-14
TM9-2815-202-34
4-15
TM 9-2815-202-34
4-8.
THERMOSTAT, THERMOSTAT HOUSING, AND CROSSOVER TUBES
REPLACEMENT
This task covers:
a. Removal
b. Inspection
c. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395 7083-7398
1 Lockwasher (App F, Item 92)
TOOLS AND SPECIAL TOOLS
9
1
2
1
2
General mechanics tool kit (App B, Item 96)
Seal installer (App B. Item 59)
Driver handle (App B, Item 41)
Torque wrench (App B, Item 101)
Lockwashers (App F, Item 93)
Lockvvasher (App F, Item 94)
Seals (App F, Item 152)
Gasket (App F, Item 27)
Gaskets (App F, Item 39)
EQUIPMENT CONDITION
Para. Description
4-7
Front engine lifting bracket removed
a. Removal
(1) Loosen four clamps (1) and two rubber connectors (2) securing water crossover tube (3) to
thermostat housing (4) and water outlet connection (5).
(2) Slide clamps (1) and rubber connectors (2) onto water crossover tube (3). Remove tube.
(3) Remove clamps (1) and rubber connectors (2) from crossover tube (3).
(4) Remove bolt (6), flat washer (7), Iockwasher (8), and nut (9) securing water bypass tube
clamp (10) to angle bracket (11). Discard Iockwasher.
(5) Loosen four clamps (12) and two rubber connectors (13) securing water bypass tube (14) to
thermostat housing (4) and water pump (15).
4-16
TM9-2815-202-34
(6) Slide clamps (12) and rubber connectors (13) onto water bypass tube (14). Remove tube.
(7) Remove clamps (12) and rubber connectors (13) from bypass tube (14).
(8) Remove two bolts (16) and two flat washers (17). Loosen bolt (18) and remove water outlet
connection (5) by sliding upward.
(9) Remove bolt (18), Iockwasher (19), flat washer (20), and gasket (21) from right bank cylinder
head (22). Discard Iockwasher and gasket.
(10) Remove five bolts (23) and five Iockwashers (24) securing thermostat cover (25) to
thermostat housing (4). Remove gasket (26) and two thermostats (27). Discard gasket and
Iockwashers.
(11) Remove two thermostat seals (28)
from thermostat cover (25). Discard
seals.
(12) Remove bolts (29, 30, and 31), three
Iockwashers (32) flat washer (33).
bolt (34), and Iockwasher (35)
securing thermostat housing (4) to left
cylinder head (36). Remove
thermostat housing (4) and gasket
(37). Discard gasket and
Iockwashers.
b. Inspection
(1) Immerse thermostat in container of
water and apply heat to container.
(2) Place a thermometer in the container,
but do not allow it to touch bottom of
container.
(3) Agitate water to maintain an even
temperature throughout the container.
When temperature reaches
o
approximately 167°F to 172 F, the
thermostat should begin to open. The
thermostat should be fully opened
when the water temperature reaches
o
approximately 187 F. Allow at least
10 minutes for thermostat to react. If
thermostats do not meet
requirements, replace thermostats.
4-17
TM 9-2815-202-34
4-8. THERMOSTAT, THERMOSTAT HOUSING, AND CROSSOVER TUBES
REPLACEMENT (Cont)
c. Installation
NOTE
Using seal installer assures seal is positioned the correct distance from bottom face of
cover and parallel with cover face.
(1) Install two thermostat seals (28) in thermostat cover (25) using installer and driver handle.
Position seals so Iip of seal faces up toward top of thermostat cover.
(2) Install bolts (29,30, and 31), three lockwashers (32), flatwasher (33), bolt (34), and
Iockwasher (35) securing thermostat housing (4) and housing gasket (37) to left bank
cylinder head. Torque bolts (29, 30, and 31) to 30-35 Ib-ft (41-47 N-m). Torque bolt (34) to
46-50 Ib-ft (62-68 N-m).
(3) Position thermostat cover gasket (26) and two thermostats (27) in thermostat housing (4).
(4) Install five bolts (23) and five Iockwashers (24) securing thermostat cover (25) to thermostat
housing (4). Torque five bolts to 30-35 Ib-ft (41 -47 N-m).
(5) Start bolt (18), Iockwasher (1 9), and flat washer (20) in right bank cylinder head (22).
(6) Position water outlet connection (5) and gasket (21 ) on cylinder head (22) by sliding down
onto bolt (18).
(7) Install two bolts (16) and two flat washers (17) securing water outlet connection (5) to
cylinder head (22). Torque all bolts (16 and 18) to 30-35 Ib-ft (41-47 N-m).
4-18
TM9-2815-202-34
(8) Slide two rubber connectors (13) and four clamps (12) onto ends of water bypass tube (14).
(9) Install water bypass tube (14) between water pump (15) and thermostat housing cover (25).
Slide rubber connectors (13) onto water pump and thermostat housing; secure with clamps
(12).
(10) Install bolt (6), flatwasher (7), lockwasher (8), and nut(9) securing water bypass clamp (10)
to angle bracket(11). Loosely secure bolt to clamp and angle bracket until front engine lifting
bracket is installed.
(11) Slide rubber connectors (2) and four clamps (1) onto ends of water crossover tube (3).
(12) Install water crossover tube (3) between thermostat housing (4) and water outlet connection
(5). Slide rubber connectors (2) onto thermostat housing and water outlet connection; secure
with clamps (1).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
Install Engine Front Lifting Bracket
4-7
4-19
TM 9-2815-202-34
4-9. WATER PUMP REMOVAL/lNSTALLATION
This task covers:
a. Removal
b. Installation
c. Gear Backlash
Adjustment
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395 7083-7398
3 Lockwashers (App F, Item 94)
1 Seal ring (App F, Item 133)
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Magnetic base dial indicator (App B, item 45)
Torque wrench (App B, Item 101)
Para
4-4
4-6
4-8
3-6
Description
Fuel filter bracket removed
Fuel line clip removed
Water bypass tube removed
Water outlet removed
a. Removal
(1) Remove bolt (1), two bolts (2), three Iockwashers (3), and flat washer (4) securing water
pump (5) to engine front cover (6). Discard Iockwashers.
CAUTION
Use care when removing water pump to prevent damage to gear teeth.
(2) Remove water pump (5) from engine front cover (6). Remove seal ring (7) and discard.
b. Installation
(1) Affix seal ring (7) to back of water
pump (5).
(2) Install water pump (5), alining gear
teeth with drive gear in engine front
cover (6).
(3) Install bolt (1), two bolts (2), three
lock- washers (3), and flat washer (4)
securing water pump (5) to front cover
(6). Torque bolts to 46-50 Ib-ft (62-68
N-m).
4-20
TM9-2815-202-34
c. Gear Backlash Adjustment
.
(1) Remove five bolts (8), pump cover (9), and gasket (10).
(2) Check gear backlash by installing a bolt or equivalent in impeller puller hole. Measure
backlash with a dial indicator at this point. Backlash setting should be between 0.001 and
0.006 inch. If setting is not correct, loosen bolts (1 and 2); pivot water pump until proper
setting is obtained. Tighten bolts (1 and 2).
(3) Install gasket (10), pump cover (9), and five bolts (8). Torque bolts to 13-17 Ib-ft (1 8-23 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para
4-8
4-6
4-4
3-6
Description
Install water bypass tube
Install fuel line clip
Install fuel filter bracket
Install water outlet hose and elbow
4-21
TM9-2815-202-34
4-10. AIR BOX HEATER REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Test/Adjustment
c Cleaning/Inspection
f. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395 7083-7396
2 Lockwashers (App F, Item 90)
4 Lockwashers (App F, Item 89)
1 LockWasher (App F, Item 91 )
2 LockWashers (App F, Item 92)
6 Lockwashers (App F, Item 93)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Test lead (App D, Item 1)
EXPENDABLE/DURABLE SUPPLIES
Cleaning solvent (App C, Item 10)
MANDATORY REPLACEMENT PARTS
EQUIPMENT CONDITION
1 Vane set (App F, Item 159)
1 Gasket (App F, Item 68)
Para Description
4-8
Left lifting bracket removed
4-9
Crossover tubes removed
AIR PUMP
a. Removal
(1) Disconnect hose (1) from check valve (2).
(2) Disconnect hose (3) from elbow (4) on air pump (5).
NOTE
Only model 7083-7396 has clamp (6) on hose (3) and uses an elbow (7) instead of an
adapter (7).
(3) Remove screw assembly (8) and clamp (6) from governor cover. If necessary, remove
adapter (7) and clamp from hose (3). Remove hose and reinstall screw assembly on cover.
(4) Remove nuts (9 and 10) securing wiring harness leads(11 and 12) to terminals (13 and 14)
on air pump (5). Disconnect leads from pump.
(5) Remove bolt (15), Iockwasher (16), flat washer (17), air pump clamp (18), cushion (19), and
air pump (5) from bracket (20). Discard Iockwasher.
(6) Remove hose (21 ) and check valve (2) from adapter (22). Remove hose from check valve.
(7) Remove adapter (22) from elbow (23).
4-22
TM9-2815-202-34
b. Disassembly
(1) If necessary, remove elbows (4 and 23) from air pump (5).
(2) Remove three screws (24) and cover (25) from air pump (5).
(3) Remove three vanes (26) from eccentric hub (27). Discard vanes.
4-23
TM 9-2815-202-34
4-10. AIR BOX HEATER REPLACEMENT (Cont)
c. Cleaning/inspection
WARNING
●
Dry cleaning solvent P-D-680 Is toxic and flammable. Wear protective
goggles and gloves and use only in well-ventilated areas. Avoid
contact with skin, eyes, and clothes. Don’t breathe vapors. Do
not use
o
near open flames or excessive heat. The flash point is 100 F-138°F
o
(38°C-50 C). If you become dizzy while using cleaning solvent, get
medical aid. If contact with eyes is made, wash your eyes with water
and get medical aid immediately.
●
Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves etc.).
(1) Clean outside surface of pump with cleaning solvent and dry with compressed air.
(2) Inspect electrical terminals for damage or corrosion. Remove corrosion with a wire brush.
(3) Inspect pump rotor and body for excessive wear, corrosion, or other damage.
(4) Inspect air hose for cuts, tears, kinks, or damage.
d. Assembly
(1) Install three vanes (26) in eccentric hub (27).
(2) Install three screws (24) and cover (25) on air pump (5). Tighten screws securely.
(3) If removed, install elbows (4 and 23) to air pump (5).
e. Test/Adjustment
CAUTION
Do not exceed 18 V dc on air pump.
Excessive voltage will overspeed air
pump and damage pump vanes.
NOTE
Use fabricated test lead to reduce a
24 V dc power source to 18 V dc
and connected in series with
positive terminal of power source.
(1) Connect an 18 V dc power source to
air pump (5). Connect positive lead to
terminal (13) marked (+) and negative
lead to unmarked terminal (14).
4-24
TM9-2815-202-34
(2) Air pressure at outlet port elbow (23) should be 10 psi at 18 V dc. Pump should draw a
maximum of 25 amperes.
(3) Remove power source from terminals (13 and 14).
f. Installation
(1) Install adapter (22) to elbow (23).
(2) Position air pump (5), cushion (19), and air pump clamp (18) on bracket (20). Install bolt (15),
Iockwasher (16), and flat washer (17). Torque bolt to 35-39 Ib-ft (47-53 N-m).
(3) Install hose (21) and check valve (2) onto adapter (22).
(4) Connect hose (1) to check valve (2).
(5) Connect hose (3) onto elbow (4) of air pump (5).
NOTE
Only model 7083-7396 has clamp (6) on hose (3) and uses an elbow (7) instead of an
adapter (7).
(6) If removed, install adapter (7) and clamp (6) on hose (3). Secure clamp to governor cover
using screw assembly (8).
(7) Connect large wiring harness lead (12) to terminal (13) marked (+) on air pump (5) and
secure with nut (9). Connect wiring harness lead (11 ) to terminal (14) on pump and secure
with nut (10).
4-25
TM 9-2815-202-34
4-10. AIR BOX HEATER REPLACEMENT (Cont)
AIR BOX HEATER
a. Removal
(1) Remove high tension lead (28) from
electrode (29) on air heater assembly
(30).
(2) Disconnect hose (1) from adapter (31)
on air heater assembly (30). Remove
hose.
(3) Disconnect hose (32) from connector
(33) on air heater assembly (30).
(4) Remove two bolts (34), two
Iockwashers (35), air heater assembly
(30), and gasket (36) from block.
Discard gasket and Iockwashers.
Discard Iockwasher.
b. Disassembly
(1) Unscrew electrode (29) from air
heater body (37).
(2) Remove fuel injector nozzle (38) from
air heater body (37).
(3) Remove adapter (31) from connector
(33).
(4) Remove two connectors (33) from air
heater body (37).
4-26
TM9-2815-202-34
c. Cleaning/inspection
WARNING
●
Dry cleaning solvent P-D-680 Is toxic and flammable. Wear protective
goggles and gloves and use only in well-ventilated areas. Avoid
contact with skin, eyes, and clothes. Don’t breathe vapors. Do not
use
o
near open flames or excessive heat. The flash point 100 °F-138 F
o
(38°C-50 C). If you become dizzy while using cleaning solvent, get
medical aid. If contact with eyes Is made, wash your eyes with water
and get medical aid immediately.
●
Compressed air used for cleaning purposes will not exceed 30 PSI.
Use ‘only with effective chip guarding and personal protective
equipment (goggles/shield, gloves etc.).
(1) Clean air heater body and fuel injector nozzle with cleaning solvent and dry with
compressed air.
(2) Inspect electrode, fuel injector nozzle, and air heater body for cracks, pitting, or wear.
d. Assembly
(1) Install two connectors (33) into air heater body (37).
(2) Install adapter (31) into connector (33).
(3) Install fuel injector nozzle (38) into air heater body (37).
(4) Screw electrode (29) into air heater body (37).
e. Test/Adjustment
Using gap gages, adjust wire (39) to electrode (29) to obtain air gap of 0.080 inch.
f. Installation
NOTE
Do not install air box heater body on engine until all ignition coil testing is complete.
(1) Install two bolts (34), two Iockwashers (35), air heater assembly (30), and gasket (36) onto
block. Torque bolts to 13-17 Ib-ft (1 8-23 N-m).
(2) Connect hose (1) to adapter (31) on air heater assembly (30).
NOTE
Test air nozzle assembly (38) by applying power (18 V dc) to air pump and feel for
suction at fuel line connector (33). If no suction is felt, replace air nozzle assembly.
(3) Connect hose (32) to connector (33) on air heater assembly (30).
(4) Connect high tension lead (28) to electrode (29).
4-27
TM9-2815-202-34
4-10. AIR BOX HEATER REPLACEMENT (Cont)
IGNITION COIL
a. Removal
(1) Disconnect high tension lead (28)
from ignition coil (40). Remove lead.
(2) Disconnect wiring harness connector
(41) from ignition coil (40).
(3) Remove bolt (42), Iockwasher (43),
and flat washer (44) securing bracket
(45) and ignition coil (40) to air inlet
housing. Remove coil and bracket as
an assembly. Discard Iockwasher.
(4) Remove bolt (46), nut (47), and
Iockwasher (48) from bracket (45).
Remove ignition coil (40) from bracket.
Discard Iockwasher.
c. Cleaning/inspection
WARNING
●
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in well-ventilated areas. Avoid
contact with skin, eyes, and clothes. Don’t breathe vapors. Do
noto use
o
F-138
F
near open
flames
or
excessive
heat.
The
flash
point
is
100
o
(38°C-50 C). If you become dizzy while using cleaning solvent, get
medical aid. If contact with eyes is made, wash your eyes with water
and get medical aid immediately.
●
Compressed air used for cleaning purposes wiII not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves etc.).
(1) Clean outside surface with cleaning solvent and dry with compressed air.
(2) Inspect ignition coil for oil seepage or damage to electrical connectors.
4-28
TM 9-2815-202-34
e. Test/Adjustment
(1) Connect high tension lead (28) to ignition
coil (40) and electrode (29).
(2) Connect air heater assembly (30) to
common ground.
WARNING
Do not touch ignition coil or
air heater assembly while
performing test. High voltage
is present. Personal injury
may result.
CAUTION
not apply voltage to ignition coil without a coil to air heater connection. Coil and
air heater must be grounded.
● Do
● Apply
positive lead to pin (A) and negative lead to pin (B) or damage to coil will
result.
(3) Connect a 24 V dc power source to the coil input side of ignition coil (40). Observe electric
arc between electrode (29) and wire (39). Arc “may be steady or intermittent (about ten pulses
a second) with a popping noise.
(4) Disconnect power source to coil (40) and remove lead (28).
(5) Disconnect air heater assembly (30) from common ground.
f. Installation
(1) Insert ignition coil (40) into bracket (45). Secure with bolt (46), Iockwasher (48), and nut (47).
Torque bolt to 7-9Ib-ft(10-12 N-m).
(2) Position coil (40) and bracket (45) on air inlet housing. Secure with bolt (42), Iockwasher
(43), and flat washer (44). Torque bolt to 16-20 Ib-ft (22-27 N-m).
(3) Connect high tension lead (28) to ignition coil (40).
4-29
TM 9-2815-202-34
4-10. AIR BOX HEATER REPLACEMENT (Cont)
SOLENOID VALVE AND BRACKET
a. Removal
NOTE
● Remove air pump, ignition coil, and air box heater before removing solenoid valve
and bracket.
● Only model 7083-7396 has no clamp (6) on hose (50) and uses a connector (49)
. .
instead of an elbow (49) on the solenoid valve inlet.
(1) Disconnect fuel hoses (50 and 32) from elbows (49 and 51) on solenoid valve (52). Remove
screw assembly (8) and clamp (6) from governor cover. Reinstall screw assembly.
NOTE
Tee (53) is on the front of left cylinder head on model 7083-7395 and on the rear inboard
side of left cylinder head on model 7083-7396.
(2) For model 7083-7395, disconnect hose (50) from tee (53) on left cylinder head. If necessary,
remove clamp (6) from hose. Remove hose.
(3) For model 7083-7396, disconnect hose (50) from connector (54) on left cylinder head.
Remove connector from tee (53). Remove hose.
(4) For model 7083-7396, remove connector (55) from tee (53).
(5) For model 7083-7396, remove connector (56), check valve (57), elbow (58) from tee (53).
4-30
TM9-2815-202-34
(6) Remove tee (53) from left cylinder head.
(7) Remove two bolts (59), two Iockwashers (60), and two flat washers (61) securing two wiring
harness leads (62 and 63) to air inlet housing. Remove leads and discard Iockwashers.
(8) Remove two bolts (64) and two Iockwashers (65) securing solenoid valve and bracket
assembly (66) to support (67).
(9) Remove two screw assemblies (68) and four flat washers (69) securing solenoid valve and
bracket assembly (66) to governor housing. Remove assembly.
b. Disassembly
(1) Disconnect wiring harness connector (70) from solenoid valve (52).
(2) Remove four screws (71), four nuts (72), and four Iockwashers (73) securing wiring harness
connector (74) to bracket (20). Remove wiring harness (75). Discard Iockwashers.
(3) Remove two screws (76) and two Iockwashers (77) securing solenoid valve (52) to bracket
(20). Remove solenoid valve. Discard Iockwashers.
NOTE
Model 7083-7396 uses a connector instead of an elbow for item (49) on the solenoid
valve inlet.
(4) Remove elbows (49 and 51) from solenoid valve (52).
4-31
TM 9-2815-202-34
4-10. AIR BOX HEATER REPLACEMENT (Cont)
c. Cleaning/inspection
WARNING
● Dry cleanlng solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only In well-ventilated areas. Avoid
contact with skin, eyes, and clothes. Don’t breathe vapors. Do
not use
o
near open flames or excessive heat. The flash point Is 100 F-138°F
o
(38°C-50 C). If you become dizzy while using cleaning solvent, get
medical aid. If contact with eyes is made, wash your eyes with water
and get medical aid immediately.
● Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves etc.).
(1) Clean solenoid valve and bracket with cleaning solution. Dry with compressed air.
(2) Inspect fuel hoses for cuts, tears, kinks, or damage.
(3) Inspect wiring harness for cuts, tears, burns, or damage.
d. Assembly
(1) Install two screws (76), two Iockwashers (77), and solenoid valve (52) to bracket (20).
Tighten securely.
NOTE
Model 7083-7396 uses a connector instead of an elbow for item (49) on the solenoid
valve inlet.
(2) Install elbows (49 and 51) to solenoid valve (52). Tighten securely.
(3) Install four screws (71), four Iockwashers (73), and four nuts (72) securing wiring harness
connector (74) to bracket (20).
(4) Screw wiring harness connector (70) onto solenoid valve (52).
e. Test/Adjustment
(1) Connect fabricated test lead to terminal on solenoid valve (52). Apply a 24 V dc power
source and listen or feel to confirm valve is opening and closing as power is applied. If no
indication of movement is present, replace solenoid valve.
(2) Disconnect power source and test lead from solenoid valve (52).
4-32
TM 9-2815-202-34
4-33
TM9-2815-202-34
4-10. AIR BOX HEATER REPLACEMENT (Cont)
f. Installation
(1) Secure wiring harness connectors (62 and 63) to air inlet housing with two bolts (59), two
Iockwashers (60), and two flat washers (61). Torque bolts to 16-20 Ib-ft (22-27 N-m).
(2) Install hose (50) onto elbow (49) on solenoid valve (52).
(3) Position solenoid valve and bracket assembly (66) on governor housing and inboard of
bracket (67). Route harness wiring to prevent cuts, chaffing, burns, or interference with
components. Loosely secure assembly to governor housing with two screw assemblies (68)
and four flat washers (69).
(4) Install two bolts (64) and two Iockwashers (65) securing solenoid valve and bracket
assembly (66) to support (67). Torque bolts to 30-35 Ib-ft (41 -47 N-m). Tighten two screw
assemblies (68).
NOTE
● Tee
(53) is on the front of the left cylinder head on model 7083-7395 and on the
inside rear of the left cylinder head on model 7083-7396.
● For
model 7083-7396, position arms of tee (53) at 12 o’clock and 3 o’clock positions.
(5) Install tee (53) into left cylinder head.
(6) For model 7083-7395, install connector (55) to tee (53).
(7) For model 7083-7396, install elbow (58), check valve (57), and connector (56) to tee (53).
NOTE
Model 7083-7396 has no clamp (6) on hose (50) and uses a connector (49) instead of
an elbow (49) on the solenoid inlet.
(8) For model 7083-7395, install hose (50) into tee (53) on left cylinder head. If removed, install
clamp (6) on hose (50) and secure to governor cover using screw assembly (8).
(9) For model 7083-7396, install hose (50) into connector (54) in tee (53) on left cylinder head.
(10) Install hose (32) onto elbow (51) on solenoid valve (52).
NOTE
Install air pump, ignition coil, and air box heater after installation of solenoid valve and
bracket.
4-34
TM9-2815-202-34
FOLLOW-ON MAINTENANCE
Para Description
4 - 9 Crossover tubes installed
4-8
Left rear lifting bracket installed
4-35
TM9-2815-202-34
4-11. ENGINE ROCKER ARM COVER AND CRANKCASE BREATHER REPLACEMENT
This task covers:
a. Removal
b. Cleaning/Inspection
c. Installation
MODELS
EXPENDABLE/DURABLE SUPPLIES
All
Engine oil (App C, Item 16)
Cleaning solvent (App C, Item 10)
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Para Description
4-13 Ai r inlet housing removed (7083-7399)
5 - 2 Air inlet tube removed (7083-7396)
MANDATORY REPLACEMENT PARTS
1 Gaskets (App F, Item 24)
NOTE
This procedure is for the left bank. Removal and installation for the right bank is similar
except the right bank has no oil fill hole. Repeat the same steps for the right bank
except those involving the filler cap, cap chain, chain hook, and sediment strainer.
a. Removal
(1) Remove hose clamp (1) securing breather hose (2) to breather (3). Remove hose.
(2) Remove two bolts (4 and 5), two flat washers (6), and two resilient mounts (7) securing
rocker arm cover (8) to cylinder head. Remove rocker arm cover.
(3) Remove rocker arm cover gasket (9) from rocker arm cover (8).
(4) Remove three screws (10) securing filtering disk retainer(11), fluid filtering disk (12), and
breather retainer (13) to breather (3).
(5) Remove seal (14) from rocker arm cover (8).
4-36 C h a n g e
1
TM9-2815-202-34
(6) Unscrew and remove filler cap (15) and cap chain (16) from rocker arm cover (8).
(7) Remove cap chain (16) and chain hook (17) from filler cap (15).
(8) If necessary, drive sediment strainer(18) out of rocker arm cover (8). Remove sediment
strainer from chain hook (17).
4-37
TM9-2815-202-34
4-11. ENGINE ROCKER ARM COVER AND CRANKCASE BREATHER REPLACEMENT
(Cont)
b. Cleaning/Inspection
WARNING
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid contact
with skin, eyes, and clothes. Don’t breathe vapors.o Do not
useo near
open
o
o
flames or excessive heat. The flash point is 100 F-138 F (38 -50 C). If
you become dizzy while using cleaning solvent, get fresh air immediately
and get medical aid. If contact with eyes is made, wash your eyes with
water and get medical aid immediately.
(1) Clean rocker arm cover with cleaning solvent. Inspect cover for cracks, dents, or other
damage.
WARNING
Compressed air used for cleaning purposes will not exceed 30 PSI. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves etc.)
(2) Dry rocker arm cover with compressed air,
(3) Inspect fluid filtering disk and sediment strainer. Clean or repair as necessary.
(4) Inspect seal and gasket for cracks, deformation, or wear.
(5) Inspect breather hose for cracks, tears, or damage.
c. Installation
(1) Install seal (14) on rocker arm cover (8).
(2) Install breather (3) to rocker arm cover (8).
(3) Install breather retainer (13), fluid filtering disk (12), and filtering disk retainer (11 ) to breather
(3). Secure with three screws (1 O).
(4) Install chain hook (17) and cap chain (16) to filler cap (15).
(5) If removed, press sediment strainer(18) into rocker arm cover (8). Install chain hook(17) to
sediment strainer and cap chain (16). Crimp hook to secure on chain.
(6) Install gasket (9) into four corners of rocker arm cover (8). Press remainder of gasket into
rocker arm cover.
NOTE
●
Rocker arm cover with oil filler is installed on left side with filler toward fronton
models 7083-7395 and 7083-7398. For models 7083-7391, 7083-7396, and
7083-7399, install rocker arm cover on right side with oil filler toward rear.
●
When gasket is properly installed, it should not fall out of rocker arm cover.
4-38 C h a n g e 1
TM 9-2815-202-34
(7) Lubricate surface of gasket (9) with a thin
film of engine oil.
(8) Install rocker cover (8) to cylinder head.
(9) With rocker arm cover (8) properly alined
and seated on cylinder head, install two
bolts (4 and 5), two flat washers (6), and
two resilient mounts (7).
(10) Torque bolts (4 and 5) to 15-20 Ib-ft (20-27
N-m).
(11) Install and tighten filler cap (15) to rocker
arm cover (8).
(12) Install breather hose (2) to breather (3)
and secure with hose clamp (1).
Tighten clamp securely.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
5-2 Install air inlet tube (7083-7396)
4-13 Install air inlet housing (7083-7399)
Change
1 4-39
TM9-2815-202-34
4-12. FUEL PUMP REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning/Inspection
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
Fuel oil (App C, Item 21)
Engine oil (App C, Item 16)
Sealant (App C, Item 39)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Oil seal remover (App B, Item 97)
Installer handle (App B, Item 97)
Adapter (App B, Item 97)
Torque wrench (App B, Item 101)
MANDATORY REPLACEMENT PARTS
1 Gasket (App F,ltem 72)
4 Lockwashers (App F,ltem 91)
1 Gasket (App F, Item 70)
2 Seals (App F, ltem 147)
a. Removal
(1) Remove three bolts (1)securing fuel
pump assembly (2) and gasket (3) to
governor. Remove fuel pump assembly
and discard gasket.
(2) Remove drive coupling fork (4) from drive
shaft (5).
b. Disassembly
(1)
Place fuel pump assembly in a soft-jawed
vise. Remove four bolt and Iockwasher
assemblies (6) securing pump body
cover (7) to fuel pump body (8).
(2) Remove four bolts (9) and four
Iockwashers (10) securing pump body
cover (7) to fuel pump body (8). Separate
cover and body. Discard Iockwashers.
(3) Remove drive shaft (5) and drive gear
(11).
(4) Remove driven gear assembly (12).
4-40 C h a n g e 1
EQUIPMENT CONDITION
Para Description
4-6
Fuel lines removed (7083-7395 and
7083-7398)
4-8
Thermostat housing and crossover tubes
removed (Except on 7083-7391,
7083-7396, and 7083-7399)
Fuel lines removed (7083-7396 and
5-4
7083-7399)
5.1-4 Fuel lines removed (7083-7391)
TM 9-2815-202-34
NOTE
Driven gear is an assembly. Do not remove gear from shaft.
(5) Press drive shaft (5) far enough to remove check ball (13). Invert drive shaft (5), and press
drive gear (11) off from round end of drive shaft (5). Remove drive gear.
(6) Unscrew plug (14). Remove gasket (15), spring (16), straight pin (17), and relief valve (18)
from fuel pump body (8). Discard gasket.
(7) Using seal remover (19), remove two oil seals (20) from fuel pump body (8). Discard seals.
(8) If necessary, unscrew two pipe plugs (21) from fuel pump body (8).
(9) If necessary, unscrew pipe plug (22) from pump body cover (7).
(10) If necessary, remove two straight pins (23) from fuel pump body (8).
4-41
TM 9-2815-202-34
4-12. FUEL PUMP REPLACEMENT (Cont)
c. Cleaning/inspection
(1) Clean all parts with fuel oil.
WARNiNG
Compressed air used for cleaning
purposes will not exceed 30 PSI.
Use only with effective chip
guarding and personal equipment
(goggles/shieid, gloves, etc.).
(2) Dry all parts with compressed air.
(3) Inspect drive gear and drive shaft for
scoring, burrs, or wear.
(4) Inspect driven gear assembly for
scoring, burrs, or wear.
NOTE
Any slight damage on fuel pump body
and pump body cover sealing surfaces
may result in pressure leaks.
(5) Inspect fuel pump body and pump
body cover carefully for scratches,
nicks, or burrs.
(6) inspect relief valve for scoring or
burrs.
d. Assembly
(1) Lubricate oil seals (20) with a thin
coat of clean engine oil or vegetable
shortening.
NOTE
Install new oil seals with seaI lips
facing each other. Refer to
illustration on right.
(2) Support fuel pump body (8) on wood
blocks. Using installer (24), install
inner oil seal (20) into fuel pump body
(8).
(3) Using adapter (25), install outer seal
(20) into fuel pump body (8).
(4) Lubricate outside diameter of relief valve
(18) with clean engine oil. Insert valve into
fuel pump body (8) with hollow end of valve
facing outward.
4 - 4 2 Change 1
TM9-2815-202-34
(5) Install spring (16) and straight pin (17) into relief valve (18).
(6) Install gasket (15) on plug (14) and screw into fuel pump body (8). Torque plug to 18-22 Ib-ft
(24-30 N-m).
(7) If removed, install two pipe plugs (21) into fuel pump body (8).
(8) If removed, install pipe plug (22) into pump body cover (7).
(9) If removed, install two straight pins (23) into fuel pump body (8).
NOTE
Install drive gear with slot facing round end of drive shaft.
(10) Install drive gear(11) on round end of drive shaft (5). Press drive gear beyond check ball
(13) detent on drive shaft (5).
(11) Install check ball (13) into drive shaft (5) detent. Invert drive shaft and press drive gear (11)
until slot of gear contacts check ball.
4-43
TM 9-2815-202-34
4-12. FUEL PUMP REPLACEMENT (Cont)
(12) Lubricate drive shaft (5) with clean engine oiI. lnsert square end of drive shaft (5) from gear
side of fuel pump body (8) through oil seals (20).
NOTE
If driven gear assembly is chamfered, install gear facing fuel pump body. If driven gear
assembly has a slot, install gear so slot faces pump body cover.
(13) Install driven gear and shaft assembly (12) in fuel pump body (8).
(14) Lubricate gears and shafts with clean engine oil.
(15) Apply a very thin coat of sealant on pump body cover (7) surface. Do not allow sealant to
enter gear compartment.
(16) Aline fuel pump body (8) with pump body cover (7). Secure with four bolt and Iockwasher
assemblies (6).
4-44
TM 9-2815-202-34
(17) Install four bolts (9) and four
Iockwashers (10). Tighten all bolts
alternately and evenly. Torque bolts
to 7-9 Ib-ft (10-12 N-m).
(18) Rotate drive shaft (5) by hand. Shaft
should rotate freely. If not, gently tap
corner of fuel pump body (8) with
hammer to free up.
e. Installation
(1) Install gasket (3) on fuel pump body
(8).
(2) Install drive coupling fork (4) on
square end of drive shaft (5).
(3) Position inlet opening on pump body
cover (7) (marked L.H. IN) facing
down.
(4) Install fuel pump assembly (2) to
governor housing.
NOTE
Insure drive coupling fork (4) is
alined and contacts slots in the drive
disc.
(5) Install three bolts (1) securing fuel
pump assembly (2) to governor
housing. Torque bolts to 13-17 Ib-ft
(18-23 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4 - 8 Thermostat housing and crossover tubes installed (Except on 7083-7391, 7083-7396, and
7083-7399)
Fuel lines installed (7083-7395 and 7083-7398)
4-6
Fuel lines installed (7083-7396 and 7083-7399)
5-4
5.1-4 Fuel lines installed (7083-7391)
Change
1 4-45
TM 9-2815-202-34
4-13. AIR INLET HOUSING REPLACEMENT
This task covers:
b. Cleaning/Inspection
a. Removal
c. Installation
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
7083-7395 7083-7396
7083-7398 7083-7399
Cleaning solvent (App C, Item 10)
EQUIPMENT CONDITION
TOOLS AND SPECIAL TOOLS
Para Description
4-2
Air inlet tube removed (7083-7395)
4-10 Air box heater removed (7083-7395 and
7083-7396)
5-2
Air inlet tube removed (7083-7396)
6-3
Air inlet tube removed (7083-7398)
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
MANDATORY REPLACEMENT PARTS
3 Lockwashers (App F, Item 93)
1 Gasket (App F, Item 23)
a. Removal
(1) Remove three bolts (1), three flat washers (2), and three Iockwashers (3) securing air inlet
housing (4) and gasket (5) to blower. Remove air inlet housing and gasket. Discard
Iockwashers and gasket.
NOTE
For models 7395 and 7398 only.
(2) If necessary, remove pipe plugs (6 and 7) from air inlet housing (4).
b. Cleaning/Inspection
WARNING
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid contact
with skin, eyes, and clothes. Don’t breathe vapors. Do not use near open
o
o
o
flames or excessive heat. The flash point is 100 F-138 F (38°-50 C). If
you become dizzy while using cleaning solvent, get fresh air immediately
and get medical aid. If contact with eyes is made, wash your eyes with
water and get medical aid immediately.
(1) Clean air inlet housing with cleaning solvent.
4 - 4 6 Change 1
I
TM 9-2815-202-34
WARNING
Compressed air used for cleaning purposes will not exceed 30 PSI. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.).
(2) Dry air inlet housing with compressed air.
(3) Inspect air inlet housing for cracks, warps, or other damage.
Installation
NOTE
For models 7395 and 7398 only
(1) If removed, install pipe plugs (6 and 7).
(2) Install & inlet housing (4) with gasket (5) to blower. Secure with three bolts (1), three
Iockwashers (3), and three flat washers (2). Torque bolts to 16-20 Ib-ft (22-27 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-10 Air box heater installed (7083-7395
and 7083-7396)
4-2
Air inlet tube installed (7083-7395)
Air inlet tube installed (7083-7396)
5-2
Air inlet tube installed (7083-7398)
6-3
Change
1 4-47
TM9-2815-202-34
4-14. TACHOMETER DRIVE REPLACEMENT
This task covers:
a. Removal
b. inspection
c. -Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
All
1 Gasket (App F, Item 75)
EXPENDABLE/DURABLE SUPPLIES
TOOLS AND SPECIAL TOOLS
Engine oil (App C, Item 16)
General mechanics tool kit (App B,Item 96)
a. Removal
(1) Unscrew tachometer drive adapter (1) from adapter fitting (2). Remove key (3).
(2) Unscrew adapter fitting (2) from rear blower cover and remove gasket (4). Discard gasket.
b. Inspection
(1) Inspect key for damage or wear.
(2) Inspect tachometer drive adapter for
damage or cracks.
NOTE
Check for free movement of internal shafts
in tachometer drive adapter.
c. Installation
(1) Install adapter fitting (2) with gasket (4) to
rear blower cover.
(2) Install key (3) to shaft assembly.
(3) Screw tachometer drive adapter (1) onto
adapter fitting (2). Tighten securely.
END OF TASK
4-48
Change 1
TM 9-2815-202-34
4-15. BLOCK MOUNTED CRANKCASE BREATHER REPLACEMENT
This task covers:
a. Removal
b. Inspection
c. -Installation
INITIAL SETUP
MANDATORY REPLACEMENT PARTS
MODELS
■ 7083-7391 7083-7395 7083-7396
4 Lockwashers (App F, Item 91)
2 Gaskets (App F, Item 49)
TOOLS AND SPECIAL TOOLS
EXPENDABLE/DURABLE SUPPLIES
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Gasket cement (App C, Item 39)
a. Removal
(1) Remove two bolts (1) and two
lockwashers (2) securing breather
elbow (3) and gasket (4) to cylinder
head. Discard gasket and
Iockwashers.
(2) Loosen two hose clamps (5) securing
hose (6) to breather Y-tube (7) and
breather elbow (3).
(3) Remove breather elbow (3), hose (6),
and two hose clamps (5).
(4) Remove two bolts (8) and two
lockwashers (2) securing breather
tube (9) and gasket (4) to cylinder
head. Discard gasket and
Iockwashers.
(5) Loosen two hose clamps (10)
securing hose (11) to breather Y tube
(7) and breather tube (9).
(6) Remove breather tube (9), hose 11),
and two hose clamps (1 O).
NOTE
Do not remove breather Y-tube
unless damaged or loose. Removal
requires replacement with new tube.
(7) If necessary, remove breather Y-tube
(7) from block.
Change 1
4-49
TM 9-2815-202-34
4-15. BLOCK MOUNTED CRANKCASE BREATHER REPLACEMENT (Cont)
b. Inspection
(1) Inspect breather tube, breather elbow, and breather Y-tube for cracks, holes, or damage.
(2) Inspect all clamps for wear or damage.
(3) Inspect all hoses for cracks, tears, or damage.
c. Installation
(1) If removed, drive new breather Y-tube (7) into block with a collar and soft hammer. Tube is
seated when distance from block surface to top of tube is 3.85 in. (9.78 cm).
(2) Install hose (6) onto breather Y-tube (7) and snug with hose clamp (5).
(3) Install breather elbow (3) and hose clamp (5) to hose (6). Snug hose clamp (5).
(4) Install breather tube (9), hose (11), and two hose clamps (10). Snug hose clamps (10).
(5) Install hose (11) to breather Y-tube (7). Snug with hose clamp (10).
(6) Apply gasket cement to two gaskets (4).
(7) Install gaskets (4) on cylinder heads.
(8) Aline breather elbow (3) with gasket (4). Secure with two bolts (1) and two Iockwashers (2).
Torque bolts to 7-9Ib-ft(10-12 N-m).
(9) Aline breather tube (9) with gasket (4). Secure with two bolts (8) and two Iockwashers (2)
Torque bolts to 7-9Ib-ft(10-12 N-m).
(lo) Tighten four hose clamps (5 and 10).
END OF TASK
4-50
TM 9-2815-202-34
.
4-51
TM 9-2815-202-34
4-16. BLOWER DRIVE SHAFT AND HUB REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning/Inspection
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
7083-7395 7083-7398
Bolt 10-32 x 1 (App C, Item 33)
Dry cleaning solvent (App C, Item 10)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
EQUIPMENT CONDITION
Para Description
4-2
Turbocharger removed (7083-7395)
Turbocharger removed (7083-7398)
6-3
MANDATORY REPLACEMENT PARTS
6 Lockwashers (App F, Item 95)
1 Gasket (App F,ltem 26)
a. Removal
(1) Remove three bolts (1), two bolts (2), bolt (3), nut (4), flat washer (5), and six lockwashers (6)
securing cover (7) to flywheel housing (8).
(2) Remove cover (7) and cover gasket (9) from flywheel housing (8). Discard gasket.
4-52 C h a n g e 1
TM 9-2815-202-34
(3) Install 10-32 x 1 inch bolt (10) in blower drive shaft(11). Remove snap ring (12) and extract
blower drive shaft. Remove bolt.
NOTE
Place a rag below the hub and spring plate assembly to prevent bolts from falling into
the flywheel housing
(4) Remove three bolts (13) securing hub and spring plate assembly (14) to blower drive gear
(15). Remove hub and spring plate assembly (14).
b. Disassembly
Remove three bolts (16) securing two spring plates (17) to blower drive hub (18).
c. Cleaning/Inspection
WARNING
● Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do not
o
useo nearo open frame or excessive heat. The flash point is 100°F-138 F
(38 C-50 C). If you become dizzy while using cleaning solvent, get
fresh air immediately and get medical aid. If contact with eyes is made,
wash your eyes with water and get medical aid immediately.
● Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shieid, gloves, etc).
(1) Clean all parts with dry cleaning solvent P-D-680 and dry with compressed air.
(2) Examine blower drive shaft. Replace blower drive shaft if splines are worn, cracked, or
otherwise damaged.
(3) Examine blower drive hub. Replace hub if cracked or damaged or if spline is cracked, worn,
or otherwise damaged.
4-53
TM 9-2815-202-34
4-16. BLOWER DRIVE SHAFT AND HUB REPLACEMENT (Cont)
(4) Examine spring plates. Replace if cracked, kinked, or if bolt holes show signs of distortion.
d. Assembly
Attach two spring plates (17) to blower drive hub (18) using three bolts (16). Torque bolts to
35-39 Ib-ft (47-53 N-m).
e. Installation
(1) Attach drive hub and spring plate assembly (14) to blower drive gear (15) using three bolts
(13). Torque bolts to 35-39 lb-ft (47-53 N-m)
(2) Insert 10-32 x l-inch bolt (10) in blower drive shaft (1 1).
4-54
TM 9-2815-202-34
(3) lnsert drive shaft (11)through blower drive gear(15). lf binding occurs, refer to blower
alinement procedure in para 4-18.
(4) Install snap ring (12) in blower drive hub (18). Remove 10-32 x 1- inch bolt (10 ) from shaft
(11).
(5) Install blower drive cover (7) and gasket (9) on flywheel housing (8) and secure with two
bolts (1) and two Iockwashers (6).
(6) Install bolt (1), two bolts (2), bolt (3), two Iockwashers (6), flat washer (5), and nut (4) in
remaining holes.
(7) Torque bolt (3) and nut (4) to 35-39 Ib-ft (47-53 N-m). Torque five remaining bolts to
30-35 Ib-ft (41-47 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-2
Turbocharger installed (7083-7395)
6-3
Turbocharger installed (7083-7398)
Change
1 4-55
TM 9-2815-202-34
4-17. GOVERNOR COVER AND THROTTLE CONTROL ROD
This task covers:
INITIAL
a. Removal
REMOVAL/INSTALLATION
b. Installation
SETUP
MANDATORY REPLACEMENT PARTS
MODELS
1 Gasket (App F, Item 82)
2 Cotter pins (App F, Item 7)
All
EQUIPMENENT CONDITION
Para Description
4-10 Air box heater removed (7083-7395 and
7083-7396)
4-11
Rocker arm covers removed
6-11 Air box heater removed (7083-7398 and
7083-7399)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
a. Removal
(1) Remove eight screw assemblies (1) from governor cover (2).
(2) Remove governor cover (2) and gasket (3). Discard gasket.
NOTE
Position clean rag over cylinder head oil drain holes, left and right bank, to prevent
cotter pins from failing into engine.
(3) Remove two cotter pins (4) and two clevis pins (5) on left and right bank of engine. Discard
two cotter pins (4).
(4) Remove connecting pin (6) and connecting screw (7) from governor (8).
(5) Remove two fuel connecting rods (9 and 10) through ieft and right bank cylinder heads (11).
b. Installation
4-56
(1)
Install fuel control rod (10) through left bank and fuel control rod (9) through right bank,
cylinder heads.
(2)
Connect right bank control rod (9) in governor (8) with connecting screw (7).
(3)
Connect left bank control rod (10) in governor (8) with connecting pin (6).
(4)
Install two clevis pins (5) in right and left bank fuel control tube clevs (12) and fuel control
rods (9 and 10).
(5)
Install two cotter pins (4) in clevis pins (5) on left and right banks.
Change 1
TM9-2815-202-34
NOTE
Remove rag from cylinder head oil drain holes left and right bank.
Insure throttle control arm pin (13) is engaged in fork (14).
(6) Position gasket (3) and governor cover (2) on governor (8). Secure with eight screw
assemblies (1).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-11 Rocker arm covers installed
4-10 Air box heater installed (7083-7395 and 7083-7396)
6-11 Air box heater installed (7083-7398 and 7083-7399)
Change 1 4-57
TM 9-2815-202-34
4-18. GOVERNOR AND BLOWER ASSEMBLY REMOVAL/lNSTALLATION
This task covers:
a: Removal
b: Installation
INITIAL SETUP
MODELS
EQUIPMENT CONDITION
All
Para
4-2
4-10
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Multiple sling (App B, [tern 83)
Torque wrench (App B, Item 101)
MANDATORY REPLACEMENT PARTS
1 Gasket (App F,ltem 56)
1 Gasket (App F,ltem 65)
2 Copper washers (App F, Item 164)
8 Lockwashers (App F, Item 92)
1 Hose (App F,ltem 84)
2 Hoses (App F, Item 85)
a. Removal
(1) Loosen four clamps (1). Slide two
hoses (2) up on governor fuel rod
tubes (3) clear of cylinder heads.
(2) Disconnect oil tube nuts (4 and 5) on
tube (6). Slide oil tube into fitting (7).
(3) Loosen two clamps (8) on hose
assembly (9).
(4) Remove two bolts (10) and flat
washers (11) securing blower (12) to
engine block (13).
(5) Remove six bolts (14) and retaining
clips (15) securing blower (12) to
engine block (13).
NOTE
When removing blower, lift blower
up slightly and move blower forward
to detach from hose.
(6) Using multiple sling, lift blower (12)
up from engine block (13). Remove
blower gasket (16). Discard gasket.
4 - 5 8 Change 1
Description
Turbocharger removed (7083-7395)
Air box heater removed (7083-7395 and
7083-7396)
4-11 Rocker arm covers removed
4-12 Fuel Dump removed
4-13 Air inlet housing removed (Except
7083-73911
4-16 Blower drive shaft removed (7083-7395
and 7083-7398)
4-17 Governor rover and throttle
control rods removed
5-15 Blower drive shaft removed (7083-7391,
7083-7396, and 7083-7399)
5.1-11 Air inlet housing removed (7083-7391)
Turbocharger removed (7083-7398)
6-3
6-11 Air box heater removed (7083-7398 and
7083-7399)
TM 9-2815-202-34
(7) Remove four clamps (1) and two
hoses (2) from left and right governor
fuel rod tubes (3). Discard hoses.
(8) Remove two clamps (8) and blower
drive hose (9) from flange (17).
Remove cover (18) from inside of
hose (9), Discard hose.
(9) Remove tube (6) with oil tube nuts (4
and 5). Remove oil tube fitting (7).
Remove bolts (19 and 20) and two
copper washers (21) from governor
assembly. Discard copper washers.
NOTE
Two bolts (22) are inside governor housing assembly.
(11) Remove eight bolts (22), eight Iockwashers (23), and eight washers (24). Discard
Iockwashers.
(12) Tap sides of governor housing (25) lightly with soft hammer to loosen governor from
blower.
(13) Remove governor housing (25) and gasket (26) from blower housing (12). Discard gasket.
b. Installation
(1) Position governor to blower gasket (26) on blower housing (12).
(2)
Install governor housing (25) on blower housing (12).
(3)
Install bolt (19) and copper washer (21). Torque bolt to 13-17 Ib-ft (18-23 N-m).
(4)
Install bolt (20) and copper washer (21). Torque bolt to 13-17 Ib-ft (18-23 N-m).
(5)
Install eight bolts (22), eight Iockwashers
(23), and eight washers (24). Torque bolt
to 13-17 Ib-ft (18-23 N-m).
Change 1 4 - 5 9
TM 9-2815-202-34
4-18. GOVERNOR AND BLOWER ASSEMBLY REMOVAL/lNSTALLATION (Cont)
(6) Aline holes in new gasket (1 6). Place gasket (16) on engine block (1 3).
(7) Position cover (18) in hose assembly (9). Install hose assembly (9) and two clamps (8) on
blower drive support (27).
(8) Install oil tube fitting (7) on blower. Tighten securely.
(9) Slide oil tube (6) with oil tube nuts (4 and 5) into oil tube fitting (7).
(10) Position two hoses (2) and four clamps (1) on governor housing fuel rod tubes (3).
CAUTION
Lower blower assembly carefully onto block to avoid damaging or moving gasket.
NOTE
Attach sling to blower. Lift blower assembly at a slight angle. Lower blower on top of
cylinder block with flange of rear end plate cover inside of seal ring.
(11) Install two bolts (10) and two washers (11) securing blower (12) to block (1 3). Hand tighten.
NOTE
Lip on beveled end of retaining clip (15) goes in small recess in blower housing.
4-60
TM
9-2815-202-34
(12) Install six bolts (14) and six retaining clips (15) securing blower to block. Hand tighten only.
(13) Thread blower drive shaft (28) on 10-32 x 1 inch bolt (29). Position blower so shaft can be
removed and installed easily without drag.
o
(14) Install blower drive shaft (28) using bolt (29). Rotate rotors of blower in 90 increments while
removing and inserting drive shaft. Position blower as necessary. Check alinement at 90°
increments through full 360° of blower rotation.
(15) Torque two bolts (10) to 40-45 Ib-ft (54-61 N-m). Securing blower to cylinder block.
(16) Torque six side angle bolts (14) uniformly to 30-35 Ib-ft (41-47 N-m) in 5 Ib-ft (7 N-m)
increments.
(17) Remove blower drive shaft (28) using bolt (29).
(18) Remove bolt (29) from blower drive shaft (28).
(19) Position hose (9). Tighten two clamps (8) on hose assembly (9).
(20) Tighten oil tube nut (5) to fitting (7) and oil tube nut (4) to blower drive support (27).
(21) Position two hoses (2) on governor fuel rod tubes (3) and tighten four clamps (1).
END OF TASK
FOLLOW-ON MAINTENANCE
Para
6-11
6-3
5-15
5.1-11
4-17
4-16
4-13
4-12
4-11
4-10
4-2
Description
Air box heater installed (7083-7398 and 7083-7399)
Turbocharger installed (7083-7398)
Blower drive shaft installed (7083-7391, 7083-7396, and 7083-7399)
Air inlet housing installed (7083-7391 )
Governor cover and throttle control rods installed
Blower drive shaft installed (7083-7395 and 7083-7398)
Air inlet housing installed (Except 7083-7391 )
Fuel pump installed
Rocker arm covers installed
Air box heater installed (7083-7395 and 7083-7396)
Turbocharger installed (7083-7395)
C h a n g e 1 4-61
TM 9-2815-202-34
4-19. BLOWER DRIVE GEAR AND SUPPORT REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. -Cleaning/Inspection
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
ALL
Engine oil (App C, Item 16)
4 Bolts 3/8-24 x 4-1/2 (App C, Item 5)
Nut 3/8-24 (App C, Item 29)
Dry cleaning solvent (App C, Item 10)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Dial indicator (App B, Item 44)
Micrometer (1-2") (App B, Item 65)
Vernier caliper (App B, Item 10)
Torque wrench (App B, Item 101)
MANDATORY REPLACEMENT PARTS
1 Gasket (App F, Item 69)
1 Key washer (App F, Item 167)
2 Copper washers (App F, Item 163)
a. Removal
(1) Remove two bolts (1) and two copper
washers (2) securing blower drive
support assembly (3) to rear end
plate. Discard copper washers.
(2) Remove blower drive gear support
assembly (3) and gasket (4) from rear
end plate. Discard gasket.
b. Disassembly
(1) Clamp blower drive gear support
assembly (3) in a soft-jawed vise with
blower drive gear (5) on top.
(2) Straighten tangs on key washer (6).
Remove nut (7). Discard key washer.
(3) Remove thrust washer (8), thrust
bearing (9), gear (5), and thrust
bearing (10) from gear support (11).
4-62
Change 1
EQUIPMENT CONDITION
Para Description
4-15 Breather removed
4-16 Blower drive shaft and hub removed
■
(7083-7395 and 7083-7398)
4-18 Blower removed
5-15 Blower drive shaft and hub removed
(7083-7391, 7083-7396, and 7083-7399)
.
TM
9-2815-202-34
c. Cleaning/lnspection
WARNING
● Dry cleaning solvent P-D-680 Is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do noto
use nearo open flame or excessive heat. The flash point is 100°F-138 F
(38°C-50 C). If you become dizzy while using cleaning solvent, get
fresh air immediately and get medical aid. If contact with eyes is made,
wash your eyes with water and get medical aid immediately.
Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves, etc.)
(1) Clean all parts with dry cleaning solvent and dry with compressed air.
(2) Insure oil passage in gear support (11) is not clogged.
(3) Examine thrust washer (8) and thrust bearings (9 and 10). Replace if scored or worn.
(4) Using micrometer, measure outside diameter of blower drive gear support shaft (11).
Diameter must be between 1.6240 inches minimum and 1.6250 inches maximum. Replace
blower drive gear support if diameter is not within limits.
(5) Examine teeth of blower drive gear (5). Replace gear if teeth are scored, pitted, worn, or
missing.
(6) Using vernier caliper, measure inside diameter of blower drive gear bearing (5). Replace
gear if inside diameter is more than 0.005 inches larger than outside diameter of blower
drive gear support shaft.
4-63
TM 9-2815-202-34
4-19. BLOWER DRIVE GEAR AND SUPPORT REPLACEMENT (Cont)
d. Assembly
(1) Clamp blower drive gear support (11 ) in a soft-jawed vise with drive gear support shaft on
top.
(2) Lubricate blower drive gear support shaft (11), blower drive gear bearing (5) inside diameter,
thrust bearings (9 and 10), and thrust washer (8) with clean engine oil.
(3) Install thrust bearing (10) on drive gear support (11) with tang alined with slot in support,
(4) Install blower drive gear (5) on drive gear support (11) with flat side of gear towards support.
(5) Install thrust bearing (9) on drive gear support (11) with flat side towards gear (5).
(6) Install thrust washer (8) on drive gear support (11) with slots alined to tangs on thrust bearing
(9) and alining tab in slot of drive gear support shaft.
(7) Install lock plate (6) on drive gear support shaft (11) with alining tab in slot of shaft.
NOTE
Blower drive gear (5) must turn freely after torque is applied.
(8) Install nut (7) on drive gear support shaft and torque to 50-60 Ib-ft (68-81 N-m).
(9) Using a set of feeler gages, measure clearance between thrust washer (8) and thrust
bearing (9). Minimum allowable clearance is 0.005 and maximum allowable clearance is
0.010 inches for new parts or 0.012 inches for used parts.
(10) Bend tangs on lock plate (6) to secure nut (7).
4-64
TM 9-2815-202-34
e. Installation
(1) Install a drive gear support gasket (4) on drive gear support assembly (3).
(2) Insert drive gear support assembly through rear end plate so blower drive gear meshes with
right bank camshaft gear.
(3) Install two bolts (1) and two copper flat washers (2) in two lower holes of blower drive
support assembly (3). Torque bolts to 25-30 Ib-ft (34-41 N-m).
(4) Install four bolts (12) , 3/8-24 x 4 1/2 inch, and one nut (13), 3/8-24, in remaining four holes of
blower drive support. Bolts to be installed from rear to front. Torque bolts to 25-30 Ib-ft (34-41
N-m).
(5) Using dial indicator, measure backlash between blower drive gear and right bank camshaft
gear. Backlash must be between 0.002 inches minimum and either 0.008 inches maximum
with new gears or 0.010 inches maximum with used gears.
(6) Remove four bolts (12), 3/8-24 x 4 1/2 inch, and one nut (13), 3/8-24.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
5-15 Blower drive shaft and hub installed (7083-7391, 7083-7396, and 7083-7399)
4-18 Blower installed
4-16 Blower drive shaft and hub installed (7083-7395 and 7083-7398)
4-15 Breather installed
Change
1 4-65
TM 9-2815-202-34
4-20. OIL PAN REPLACEMENT
This task covers:
a. Removal
b. Cleaning/Inspection
c. -Installation
INITIAL SETUP
MANDATORY REPLACEMENT PARTS
MODELS
■ All
1 Gasket (App F, Item 30)
2 Lockwashers (App F,ltem 93)
TOOLS AND SPECIAL TOOLS
EXPENDABLE/DURABLE SUPPLIES
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Gasket cement (App C, Item 39)
Fuel oil (App C, Item 21)
a. Removal
(1) Remove two bolts (1) and two Iockwashers (2) from flywheel housing (3). Discard
Iockwashers.
(2) Remove two bolts (4) and two flat washers (5) from rear corners of oil pan (6).
(3) Remove twenty-six bolts (4) from oil pan (6).
(4) Remove oil pan (6) and gasket (7). Discard gasket.
(5) If required, remove following fittings from oil pan:
(a) For models 7083-7395 and 7083-7398, two plugs (8), plug (9), and plug (10).
(b) For models 7083-7391,7083-7396, and 7083-7399, plug (8), plug (9), dipstick adaptor (11),
and turbocharger drain elbow (12).
(c) For models 7083-7391 and 7083-7396, bushing (13).
b. Cleaning/Inspection
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/ shield, gloves, etc).
(1) Clean oil pan with fuel oil and dry with compressed air.
(2) Inspect pan for holes, cracks, and other damage which may require replacement. Check for
misalined flanges or raised surfaces surrounding bolt holes.
4-66 Change 1
TM
9-2815-202-34
c. Installation
(1) Coat upper flange of oil pan (6) with gasket cement.
(2) Install cork gasket (7) by alining holes in gasket with holes in oil pan (6).
(3) Position oil pan and gasket on cylinder block.
(4) Install two bolts (4) in right and left center holes of oil pan (6).
(5) Install two bolts (4) and two flat washers (5) in rear corners of oil pan.
(6) Install twenty-four bolts (4) in oil pan and tighten finger tight.
(7) Install two bolts (1) and two Iockwashers (2) to flywheel housing (3).
(8) Torque twenty-eight oil pan bolts (4) to 10-20 Ib-ft (14-27 N-m) starting with center bolts and
working alternately towards each end.
(9) Torque two bolts (1) to 30-35 Ib-ft (41-47 N-m).
END OF TASK
Change
1 4-67
TM 9-2815-202-34
4-21. CAMSHAFT FRONT GEAR COVER REPLACEMENT
This task covers:
a. Removal
b. Inspection
c. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395 7083-7398
1 Gasket (App F, Item 46)
1 Gasket (App F, Item 48)
Lockwasher (App F, Item 95)
1 Lockwashers (App F, Item 93)
1 Jam nut (App F, Item 86)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
EQUIPMENT CONDITION
Para
4-5
4-7
4-9
Description
Fuel strainer bracket removed
Front lifter bracket removed
Water pump removed
a. Removal
(1) Remove two self tapping bolts (1) securing access cover (2) and gasket (3) to assembly
cover (4). Discard gasket.
NOTE
Bolts securing assembly cover vary in length and diameter. For ease of assembly note
location of bolts, washers, and nuts when removing.
(2) Remove five bolts (5), four nuts (6), five Iockwashers (7), and five flat washers (8). Remove
bolt (5), jam nut (9), and Iockwasher (7). Discard Iockwashers and jam nut.
(3) Remove bolt (10), Iockwasher (11), and flat washer (12). Discard Iockwasher.
(4) Remove two bolts (13), two Iockwashers (7), and two flat washers (8). Discard Iockwashers.
(5) Remove bolt (14) and flat washer (15).
(6) Remove assembly cover (4) and gasket (16) from block. Discard gasket.
b. Inspection
Inspect assembly cover and access cover for cracks, pitting, or damage.
4-68
TM 9-2815-202-34
c. Installation
(1) Install access cover (2), gasket (3), and two self tapping bolts (1) to assembly cover (4).
Torque bolts to 13-17 Ib-ft (18-23 N-m).
NOTE
Assemble top three bolts with nuts toward front of engine.
(2) Install assembly cover (4) and gasket (16) to block. Secure with five bolts (5), five flat
washers (8), five Iockwashers (14), and four nuts (6). Torque bolts to 30-35 Ib-ft (41-47 N-m).
(3) Install bolt (5), Iockwasher (7), and jam nut (9). Torque bolt to 30-35 Ib-ft (41-47 N-m).
(4) Install bolt (10), Iockwasher (11), and flat washer (12). Torque bolt to 71-75 Ib-ft
(96-102 N-m).
(5) Install two bolts (13), two Iockwashers (7), and two flat washers (8). Torque bolts to
30-35 Ib-ft (41-47 N-m).
(6) Install bolt (14) and flat washer (15). Torque bolt to 137-147 Ib-ft (186-200 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-9
Water pump installed
4-7
Front lifter bracket installed
4-5
Install fuel strainer bracket
4-69
TM 9-2815-202-34
4-22. FLYWHEEL ASSEMBLY REPLACEMENT
This task covers:
a. Removal
d. Installation
b. Cleaning/Inspection
e. Test
c. Repair
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
All
8 Bolts (App F, Item 3)
EXPENDABLE/DURABLE SUPPLIES
TOOLS/SPECIAL TOOLS
Cleaning solvent (App C, Item 10)
Heat indicating crayon (App C, ltem 23)
Wood block (App C, Item 46)
International compound no.2
(App C, Item 24)
General mechanics tool kit (App B, Item 96)
Multiple sling (App B, Item 83)
Guide studs (App B, Item 86)
Torque wrench (App B, Item 101)
Dial indicator gage (App B, Item 44)
Flywheel housing gage (App B, Item 30)
a. Removal
NOTE
To aid in reinstallation, aline and mark two holes of scuff plate, crankshaft, and flywheel
assembly.
(1) Attach multiple sling (1) to flywheel (2) with two 3/8-16 eye bolts (3).
(2) Attach lifting sling (1) to chain hoist (4).
(3) Remove two flywheel attaching bolts (5) and discard. Install two guide studs (6) in bolt holes
to support flywheel assembly (2).
(4) Remove six remaining flywheel attaching bolts (5) and scuff plate (7). Discard bolts.
(5) Remove flywheel assembly (2) from crankshaft (8) and flywheel housing (9).
(6) Remove guide studs (6) from crankshaft (8).
4-70
Change 1
TM
9-2815-202-34
b. Cleanlng/inspection
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid contact
with skin, eyes, and clothes and don’t breathe vapors.o Do not use o near
o
open flame or excessive heat. The flash point is 100 F-138°F (38 -50 C).
If you become dizzy while using cleaning solvent, get fresh air
immediately and get medical aid. If contact with eyes is made, wash your
eyes with water and get medical aid immediately.
(1) Clean flywheel assembly with cleaning solvent.
NOTE
Although flywheels seldom require replacement, flywheel ring gear may become worn
due to normal usage or damaged by improper use of starting motor. If gear is worn or
damaged, a new replacement gear is required.
(2) Check flywheel assembly for cracks,
worn teeth, or other damage.
(3) Check end of crankshaft and flywheel
mating surface for fretting or
brinelling. If this condition is light,
lightly stone surface to remove.
4-71
TM 9-2815-202-34
4-22. FLYWHEEL ASSEMBLY REPLACEMENT (Cont)
c. Repair
(1) Remove ring gear (10)from flywheel as follows:
(a) Place flywheel assembly (2), crankshaft side down, on a solid flat surface or hardwood
blocks which fit inside diameter of flywheel.
(b) Drive gear (10) off flywheel using a brass drift and hammer. Work around circumference
of ring gear to avoid binding.
4-72
TM 9-2815-202-34
(2) Install ring gear (10) on flywheel (2) as follows:
(a) Place flywheel (2), crankshaft side up, on a solid flat surface.
CAUTION
If a torch is used, keep torch moving around circumference of gear to avoid hot spots.
o
o
Under no circumstances should gear be heated over 400 F (204 C). Excessive heat
may destroy original heat treatment. Heat indicating “crayon”, which melts at a
predetermined temperature, should be placed on work surface to determine heat
range.
(b) Place ring gear (10) on a metal surface and heat uniformly. Heat source can be a blow
torch, acetylene torch (11), or oven.
(c) After ring gear has been heated, place it in position on flywheel (2) with chamfer side up.
(d) Tap ring gear into place against shoulder of flywheel. Working around circumference to
avoid binding.
NOTE
If ring gear cannot be tapped into place readily, remove ring gear and apply additional
heat. Follow above caution about not overheating ring gear.
4-73
TM 9-2815-202-34
4-22. FLYWHEEL ASSEMBLY REPLACEMENT (Cont)
d. Installation
(1) Apply International Compound No. 2 or equivalent to threads and to bolt head contact area
(underside) of all flywheel attaching bolts (5). Threads must be completely filled with
compound and excess removed.
(2) Insert two guide studs (6) into crankshaft flywheel bolt holes.
(3) Attach flywheel lifting sling (1) to flywheel assembly (2) using two eye bolts (3).
(4) Using chain hoist (4), lift and guide flywheel assembly (2) into flywheel housing (9).
(5) Aline flywheel bolt holes with crankshaft bolt holes marked at removal. Guide flywheel
assembly (2) onto guide studs (6).
(6) Install scuff plate (7) and two bolts (5) 180 degrees apart. Snug bolts to hold scuff plate and
flywheel assembly (2) in place on crankshaft (8).
(7) Remove lifting sling (1) and two eye bolts (3) from flywheel (2).
(8) Remove two guide studs (6). Install remaining six bolts (5) and run in snug.
(9) Using torque wrench, tighten eight bolts
(5) to 50 Ib-ft (68 N-m) torque.
NOTE
(10)
4-74
TM9-2815-202-34
4-22. FLYWHEEL ASSEMBLY REPLACEMENT (Cont)
e. Testing
(1) Flywheel face runout
a.
Mount dial indicator (12) on
flywheel housing (9) with dial
indicator needle against clutch
contact face.
b.
Pry flywheel toward engine block
(at six o’clock position) to insure
end play is in one direction,
c.
Adjust dial indicator to read zero
at twelve o’clock position.
CAUTION
When using hexagon head bolt at
front of crankshaft to turn crankshaft,
always turn bolt clockwise. Serious
engine damage may result if bolt
becomes loose.
d. Rotate crankshaft and record readings at 60 degree intervals (6 readings). Pry flywheel
toward engine block before taking each reading.
NOTE
●
Runout is the maximum negative reading plus the maximum positive reading. For
example, if maximum readings were 0.004 and -0.007 inch, then runout is 0.011
inch.
●
Maximum allowable runout is 0.001 inch per inch of radius. Measure radius from
center of flywheel to dial indicator needle (clutch contact face). For example if the
radius is 12 inches, then the runout should be less than 0.012 inch.
e.
If flywheel face runout exceeds its maximum limit, remove flywheel and check for dirt or
foreign material between crankshaft and flywheel. Remount flywheel. If readings are still
out of limits, replace flywheel.
4-75
TM 9-2815-202-34
4-22. FLYWHEEL ASSEMBLY REPLACEMENT (Cont)
(2) Flywheel housing bore concentricity
and face runout
a.
Mount dial indicator base (12) to
flywheel (2).
b. Position one dial indicator(13)
perpendicular to flywheel
housing bell face and a second
dial indicator (14) against
flywheel housing bell bore.
c.
Pry flywheel toward engine block
(at six o’clock position) to insure
end play is in one direction.
d. Adjust dial indicators to read zero
at twelve o’clock position.
CAUTION
When using hexagon head bolt at front of crankshaft to turn crankshaft, always turn bolt
clockwise. Serious engine damage may result if bolt becomes loose.
NOTE
● Total
indicator reading is the maximum negative reading plus the maximum positive
reading. For example, if maximum readings were 0.004-and-0.007 inch, then runout
is 0.011 inch.
● Maximum
total indicator reading must not exceed 0.013 inch for either bore
concentricity or face runout.
e.
Rotate crankshaft and record readings at 60 degree intervals (6 readings each for bell
bore and face). Pry flywheel toward engine block before taking each reading.
f.
If bore concentricity or face runout exceeds its maximum limit, remove flywheel housing
and check for foreign material on end plate, flywheel housing, and cylinder block
mounting surfaces. Remount end plate and housing. If either reading is still out of limits,
replace flywheel housing (see Para 4-24).
END OF TASK
4-76
TM
9-2815-202-34
4-23. REAR OIL SEAL REPLACEMENT
This task covers:
a. Removal
b. Cleaning/Inspection
c. -Installation
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
■ All
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Magnetic base dial indicator
(App B, Item 45)
Seal expander (App B, Item 17)
Seal installer (App B, Item 51 )
Installer handle (App B, Item 51 )
Guide studs (App B, Item 86)
Guide studs, seal installer (App B, Item 51)
Engine oil (App C, Item 16)
2 Metal screws (App C, Item 34)
2 Flat washers (App C, Item 17)
Crocus cloth (App C, Item 12)
Nonhardening sealant (App C, Item 38)
EQUIPMENT CONDITION
Para Description
4-22 Flywheel removed
MANDATORY REPLACEMENT PARTS
Oil seal (App F, Item 106)
a. Removal
(1) Center punch two holes in oil seal
casing (1) on opposite sides.
(2) Install two #10 x 1-1/4 inch metal
screws (2) and two flat washers (3).
CAUTION
Do not pry against crankshaft or
gouging will result.
(3) Remove seal by prying against
washers with pry bars. Discard seal.
Change
1
4-77
TM 9-2815-202-34
4-23. REAR OIL SEAL REPLACEMENT (Cont)
b. Cleaning/Inspection
(1) Clean flywheel housing seal bore.
CAUTION
Do not polish parallel to crankshaft
or ridges will result and cause oil
leakage.
(2) Inspect rear end of crankshaft (4) for
wear due to rubbing action of oil seal
(5), dirt build up, or fretting by action
of flywheel. Remove slight ridges from
crankshaft by polishing with crocus
cloth in circular motion.
CAUTION
Rotate crankshaft in counterclockwise direction only. Do not rotate crankshaft bolt
clockwise or loosening will result.
(3) Check runout of seal bore by mounting a dial indicator on crankshaft and note reading while
crankshaft is rotated. Measure with flywheel housing installed on engine and seal removed.
Maximum runout of bore is 0.008 inch.
c. Installation
CAUTION
● Crankshaft
surface must be clean and smooth to prevent damage to seal lip when a
new seal is installed.
● Do
not scratch or nick sealing edge of oil seal or oil leakage past seal will result.
NOTE
If new seal is not precoated, apply a nonhardening sealant to metal casing.
(1) Coat lip of rear oil seal (5) with engine oil.
(2) Install two guide studs (6) and oil seal expander (7) to end of crankshaft.
(3) Position seal (5) with lip pointed toward inner face of housing. Slide seal over seal expander
(7) and onto crankshaft. Remove seal expander and guide studs.
(4) Using seal installer (8), guide studs (9), and driver handle (10), drive seal in place.
(5) Remove seal installer (8) and guide studs (9).
(6) Remove excess sealant from flywheel housing or seal.
4-78
TM 9-2815-202-34
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-22 Install flywheel
4-79
TM 9-2815-202-34
4-24. FLYWHEEL HOUSING REPLACEMENT
This task covers:
a. Removal
b. Cleaning/Inspection
c. -Installation
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
All
Engine oil (App C, Item 16)
Grease (App C, Item 22)
Cleaning solvent (App C, Item 10)
Nonhardening sealant (App C, 39)
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General Mechanics Tool Kit (App B, Item 96)
Torque wrench (App B, Item 101)
Guide studs (App B, Item 86)
Multiple sling (App B, Item 83)
Para Description
4-2
Turbocharger mounting bracket removed
(7083-7395)
4-19 Blower drive removed
4-20 Oil pan removed
4-22 Flywheel removed
4-23 Rear oil seal removed
Exhaust manifold and tube removed
6-4
(7083-7398)
6-16 Crankcase breather removed
MANDATORY REPLACEMENT PARTS
21 Lockwashers (App F,ltem 93)
8 Lockwashers (App F,ltem 95)
1 Gasket (App F, Item 66)
2 Gasket (App F, Item 25)
2 Gasket (App F, Item 26)
1 Copper washer (App F, Item 163)
a. Removal
NOTE
When removing flywheel housing bolts, note location of various size bolts and washers
so they may be reinstalled in their proper location.
(1) Install two eye bolts (1) to top of flywheel housing (2). Attach multiple sling (3) to eye bolts.
NOTE
Effective after engine number 8VA-349268, bolt (4) and flat washer (5) replaced three
bolts (6) and three flat washers (7) on left side of flywheel housing.
(2) Remove bolt (4), flat washer (5), three bolts (6), three flat washers (7), six bolts (8), and six
flat washers (9) from bell of flywheel housing.
4-80
Change 1
TM 9-2815-202-34
(3) Thread four guide studs (10) into cylinder block to guide flywheel housing clear of
crankshaft.
(4) Remove seven bolts (11 ) and seven lockwashers (12) from upper part of flywheel housing.
Discard Iockwashers.
(5) Remove two bolts (13) and two Iockwashers (14) from front of flywheel housing. Discard
Iockwashers.
(6) Remove four nuts (15), four Iockwashers (16), four bolts (17), and four flat washers (18) from
access cover (19). Remove two bolts (20) and two Iockwashers (21) from cover (19). Remove
cover (19) and gasket (22) from flywheel housing. Discard gasket and Iockwashers.
C h a n g e
1 4-81
TM 9-2815-202-34
4-24. FLYWHEEL HOUSING REPLACEMENT (Cont)
(7) For models 7083-7391,7083-7395, and 7083-7396, remove five bolts. (23), five Iockwashers
(24), bolt (25), and copper washer (26) from right bank flywheel housing cover (27). Remove
cover (27) and gasket (28) from flywheel housing. Discard gasket, copper washer, and
Iockwashers.
(8) Remove bolt (29) and Iockwasher (30) from right side of flywheel housing behind cover (27).
Discard Iockwasher.
NOTE
■
For model 7083-7395, remove four bolts (31) and four Iockwashers (32) (other four
attaching bolts and Iockwashers were removed with turbocharger mounting bracket).
For models 7083-7391,7083-7396, 7083-7398, and 7083-7399, remove eight bolts (31)
and four Iockwashers (32).
(9) Remove two bolts (33), two flat washers (34), bolts (31 ), and Iockwashers (32) from two
flywheel housing inspection covers (35). Remove covers and mating gaskets (36) from
flywheel housing. Discard gaskets and Iockwashers.
NOTE
Effective after engine number 8VA-349268, shim (37) is used with flywheel housing.
(1 O) Strike front face of housing on each side alternately with a soft headed hammer to work it off
dowels and away from cylinder block end plate. Remove housing (2), shim (37), and
flywheel housing gasket (38) from engine. Discard gasket.
(11) Remove four guide studs (10) from cylinder block.
b. Cleaning/Inspection
WARNING
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid contact
with skin, eyes, and clothes and don’t breathe vapors. Do not use near
o
o
open flame or excessive heat. The flash point is 100 F-138°F (38°-50 C).
If you become dizzy while using cleaning solvent, get fresh air
immediately and get medical aid. If contact with eyes is made, wash your
eyes with water and get medical aid immediately.
(1) Clean the flywheel housing with cleaning solvent.
(2) Inspect flywheel housing for cracks or damage.
4 - 8 2 Change 1
TM 9-2815-202-34
c. Installation
(1) Lubricate gear teeth with clean engine oil.
NOTE
Effective after engine number 8VA-349268, shim (37) is used with flywheel housing.
(2) Affix gasket (38) to flywheel housing (2) using nonhardening sealant. Install shim (37) to
integral cast spacer on flywheel housing using grease to hold it in position.
(3) Thread four guide studs (1 O) into cylinder block to guide housing in position.
(4)
Using multiple sling (3) and chain hoist, position flywheel housing over crankshaft and up
against cylinder block end plate.
4-83
TM9-2815-202-34
4-24. FLYWHEEL HOUSING REPLACEMENT (Cont)
NOTE
•
Install all flywheel housing attaching bolts finger tight.
•
Insure shim (37) is in position before installing bolt (4) and flat washer (5).
•
Effective after engine number 8VA-349268, bolt (4) and flat washer (5) is used with
flywheel housing.
(5) Install bolt (4), flat washer (5), three bolts (6), and three flat washers (7) into bell area of
flywheel housing.
(6) Remove four guide studs (10). Install six bolts (8) and six flat washers (9) into bell area of
flywheel housing.
(7) Install seven bolts (11) and seven Iockwashers (12) to upper partof flywheel housing.
(8) Install two bolts (13) and two Iockwashers (14) to front of flywheel housing (one on each
side).
(9) Install gasket (22) and access cover (19) to left bank inspection hole in flywheel housing.
Secure in place with four bolts (17), four flat washers (18), four Iockwashers (16), four nuts
(15),t wo bolts (20), and two Iockwashers (21). Torque two bolts (20) to 30-35 Ib-ft
(41-47 N-m).
4 - 8 4
Change 1
TM 9-2815-202-34
(10) Install bolt (29) and Iockwasher (30) to right side of flywheel housing.
When tightening idler gear hub bolts, turn engine crankshaft to prevent any bind of idler
gear bearing. Also rotate crankshaft when tightening flywheel housing bell bolts.
(11 ) Tighten flywheel housing attaching bolts to specifications shown in Table 4-1 (Operation 1).
Draw mating parts together evenly. See Operation 1 figure for initial bolt tightening
sequence.
(12) Torque all flywheel housing attaching bolts to specifications shown in Table 4-1
(Operation 2). Refer to Operation 2 figure for final bolt tightening sequence.
TABLE 4-1
Three 3/8-24x4 1/2 inch bolts and one 3/8-24x4 3/4 inch bolt required for model 7083-7398.
OPERATION 1
OPERATION 2
4-85
TM 9-2815-202-34
4-24. FLYWHEEL HOUSING REPLACEMENT (Cont)
NOTE
Cover (27) is not used on models 7083-7398 and 7083-7399.
(13)
Install gasket (28) and cover (27) to right side of flywheel housing. Secure in place with five
bolts (23), five Iockwashers (24), bolt (25), and copper washer (26). Torque bolts to 30-35 lbft (41-47 N-m).
NOTE
● Do not torque cover bolts until turbocharger mounting bracket is installed (model
7083-7395).
● For model 7083-7395, install four bolts (31) and four Iockwashers (32). For models
7083-7391, 7083-7396, 7083-7398, and 7083-7399, install eight bolts (31) and four
Iockwashers (32).
(14) Install two gaskets (36) and two covers (35) to flywheel housing. Secure in place with two
bolts (33), two flat washers (34), bolts (31), and Iockwashers (32). Torque bolts to 30-35 Ib-ft
(41-47 N-m).
(15) Remove lifting sling (3) and two eye bolts (1) from flywheel housing (2).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
6-16 Install crankcase breather
Install exhaust manifold and tube
6-4
(7083-7398)
4-23 Install rear oil seal
4-22 Install flywheel
4-20 install oil pan
4-19 Install blower drive
Install turbocharger mounting
4-2
bracket (7083-7395)
■
4-86
Change 1
TM9-2815-202-34
4-25. IDLER GEAR REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning/Inspection
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT (PARTS)
All
6 Bolts (App F, Item 4)
EXPENDABLE/DURABLE SUPPLIES
TOOLS/SPECIAL TOOLS
Fuel oil (App C, Item 21)
Engine oil (App C, Item 16)
Lintless cord (App C, Item 26)
General mechanics tool kit (App B, Item 96)
Bearing test fixture (App D, Item 2)
Magnetic base dial indicator
(App B, Item 45)
Spring scale (App B, Item 24)
Torque wrench (App B, Item 101)
EQUIPMENT CONDITION
Para Description
4-24 Flywheel housing removed
NOTE
Before removing idler gear
assembly from engine, check idler
gear assembly for any wobble or
shake. Firmly grasp rim of gear with
both hands and rock it. If gear
wobbles or shakes, bearing is bad
and must be replaced.
a. Removal
(1) Remove bolt (1) and flat washer (2)
securing idler gear assembly (3) to
cylinder block. Remove idler gear
assembly from engine block.
NOTE
Effective up to engine number
8VA-349267, a dummy hub was
installed opposite idler gear hub to
fit the original flywheel housing.
4.
(2) Remove bolt (4) and flat washer (5)
securing dummy hub (6) to cylinder
block. Remove dummy hub (6) from
engine block.
Change 1
4-87
TM 9-2815-202-34
4-25. IDLER GEAR REPLACEMENT (Cont)
b. Disassembly
(1) Remove six bolts (7) securing bearing
retainer (8) to idler gear assembly (3).
Remove retainer. Discard bolts.
NOTE
Each bearing cone and bearing cup
of idler gear assembly are a
matched set. During disassembly,
match mark bearing to cup to
ensure proper reassembly.
(2) Place idler gear assembly (3) in arbor
press with inner bearing cone
supported on steel blocks.
CAUTION
Idler gear assembly (3) must be
rotated during pressing operation to
prevent damage to bearing cones (9
and 10).
(3) Simultaneously rotate idler gear
assembly (3) and press hub (11) out
of bearing cones (9 and 10). Remove
gear assembly from press.
(4) Remove bearing cones (9 and 10)
and inner spacer ring (12).
4-88
TM
9-2815-202-34
NOTE
Do not remove bearing cups (13
and 14) and spacer ring (15) unless
loose or damaged.
(5) Tap bearing cups (13 and 14) and
outer spacer ring (15) out of idler gear
(16) using a brass rod alternating
around four notches on shoulder of
gear.
c. Cleaning/Inspection
Compressed air used for cleaning purposes will not exceed 30 PSI. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
(1) Clean all parts using fuel oil. Dry with compressed air.
(2) Inspect all parts and replace if worn or damaged.
NOTE
Replace bearing cones, cups, and spacer rings as a set.
(3) Coat all parts with engine oil.
d. Assembly
(1) Place idler gear (16) shoulder down
on bed of arbor press.
(2) Place inner bearing cup (13),
numbered side up, into bore of gear.
Press bearing cup against shoulder of
gear (16) using a steel plate under
ram of arbor press.
(3) Lay outer spacer ring (15) on face of
bearing cup (13).
4-89
TM 9-2815-202-34
4-25. IDLER GEAR REPLACEMENT (Cont)
(4) Lay outer bearing cup (14), numbered side down, on top of outer spacer ring (1 5). Using a
steel plate under ram of arbor press, press bearing cup into bore of gear until seated against
outer-spacer ring.
(5) Place inner bearing cone (9), outside face down, on parallel bars on bed of arbor press.
Press idler gear hub (11) into inner bearing cone until inner hub mounting face is flush with
inner bearing cone outside face.
(6) Install inner spacer ring (12) on idler gear hub so oil hole in hub is 180° from gap in inner
spacer ring.
(7) Place idler gear (16) and cups over hub (11) and inner bearing cone. Place outer bearing
cone (10) over hub.
CAUTION
•
Inner bearing cone and hub
mounting face must be supported
so bearing rollers are not loaded
during this assembly operation.
•
Turn idler gear while installing
outer bearing cone on hub to
prevent damage.
(8) Press outer bearing cone (10) onto
hub while rotating idler gear (16) to
seat rollers.
(9) Hold hub (11 ) and turn gear assembly
(3) to see if binding occurs.
NOTE
Bearings must be clean and
lubricated with engine oil before
checking preload. Work in bearings
by rotating gear back and forth
several times.
4-90
TM 9-2815-202-34
4-25. IDLER GEAR REPLACEMENT (Cont)
(10) Mount idler gear assembly (3) in soft
jaw vise.
(11) Install retainer (8) and six bolts (7) on
idler gear assembly (3). Torque bolts
to 24-29 Ib-ft (33-39 N-m).
(12) Mount two test fixture plates (17 and
18) on idler gear (3) with bolt (19) and
nut (20). Torque to 80-90 Ib-ft
(108-122 N-m).
(13) Mount test fixture plate (21 ) to gear
assembly (3) with three bolts (22),
three Iockwashers (23), and three flat
washers (24). Torque bolts to
25-40 Ib-ft (34-54 N-m).
(14) Secure plate (18) in jaws of vise.
(15) Wrap Iintless cord several times
around gear assembly (3) and attach
to spring scale.
(16) Pull gear assembly (3) at least three
times and record pull required to start
moving gear.
NOTE
Pull must be more than 0.5 Ibs
(0.23 kg) and less than 4.0 Ibs
(1.8 kg) and fluctuation less than 2.7
Ibs (1.22 kg) to assure idler gear
and bearing assembly are
satisfactory for use.
(17) Secure gear assembly (3) in soft jaw
vise.
(18) Remove three bolts (22), three
Iockwashers (23), three flat washers
(24), and test fixture plate (21).
(19) Remove nut (20), bolt (19), and two
test fixture plates (17 and 18).
4-91
TM 9-2815-202-34
4-25. IDLER GEAR REPLACEMENT (Cont)
e. Installation
(1) Aline timing marks on camshaft gear
(25) and crankshaft gear (26) with
timing marks on idler gear assembly
(3).
(2) Slide idler gear assembly (3) into
position until crankshaft gear and
camshaft gear are fully meshed.
(3) Rotate gear hub (11 ) until dowel
alines with hole in end plate. Tap hub
until it seats against end plate.
(4) Install bolt (1) and flat washer (2)
securing idler gear assembly (3) to
cylinder block. Torque bolt to
80-90 Ib-ft (108-122 N-m).
NOTE
Backlash can only be checked with
cylinder head removed,
(5) Mount dial indicator on end plate and
check backlash between idler gear
assembly (3) and mating gears.
Minimum backlash is 0.002 in..
Maximum backlash is 0.008 in. for
new gears and 0.010 in. for used
gears.
NOTE
Effective up to engine number 8VA349267, a dummy hub was installed
opposite idler gear hub to fit the original
flywheel housing.
(6) Install dummy hub (6) on end plate. Install
bolt (4) and flat washer (5). Torque bolt to
80-90 Ib-ft (108-122 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-24 Install flywheel housing
4-92
TM9-2815-202-34
4-26. INJECTOR CONTROL TUBES & THROTTLE DELAY REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning/Inspection
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
■ All
Fuel oil (App C, Item 21)
EQUIPMENT CONDITION
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Para Description
4-11 Rocker arm covers removed
4-17 Fuel control rods disconnected
MANDATORY REPLACEMENT PARTS
1 Cotter pin (App F, Item 7)
2 Lockwashers (App F, Item 91)
a. Removal
NOTE
Steps (1) and (2) for throttle delay
assembly only apply to models
7083-7395 and 7083-7396.
(1) Remove two nuts (1), two
Iockwashers (2), and U-bolt (3) from
throttle delay bracket (4). Discard
Iockwashers.
(2) Remove piston and linkage assembly
(5) from throttle delay housing (6).
(3) Remove four bolts (7) securing
injector control tube brackets (8) to
cylinder head.
(4) Disengage rack levers (9) from
injector control racks (10) and lift tube
assembly (11 ) from cylinder head.
Change 1
4-93
TM 9-2815-202-34
b. Disassembly
(1) Injector control tube
(a) Remove bracket (8) from rear of left bank injector control tube assembly.
(b) Loosen four nuts (12) and four adjusting screws (13) from control levers (9).
(c) Disconnect three right hand helix yield springs (14) and left hand helix yield spring (15)
from four control levers (9). Roll yield springs out of slots and notches of control tube
(16).
(d) Disconnect return spring (17) from bracket (8) and control lever (9) at front of left bank
control tube and at rear of right bank control tube.
(e) Remove bracket (8) from rear of right bank control tube assembly.
(f) Slide four control levers (9), four yield springs (14) and (15), and return spring (17) off
rear of each control tube (16).
(2) Throttle delay assembly
(a) Remove cotter pin (18) from pin
(19). Slide pin (19) from bracket
(4) and link (20).
(b) Remove pin (21 ) from piston (22)
and link (20).
4-94
Change 1
TM
9-2815-202-34
c. Cleanlng/inspection
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/ shield, gloves, etc).
(1) Wash components with fuel oil and dry with compressed air.
(2) Inspect components for excessive wear, cracks, or damage and replace if necessary.
d. Assembly
(1) Left bank injector control tube
(a) Install return spring (17) on control tube (16) and against front bracket (8).
(b) Install control lever (9) and left hand helix yield spring (15) on control tube (16). Control
lever must face rear of control tube.
(c)
Install three right hand helix yield springs (14) and three control levers (9) on control
tube (16). Control levers must face rear of control tube.
(d) Attach curled end of four yield springs (14 and 15) to four control levers (9) and roll yield
springs into notch or slots in control tube (16). Turn four adjusting screws (13) with four
nuts (12) into slots far enough to position levers on control tube.
(e) Attach curled end of control tube return spring (17) to control lever (9) and extended end
of spring behind front bracket (8).
(f)
Install bracket (8) to rear of control tube (16).
4-95
TM 9-2815-202-34
(2) Right bank injector control tube
(a) Install three control levers (9) and three right hand helix yield springs (14) on control
tube (16). Control lever must face front of control tube.
(b) Install left hand helix yield spring (15) and control lever (9) on control tube (16). Control
lever must face front of control tube.
(c) Attach curled end of four yield springs (14 and 15) to four control levers (9) and roll
springs into notch or slots in control tube (16). Turn four adjusting screws (13) with four
nuts (12) into slots far enough to position levers on control tube.
(d) Install control tube return spring (17) and bracket (8) at rear of control tube (16). Attach
curled end of return spring to control lever and extended end of spring behind bracket.
(3) Throttle delay assembly
(a) Connect link (20) to piston (22) with
pin (21).
(b) Connect link (20) to bracket (4) with
pin (19) and cotter pin (18).
4-96
TM
9-2815-202-34
e. Installation
(1) Place injector control tube assembly (11) on cylinder head and install four bolts (7) through
end brackets (8) and into cylinder head. Tighten bolts finger tight. Insure ball end of injector
rack control lever engages in slot of injector control rack. Torque bolts (7) to 10-12 Ib-ft
(14-16 N-m).
(2) Check control tube to be sure it is free in brackets. If necessary, tap control tube lightly to
aline bearing in brackets.
NOTE
Steps (3) and (4) for throttle delay assembly only applies to models 7083-7395 and
7083-7396.
(3) Slide throttle delay piston and linkage assembly (5) in bore of housing (6),
(4) Place U-bolt (3) around control tube and through bracket (4). Secure in position with two
nuts (1) and two Iockwashers (2). Tighten nuts to 7-9 Ib-ft (9~12 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-17 Connect fuel control rods
4-11 Install rocker arm covers
4-97
TM 9-2815-202-34
4-27. CYLINDER HEAD ASSEMBLY REMOVAL/INSTALLATION
This task covers:
a. Removal
b. Installation
INITIAL SETUP
EQUIPMENT CONDITION (Cent)
MODELS
■ All
Para
4-6
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B Item 96)
Cylinder head lifting fixture (App B Item 19)
Guide studs (App B, Item 88)
Torque wrench (App B, Item 101)
MANDATORY REPLACEMENT PARTS
2
8
2
12
Seal rings (App F, Item 134)
Compression gaskets (App F, Item 83)
Seal rings (App F, Item 136)
Seal rings (App F, Item 137)
Seal rings (App F, Item 138)
4-8
4-10
4-11
4-15
4-17
4-18
4-26
5-3
5-4
EXPENDABLE/DURABLE SUPPLIES
5-6
International compound no. 2 (App C, Item 24)
5.1-4
5.1-6
5.1-8
5.1-11
EQUIPMENT CONDITION
Para Description
Turbocharger oil line clips removed
4-2
(7083-7395)
Exhaust manifolds removed (7083-7395)
4-3
a. Removal
(1) Attach lifting bracket (1) to center three
exhaust manifold studs (2) located at
outboard side of cylinder head. Secure in
place with three 7/1 6-20-inch nuts (3).
(2) Attach a chain to lifting bracket (1) and take
up slack in chain.
(3) Remove two cylinder head bolts (4) at
outboard corners of cylinder head and
install guide studs (5). Remove remaining
eight cylinder head bolts (4).
(4) Lift cylinder head assembly (6) from
cylinder block.
4-98
Change 1
6-4
6-11
7 - 4
Description
Fuel lines removed (7083-7395 and
7083-7398)
Thermostat housings removed (7083-7395
and 7083-7398)
Air box heater removed (7083-7395 and
7083-7396)
Rocker arm covers removed
Block mounted breather disconnected
(Except 7083-7398 and 7083-7399)
Governor cover and throttle-control rods
Fuel rod hoses detached
Injector control tubes removed
Exhaust manifolds removed (7083-7391
and 7083-7396)
Fuel lines removed (7083-7396 and
7083-7399)
Water manifolds removed (7083-7396
and 7083-7399)
Fuel lines removed (7083-7391)
Water manifolds removed (7083-7391)
Glow plug harness removed (7083-7391)
Air inlet by-pass valve hoses detached
(7083-7391)
Exhaust manifolds removed (7083-7398)
Air box heater removed (7083-7398
and 7083-7399)
Exhaust manifolds removed (7083-7399)
TM 9-2815-202-34
CAUTION
• Model 7083-7391 has exhaust shields cast in place in the exhaust ports of cylinder
head. Do not pry or lift in exhaust ports or damage to cylinder head will result.
• When placing cylinder head on bench, protect cam followers, glow plugs (7083-7391
only), and fuel injector tips by placing two-inch thick wooden blocks underneath each
end of head,
(5) Remove two guide studs (5) from cylinder block.
(6) Remove figure eight seal ring (7), three seal rings (8), six seal rings (9), four compression
gaskets (10), and gasket (11) from cylinder bank. Discard seal rings and gaskets.
(7) Remove lifting bracket (1) from
cylinder head by removing three nuts
(3).
(8) Repeat steps (1) thru (7) for opposite
cylinder head.
b. Installation
(1) Install figure eight seaI ring (7), three
seal rings (8), six seal rings (9), four
compression gaskets (10), and gasket
(11 ) to cylinder bank.
(2) Install two guide studs (5) in cylinder
head bolt holes at outboard corner
positions in cylinder block.
(3) Attach lifting bracket (1) to center
three exhaust manifold studs (2)
located at outboard side of cylinder
head. Secure in place with three
7/1 6-20 inch nuts (3).
CAUTION
Before installing cylinder head,
insure all seal rings and gaskets are
in place.
(4) Using chain hoist, lift cylinder head
above cylinder block and lower over
guide studs (5). Lower head to 1/2
inch from surface of cylinder block.
Change
1 4-99
TM
9-2815-202-34
4-27. CYLINDER HEAD ASSEMBLY REMOVAL/INSTALLATION (Cont.)
(5)
Apply International Compound No. 2 to cylinder head bolt threads arid underside of bolt
heads. Install eight bolts (4) through cylinder head and thread into cylinder block, Continue
to lower head onto cylinder block and tighten bolts snug.
(6)
Remove two guide studs (5) and install remaining two bolts (4). Tighten all bolts to 15-20 Ib-ft
(20-27 N-m) torque.
(7)
Remove lifting bracket (1) from cylinder head (6) by removing three nuts (3).
NOTE
Repeat tightening sequence at least once because first bolts tightened tend to lose
significant clamping load during tightening of remaining bolts. Apply a steady pressure
for two or three seconds at prescribed torque to allow bolts to turn while gaskets yield
to their designed thickness.
(8) Torque cylinder head bolts to 170-180 Ib-ft (231-244 N-m) in 50 Ib-ft (68 N-m) increments.
Tighten bolts in sequence shown in cylinder head illustration below.
FOLLOW-ON MAINTENANCE
Para Description
7-4 Install exhaust manifolds (7083-7399)
6-11 Install air box heater (7083-7398 and 7083-7399)
6-4
Install exhaust manifolds (7083-7398)
5.1-11 Attach air inlet by-pass valve hoses (7083-7391)
5.1-8 Install glow plug harness (7083-7391)
5.1-6 Install water manifolds (7083-7391)
5.1-4 Install fuel lines (7083-7391)
5-6
Install water manifolds (7083-7396 and 7083-7399)
5-4
Install fuel lines (7083-7396 and 7083-7399)
5-3
Install exhaust manifolds (7083-7391 and 7083-7396)
4-26 Install injector control tubes
4-18 Attach fuel rod hoses
4-17 Install governor cover and throttle control rods
4-15 Connect block mounted breather (Except 7083-7398 and 7083-7399)
4-11 Install rocker arm covers
4-10 Install air box heater (7083-7395 and 7083-7396)
4 - 8 Install thermostat housings (7083-7395 and 7083-7398)
4-6
Install fuel lines (7083-7395 and 7083-7398)
4-3
Install exhaust manifolds (7083-7395)
4-2
Install turbocharger oil line clips (7083-7395)
4-100
Change 1
TM9-2815-202-34
4-28. ENGINE LOWER FRONT COVER REPLACEMENT
This task covers:
a. Removal
d. Installation
b. Cleaning/Inspection
c. Repair/Replacement
INITIAL SETUP
6 Lockwashers (App F, Item 95)
1 Seal (App F, Item 150)
MODELS
7083-7395 7083-7398
EXPENDABLE/DURABLE SUPPLIES
TOOLS AND SPECIAL TOOLS
Grease (App C, Item 22)
Nonhardening sealant (App C, Item 38)
Crocus cloth (App C, Item 12)
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Torque wrench (App B, Item 102)
Oil seal installer (App B, Item 50)
EQUIPMENT CONDITION
Para Description
Fuel strainer removed
4-5
4-20 Oil pan removed
MANDATORY REPLACEMENT PARTS
1 Gasket (App F, Item 42)
2 LockWashers (App F, Item 93)
a. Removal
NOTE
Secure gear train in place to prevent crankshaft from turning when loosening
crankshaft end bolt.
(1) Remove bolt (1) and washer (2) from front of crankshaft. Slide end cap (3) off crankshaft.
(2) Remove four bolts (4), two bolts (5), six Iockwashers (6), two bolts (7), and two Iockwashers
(8) from front lower cover (9). Discard Iockwashers.
(3) Strike edges of cover on each side alternately with a soft head hammer to free it from
dowels. Pull cover straight off end of crankshaft.
(4)
(5)
4-101
TM 9-2815-202-34
4-28. ENGINE LOWER FRONT COVER REPLACEMENT (Cent)
b. Cleaning/inspection
(1) Clean front cover and inspect sealing and mating surfaces for cracks, nicks, and damage
that would prevent proper sealing.
(2) Check inside of spacer and crankshaft for burrs and nicks. Clean up burrs using crocus cloth
in circular motion.
(3) Inspect spacer ring for nicks or burrs that would prevent proper sealing.
c. Repair/Replacement
(1) Support outer face of front cover (9)
on two wooden blocks and drive seal
(13) out with a soft drift. Discard seal.
(2) Clean seal bore.
NOTE
If new oil seal is not precoated,
apply nonhardening sealant to outer
edge of metal casing.
(3) Position seal (13) in front cover (9)
with seal lip pointed toward inner face
of cover.
(4) Drive seal in with seal installation tool
(14).
(5) Remove any excess sealant.
d. Installation
(1) Affix gasket (12) to inner face of front
cover (9).
(2) Install dirt deflector (11 ) onto
crankshaft with flat surface toward
engine.
(3) Coat lip of oil seal lightly with grease
or vegetable shortening.
4-102
TM9-2815-202-34
(4)
Position front cover (9) over two alinement pins and tap cover until it contacts cylinder block.
(5)
Install four bolts (4), two bolts (5), six Iockwashers (6), two bolts (7), and two Iockwashers (8)
to lower front cover (9).
(6) Torque bolts (7) to 25-30 Ib-ft (34-41 N-m) and bolts (4 and 5) to 80-90 Ib-ft (108-122 N-m),
(7)
Install spacer ring (10) onto crankshaft.
(8)
Install end cap (3), flat washer (2), and bolt (1) to front of crankshaft.
(9) Tighten crankshaft end bolt (1) as follows:
NOTE
Secure gear train in place to prevent crankshaft from turning when loosening
crankshaft end bolt.
(a) Torque bolt to 180 Ib-ft (244 N-m).
(b) Strike end of bolt a sharp blow three times with a 3 pound soft head hammer.
(c)
Torque bolt to 300 Ib-ft (407 N-m) and strike bolt again three times.
(d) Torque bolt to 290-310 Ib-ft (393-421 N-m). Do not strike bolt after final torque has been
applied.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-20 Install oil pan
4-5
Install fuel strainer
4-103
TM9-2815-202-34
4-29. CAMSHAFT AND GEAR ASSEMBLIES REPLACEMENT
This task covers:
a. Removal
d. Inspection
b. Disassembly
e. Assembly
c. -Cleaning
f. Installation
INITIAL SETUP
MANDATORY REPLACEMENT PARTS
MODELS
■ All
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Magnetic base dial indicator (App B, Item 45)
Universal puller (App B, Item 71)
Mechanical puller (App B, Item 69)
Adaptor (App B, Item 1)
Slide hammer (App B, Item 39)
Adapter (App B, Item 2)
Torque wrench (App B, Item 102)
20 Lockwashers (App F,ltem 93)
1 Gasket (App F, Item 31 )
2 Lockwashers (App F, Item 100)
1 Camshaft oil seal (App F, Item 146)
3 Lockwashers (App F, Item 92)
4 Camshaft plugs (App F, Item 116)
EXPENDABLE/DURABLE SUPPLIES
Engine oil (App C, Item 16)
Grease (App C, Item 22)
Crocus cloth (App C, Item 12)
Oil stone (App B, Item 43)
EQUIPMENT CONDITION
Para Description
4-21 Camshaft front cover removed
4-24 Flywheel housing removed
4-27 Cylinder heads removed
a. Removal
(1) Remove four bolts (1), four
Iockwashers (2), and retainer plate (3)
from each rear camshaft gear.
Discard Iockwashers.
(2) For models 7083-7391, 7083-7396, and
7083-7399 only, remove three bolts (4),
three Iockwashers (5), and camshaft
adaptor (6) from water pump drive gear (7).
Discard Iockwashers.
(3) Wedge a rag between teeth of
camshaft gears and loosen nuts (8) at
each camshaft end.
4-104
Change 1
TM 9-2815-202-34
(4) Remove nut (8) and Iockwasher (9)
from front of each camshaft. Discard
Iockwashers.
(5) Remove pulley (10) at front of engine
using puller (1 1). Use an adaptor (12)
between end of camshaft and puller
screw to protect end of camshaft.
(6) Using puller (13) and adaptor (12),
remove water pump drive gear (7)
from front of engine.
MODELS:
■ 7083-7391
7083-7396
7083-7399
(7) Remove woodruff key (14) and spacer
(15) from front of each camshaft.
(8) Remove three camshaft intermediate
bearing lock screws (16) from top of
each cylinder block bank.
Change
1 4-105
TM9-2815-202-34
4-29. CAMSHAFT AND GEAR ASSEMBLIES REPLACEMENT (Cent)
(9) Rotate each camshaft gear (17) until
three bolts (18) are accessible.
Remove three bolts (18) and three
Iockwashers (19) from each rear
camshaft end bearing (20). Discard
Iockwashers.
(lo)
Remove two camshaft, bearing, and
gear assemblies (21 ) from cylinder
block.
(11)
Remove three bolts (22) and three
Iockwashers (23) from each front
camshaft end bearing (24 and 25).
Remove end bearings from cylinder
block. Discard Iockwashers.
~d
(12) Remove camshaft end bearing gasket
(26) from left bank front positi~n~
Discard gasket.
b. Disassembly
NOTE
● Use
gear puller if press is
unavailable to remove gear.
● Disassemble
left and riaht
camshafts by same pro~edure.
(1) Remove nut (8) from end of camshaft.
Place camshaft, bearing, and gear
assembly (21 ) in an arbor press.
Insert short one-inch diameter brass
rod (27) on end of camshaft. Press
camshaft from gear.
(2) Remove woodruff key (28), two thrust
washers (29), and rear end bearing
(20) from end of camshaft (30).
FRONT OF ENGINE
.
ARBOR
PRESS
.
(3) Remove six lock rings (31 ) from
camshaft (30). Remove six
intermediate bearing halves (32).
(4) Remove two screws (33) and two nuts
(34) from rear camshaft gear (17).
Remove balance weight (35) from
gear.
(5) Remove two bolts (36) from water
pump drive gear (7) (right camshaft
only). Remove balance weight (37).
4-106
—
PI
\
TM9-2815-202-34
(6) Remove two camshaft end plugs (38) from camshaft in following manner:
(a) Clamp camshaft in a soft-jawed
vise. Use care not to damage’
cam lobes or machined surfaces
of shaft.
(b) Make indentation in center of end
plug with 31/64-inch drill.
(c) Punch a hole as deep as
possible with a center punch to
aid in breaking through hardened
surface of plug.
(d) Drill a hole straight through
center of plug with a 1/4-inch drill.
(e) Use l/4-inch drilled hole as a
guide and redrill plug with
5/1 6-inch drill.
(f)
●
●
Tap drilled hole with a 3/8-16 tap.
(9) Thread 3/8-1 6 adaptor (39) into
plug. Attach a slide hammer to
adaptor. Remove plug.
NOTE
If suitable rod is not available, remove remaining plug by repeating steps (a) thru (g).
(h) Insert a long 3/8-inch steel rod in camshaft. Drive out remaining plug. Discard plug.
(7) Remove camshaft oil seal (40) from left bank front end bearing (25). Discard seal.
4-107
TM9-2815=202-34
4-29. CAMSHAFT AND GEAR ASSEMBLIES REPLACEMENT (Cent)
c. Cleanlng
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/ shield, gloves, etc).
(1) Soak camshafts in clean fuel oil. Run a bore brush through oil gallery to remove any sludge
or foreign material. Clean exterior of camshaft. Blow out oil gallery and oil holes with
compressed air.
(2) Clean gears, bearirqjs, and related parts with fuel oil. Dry with compressed air.
d. Inspection
(1) Check camshaft keyways and threads for damage.
(2) Inspect camshaft journals and lobes for wear and scoring. Check wear on camshaft lobes as
follows:
(a) Measure flat of cam lobes with a set of tapered feeler gages (41) and straight edge (42).
(b) Replace camshaft if flats are more than 0.003 inch deep.
4-108
●
TM 9-2815 -202-34
43
30
(3) Using dial indicator (43), measure runout of center camshaft journal with end journals
mounted on V-blocks. Replace camshaft if runout exceeds 0.002 inch.
●
(4) Check camshaft thrust surfaces for scoring or wear. Thrust surfaces maybe smoothed with
an crocus cloth if only slightly scratched.
(5) Examine faces of camshaft rear end bearings, thrust washers, and camshaft gear hubs for
scoring. Camshaft gear hubs not severely scored may be smoothed with an oil stone.
(6) Inspect bushings in end bearings for wear and scoring. Using calipers, measure outside
diameter of camshaft journals and inside diameter of camshaft end bearing bushings.
Difference must be between 0.0035 to 0.005 inch with new parts and a maximum of 0.006
inch with used parts.
(7) Inspect spacers and seal at front end of camshafts. Outside diameter of spacer on left bank
must provide a smooth oil seal contact surface.
●
●
(8) Inspect camshaft intermediate bearings. Replace bearings if excessively scored or worn.
Clearance between camshaft journals and intermediate bearings is 0.0025 to 0.005 inch
with new parts and a maximum of 0.009 inch with used parts.
(9) Examine intermediate bearing lock screws and tapped holes in cylinder block for damaged
threads.
(1 O) Inspect teeth on water pump drive gear and camshaft gears for scoring, pitting, and wear.
Examine keyways and tapped holes in gears and camshaft pulley for damage.
4-109
TM9-2815-202-34
4-29. CAMSHAFT AND GEAR ASSEMBLIES REPLACEMENT (Cent)
e. Assembly
(1) Install two plugs (38) in ends of camshaft.
NOTE
Steel faces of thrust washers must face toward flange on rear end bearings.
(2) Apply grease to steel face of each thrust washer (29). Place washer against end of rear
camshaft end bearing (20).
(3) Lubricate rear camshaft bearing journal with engine oil. Slide rear end bearing (20) on
camshaft with bolting flange of bearing toward camshaft gear (17).
(4) Install rear camshaft gear on camshaft as follows:
NOTE
Install camshaft gear stamped ‘R’ on right bank camshaft.
(a) Install woodruff key (28) in camshaft keyway.
(b) Aline keyway in gear (17) with key (28) in shaft. Start gear over end of shaft.
,d q
v
//,nY7
29
I
3a
17
31
8
/
4-110
TM9-2815-202-34
(c) Support camshaft (30) in arbor press. Place a sleeve (44) on top of gear (1 7). Press
gear tight against shoulder on shaft.
(d) Thread camshaft gear retaining nut (8) on camshaft. Hand tighten.
(e) Install gear on other camshaft in similar manner.
(5) Lubricate camshaft intermediate bearing journals. Place two halves of each intermediate
bearing (32) on camshaft journal. Lock halves together with two lock rings (31). Assemble
each lock ring with gap over upper bearing and ends an equal distance above split line of
bearing.
(6) Attach balance weight (35) to front of each camshaft gear(17) with two bolts (33) and two
nuts (34). Torque nuts to 25-30 Ib-ft (34-41 N-m).
f. I n s t a l l a t i o n
(1) Insert front end of camshaft assembly (21) with right hand helix gear through opening on
right bank side in rear end plate. Work camshaft and intermediate bearings (32) into cylinder
block until camshaft gear teeth are about to engage teeth on mating gear (if installed). Aline
timing marks (V) on camshaft gears as shown. Slide camshaft assembly in place.
4-111
TM9=2815-202-34
4-29. CAMSHAFT AND GEAR ASSEMBLIES REPLACEMENT (Cent)
(2) Rotate camshafi gear(17) until webingear alineswith camshaft end bearing bolt hoIe.
Install three bolts (18) and three Iockwashers (19) to rear end bearing. Torque bolts to 35-40
lbJft (47-54 N-m).
@
NOTE
Intermediate bearings must have a slight play when locked in position in block bore.
(3) Revolve camshaft intermediate bearings (32) as required to aline locking hole in upper half
of bearing with tapped hole in top of cylinder block. Install three lock screws (16) to each
bank and torque screws to 15-20 Ib-ft (47-54 N-m).
(4) Install other camshaft assembly in same manner.
16
22
@
4-112
TM9-2815=202-34
(5) lnstaIl seal(40) inleftbank front end bearing (25).
●
a
(6) Attach gasket (26)to Ieftbank front end bearing (25). Lubricate bearing journal with engine
oil. Slide end bearing over end of camshaft and against front end plate. Secure bearing in
place with three bolts (22) and three Iockwashers (23). Torque bolts to 35-40 Ib-ft (47-54 Nm).
(7) Lubricate right bank front end bearing journal (24) with engine oil. Slide it over end of
camshaft and against front end plate. Secure bearing in place with three bolts (22) and three
Iockwashers (23). Torque bolts to 35-40 Ib-ft (47-54 N-m).
NOTE
*
Nonmachined spacer is used only on right bank camshaft.
(8) Install spacer (15) to front of each camshaft. Lubricate left bank spacer with engine oil prior to
installation.
(9) Install woodruff key (14) to front of each camshaft.
(1 O) Install pulley (1 O) to left bank camshaft.
14
A
10
4-113
TM9-2815-202-34
4-29. CAMSHAFT AND GEAR ASSEMBLIES REPLACEMENT (Cent)
(11) Install water pump drive gear (7) to right bank camshaft.
(12) Slip Iockwasher (9) over front end of each camshaft. Install nut (8) to front end of each
camshaft and finger tighten.
(13) Wedge a rag between rear camshaft gears to prevent rotation. Torque nut (8) on each end of
both camshafts to 300-325 Ib-ft (407-441 N-m),
■ (14)
For models 7083-7391, 7083-7396, and 7083-7399, install camshaft adaptor (6) to water pump
drive gear (7). Secure in place with three bolts (4), and three Iockwashers (5). Torque bolts to
15-19 Ib-ft (20-26 N-m).
●
e
,
(15) Install camshaft gear nut retainer (3) to each camshaft gear. Secure retainer plate in position
with four bolts (1) and four Iockwashers (2). Torque bolts to 35-39 Ib-ft (47-53 N-m).
.
4-114
Change 1
TM9-2815-202-34
4-29. CAMSHAFT AND GEAR ASSEMBLIES REPLACEMENT (Cent)
NOTE
●
Oversize thrust washers are available in sizes of 0.005 and 0.010 inch to compensate
for excessive end thrust.
(16) Using feeler gage, measure end thrust between thrust washer (29) and thrust shoulder (44)
on each camshaft assembly. Required clearance is 0.003 to 0.015 inch with new parts and a
maximum of 0.018 inch with used parts. If necessary, install an oversize thrust washer for
required end thrust clearance.
.
FEELER
END OF TASK
FOLLOW-ON MAINTENANCE
e
Para
4-27
4-24
4-21
Description
Install cylinder heads
Install flywheel housing
Install camshaft front cover
o
4-115
TM9-2815=202-34
4-30. CYLINDER BLOCK END PLATES REPLACEMENT
Thistaskcovers:
a. Removal
d. Installation
b. Cleaning/Inspection
c. Repair
. .
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
■ All
Gasket nonhardening cement (App C, Item 39)
Cleaning solvent (App C, Item 10)
f
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Para Description
Fuel strainer bracket removed
4-5
(7083-7395 and 7083-7398)
4-19 Blower drive-support removed
4-25 Idler gear removed
4-29 Camshaft and camshaft end bearings
removed
MANDATORY REPLACEMENT PARTS
2 Lockwashers (App F, Item 95)
13 Lockwashers (App F,ltem 93)
1 Gasket (App F,ltem 22)
1 Gasket (App F,ltem 43)
1 Gasket (App F, Item 67)
a. Removal
(1) Front End Plate
NOTE
■
Models 7083-7391, 7083-7396, and 7083-7399 require removal of two bolts (1) and two
Iockwashers (2).
(a) Remove bolt (1) and lockwasher (2) from end plate (3). Discard Iockwasher.
NOTE
■
Models 7083-7391, 7083-7396, and 7083-7399 require five bolts (4) and five
Iockwashers (5).
(b) Remove four bolts (4) and four Iockwashers (5) from end plate. Discard Iockwashers.
(c) Remove end plate (3) and gaskets (6 and 7) from cylinder block (8). Discard gaskets.
(d) If required, remove screw insert (9) by pressing from end plate. Support end plate on a
flat surface when removing insert to prevent warping or bending.
4-116
Change 1
1
.
TM9-2815-202-34
3
(2) Rear End Plate
(a) Remove eight bolts (1 O) and eightIockwashers(11 ) from end plate (1 2). Discard
Iockwashers.
(b) Remove end plate (12) and gasket (13) from cylinder block (8). Discard gasket.
(c) If required, remove nine screw inserts (14) by pressing from end plate. When removing
inserts, support end plate on flat surface to prevent warping or bending.
10
CA’=-7
11
4-117
TM9=2815-202-34
4-30. CYLINDER BLOCK END PLATES REPLACEMENT (Cent)
b. Cleanlng/inspection
9
(1) Remove allgasket material from end
plates (3 and 12).
WARNING
Dry cleanlng solvent P-D-680 Is
toxic and flammable. Wear
protective goggles and gloves
and use only in a well-ventilated
area. Avoid contact with skin,
eyes, and clothes and don’t
breathe vapors. Do not use near
open flame or excessive heat.
The flash point is 1OO”F-138”F
(38”-50”C). If you become dizzy
while using cleaning solvent, get
fresh air immediately and get
medical aid. If contact with eyes
is made, wash your eyes with
water and get medical aid
immediately.
3
(2) Clean end plates with suitable
cleaning solvent.
(3) Check plates for nicks, dents,
scratches, score marks, and warpage.
(4) Inspect screw inserts for cracks and
damaged threads.
c. Repair
(1) If screw insert (9) was removed from front
end plate, install new insert by supporting
end plate (3) on flat surface and press
insert into back of end plate until head on
insert seats on end plate.
(2) If screw inserts were removed from rear
end plate, install new inserts (nine total)
by supporting end plate (12) on flat
surface and press inserts into end plate
until head on insert seats on end plate.
Two inserts (15) are pressed from back
and seven (16) inserts are pressed from
front of end plate.
d. Installation
A
(1) Front End Plate
(a) Affix gaskets (6 and 7) to front of cylinder
block (8) using non-hardening gasket
cement. Also apply coat of non-hardening
gasket cement to outer surface of each
gasket.
4-118
r’”
///,
-.
II h
l/M-fv+
8
TM9-2815-202-34
●
NOTE
m
ModeIs 7083-7391, 7083-7396, and 7083-7399 require removal of five bolk (4) and five
Iockwashers (5).
(b) Attach front end plate (3) to cylinder block with bolt(1), Iockwasher (2), four bolts (4), and
four Iockwashers (5). Tighten bolts finger tight.
(c) Wipe excess gasket cement from bores in end plate and cylinder block.
NOTE
Holes in end plate for camshaft end bearings are not same size. Smaller hole is
accurately machined for alinement purposes and is always located on right side of
engine.
(d) Insert right bank camshaft end bearing (17) through smaller bearing bore in end plate
and into bore of block to accurately aline plate with block.
(e) With end bearing in place, torque bolts (1) to 71-75 Ib-ft (96-102 N-m) and bolts (4) to
30-35 Ib-ft (41-47 N-m).
(f) Remove camshaft end bearing (17) which served as a pilot while attaching end plate.
.
Change 1
4-119
TM9-2815-202=34
4-30. CYLINDER BLOCK END PLATES REPLACEMENT (Cent)
(2) Rear End Plate
(a) Apply nonhardening gasket cement on cylinder block. Then install gasket (13) over two
dowel pins (18) on cylinder block (8).
(b) Apply coat of nonhardening gasket cement to outer surface of gasket (13).
e
(c) Attach rear end plate (12) to cylinder block with eight bolts (1 O) and eight Iockwashers
(11 ). Tighten bolts finger tight.
(d) Wipe excess gasket cement from bores in end plate and cylinder block.
NOTE
Holes in end plate for camshaft end bearings are not same size. Smaller hole is
accurately machined for alinement purposes and is always located -on right side of
engine.
(e) Insert right bank camshaft end bearing (19) through smaller bearing bore in end plate
(12) and into bore of block to accurately aline plate with block.
(f)
With end bearing in place, torque all bolts to 30-35 Ib-ft (41-47 N-m).
(9) Remove camshaft end bearing (19) which served as a pilot while attaching end plate.
e
.
END OF TASK
FOLLOW-ON MAINTENANCE
\
19
0
,./l,
d
9
[)( 1
n
3
9
9
~1
Para Description
.91
4-29 Install camshafts and camshaft
end bearings
4-25 Install idler gear
4-19 Install blower drive support
Install fuel strainer bracket (7083-7395 and 7083-7398)
94-5
4-120
Change 1
fll
9
13 4
/K’pA
TM9-2815-202-34
●
●
4-31. OIL PRESSURE REGULATOR AND RELIEF VALVE REPLACEMENT
This task covers:
a. Removal
b. Repair
c. -Installation
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
■ All
Engine oil (App C, Item 16)
Fuel oii(App C,ltem 21)
Crocus cloth (App C, Item 12)
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Para Description
4-20 Oil pan removed
MANDATORY REPLACEMENT PARTS
1 Gasket (App F,ltem47)
2 Gaskets (App F,ltem 33)
6 LockWashers (App F, Item 93)
●
a. Removal
(1) Oilpressure regulator valve
(a) Remove Wobolts (l), Wolockwashers (2), and Woflatwashers (3)secuting oil
pressure regulator valve (4) to cylinder block (5).
(b) TapreguIator valve body lightly toloosen it from gasket (6). Remove regulator and
discard gasket.
$?!-,
,—,
(2) Oilpressure relief valve
(a) Remove four bolts (7)and four
Iockwashers (8) securing oil
pressure relief valve (9) to
cylinder block(5) and oil pump
(lo).
(b) Taprelief valve bodylightlyto
Ioosenit from gaskets(ll and
12). Remove relief valve and
discard gaskets.
Change 1
4-121
TM9-2815-202-34
4-31. OIL PRESSURE REGULATOR AND RELIEF VALVE REPLACEMENT (Cent)
b. Repair
(1) Regulator Valve
WARNING
Firmly secure spring during removal. A spring loaded mechanism ejects
parts at high speed If released In an uncontrolled manner. Personal
injury may result.
●
+
(a) Clamp regulator assembly in a
vise with soft jaws. Compress
spring (13) and remove retaining
pin (14) from regulator body (15).
(b) .Remove spring seat (16), spring
(13), and valve (17) from
regulator body (15).
●
.
13
16
WARNING
Compressed air used for cleaning
purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/ shield, gloves, etc).
(c) Clean all parts with fuel oil and dry with compressed air.
(d) Inspect parts for wear and damage. Regulator valve must move freely in valve body.
Replace valve and valve body if parts are scored and cannot be cleaned with crocus
cloth.
(e) Replace a pitted or fractured spring.
(f)
Assemble valve assembly by first applying engine oil to outer face of valve (17) and
slide it into regulator body (15), closed end first.
(9) Install spring (13) and spring seat (16) into regulator body (15).
(h) While compressing spring, install retaining pin (14) above spring seat (16).
(2) Relief Valve
WARNING
Firmly secure spring during removal. A spring loaded mechanism ejects
parts at high speed If released In an uncontrolled manner. Personal
injury may result.
(a)
. . Clamp relief valve assembly in a vise with soft iaws. [email protected](18 and - 19) and
remove retaining pin (20) f~om relief valve body (21). “ “ ‘ ‘
(b) Remove spring seat (22), springs (18 and 19), two inner spring seats (23), and valve
(24) from relief valve body (21 ).
4-122
●
e
TM9-2815-202-34
WARNING
Compressed air used for
cleaning purposes will not
exceed 30 psi. Use only with
effective chip guarding and
personai protective equipment
(goggies/ shieid, gioves, etc).
b
LL
(c)
Ciean aii parts with fuei oii and
dry with compressed air.
(d)
inspect parts for wear and damage. Reiief valve must move freely in valve body.
Repiace vaive and vaive body if parts are scored and cannot be cleaned with crocus
cioth.
(e)
Repiace pitted or fractured springs.
(f)
Assembie vaive assembly by first appiying engine oii to outer face of vaive (24) and
siide it into reiief vaive body (21), ciosed end first.
(9)
instaii two inner spring seats (23), springs (18 and 19), and spring seat (22) into relief
vaive body (21).
(h) Whiie compressing springs, instaii retaining pin (20) above spring seat (22).
c. installation
(1) Oii pressure reguiator vaive
(a)
instaii gasket (6) and oii pressure reguiator valve (4) to cylinder block (5).
(b) Secure reguiator vaive to block with two bolts (1), two Iockwashers (2), and two flat
washers (3). Torque bolts to 30-35 Ib-ft (41-47 N-m).
(2) Oii pressure reiief vaive
*
(a)
@
instaii gaskets (11 and 12) and oil
pressure reiief vaive (9) to
cyiinder biock (5).
(b) Secure reiief valve to block and
oii pump (10) with four boits (7)
and four iockwashers (8). Torque
boits to 30-35 ib-ft (41-47 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-20 instaii oii pan
4-123
TM9=2815-202-34
4-32. OIL PUMP REPLACEMENT
This task covers :
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. ‘Cleaning/inspection
●
INITIAL SETUP
MANDATORY REPLACEMENT PARTS
MODELS
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, [tern 96)
Gear installer (App B, Item 55)
Gear installer (App B, Item 56)
Gear puller (App B, Item 70)
Magnetic base dial indicator (App B, Item 45)
Torque wrench (App B, Item 101)
7 Lockwashers (App F, Item 93)
2 Self-locking nuts (App F, Item 101)
2 Lockwashers (App F, Item 92)
1 Spring washer (App F, Item 168)
1 Gasket (App F, Item 54)
2 Gaskets (App F, Item 55)
f
EXPENDABLE/DURABLE SUP.PLIES
Engine oil (App C, Item 16)
Cleaning solvent (App C, Item 10)
EQUIPMENT CONDITION
Para Description
4-20 Oil pan removed
4-31 Oil pressure relief valve removed
a. Removal
(1) Remove two bolt and lockwasher
assemblies (1) securing two bracket
assemblies (2) to rear bearing cap
(3).
(2) Remove four nuts (4) and four
Iockwashers (5) securing oil pump
assembly (6) to main bearing caps
(7). Discard Iockwashers.
(3) Lift oil pump assembly (6) off main
bearing caps (7) and four studs (8).
NOTE
Mark quantity and location of shims
on main bearing caps. Shims must
be installed in same location as
removed.
(4) Fl~p~fi shims (9) from main bearing
.
(5) If necessary, remove four studs (8)
from main bearing caps (7).
4-124
Change 1
m.I
●
4,
““6$
.
TM 9-2815 -202-34
●
●
b. Disassembly
(1)
Remove four bolts (1 O), four flat washers (11), and two strainer element screens (12) from
tube assembly (13) and adaptor (14).
(2) Remove two bolts (15), two Iockwashers (16), tube assembly (13), baffle (17), and two
gaskets (18) from oil pump assembly (6). Discard Iockwashers and gaskets.
(3) Remove two bolt and Iockwasher assemblies (19) securing two bracket assemblies (2) to
tube assembly (13).
(4) If necessary to separate bracket (2) assemblies, remove two bolts (20), two self-locking nuts
(21 ), and eight flat washers (22) from four brackets. Discard self-locking nuts.
(5) Remove two bolts (23), two Iockwashers (24), adapter (14), and gasket (25) from oil pump
assembly (6). Discard Iockwashers and gasket.
(6) Secure oil pump assembly (6) in a soft-jawed vise.
(7) Remove bolt (26) and spring washer (27) securing spur gear (28) to drive shaft on oil pump
assembly (6). Discard spring washer.
(8) Using puller (29), remove spur gear (28) from drive shaft. Remove puller from spur gear.
(9) Remove oil pump assembly (6) from soft-jawed vise.
2 8 ”
29
28
4-125
TM9-2815-202-34
4-32. OIL PUMP REPLACEMENT (Cent)
(lo) Remove four bolts (30) securing
scavenger pump housing (31 ) to oil
pump housing (32). Remove
scavenger pump housing.
(11) Remove scavenger side helical gear
(33) from drive shaft (34).
(12) Remove scavenger side oil pump
gear (35) from driven shaft (36).
(13) Remove spacer plate (37) from drive
and driven shafts (34 and 36).
(14) Remove driven shaft (36) and helical
gear (38) as an assembly from oil
pump housing (32).
45
0
e
46
47
,(\=
?JJii#
‘\\ - ,. \
43
I
$’b ~+
. c
32 w
)
31
30
(15) Remove drive shaft (34) and oil pump
gear (39) as an assembly from oil
pump housing (32).
(16) Remove two woodruff keys (40) from
drive shaft (34).
(17) Using arbor press, remove oil pump
gear (39) from drive shaft (34).
Remove woodruff key (41 ) from drive
shaft.
(18) Using arbor press, remove helical
gear (38) from driven shaft (36).
Remove woodruff key (42) from driven
shaft.
(19) Remove screw (43), bolt (44), and
Iockwasher (45) securing access
cover (46) and gasket (47) to oil pump
housing (32). Discard Iockwasher and
gasket.
c. Cleanlng/inspection
WARNING
● Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes and clothes and don’t breathe vapors. Do not
use near open flames or excessive heat. The flash point is 100”F-138°F
(38°C-500C). If you become dizzy while using cleaning solvent, get
fresh air Immediately and get medical aid. If contact with eyes Is made,
wash your eyes with water and get medical aid immediately.
● Compressed alr used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guaiding and personal protective
equipment (goggles/shield, gloves etc.)
(1)
Clean all parts with dry cleaning solvent and dry with compressed air.
(2) Inspect scavenger pump housing, oil pump housing, and access cover for cracks or damage.
4-126
●
TM9-2815-202-34
(3) Inspect four helical gears, two oil pump gears, and spur gear for chipped teeth, burrs, wear,
or damage.
(4) Inspect drive and driven shaft for scoring, wear, or damage.
(5) Inspect bushings in oil pump housing and scavenger pump housing for wear, If worn,
replace oil pump housing and scavenger pump housing.
(6) inspect strainer element screens for cracks, tears, or damage.
(7) Inspect tube assembly and adaptor for cracks or damage.
(8) Inspect studs for continuity or damage to threads.
DRIVEN
SHAFT
d. Assembly
(1)
DRIVE
SHAFT
Insert woodruff key (42) into driven
shaft (36).
(2) Lubricate driven shaft (36) with
engine oil, and aline helical gear (38)
ke~ay with woodruff key (42) on
driven shaft.
NOTE
1
6!01
J- U
T
3
7.i50
dl
Position of helical gear should be
6.01 inch from end of driven shaft.
ARBOR
PRESS
(3) Using driven gear installer (48) and
arbor press, install helical gear (38)
onto driven shaft (36).
48
34,36
(4) Insert woodruff key (41 ) into drive
shaft (34).
(5) Lubricate drive shaft (34) with engine
oil and aline oil pump gear (39)
keyway with woodruff key (41) on
drive shaft.
0‘+ 41,42
0
F
6,39
NOTE
Position of oil pump gear should be
7.750 inch from end of drive shaft.
+ WI
I
I
I
(6) Using drive gear installer (48) and
arbor press, install oil pump gear (39)
onto drive shaft (34).
(7) Install drive shaft (34) and oil pump gear (39) as an assembly into oil pump housing (32).
(8) Install driven shaft (36) and helical gear (38) as an assembly into oil pump housing (32).
(9) Place oil pump housing (32) in a soft-jawed vise and place a rag between oil pump gear (39)
and helical gear (38).
4-127
TM9-2815-202-34
4-32. OIL PUMP REPLACEMENT (Cent)
NOTE
Install spring washer with crown side toward bolt.
(10) Position spurgear (28)onto drive shaft (34)and secure withspring washer (27)and bolt
(26). Tighten bolt to install spur gear. Torque bolt to 60-65 Ib-ft (81-85 N-m). Remove oil
pump housing (32) from soft-jawed vise and rag from gears (38 and 39).
●
(11 ) Install two remaining woodruff keys (40) onto drive shaft (34).
(12) Install spacer plate (37) on shafts (34 and 36).
(13) Install scavenger side helical gear (33) onto drive shaft (34).
(14) Install scavenger side oil pump gear (35) onto driven shaft (36) .
NOTE
The scavenger side oil pump gear and helical gear must be in the same relative
position as the oil pump gear and helical gear on the housing side.
(15) Position shafts (34 and 36) into scavenger pump housing (31 ) and join with oil pump
housing (32). Secure housings with four bolts (30). Torque bolts to 30-35 Ib-ft (41-47 N-m).
NOTE
Oil pump gears must turn freely. Any bind in pump gears must be eliminated before oil
pump is installed on engine.
(16) Install gasket (47) and access cover (46) to oil pump housing (32) and secure with screw
(43), bolt (44), and Iockwasher (45). Torque bolt to 23-26 Ib-ft (31-35 N-m).
4-128
●
TM 9-2815 -202-34
●
—
●
(17) Secure gasket (25) and adaptor (14) to oil pump assembly (6) with two bolts (23) and two
Iockwashers (24). Torque bolts to 10-13 Ib-ft (1 4-18 N-m).
(18) Secure tube assembly (13), two gaskets (18), and baffle (17) to oil pump assembly (6) with
two bolts (15) and two Iockwashers (16). Torque bolts to 23-26 Ib-ft (31-35 N-m).
(19) If separated, assemble four brackets (2) with two bolts (20), eight flat washers (22), and two
self-locking nuts (21 ). Snug bolts.
(20) Secure two bracket (2) assemblies to tube assembly(13) with two bolt and Iockwasher
assemblies (19). Torque bolts to 10-13 Ib-ft (14-18 N-m).
(21 ) Install two strainer element screens (12) on tube assembly (13) and adaptor (1 4). Secure
with four bolts (10) and four flat washers (1 1). Torque bolts to 10-13 Ib-ft (14-18 N-m).
19
6
. \
(n
*Q., :
P
4-129
TM 9-2815-202-34
4-32. OIL PUMP REPLACEMENT (Cont)
e. Installation
(1) If removed, install four studs (8) into
main bearing caps (7).
(2) Place same number of shims (9) as
were removed on main bearing caps
(7).
(3) Position oil pump assembly (6) over
studs (8) and onto main bearing caps
(7 and 3). Aline teeth on spur gear
(30) with teeth on drive gear (49).
(4) Secure oil pump assembly (6) with
four Iockwashers (5) and nuts (4).
Torque nuts to 26-29 Ib-ft (35-40
N-m).
(5) Install two bolts (1) through brackets
(2) into rear main bearing cap (3).
Torque bolts to 23-26 Ib-ft (31-35
N-m).
(6) Aline four brackets (2), eight flat
washers (22) and two self-locking
nuts (21 ). Torque nuts to 26-29 Ib-ft
(35-40 N-m).
(7) With engine in upright position, check
gear tooth clearance between driven
gear (28) and drive gear (49). Using
dial indicator (50) mounted on
cylinder block, measure clearance.
Gear tooth clearance should be 0.006
to 0.012 inch.
NOTE
Shims control gear tooth clearance.
One set of 0.005 inch shims will
change gear tooth clearance by
0.0035 inch.
(8) If gear tooth clearance is not within
specifications, follow steps (a) thru
(d).
(a) Invert engine.
(b) Loosen four nuts (4) and two
bolts (1). Lift oil pump assembly
(6) enough to remove shims (9).
(c)
Install new quantity or correct
thickness of shims (9).
(d) Repeat steps (4), (5), and (7).
4-130
TM9-2815-202-34
●
●
(9) Remove dial indicator (50) from
cylinder block.
END OF TASK
FOLLOW-ON MAINTENANCE
Para t)escriDtion
4-31 Oilpressure relief valve installed
4-20 Oil pan installed
1
o
/\
50
30
‘-c-a
4-131
TM9-2815-202=34
DISASSEMBLY/ASSEMBLY
SECTION 111. ENGINE
4-33. PISTON AND CONNECTING ROD MAINTENANCE (CROSS-HEAD)
This task covers:
a. Removal
d. Inspection
g. Assembly
c. Cleaning
b. Disassembly
f. Fitting Piston Rings
e. Fitting Piston
h. Installation-Cylinder Kit Assembly
●
●
INITIAL SETUP
2
1
2
2
2
1
MODELS
■ All *
Expanders (App F, Item 13)
Ring (App F, Item 120)
Piston pin retainers (App F, Item 118)
Piston pin bolts (App F, Item 5)
Piston pin bolt spacers (App F, Item 157)
Seal ring (App F, Item 142)
*
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Piston ring pliers (App B, Item 66)
Micrometer 1-2 inch (App B, Item 65)
Piston pin retainer installer (App B, Item 57)
Piston pin retainer leak detector (App B, Item 63)
Piston ring compressor (App B, Rem 12)
Cylinder liner hold down clamps (App B, Item 11)
Spring scale (App B, Item 24)
Feeler gage set (App B, Item 24)
Torque wrench (App B, Item 101)
Micrometer O-1 inch (App B, Item 65)
Micrometer 4-5 inch (App B, Item 65)
Piston groove gage (App B, Item 36)
Ridge reamer (App B, Item 72)
Ball attachment (App B, Item 6)
MANDATORY REPLACEMENT PARTS
2 Rings (App F, Item 125)
1 Ring (App F, Item 124)
2 Rings (App F, Item 122)
■ 1 Ring (App F, Item 169)**
EXPENDABLE/DURABLE SUPPLIES
Flat stone (App C, Item 43)
Carbon-removing compound (App C, Item 7)
Plastic gage (App C, Item 30)
Engine oil (App C, Item 16)
International compound no. 2 (App C, Item 24)
Wood block (App C, Item 46)
Crocus cloth (App C, Item 12)
Fuel oil ( App C, Item 21)
●
EQUIPMENT CONDITION
Para Description
4-20 Oil pan removed
4-27 Cylinder head removed
4-31 Oil pressure regulator and relief
valve removed
4-32 Oil pump and oil pump tubes removed
* Applies to engine serial number
8VA-294357 and above for models
7083-7398 and 7083-7399.
** Model 7083-7391 only.
+
n
m
-
a. Removal
CAUTION
f
RIDGE
Remove ridge at top of liner or
piston ring breakage can occur.
(1) Remove carbon deposits and ridge
from upper inner surface of cylinder
liner (1) using ridge removing tool.
4-132
Change 1
lllaoooo~
-1
●
e
TM9-2815-202-34
(2) Remove two nuts (2), cap (3), and lower bearing shell (4) from connecting rod (5).
NOTE
Tag piston to insure it is installed
with same liner.
(3) Push piston and rod assembly out
through top of cylinder block (6).
(4) Reassemble bearing cap (3) and
lower bearing shell (4) to connecting
rod (5).
b. Disassembly
(1) Secure connecting rod (5) in a vise
equipped with soft jaws and remove
piston rings (7) with piston ring pliers
(8). Discard piston rings.
CAUTION
Do not damage piston or bushing
while removing piston pin retainers.
(2) Punch a hole through center of one
piston pin retainer (9) with a narrow
chisel or punch and pry retainer from
piston assembly (1 O). Remove
opposite retainer in same manner.
Discard retainers.
(3) Loosen two bolts (11 ) which secure
connecting rod (5) to piston pin (12).
Remove rod and piston assembly
from vise and place assembly on a
bench. Remove two bolts (11 ), two
spacers (13), and connecting rod (5).
Discard bolts and spacers.
NOTE
Match mark used piston dome, piston
pin, and pin bushing and keep together
as a set for reassembly to maintain
proper fit and wear.
(4) Remove piston pin (12) from piston
assembly (10).
4-133
TM9=2815-202-34
4-33. PISTON AND CONNECTING ROD MAINTENANCE (CROSS-HEAD) (Cent)
WARNING
Keep fingers out of piston pin holes and wear steel-toed shoes when
disassembling piston dome from skirt. Personal Injury may result.
(5) Separate piston skirt (14) from piston
dome (15).
(6) Remove seal ring (16) from piston
dome (15). Discard seal.
(7) Remove piston pin bushing (17) from
piston dome (15).
c. Cleaning
WARNING
●
●
(1)
Use goggles, rubber gloves,
and rubber apron when
cleanlng parts In carbonremovlng compound.
Provide adequate
ventilation. Avoid inhaling
fumes and skin contact. If
compound Is splashed on
skin, flush with fresh water
and wash with alcohol.
Alcohol containing 2 to 3
percent camphor Is
preferable.
16
u
o
Compressed ah’ used for
cleaning purposes will not
exceed 30 psi. Use only with
effective chip guarding and
personal protective
equipment (goggles/ shield,
gloves, etc).
14
Clean piston components with fuel oil and dry with compressed air. If fuel oil does not
remove carbon deposits, use carbon-removing compound which will not harm bushings or
tin plate on piston.
(2) Clean ring grooves in dome with suitable tool or piece of an old compression ring ground to
Ibevel edge.
CAUTION
Do not wire brush or glass bead piston skirt. Skirt is tin plated, and wire brushing or
glass beading will remove plating.
(3) Clean inside surfaces of piston dome and skirt. Clean oil drain holes in lower half of piston
skirt. Do not enlarge holes while cleaning them.
4-134
●
TM9-2815-202-34
CAUTION
Do not use crocus cloth on bushing side of pin. Bushing side requires a polished finish.
(4) Use crocus cloth wet with fuel oil to remove any trace of fretting and/or corrosion on
connecting rod saddle to piston pin contact surface.
d. Inspection
(1) Dome and Skirt
NOTE
Indications of overheating or burned spots may be result of an obstruction in
connecting rod oil passage.
(a) Examine piston skirt and dome
for score marks, cracks, damaged
ring groove lands, loss of tin
plating, or indications of
overheating. Replace any piston
severely scored or overheated.
(b) Check tapered fire ring groove
width with piston groove gage
(18). Slide NO-GO wire (0.106
inch diameter) of tool completely
around fire ring groove. Replace
dome if wire is below flush at any
one area. The GO wire (0.100
inch diameter) should be flush or
protrude slightly from fire ring
groove.
(c) Check cylinder liner and block
bore for excessive out of round,
taper, or high spots which could
cause failure of piston (see Para
4-34).
(2) Piston Pin
CAUTION
When using a piston pin, do not refinish highly polished and lapped surface of pin in
any way.
NOTE
New piston pin has diameter of 1.4996 to 1.5000 inches. Replace piston pin if worn to
diameter of 1.4980 inches or less.
Inspect piston pin for signs of fretting.
4-135
TM9-2815-202-34
4-33. PISTON AND CONNECTING ROD MAINTENANCE (CROSS-HEAD) (Cent)
(3) Connecting Rod
(a) Check connecting rod for visual damage. Scrap rod if it is bent, had previous bearing
failure. was overheated {blue) at to~ or bottom end, is fretted at split line between rod
and cap, or has excessive pound-in of bolt head or nut.
(b) Check for cracks by magnetic particle method.
(gqjgg&!.,,.,..
RODS WITH INDICATIONS OVER .DD5 DEEP
SECTION A-A
VIEW A
-A
/
*
VIEW A
=qg
WA
EXAMPLE OF AN INDICATION
FOLLOWING LONGITUDINAL
FORGING FLOW LINES.
EXAMPLE OF A TRANSVERSE INDICATION
THAT DOES NOT FOLLOW LONGITUDINAL
FORGING FLOW LINES CAN SE EITHER A
FORGING LAP, HEAT TREAT CRACK, OR
START OF A FATIGUE CRACK.
CRITICAL AREA
ACCEPTABLE LIMITS
~—Not+.i3,T,cALAREA-+
+
INDICATIONS IN NON-CRITICAL AREAS
ARE ACCEPTABLE UNLESS THEY CAN BE
OBSERVED AS OBVIOUS CRACKS
WITHOUT MAGNETIC INSPECTION.
LONGITUDINAL INDICATIONS
FOLLOWING FORGED FLOW LINES ARE
uSUALLY SEAMS AND ARE NOT
CONSIDERED HARMFUL IF LESS THAN
1/32 DEEP DEPTH CAN BE DETERMINED
BY GRINDING A SMALL AREA NEAR THE
CENTER OF THE INDICATION.
TRANSVERSE INDICATIONS (ACROSS FLOW LINES).
HAVING A MAXIMUM LENGTH OF 1/2, WHICH CAN BE
REMOVED BY GRINDING NO DEEPER THAN 1/64. ARE
ACCEPTABLE AFTER THEIR COMPLETE REMOVAL
AN EXCEPTION TO THIS ISA ROD HAVING AN
INDICATION WHICH EXTENDS OVER THE EDGE OF W
SECTION AND IS PRESENT ON BOTH SIDES OF THE
FLANGE. IN THIS CASE, MAXIMUM ALLOWABLE
DEPTH IS .005 (SEE SECTION A-A).
GRINDING NOTES
CARE SHOULD BE TAKEN IN GRINDING
oUT INDICATIONS TO ASSURE PROPER
BLENDING OF GROUND AREA INTO
UNGROUND SURFACE SO AS TO FORMA
SM~TH CONTOUR.
~~
POOR PRACTICE
GOOD PRACTICE
(c) Inspect connecting rod bearing
bores for burrs or foreign
particles. Clean up minor burrs
with crocus cloth using circular
motion.
(d) If new connecting rod is required,
stamp cylinder number on
connecting rod (5) and cap (3).
5
(4) Connecting Rod Bearings
(a) Inspect bearing shells for scoring,
pitting, flaking, etching, and dirt
grooving. If any of these defects
are present, discard bearing
shells.
(b) Discard bearing shells with bright
spots on backs indicating
movement in bearing caps or
supports.
4-136
3
●
TM 9-2815-202-34
NOTE
If one bearing shell is less than minimum thickness shown in Table 4-2, replace both
bearing shells (upper and lower).
(c) Using a micrometer and ball attachment, measure thickness of bearing shells (4) at
point "C", 90 degrees from parting line.
TABLE 4-2
Using micrometer, measure piston
skirt outside diameter parallel and
perpendicular to piston pin bore,
obtain measurements at room
temperature (70°F-21°C). Diameter
must be 4.2428 to 4.2450 inches
(Diameter above and below pin bore
may be 4.2414 inches).
(1)
BEARING SHELL CONNECTING ROD THICKNESS
BEARING
SIZE
*NEW BEARING
THICKNESS
MINIMUM WORN
THICKNESS
STANDARD
.1240"/.1245"
.1230"
.002” UNDERSIZE
.1250'/.1255'
.1240'
.010” UNDERSIZE
.1290'/.1295'
,1280”
.020" UNDERSIZE
.1340'/.1345"
.1330”
.030” UNDERSIZE
.1390"/.1395"
.1380”
‘Thickness 90° from parting line of bearing.
NOTE
●
Use feeler gage to check piston skirt to liner clearance. Use a spring scale attached
to feeler gage to measure amount of force in pounds required to withdraw feeler
gage from between piston and liner. Select feeler gage with thickness that will
require six pounds pull to move. Piston to liner clearance will be 0.001 inch greater
than thickness of feeler gage used. For example, a 0.004 inch feeler gage indicates
0.005 inch clearance when withdrawn with a six pound pull.
●
Feeler gage must be perfectly flat and free of nicks and bends.
(2)
With cylinder liner (1) installed in
cylinder block, hold piston skirt (14)
upside down in liner and check
clearance in four places 90 degrees
apart. Clearance must be 0.0045 to
0.0083 inch with new parts. Maximum
clearance of 0.012 inch is allowed for
used parts.
(3)
If binding occurs between piston and
liner, remove piston and examine
piston and liner for burrs. Remove
burrs with fine flat hone and recheck
clearance.
Change 1
4-137
TM
9-2815-202-34
4-33. PISTON AND CONNECTING ROD MAINTENANCE (CROSS-HEAD) (Cont)
f. Fitting Piston Rings
(1)
Insert top piston ring inside cylinder liner in normal area of ring travel. Use a piston skirt to
push ring down to insure ring is parallel with top of liner. Measure ring gap with feeler gage.
Refer to Table 4-3 for ring gap specifications. Repeat procedure for balance of compression
TABLE 4-3 PISTON RING
SPECIFICATIONS
MAXIMUM
MINIMUM
GAP (NO.2, AND 3)
CLEARANCE RING TO GROOVE:
TOP RING
NO.2
NO03
OIL CONTROL RINGS
GAP (TWO RINGS IN
LOWER GROOVE)
GAP (ONE RING IN
UPPER GROOVE)
CLEARANCE (TWO RINGS
IN LOWER GROOVE)
CLEARANCE (ONE RING
IN UPPER GROOVE)
CAUTION
File or stone both ends of
compression ring from outer surface
to inner surface to prevent chipping
or peeling of chrome plating on ring.
Ends of ring must remain square,
and chamfer on outer edge must be
approximately 0.015 inch.
(3) Using feeler gage, measure ring side
clearance by inserting edge of ring in
appropriate groove of piston.
Refer to Table 4-3 for ring side
clearance specifications.
g. Assembly
(1) Piston and Rod Assembly
(a) Install pin bushing (17) in piston
dome (15). It should slide into
piston dome without force.
NOTE
Soak seal rings in engine oil for 15
minutes prior to installation on
dome.
(b) Lubricate seal ring (16) and
install in groove on piston dome
(15).
4-138
Change 1
.0230 IN (.0286CM
.0180 IN. (.0457CM)
.0380 IN. (.0965CM)
.0430 IN. (.1092CM)
.C080 IN. (.0025CM)
,0100 IN. (.0254CM)
.0040 IN. (.0101CM)
.0050 IN (.0127CM)
.0130 IN (.0330CM)
.0070 IN. (.0177 CM)
.0080 IN (.0203CM)
I
.0230 IN. (.0584CM)
.0050 IN. (.0127CM)
.0140 IN. (.0356CM)
.)015 IN. (.0038CM)
.0055 IN. (0139CM)
.0010 IN. (.0025CM)
.0040 IN (.0101CM)
TM9-2815-202-34
(c) Aline piston pin holes in skirt (14) and dome (15), then push skirt into position on dome.
(d)
Lubricate piston pin (12) and piston pin bushing (17) with engine oil and install piston
pin.
(e)
Install spacers (13) on piston pin bolts (11). Apply small amount of International
Compound No. 2, or equivalent, to bolt threads and bolt head contact surfaces.
(f)
Attach connecting rod (5) to piston pin (12) with two bolts (11) and two spacers (13).
Tighten bolts finger tight.
(9) Clamp connecting rod (5) in softjawed vise and torque piston pin
bolts (11 ) to 55-60 Ib-ft (75-81 Nm). Do not exceed this torque.
CAUTION
Insure piston pin retainers do not
buckle during installation and seat
completely in counterbore with
width of land even around retainer
to seal properly.
(h) Insert piston pin retainer (9) in
position. Place crowned end of
piston pin installer (19) against
retainer. Strike tool just hard
enough to deflect retainer and to
seat it evenly in skirt (14), Install
second retainer in same manner.
(i) Check each retainer for proper
sealing with leak detector (20).
Place suction cup over retainer
and hand operate lever to pull a
vacuum of ten inches of Hg. on
gage. A drop in gage reading
indicates air leakage at retainer.
(2) Installation - Piston Rings
(a) Lubricate piston rings and piston
with engine oil before installing
rings.
Change 1
4-139
TM 9-2815-202-34
4-33. PISTON AND CONNECTING ROD MAINTENANCE (Cont)
CAUTION
● Do
not allow ends of oil ring expanders to overlap. An overlapped expander will
cause oil ring to protrude beyond allowable limits and result in breakage when piston
is inserted in ring compressor during installation in cylinder liner.
● Do
not cut or grind ends of expanders to prevent overlapping. Cutting or grinding
ends will decrease expanding force on oil control rings and result in high lubricating
oil consumption.
NOTE
Upper oil ring groove requires a one-piece oil ring and lower groove requires a
two-piece oil ring (upper and lower halves).
(b) Install two ring expanders (21 ) in oil control ring grooves in piston skirt (14) with legs of free
ends toward top of piston.
CAUTION
. For all models except 7083-7391, scraper edges of all oil control rings must face down
(toward bottom of piston) for proper oil control.
. For model 7083-7391, the upper oil ring in the lower groove must face up (toward top of
piston) for proper oil control.
(c) Install upper and lower halves of lower oil control ring by hand. Install lower half (22) in
bottom groove with gap 180° from gap in expander. Install upper half (23) in lower groove wtih
gap 45° from gap in Iower half of ring and scraper edge facing down. For model 7083-7391 only, the
scraper edge of the upper oil ring half (23) in the lower groove MUST face up for proper oil control.
(d) Using piston ring pliers, install upper oil ring (24) by positioning it over upper ring groove
with scraper edge facing down. Align oil ring gap 180° from gap in expander (21). Press
ring against gap side of expander to prevent ends of expander from overlapping. Then
align ring with groove and release tension on ring pliers permitting ring to slip in position.
CAUTION
Do not spread rings any more than necessary to slip them over piston. Ring breakage
and overstressing will result.
NOTE
● Compression
rings have one mark on top of ring and fire ring has two marks on top
of ring. Clamp connecting rod of piston assembly in soft-jawed vise.
Model 7083-7391 has a nongrooved-face fire ring. All other models have a grooved
face fire ring.
(e) Starting with bottom compression ring, install two compression rings (25) and fire ring (26)
using piston ring pliers. Install rings with marks toward top of piston.
(f) Stagger ring gaps around piston 90° from each other.
4-140
Change 1
TM9-2815-202-34
●
●
k
(c) Aline piston pin holes in skirt (14) and dome (15), then push skirt into position on dome.
(d)
Lubricate piston pin (12) and piston pin bushing (17) with engine oil and install piston
pin.
(e)
Install spacers (13) on piston pin bolts (11). Apply small amount of International
Compound No. 2, or equivalent, to bolt threads and bolt head contact surfaces.
(f)
Attach connecting rod (5) to piston pin (12) with two bolts (11) and two spacers (13).
Tighten bolts finger tight.
(9) Clamp connecting rod (5) in softjawed vise and torque piston pin
bolts (11 ) to 55-60 Ib-ft (75-81 Nm). Do not exceed this torque.
CAUTION
Insure piston pin retainers do not
buckle during installation and seat
completely in counterbore with
width of land even around retainer
to seal properly.
(h) Insert piston pin retainer (9) in
position. Place crowned end of
piston pin installer (19) against
retainer. Strike tool just hard
enough to deflect retainer and to
seat it evenly in skirt (14), Install
second retainer in same manner.
(i) Check each retainer for proper
sealing with leak detector (20).
Place suction cup over retainer
and hand operate lever to pull a
vacuum of ten inches of Hg. on
gage. A drop in gage reading
indicates air leakage at retainer.
(2) Installation - Piston Rings
(a) Lubricate piston rings and piston
with engine oil before installing
rings.
Change 1
4-139
TM 9-2815-202-34
4-33. PISTON AND CONNECTING ROD MAINTENANCE (Cent)
CAUTION
● Do
not allow ends of oil tina expanders to overlap. An overlapped expander will
cause oil ring to protrude beyond allowable limits and result in breakage when piston
is inserted in ring compressor during installation in cylinder liner.
● Do
not cut or grind ends of expanders to prevent overlapping. Cutting or grinding
ends will decrease expanding force on oil control rings and result in high lubricating
oil consumption.
●
●
NOTE
Upper oil ring groove requires a one-piece oil ring and lower groove requires a
two-piece oil ring (upper and lower halves).
.
(b) Install two ring expanders (21 ) in oil control ring grooves in piston skirt (14) with legs of free
ends toward top of piston.
CAUTION
. For all models except 7083-7391, scraper edges of all oil control rings must face down
(toward bottom of piston) for proper oil control.
. For model 7083-7391, the upper oil ring in the lower groove must face up (toward top of
piston) for proper oil control.
(c) Install upper and lower halves of lower oil control ring by hand. Install lower half (22) in
bottom c!roove with Qap 180° from qa~ in expander. Install urwer half (23) in lower wove Wtih
●
gap 45° km gap in Io;er half of ring ;nd scraper edge facing down. For” model 7083-7391 only, the
scraper edge of the upper oil ring half (23) in the lower groove MUST face up for proper oil control.
(d) Using piston ring pliers, install upper oil ring (24) by positioning it over upper ring groove
with scraper edge facing down. Align oil ring gap 180° from gap in expander (21). Press
ring against gap side of expander to prevent ends of expander from overlapping. Then
align ring with groove and release tension on ring pliers permitting ring to slip in position.
CAUTION
Do not spread rings any more than necessary to slip them over piston. Ring breakage
and overstressing-will resu!t.
NOTE
● Compression
rings have one mark on top of ring and fire ring has two marks on top
of ring. Clamp connecting rod of piston assembly in soft-jawed vise.
. Model 7083-7391 has a nongrooved-face fire ring. All other models have a grooved
face fire ring.
(e) Starting with bottom compression ring, install two compression rings (25) and fire ring (26)
using piston ring pliers. Install rings with marks toward top of piston.
(f) Stagger ring gaps around piston 90° from each other.
4-140
Change 1
●
TM 9-2815-202-34
Change
1 4-141
TM 9-2815-202-34
4-33. PISTON AND CONNECTING ROD MAINTENANCE (Cont)
(3) Piston and Connecting Rod Assembly to Cylinder Liner
(a) Apply clean engine oil to piston, rings, and inside surface of piston ring compressor.
NOTE
Inspect ring compressor for nicks or burrs, especially at nontapered inside diameter
end. Nicks or burrs on inside diameter of compressor will result in damage to piston
rings.
(b) Place piston ring compressor (27) on wood block, with tapered end of ring compressor
facing up.
(c) Stagger piston ring gaps 90° apart on piston. Make sure ends of oil control ring expanders
are not overlapped.
(d) Start top of piston straight into ring compressor (27). Then push piston down until it
contacts wood block.
(e) Place liner (1) with flange end down on
wood block. Note position of
matchmark on liner.
NOTE
Numbers on side of connecting rod and cap identify rod with cap and indicate particular
cylinder in which they are used.
(f)
Place ring compressor (27) and piston
and connecting rod assembly (28) on
liner (1) with numbers on side of
connecting rod and cap aligned with
matchmark on liner.
(g) Push piston and connecting rod
assembly (28) down into liner (1) until
piston is-free of ring compressor (27).
CAUTION
Do not force piston into liner.
Expanders apply considerable
force on oil rings; therefore,
extra care must be taken during
loading operation to prevent
ring breakage.
(h) Remove connecting rod cap and ring
compressor. Then push piston down
until compression rings pass cylinder
liner ports.
4-142 C h a n g e
1
TM 9-2815-202-34
h. Installation - Cylinder Kit Assembly
NOTE
If any pistons and liners are
already in engine, use hold
down clamps (29) to retain
liners (1) in place when
crankshaft is rotated.
(1) Install cylinder liner insert (30) in block
counterbore.
(2) Rotate crankshaft (31) until connecting rod
journal (32) of particular cylinder being
worked on is at bottom of its travel. Wipe
journal clean and lubricate it with clean
engine oil.
(3) Install upper bearing shell (4) (without
continuous oil groove) in connecting rod
(5). Lubricate bearing shell with clean
engine oil.
NOTE
Distance from vertical center
line of connecting rod bolts to
edges of rod are not equal.
When installing piston and
connecting rod assembly,
ensure narrow side of two
connecting rods on crankshaft
journal are together to avoid
cocking of rod.
(4) Position piston, rod, and liner assembly (33)
above cylinder block bore. Align
identification number and letter on rod face
with outer edge of cylinder block and
matchmarks on liner. Guide end of
connecting rod (5) through block bore
carefully to avoid damaging or dislodging
bearing shell. Then slide piston, rod, and
liner assembly straight into block bore until
liner flange rests against insert in block
counterbore (6).
Push or pull piston and connecting rod into
liner until upper bearing shell is firmly
seated on crankshaft journal.
C h a n g e 1 4-143
TM 9-2815-202-34
4-33.
PISTON AND CONNECTING ROD MAINTENANCE (Cont)
(6) Check bearing to crankshaft journal
clearance by placing a plastic gage strip
(34) between crankshaft journal (32) and
connecting rod cap (3). Tighten connecting
rod nuts (2) to 60-70 Ib-ft (81-95 N-m.).
Remove connecting rod nuts and cap, and
measure width of plastic gage with
measuring strip (35). Maximum clearance
with used parts is 0.006 inch.
(7) Place lower bearing shell (4) in connecting
rod cap (3). Lubricate bearing shell with
clean engine oil.
NOTE
Ensure connecting rod bolt has
not turned in connecting rod
before torquing nuts.
(8) Install bearing cap (3) and bearing shell (4)
on connecting rod (5) with identification
numbers on cap and rod adjacent to each
other. Torque connecting rod bolt nuts (2)
to 60-70 Ib-ft (81-95 N.m.).
NOTE
If necessary, pry connecting
rods apart before measuring
side clearance.
(9) Using feeler gage (36), measure side
clearance between each pair of connecting
rods. Clearance limits are 0.008 to 0.016
inch.
(10) Install additional liners, pistons, and rod
assemblies in same manner. Use
hold-down clamps to hold each liner in
place.
(11) Remove all liner hold-down clamps.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-32 Install oil pump and oil pump tubes
4-31 Install oil pressure regulator and
relief valve
4-27 Install cylinder head
4-20 Install oil pan
4-144 C h a n g e
1
I
TM 9-2815-202-34
4-34. CYLINDER LINER MAINTENANCE
This task covers:
a. Removal
d. Measurements
g. Fitting Cylinder
Liner in Block Bore
b. Cleaning
e. Honing
h. Installation
c. Inspection f. Selection of New Cylinder Liner
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
All
Fuel oil (App C, Item 21)
EQUIPMENT CONDITION
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Depth gage (App B, Item 28)
Cylinder liner remover (App B, Item 76)
Cylinder hone (App B, Item 42)
Cylinder bore gage (App B, Item 27)
Micrometer 4-5 inch (App B, Item 65)
Cylinder liner hold-down clamps
(App B, kern 11)
Torque wrench (App B, Item 101)
a. Removal
CAUTION
Do not insert bar in liner ports and
rotate crankshaft to push out liner.
Piston may be damaged or upper
ring groove may collapse.
(1) Loosen cylinder liner (1) using
cylinder liner removing tool (2).
(2) Remove tool from liner. Then remove
liner from cylinder block.
4-144.1 Blank/4-144.2 C h a n g e 1
Para Description
4-20 Oil pan removed
4-27 Cylinder head removed
4-31 Oil pressure regulator and relief valve
removed
4-32 Oil pump and oil pump tubes removed
4-33 Piston and rod assembly removed
TM 9-2815-202-34
(3) Remove liner insert (3) and shims (4)
(if used) from counterbore in block.
(4) Tag liner, insert, and shims with
cylinder position number.
b. Cleaning
WARNING
Compressed air used for cleaningpurposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/ shield,
gloves, etc).
CAUTION
Always store liners in an upright
position until ready for use. Liners
left on their side can become
distorted.
Clean cylinder liner with fuel oil and dry with compressed air.
c. Inspection
(1) Check outside of liners for cracks, scoring, and flange irregularities.
(2) Discard cracked or excessively scored liners. Clean up slightly scored liners using cylinder
hone.
NOTE
Excessive liner to block clearance or block bore distortion will reduce heat transfer from
liner to block and to engine coolant. Stains or low pressure areas on outer surface of
liner indicate poor contact between liner and block bore.
(3) Examine outside surface of liner for fretting. Remove metal particles from surface of liner with
a coarse flat stone.
(4) Liner flange and liner insert must be smooth and flat on both top and bottom surfaces.
Replace liner if cracked at flange. Replace insert if there is evidence of brinelling.
4-145
TM 9-2815-202-34
4-34. CYLINDER LINER MAINTENANCE (Cont.)
(5) Check inside diameter of liner for
glazing, cracking, scoring, and
unusual wear.
(6) Replace cracked, scuffed, or scored
liners.
d. Measurements
(1) Measure block bore and outside diameter of liner. If liner to block clearance exceeds 0.0025
inch, block must be bored for an oversize liner.
(2) Using liner O.D. measurements from four positions (0.625, 3.375, 5.875, and 9.875 inches
from top of flange), classification of liner O.D. is determined as average of these
measurements.
(3)
Install liner in proper bore - based on measurements in step (1) - of cylinder block. Measure
inside diameter of liner at 14 places shown using cylinder bore gage (5).
4-146 C h a n g e 1
TM 9-2815-202-34
(4) Check used liner for taper and out of round. Liner taper is difference between O.D. at 0.625
and 9.875 inches positions. Taper must not exceed 0.002 inch and out of round must not
exceed 0.0025 inch. If out of round exceeds 0.0025 inch, rotate liner 90 degrees in block
bore and recheck.
NOTE
Liners, standard and oversize, have an inside diameter of 4.2489 to 4.2511 inches.
Liners are available in 0.005, 0.010, 0.020, 0.030 inch oversize on outside diameter.
(5) When an oversize liner is installed, stamp amount of oversize on top of cylinder block bore
adjacent to liner counterbore.
e. Honing
CAUTION
Do not modify surface finish of new liner. Liner is
properly finished at factory so changes will adversely
affect piston ring seating.
NOTE
Used cylinder liners must be honed to break glaze
resulting from extended operation and to remove
ridge formed at top of piston ring travel. If glaze is
not removed, time required to seat new piston rings
will be lengthened.
A scrap cylinder block makes an excellent honing
fixture.
(1) Place liner in fixture (6).
CAUTION
If liner is honed in block, completely dismantle engine
to insure all abrasive material is cleaned out.
(2) A hone (7) equipped with 120 grit stones should be
worked up and down full length of liner a few times
to produce a crisscross pattern of hone marks on 45
degree axis.
WARNING
Compressed air used for cleaning purposes
will not exceed 30 psi. Use only with effective
chip guarding and personal protective
equipment (goggles/shield, gloves, etc).
(3) Remove liner from fixture and clean thoroughly. Dry
with compressed air and check surface for burrs.
4-147
TM 9-2815-202-34
4-34 CYLINDER LINER MAINTENANCE (Cont.)
NOTE
After honing, liner must conform to same limits on taper and out of round as a new liner
and piston to liner clearance must be within specified limits.
f. Selection Of New Cylinder Liner
NOTE
Cylinder bores in a new cylinder
block are classified as #0, #1, #2, #3
or #4 (Table 4-4), designating size
range for each bore. An appropriate
cylinder liner is fitted to each bore.
This number is stamped on fire deck
of cylinder block next to each
cylinder bore.
TABLE 4-4. NEW CYLINDER LINER TO NEW CYLINDER BLOCK BORE FITS
Classification
Number Stamped
Adjacent to
Each Cyl. Bore
Standard Cylinder Liner Diameters
and Liner-to-Block Clearances
When Properly Matched
Liner (0. D.)
Liner (0. D.)
Liner/Block
Diameter
Classification
Clearance
Cylinder
Bore
Classification
Diameter (I. D.)
CAST IRON BLOCK
#1
4.6250"/4.6255"
.0001"/.0009"
4.6266"/4.6270"
#1
#2
#2
#3
4.6250"/4.6255"
4.6256"/4.6260"
4.6256"/4.6260"
4.6261"/4.6265"
.0005"/.0015"
.0000"/.0009"
.0006"/.0014"
.0001"/.0009
#3
4.6271"/4.6275"
#3
4.6261"/4.6265"
.0006"/.0014"
#4
—
#4
4.62701"/4.62800
.0005"/.0015"
#0
117.490/117.498 mm
#1
117.475/117.488 mm
.002/.023 mm
#1
117.500/117.513 mm
#2
117.516/117.526 mm
117.475/117.488
117.490/117.500
117.490/117.500
117.503/117.513
mm
mm
mm
mm
#3
117.528/117.539 mm
#1
#2
#2
#3
#4
117.503/117.513
mm
.012/.038 mm
.000/.023 mm
.0161.036 mm
.003/.023 mm
. 015/.036 mm
#0
4.6256"/4.6259"
#1
4.6260"/4.6265"
#2
METRIC
I
4-148
#4
I
—
I
#4
I
117.527/117.551 mm
I
.012/.038mm
TM 9-2815-202-34
NOTE
A new standard size cylinder liner is
also classified as #1 (stamped
below flange), #2 (stamped above
ports), #3 (stamped below ports), or
#4 (stamped between ports and
flange).
(1) Before installing liner in used cylinder block, always lightly hone block bore (Para 4-36).
■
(2) After honing block bore, check bore
measurements to determine if standard
liner (Classification #1, #2, #3 or #4) can be
used. A push fit between liner and block is
desirable. If a push fit cannot be obtained,
block must be bored to receive an oversize
liner.
TABLE 4-5.
Change
1 4-149
TM 9-2815-202-34
4-34 CYLINDER LINER MAINTENANCE (Cont.)
NOTE
●
Maximum liner out of round and taper is 0.002 inch. Maximum block bore diameter is
4.6285 inches for standard liner. If block bore exceeds limit, block must be bored
oversize.
●
Measure each liner on outside diameter for size in three places (under flange,
between flange and ports, and above ports). Cylinder bore size is average of three
measurements.
g. Fitting Cylinder Liner In Block Bore
CAUTION
If a new liner and piston are installed in block without properly fitting a liner, galling and
seizing of piston may result.
(1) Wipe inside and outside of liner clean and clean block bore and counterbore thoroughly.
(2) Place a standard size cylinder liner insert
(3) (0.1795-0.1800 inch thick) in block
counterbore.
NOTE
If a new liner cannot be pushed in place,
lightly hone block bore to obtain desired fit.
(3) Push cylinder liner (1) into cylinder block
bore (8) until liner flange rests on insert
(3). Liner should slide smoothly in place
with hand pressure.
(4) Install a cylinder liner hold down clamp
(9) at top of liner (1). Torque two bolts to
50 Ib-ft (68 N-m).
4-150 C h a n g e 1
TM 9-2815-202-34
CAUTION
Do not cut liner shims at installation. Shims must be unbroken to seat insert properly.
NOTE
Maximum liner height difference of 0.002 inch between any two adjacent liners is
allowed as measured lengthwise along cylinder center line (10).
(5) Measure distance from top of liner to
top of block with a depth gage (11).
Liner flange must be 0.045 to 0.050
inch below surface of block.
NOTE
Liner inserts 0.0015 inch thicker or 0.0015, 0.004, and 0.008 inch thinner than standard
are available.
(6) If necessary, adjust liner height by adding 0.002 inch shims underneath liner insert or use
alternate inserts.
(7) Matchmark liner and cylinder block on outboard side with felt pen so liner is reinstalled in
same position and same cylinder bore.
(8) Remove hold down clamp and cylinder liner. Do not remove liner insert.
h. Installation
Cylinder liner is installed as a complete assembly including piston assembly, connecting
rod, and cylinder liner. See Para 4-33 for installation instructions.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-33 Install piston and rod assembly
4-32 Install oil pump and oil pump tubes
4-31 Install oil pressure regulator and
relief valve
4-27 Install cylinder head
4-20 Install oil pan
4-151
TM 9-2815-202-34
4-35. CRANKSHAFT MAINTENANCE
This task covers:
a. Removal
d. Inspection
g. Installation
b. Disassembly
e. Measurements
c.- Cleaning
f. Assembly
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
Dry cleaning solvent (App C, Item 10)
Engine oil (App C, Item 16)
Plastic gage (App C, Item 30)
Crocus cloth (App C, Item 12)
Emery cloth (App C, Item 15)
Fuel oil (App C, Item 21)
International compound no. 2 (App C, Item 24)
All
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Magnetic base dial Indicator
(App B, Item 45)
Micrometer 0-1 inch (App B, Item 65)
Micrometer 2-3 inch (App B, Item 65)
Micrometer 4-5 inch (App B, Item 65)
Universal puller (App B, Item 71)
Ball attachment (App B, Item 6)
Telescoping gage set (App B, Item 25)
a. Removal
(1) Remove three bolts (1) and three flat
washers (2) from two stabilizer plates
(3).
(2) Remove four bolts (4), six bolts (5),
and ten flat washers (6) from main
bearing caps (7).
(3) Remove two stabilizer plates (3) from
rear main bearing caps (7).
4-152 C h a n g e
1
EQUIPMENT CONDITION
Para Description
4-24 Flywheel housing removed
4-25 Idler gear removed
4-28 Lower front cover removed (7083-7395
and 7083-7398)
4-33 Pistons and connecting rods removed
5-27 Lower front cover removed (7083-7391,
7083-7396, and 7083-7399)
.
TM 9-2815-202-34
CAUTION
Install main bearing caps and main
bearing shells in their original
position. Main bearing caps are
numbered 1,2,3,4, and 5. Upper
bearing shell has an oil hole and
groove for lubrication, and lower
bearing shell is smooth with no
groove or oil hole.
(4) Remove five main bearing caps (7)
from cylinder block. Attach lower shell
of main bearings (8) and lower thrust
washers (9) (rear cap only) to
appropriate cap.
WARNING
If hoist and sling are not
available, use two or more
men to remove crankshaft.
Crankshaft Is heavy and
awkward to handle. Serious
injury can result If crankshaft
Is dropped.
(5) Remove crankshaft from cylinder
block. Do not dislodge upper bearing
shells (10) and upper thrust washers
(11).
(6) Remove five upper bearing shells
(10) and two upper thrust washers
(11) from block and mark with
corresponding main bearing
identification number.
b. Disassembly
(1) Remove six bolts (12) from rear crankshaft gear (13). Use universal puller to remove gear
from crankshaft (14).
(2) Remove slip fit oil pump driving gear (15) from front of crankshaft. Remove Woodruff key (16)
and spacer ring (17) from crankshaft.
(3)
4-153
TM9-2815-202-34
4-35. CRANKSHAFT MAINTENANCE (Cont)
c. Cleaning
WARNING
● Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only In a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. oDo noto
use near
open flame or excessive heat. The flash point is 100 F-138 F
o
(38°-50 C). If you become dizzy while using cleaning solvent, get fresh
air immediately and get medical aid. If contact with eyes is made, wash
your eyes with water and get medical aid immediately.
● Compressed air used for cleaning purposes will not exceed 30 psi. Use
-
only with effective chip guarding and personal protective equipment
(goggles/shieid, gloves, etc).
(1) Clean all crankshaft oil passages thoroughly with cleaning solvent and dry with compressed
air.
(2) Clean front and rear crankshaft gears with cleaning solvent.
d. Inspection
(1) inspect gear teeth for evidence of scoring, pitting, and wear. If severely damaged or worn,
replace gear.
(2) Inspect crankshaft keyways for evidence of cracks or wear. Replace crankshaft if required.
CAUTION
● Replace crankshaft if it shows evidence of excessive overheating since heat
treatment has probably been destroyed.
● Ridges on crankshaft journals must be removed. If ridges are not removed, localized
high unit pressures are placed on new bearing shells and short bearing life can
result.
(3) Inspect crankshaft journals for ridges and grooves. Ridges exceeding 0.0002 inch must be
removed.
NOTE
Replace crankshaft if journal ridges are greater than 0.001 inch in depth.
(4) Remove crankshaft journal ridges by working crocus cloth, wet with fuel oil, around
circumference of journals. if ridges are greater than 0.0005 inch, first use 120 grit emery cloth
to clean up ridges, 240 grit emery cloth for finishing and wet crocus cloth for polishing.
4-154
TM
9-2815-202-34
(5) Inspect rear end of crankshaft at area
of oil seal contact surface for
evidence of rough or grooved
condition. Slight ridges on crankshaft
oil seal contact surface may be
cleaned up with crocus cloth. If
crankshaft cannot be cleaned up
satisfactorily, reposition oil seal in
flywheel housing.
(6) Check crankshaft thrust surfaces for
excessive wear or grooving. If only
slightly worn, surfaces may be
dressed with an oil stone.
NOTE
●
Minute cracks can be detected by using Magnetic Particle Inspection Method.
●
Crankshaft failures are rare and when one cracks or breaks completely, it is very
important to make a thorough inspection for contributory factors.
(7) Inspect crankshaft for fatigue cracks
which start at an oil hole and follow
journal surface at an angle of 45
degrees to axis. Reject crankshaft
with cracks.
(8) Inspect main bearing shells for bright
spots on backs indicating movement
in bearing caps or supports. Discard
shells if this condition is present.
CAUTION
Install all upper and lower bearing shells as a set. Do not replace one main bearing
shell alone. When new crankshaft is used, install all new bearing shells.
4-155
TM 9-2815-202-34
4-35. CRANKSHAFT MAINTENANCE (Cont.)
NOTE
Lower bearing shells, which carry the load, will normally show signs of distress before
upper bearing shells.
(9) Discard main bearings with signs of scoring, pitting, flaking, etching, overheating, or loss of
overlay.
e. Measurements
(1) Using micrometer and ball attachment, measure thickness of bearing shells at point (C),
90 degrees from parting line. Replace all bearing shells if minimum thickness is less than
0.1540 inch. A standard bearing is 0.1545 to 0.1552 inch thick. Refer to Table 4-6 for
thickness of undersize bearings.
TABLE 4-6.
If clearance between any crankshaft journal and its bearing shells exceeds 0.0060
inch, all bearing shells must be discarded and replaced. Clearance for new parts is
0.0016 to 0.0050 inch.
(2) Check clearance between main bearings and crankshaft journals by using method (a) or (b)
below:
(a) With crankshaft removed, measure outside diameter of crankshaft main bearing journals
and inside diameter of main bearing shells in place with required bearing cap bolt
torque. When installed, bearing shells are 0.001 inch larger in diameter at parting line
than 90 degrees from parting line.
4-156
TM
9-2815-202-34
(b) With crankshaft installed, place plastic gage strip (19) between crankshaft journal (20)
and main bearing cap (7). Tighten main bearing bolts (21) to required torque. Remove
main bearing bolts and cap and measure width of plastic gage with measuring strip (22).
(3) Measure intermediate main bearing journal runout with dial indicator. Support crankshaft on
its front and rear journals on V-blocks or an inverted engine block with front and rear upper
bearing shells in place. When high spots of runout on adjacent journals are in opposite
directions, sum must not exceed 0.003 inch total indicator reading. When high spots of
runout on adjacent journals is in same direction, difference must not exceed 0.003 inch total
indicator reading. When high spots of runout on adjacent journals are at right angles to each
other, sum must not exceed 0.004 inch total indicator reading or 0.002 inch on each journal.
If runout limit is greater than 0.002 inch on No. 2 and No. 4 journals or greater than 0.004
inch on No. 3 journal, crankshaft must be replaced.
4-157
TM 9-2815-202-34
4-35. CRANKSHAFT MAINTENANCE (Cont.)
NOTE
Maximum clearance between
connecting rod journal and bearing
shell is 0.0045 inch (with new
shells). Maximum clearance
between main bearing journal and
bearing shell is 0.0055 inch (with
new shells). Main bearing journal
taper must not exceed 0.0006 inch
or out of round must not be greater
than 0.0005 inch. Replace
crankshaft if measurements exceed
limits.
(4) Measure all main and connecting rod
bearing journals. Measure journals at
several places on circumference so
that taper (calculated from two end
outside diameter measurements of
journal), out of round, and bearing
clearances can be determined.
Measurements should be accurate to
nearest 0.0002 inch.
(5) Measure crankshaft thrust surfaces at points A and B. Dimension A must be 1.499 to 1.501
inches and dimension B must be 1.915 to 1.925 inches.
f. Assembly
(1) Install four pipe plugs (18) into crankshaft (14). Torque plugs to 10-12 Ib-ft (14-16 N-m).
(2) Position gear (13) on rear end of crankshaft (14) with bolt holes in gear alined with tapped
holes in crankshaft. One bolt hole is offset so gear can be attached in only one position.
Install six bolts (12) through gear and into crankshaft. Torque bolts to 35-39 lb-ft (47-53 N-m).
(3) Install spacer ring (17), with beveled side toward main bearing cap, and woodruff key (16) on
front of crankshaft. install oil pump driving gear ( 5) with chamfer toward main bearing cap
and slide gear on shaft and over woodruff key. Install gear tight against spacer ring (17).
4-158
TM
9-2815-202-34
g. Installation
CAUTION
When a new or rearound crankshaft is installed, all new main and connecting rod
bearing shells and-thrust washers must be installed. If used components are-installed,
short life will result.
(1) Install upper main bearing shells (10) in block. If bearings are being reused, install them in
same locations from which they were removed.
(2) Apply clean engine oil to upper bearing shells and crankshaft main bearing journals.
CAUTION
Do not damage journals or main
bearing shells when lowering
crankshaft into position. Damage
will result in short component life.
(3) Position crankshaft on upper bearing
shells in cylinder block using Iifting
sling (23).
(4) Install upper crankshaft thrust
washers (11) on each side of rear
main bearing support with grooved
side of thrust washers toward
crankshaft thrust surfaces.
NOTE
Install used bearings in same
bearing caps from which removed.
(5) Install lower main bearing shells (8) in
bearing caps (7) and two thrust
washers (9) to rear main bearing cap.
NOTE
Main bearing caps are bored in
position and stamped 1, 2, 3, 4, and
5, Install caps with identification
stamp on right side of engine.
(6) Install five main bearing caps (7)
along with mating lower bearing
shells (8) and lower thrust washers
(9).
4-159
TM 9-2815-202-34
4-35. CRANKSHAFT MAINTENANCE (Cont)
(7) Install two stabilizer plates (3) on rear main bearing caps.
(8) Apply a small quantity of international Compound No. 2, or equivalent to main bearing bolt
threads and bolt head contact area. Install six main bearing bolts (5) and six flat washers (6)
to front bearing caps and four main bearing bolts (4) and four flat washers (6) to rear bearing
caps. Rear bolts (4) go through stabilizer plates (3). Draw bolts up snug.
(9) Install three bolts (1) and three flat washers (2) securing stabilizer plates (3) to cylinder block.
Finger tighten bolts.
(10) Strike main bearing caps sharply with a soft-headed hammer to seat them properly. Starting
with center bearing cap bolts and working alternately towards both ends of block, torque
main bearing bolts to 45-55 Ib-ft (61-75 N-m). Turn all bolts, except two rear main bearing
bolts, an additional 110-130 degrees of bolt head rotation.
(11 ) Strike both ends of crankshaft two or three sharp blows with soft-headed hammer to insure
proper positioning of rear main bearing cap in block saddle. Turn two rear main bearing cap
bolts an additional 110-130 degrees of bolt head rotation.
(12) Tighten three stabilizer plate bolts (1) to 70-75 Ib-ft (95-102 N-m) torque.
4-160
TM 9-2815-202-34
NOTE
[f bearings are installed properly, crankshaft will turn freely with all of bearing cap bolts
drawn to specified torque.
(13) Measure Crankshaft End Play
(a) Mount dial indicator on rear of
cylinder block with indicator point
resting on end of crankshaft
assembly.
(b) Using a pry bar or large screwdriver
between main bearing cap and
crankshaft counterweight, push
crankshaft toward dial indicator. With
constant pressure on screwdriver, set
dial indicator to zero.
NOTE
If correct crankshaft end play cannot be obtained with standard size thrust washers,
use 0.005 or 0.010 inch oversize washers.
Insufficient end play can result from a misaligned rear main bearing or a burr or dirt
on inner face of one or more thrust washers.
(c) Force crankshaft in opposite direction and note amount of end play on dial. End play
must be 0.004 to 0.011 inch with new parts and maximum of 0.018 inch with used parts.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
■ 5-27 Install lower front cover (7083-7391, 7083-7396, and 7083-7399)
4-33 Install pistons and connecting rods
■ 4-28 Install lower front cover (7083-7395 and 7083-7398)
4-25 Install idler gear
4-24 Install flywheel housing
Change
1 4-161
TM 9-2815-202-34
4-36. CYLINDER BLOCK MAINTENANCE
This task covers:
a. Disassembly
d. Assembly
b. Installation
e. Pressure check
c. Inspection
INITIAL SETUP
MODELS
All
TOOLS AND SPECIAL TOOLS
EXPENDABLE/DURABLE SUPPLIES
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Plug adapter (App B, Item 67)
Bore gage (App B, Item 27)
Depth gage (App B, Item 28)
Cup plug installer (App B, Item 58)
Cylinder hone (App B, Item 42)
Water outlet plate (App D, Item 11)
Blocking plates (App D, Item 10)
Torque wrench (App B, Item 102)
Engine oil (App C, Item 16)
International compound no. 2 (App C, Item 24)
Thread sealant (App C, Item 40)
Cleaning solvent (App C, Item 10)
20 Bolts 5/8-11 X 2.0(App C, ltem 6)
Teflon pipe sealant (App C, ltem 49)
Gasket cement (App C , Item 50)
MANDATORY REPLACEMENT PARTS
Para
3-6
4-18
4-30
4-33
4-35
EQUIPMENT CONDITION
Washers (App F, Item 160)
Lockwashers (App F, Item 93)
Gaskets (App F, Item 80)
Gaskets (App F, Item 81)
Gasket (App F, Item 32)
Cup plugs (App F, Item 8)
Cup plugs (App F, Item 9)
Cup plugs (App F, Item 10)
Pins (App F, Item 109)
Cup plug (App F, Item 12)
Solid plug (App F, Item 117)
Pins (App F, Item 108)
Solid plug (App F, Item 115)
Solid plugs (App F, Item 114)
Gasket (App F, Item 37)
Cup plug (App F, Item 170) *
Description
Oil cooler
Blower removed
Front and rear end plates removed
Cylinder kits removed
Crankshaft removed
* Model 7083-7391 only.
NOTE
If pressure testing of cylinder block is required, proceed to steps (14) and (15) and then
do pressure testing (step e.) before disassembling the cylinder block.
a. Disassembly
(1) Remove two each of cup plug (1 and 2), four cup plugs (3), one each of pipe plugs
(4, 5,6, and 7) and two pipe plugs (8) from front of cylinder block. Discard cup plugs.
4-162 C h a n g e
1
TM 9-2815-202-34
(1a) For models 7083-7395, 7083-7398 and 7083-7399, remove two pipe plugs (9) from front of
cylinder block.
(1b) For models 7083-7391 and 7083-7396, remove pipe plug (9) from right front and turbocharger
oil feed elbow (9.1) from left front of cylinder block.
(2) Remove drain cock (10) from front of block.
(3) If necessary, remove two locating pins (11) from front of block.
(4) Remove cup plug (12) from bottom of block. Discard plug.
(5) Remove two cup plugs (13), two pipe plugs (14), and pipe plugs (15 and 16) from rear of
block. If necessary, remove two locating pins (17). Discard cup plugs.
(6) Remove cup plug (18) from bottom of block. Discard plug.
(7) Remove brass plug (19) from rear of block. Discard plug.
(8) If necessary, remove four pins (20) from rear main bearing cap.
(9) For models 7083-7398 and 7083-7399 only, remove breather retainers (21 and 22) and two
filter elements (23) from rear of block.
Change
14-163
TM 9-2815-202-34
4-36. CYLINDER BLOCK MAINTENANCE (Cont.)
(10) For models 7083-7395 and 7083-7398 only, remove dipstick adapter (24) from left side of
block.
(11) Remove two each of pipe plugs (25 and 26) from left side of block.
(12) For models 7083-7395,7083-7398 and 7083-7399, remove turbocharger oil feed elbow (27).
For models 7083-7391 and 7083-7396, remove pipe plug (27.1).
(12.1) Remove drain cock (28), and four cup plugs (29) from left side of block. Discard cup plugs.
(13) For models 7083-7395 and 7083-7398, remove pipe plug (30) from rear left side of block. For
models 7083-7391, 7083-7396 and 7083-7399, remove two pipe plugs (30) from left side.
(14) Remove two bolts (31 ), two nuts (32), and four Iockwashers (33) securing oil cooler flange (34)
to cylinder block. Remove flange (34) and gasket (35). Discard gasket and Iockwashers.
(15) Remove two studs (36) from right side of block.
(16) Remove two pipe plugs (37), three cup plugs (38), and one each of pipe plugs (39, 40,41, and
42) from right side of block. Discard cup plugs.
(17) Remove drain cock (43) and solid plug (44) from right side of block.
4-164 C h a n g e
1
TM 9-2815-202-34
(18)
If necessary, remove three solid plugs (45) from top surface of cylinder banks.
(19)
Remove two pipe plugs (46) from top of block.
(19.1)
For model 7083-7391: If necessary, remove cup plug (46.1) from top front of block. Discard
plug.
(20)
Using plug adaptor, remove two threaded plugs (47) and two washers (48) from floor of
airbox. Discard washers.
(21)
Remove six pipe plugs (49) from top surface of cylinder banks.
(22)
If necessary, remove fourteen pipe plugs (50) from bottom of cylinder head bolt holes.
(23)
Remove four bolts (51), four Iockwashers (52), cover plate (53), and gasket (54) from left side
of block. Discard Iockwashers and gasket.
(24)
Remove airbox drain tube elbow (55) from each side of block.
(25)
Remove seven bolts (56), cover (57), two covers (58), gasket (59), and two gaskets (60) from
each side of cylinder block. If necessary, remove two plugs (61) from each cover (57).
Discard gaskets.
Change 1
4-165
TM 9-2815-202-34
4-36. CYLINDER BLOCK MAINTENANCE (Cont)
b. Cleaning
NOTE
Remove all pipe plugs except fourteen plugs in cylinder head bolt holes. Do not
remove solid plugs.
(1) Scrape all gasket material from cylinder block.
WARNING
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well ventilated area. Avoid contact
with skin, eyes, and clothes and don’t breathe vapors.o Do not use onear
o
open frame or excessive heat. The flash point is 100 F-138°F (38 -50 C).
If you become dizzy while using cleaning solvent, get fresh air
immediately and get medical aid. f contact with eyes is made, wash your
eyes with water and get medical aid immediately.
(2) Clean inner and outer surfaces of cylinder block with cleaning solvent.
WARNiNG
Compressed air used for cleaning purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
(3) Clean water, air, and oil passages with bore brush. Wash passages by flushing with
cleaning solvent and blow out with compressed air.
(4) Dry cylinder block with compressed air.
c. Inspection
NOTE
After cylinder block is thoroughly cleaned and pressure tested (step e), cylinder bores
must be honed before inspection.
(1) Hone cylinder block bores as follows:
NOTE
Use a hone in which cutting radius of stones can be set in a fixed position to remove
irregularities in bore. Do not use spring-loaded hone. Clean stones frequently with wire
brush to prevent stone loading. Follow hone manufacturer’s instructions regarding use
of oil or kerosene on stones. Do not use such cutting agents with dry hone. Use 120grit stones.
4-166
TM 9-2815-202-34
(a)
Insert hone in bore and adjust
stones snugly to narrowest
section. When correctly adjusted,
hone will not shake in bore but
will drag freely up and down bore
when hone is not running.
(b) Start hone and “feel out” bore for
high spots which cause an
increased drag on stones. Move
hone up and down bore with
short overlapping strokes about 1
inch long. Concentrate on high
spots in first cut. As these are
removed, drag on hone will
become lighter and smoother.
CAUTION
Do not hone as long in air inlet port area as in rest of bore because this area cuts away
more rapidly. Feed lightly to avoid an excessive increase in bore diameter. Some
stones cut rapidly under low tension.
(c) When bore is fairly clean, remove hone, inspect stones, and measure bore. Determine
which spots must be honed again.
(d) Clean cylinder block thoroughly after honing operation is completed per step (b).
4-167
TM 9-2815-202-34
4-36. CYLINDER BLOCK MAINTENANCE (Cont)
(2) Check cylinder block bores as follows:
(a) After honing, check for low spots
in cylinder bore. There must not
be any low spots larger than one
inch in diameter.
(b) Measure entire bore of each
cylinder with a cylinder bore gage
(62). Take measurements on
cleaned-up surface only at
positions A, B, C, D, E, and F in
bore on axes 45 degrees apart.
Block bore I.D. is classified as #0,
#1, #2, #3, or #4 (see Para 4-34).
NOTE
Diameter of standard block bore is 4.6256 to 4.6275 inches. Maximum liner to block
clearance is 0.0025 inch with used parts and is 0.0015 inch with new parts.
(c) "A" Diameter - Must be same size as “B” diameter within +0.0006 inch and never smaller
(no bottleneck allowed).
(d) "B" Diameter - Is classification area for determining whether a cylinder bore is a #0, #1, #2,
or #3 size. "B" has a 0.0019 inch tolerance band.
(e) "C" Diameter - Should be same size as "B" diameter. However, due to a bell mouth flare
caused by honing stones traveling through air box area, a maximum +0.0022 inch
diameter flare over "B" diameter is allowed.
4-168 C h a n g e 1
TM 9-2815-202-34
(f) "D" Diameter - should be same size as "B" diameter. However, due to a bell mouth flare
caused by honing stone’s vertical travel, a maximum +0.0022 inch diameter flare over “B”
diameter is allowed in lower air box area.
(9) "E" Diameter - Must be within 0.0005 inch classification range as determined by “B”
(h) "F" Diameter - should be same size as"B" diameter. However, due to a bell mouth flare
caused by honing stone’s vertical travel, a maximum +0.0012 inch diameter flare over "B"
diameter is allowed in lower crank area of bore.
(3) Check cylinder head contact area for
flatness with straight edge (63) and
feeler gage (64). Measurements must
not vary more than 0.003 inch
crosswise and over 0.007 inch
lengthwise.
(4)
. , Check cvlinder liner counterbore
depth by using dial indicator (65).
NOTE
Counterbore depth must be 0.4770
to 0.4795 inch and must not vary
more than 0.0015 inch through
entire circumference. Counterbore
surfaces must be smooth and
square with cylinder bore and within
0.001 inch total indicator reading.
There must not be over 0.001 inch
difference between any two
adjacent cylinder counterbores
when measured along cylinder
lengthwise center line of cylinder
block.
C h a n g e
1 4-169
TM 9-2815-202-34
4-36. CYLINDER BLOCK MAINTENANCE (Cont)
(5) Using a bore gage, check main beating bore diameters with bearing caps in original position
and bolts torqued to 165-175 Ib-ft (224-238 N-m). Apply International Compound No. 2 to
bolt threads and bolt head contact area. Do not install main bearing cap stabilizers when
performing this check.
NOTE
●
Main bearing bore diameter is 4.812 to 4.813 inches. If bores do not meet these
limits, replace cylinder block.
●
Main bearing caps are numbered to correspond with their respective positions in
cylinder block. No. 1 bearing cap is located at front of block and stamped on bottom
front oil pan rail.
(6) Check remainining cylinder block surfaces and threaded holes for damage. Check all mating
surfaces or mounting pads for flatness, nicks, and burrs. Clean up damaged threads in
tapped holes with a tap or install helical thread inserts if necessary.
If cylinder block is not to be used immediately, spray machined surfaces with engine
oil. If cylinder block is to be stored for an extended period of time, spray or dip block in
polar-type rust-preventive compound. Castings free of oil will rust when exposed to
atmosphere.
d. Assembly
NOTE
Apply pipe sealant to all plugs and fittings. Install cup plugs 0.090 to 0.140 inch below
surface unless otherwise noted.
4-170
TM 9-2815-202-34
(1) Install two each of cup plugs (1 and 2), four cup plugs (3), one each of pipe plugs
(4, 5,6, and 7), and two pipe plugs (8) in front of cylinder block.
(1a) For models 7083-7395, 7083-7398 and 7083-7399, install two pipe plugs (9) in front of the
cylinder block. For models 7083-7391 and 7083-7396, install pipe plug (9) in right front of
block.
(1b) For models 7083-7391 and 7083-7396, install turbocharger oil feed elbow (9.1) in left front of
cylinder block.
(2) Install drain cock (10) on front of block.
(3) If necessary, install two locating pins (11) so they protrude 0.630 +/-0.030 inch from front face
of block.
(4) Install cup plug (12), in bottom of block
to depth of 3.40 inches below surface
using cup plug installation tool (66).
(5) For models 7083-7395 and 7083-7398
only, install dipstick adapter (24) in left
side of block.
(6) Install two each of pipe plugs (25 and
26) in left side of block.
(7) For models 7083-7395, 7083-7398 and
7083-7399, install turbocharger oil feed
elbow (27) in left side of block. For
models 7083-7391 and 7083-7396,
install pipe plug (27.1) in left side of
block.
(7a) Install drain cock (28), and four cup
plugs (29) in left side of block.
(8) For models 7083-7395 and 7083-7398,
install pipe plug (30) in left side of
block. For models 7083-7391,
7083-7396 and 7083-7399, install two
pipe plugs (30) in left side of block.
Change 1
4-171
TM 9-2815-202-34
4-36. CYLINDER BLOCK MAINTENANCE (Cont)
(9) Install two cup plugs (13), two pipe
plugs (14), pipe plugs (15 and 16),
and brass plug (19) to rear of block.
(10) If necessary, install two locating pins
(17) so they protrude 0.630 +/- 0.030
inch from rear face of block.
(11) Install cup plug (18) in bottom of block
0.12 inch below surface.
(12) If necessary, install four pins (20) in
rear main bearing cap so they
protrude 0.115 +/-0.005 inch.
(13) For models 7083-7398 and 70837399 only, install two filter elements
(23) and breather retainers (21 and
22) in rear of block.
(14) Install two pipe plugs (37), three cup
plugs (38), and one each of pipe
plugs (39, 40,41, and 42) into right
side of block.
(15) Install two studs (36) into right side of block.
(16) Install gasket (35) and oil cooler flange (34) on right side of block. Secure in place with four
Iockwashers (33), two nuts (32), and two bolts (31). Torque bolts and nuts to 30-35 Ib-ft
(41-47 N-m).
(17) Install solid plug (44) and drain cock (43) in right side of block. Install plug 0.090 to 0.140
inch below surface.
4-172
TM9-2815-202-34
(18)
If necessary, install three solid plugs (45) flush with top surface of cylinder banks.
(19)
Install two pipe plugs (46) in top of block.
(19.1) For model 7083-7391: If necessary, coat cup plug (46.1) with gasket cement and install in top
front of cylinder block at a depth of approximately 1.0 inch.
(20)
Using plug installer, install two washers (48) and two threaded plugs (47) to floor of airbox.
Torque plugs to 230-270 Ib-ft (312-366 N-m).
(21)
Install six pipe plugs (49) to a minimum depth of 0.24 inch below top surface of cylinder
banks.
(22)
If necessary, install fourteen pipe plugs (50) in bottom of cylinder head bolt holes to a
minimum depth of 2.04 inches.
(23)
Install gasket (54), cover plate (53),
four Iockwashers (52), and four bolts
(51 ) to left side of engine. Torque
bolts to 30-35 Ib-ft (41-47 N-m).
(24)
Install airbox drain tube elbow (55) to
each side of block.
(25)
Install gasket (59), two gaskets (60),
cover (57), two covers (58), and
seven bolts (56) to each side of
cylinder block. Torque bolts to 8-12
Ib-ft (1 1-16 N-m). If removed, install
two plugs (61 ) in each cover (57).
Change
1 4-173
TM 9-2815-202-34
4-36 CYLINDER BLOCK MAINTENANCE (Cont.)
e. Pressure Check
(1) With all cylinder block plugs in place,
install ten blocking plates (67) and ten
gaskets (68), found in cylinder head
pressure testing kit, over water outlet
holes. Secure plates to top of cylinder
block with twenty 5/8-11 x 2 inch bolts
(69).
(2) Install fabricated water outlet plate
(70) and rubber gasket (71). Secure
with two bolts (72), two nuts (73), and
four Iockwashers (74).
(3) Attach an air line connection at plate
(70). Immerse block ino a tank of owater
heated to 180 to 200 F (82-93 C) for
twenty minutes.
Never work on air system components without first gradually relieving air
pressure. Sudden release of air pressure can throw debris resulting in
serious personal injury.
(4) Apply 40 psi (276 kPa) air pressure to water jacket and observe water in tank for bubbles
which indicate a crack or leak in block. Replace block if cracked.
Compressed air used for cleaning purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
(5) After competing pressure test, remove block from water tank. Remove ten blocking plates
(67), ten rubber gaskets (68), twenty bolts (69), oil cooler plate (70), gasket (71), two bolts
(72), two nuts (73), and four Iockwashers (74). Dry block with compressed air.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
3 - 6 Install oil cooler
4-18 Install blower
4-30 Install front and rear end plates
4-33 Install cylinder kits
4-35 Install crankshaft
4-174
TM 9-2815-202-34
SECTION IV. COMPONENT REPAIR
4-37. TURBOCHARGER REPAIR
This task covers:
a. Disassembly
d. Assembly
b. Cleaning
c. Inspection
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
7083-7395 7083-7396
Engine oil (App C, Item 16)
Cleaning solvent (App C, Item 10)
Crocus cloth (App C, Item 12)
Silicone carbide cloth (App C, Item 41 )
Antiseize compound (App C, Item 1)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Dial indicator adaptor (App B, Item 4)
Turbocharger holding fixture (App B, Item 21)
Magnetic base dial indicator (App B, Item 45)
Torque wrench (App B, Item 100)
EQUIPMENT CONDITION
Para Description
Turbocharger removed (7083-7395)
4-2
Turbocharger removed (7083-7396)
5-2
MANDATORY REPLACEMENT PARTS
Locking plates (App F, Item 112)
Seal ring (App F, Item 140)
Piston ring (App F, Item 129)
Lock tabs (App F, Item 87)
Piston rings (App F, Item 130)
Thrust washer (App F, Item 162)
Bearing kits (App F, Item 2)
Snap rings (App F, Item 144)
LockWashers (App F, Item 93)
Gasket (App F, Item 74)
Nut, special (App F, Item 171)
a. Disassembly
(1) Mark relative position of compressor
housing (1), center housing (2), and
turbine housing (3) with a scribe to
assure reassembly in same relative
location.
Exercise care when removing
compressor housing and turbine
housing to prevent damage to
compressor and turbine wheels.
C h a n g e
1 4-175
TM 9-2815-202-34
4-37. TURBOCHARGER REPAIR (Cont)
(2) Loosen V-band clamp (4) securing compressor housing (1) to backplate assembly (5).
Remove clamp and housing.
(3) Remove two bolts (6) and two Iockwashers (7) securing turbocharger drain tube (8) to center
housing (2). Remove bracket (9) (used only on model 7083-7396), drain tube (8), and gasket
(10) from center housing. Discard Iockwashers and gasket.
(4) Remove adaptor bushing (11) from top of center housing (2).
(5) Bend down ends of four locking plates (12). Remove eight bolts (13), four locking plates (12),
and four clamps (14) from turbine housing (3). Discard locking plates.
(6) Remove turbine housing (3) from center housing (2).
Remove compressor wheel nut from shaft with a double universal socket and tee
handle to prevent bending turbine wheel shaft.
4-176
TM9-2815-202-34
Position turbine wheel assembly (15) in holding fixture. Remove wheel nut (16) from
compressor wheel (17) end of shaft. Discard nut.
CAUTION
Catch wheel shroud before it falls from press. Wheel shroud (18) will fall free when
wheel shaft assembly is removed.
(8) Remove compressor wheel (17) from wheel shaft assembly (15) by using a press.
(9) Withdraw wheel shaft assembly (15) from center housing (2).
NOTE
If groove in shaft (15) is not present, turbocharger does not require a piston ring (19)
near turbine wheel.
(10) Remove piston ring (19) from wheel shaft assembly (15). Discard piston ring.
Change
1 4-177
TM9-2815-202-34
4-37. TURBOCHARGER REPAIR (Cont)
(11) Bend down tangs on four locking plates (20). Remove four bolts (21) and locking plates (20)
securing backplate (5) to center housing (2). Discard locking plates.
(12) Remove backplate (5) from center housing (2) by tapping it lightly.
(13) Remove seal ring (22) from groove in center housing (2). Discard seal ring.
(14) Remove thrust spacer (23) and two piston rings (24) from backplate (5). Discard piston rings.
(15) Remove thrust collar (25) and thrust washer (26). Discard thrust washer.
(16) Remove bearing (27), bearing washer (28), and retaining ring (29) from center housing (2).
Discard bearing, washer, and retaining ring,
(17)
If necessary, remove two pins (30) from center housing (2).
(18) Remove two retaining rings (31), bearing washer (32), and bearing (33) from turbine end of
center housing (2). Discard retaining rings, bearing washer, and bearing.
b. Cleaning
● Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do not
o
use near open flame or excessive heat. The flash point is 100 F-138°F
o
o
(38 -50 C). If you become dizzy while using cleaning solvent, get fresh
air immediately and get medical aid. If contact with eyes is made, wash
your eyes with water and get medical aid immediately.
● Compressed air used for cleaning purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
4-178
TM 9-2815-202-34
CAUTION
Never use caustic cleaning solution for cleaning. Do not use wire brush or steel blade
scraper to clean parts. Such cleaning will damage finished surfaces of turbocharger.
NOTE
● Before
cleaning, inspect parts for signs of burning, rubbing, or other damage which
might not be evident after cleaning.
● Insure
compressor and turbine wheel blades are thoroughly clean. Deposits left on
blades will affect balance of rotating assembly.
(1) Soak all parts in cleaning solvent for 25 minutes. After soaking, use a stiff bristle brush to
remove all dirt particles. Using compressed air, dry all parts thoroughly.
(2) Clean all internal cavities and oil passages in center housing thoroughly with compressed
air.
(3) Clean oil passage in center housing thrust plate with compressed air.
CAUTION
When polishing surfaces, use silicone carbide abrasive cloth for aluminum parts and
crocus cloth for steel parts.
(4) Minor surface damage may be burnished or polished away.
c. Inspection
(1) Inspect all parts for signs of damage, corrosion, or deterioration. Check for nicked, crossed,
or stripped threads.
(2) Check turbine wheel for nicks, rubbing, and wear.
(3) Inspect shaft for signs of scoring, scratches, or bearing seizure.
(4) Check compressor wheel for signs of rubbing or blade damage. Check to see wheel bore is
not galled.
(5) Inspect seal parts for signs of rubbing or scoring of running faces.
(6) Inspect backplate for wear or damaged bore.
(7) Inspect center housing for contact with rotating parts.
4-179
TM 9-2815-202-34
4-37. TURBOCHARGER REPAIR (Cont)
d. Assembly
(1) Lubricate bearings (27 and 33) with engine oil.
(2)
Install inner retaining ring (31 ), bearing (33), bearing washer (32), and outer retaining ring
(31) in turbine end of center housing (2).
(3) Install retaining ring (29), bearing washer (28), and bearing (27) in compressor end of center
housing (2).
(4)
If removed, install two pins (30) in compressor end of center housing (2). Pins must extend
0.075 to 0.085 inch above surface.
(5) Install thrust washer (26) with hole and cutout in thrust washer in alinement with pins (30).
Install thrust washer with smooth side against center housing.
(6) Lubricate thrust collar (25) and thrust washer (26) with engine oil. With center housing
assembly (2) laying flat on bench, compressor end up, place thrust collar snugly against
thrust washer.
(7) Install seal ring (22) in groove at compressor end of center housing (2).
(8) Aline oil feed hole in center housing (2) and backplate assembly (5). Attach backplate to
center housing with four bolts (21 ) and four locking plates (20). Torque bolts to 13-15 Ib-ft
(18-20 N-m) and bend locking-plate tangs up against side of bolt head.
CAUTION
Do not cock or force piston ring (19) in groove. Ring is brittle and will snap easily.
NOTE
Piston ring (19) is used only on some turbochargers. If there is no groove in shaft, ring
is not required.
(9) Install piston ring (19) on wheel shaft assembly (15).
4-180
TM9-2815-202-34
Do not scuff or scratch bearings when installing shaft or bearing will seize during
operation.
(10) Lubricate wheel shaft assembly (15) with engine oil. Position wheel shroud (18) against
center housing (2). Insert wheel shaft assembly (15) through wheel shroud and into center
housing.
(11) Place wheel shaft assembly (15), shroud (18), center housing (2), and backplate (5) upright
in holding fixture.
CAUTION
Do not cock or force piston rings (24) in grooves. Rings are brittle and will snap easily.
(12) Install two piston rings (24) on thrust spacer (23).
(13) Lubricate thrust spacer (23) and piston rings (24) with engine oil. Slide spacer with rings
over shaft assembly (15) and into bore in backplate (5).
o
(14) With compressor wheel (17) at 68 -78 F, position it over shaft assembly (15).
(15) Lubricate shaft threads of shaft assembly (15) and wheel face on compressor wheel (17)
with engine oil. Install retaining nut (16). Torque nut to 10-12 Ib-ft (14-17 N-m) to seat
compressor wheel against thrust spacer.
(16) Loosen nut (16) and inspect nut face and front face of compressor wheel to insure they are
smooth and clean.
(17) Tighten nut to 15-25 lb-in (2-3 N-m) torque.
4-181
TM 9-2815-202-34
4-37. TURBOCHARGER REPAIR (Cont)
CAUTION
Tighten compressor wheel nut with a double universal socket to prevent bending
turbine wheel shaft.
(18) Tighten nut an additional 110 degrees of rotation.
(19) Check bearing axial end play as follows:
(a) Clamp center housing assembly in bench vise equipped with soft jaws.
(b) Fasten dial indicator and magnetic base (34) to center housing with indicator tip resting
on end of rotating shaft on compressor side.
(c) Move shaft axially back and forth by hand. Total indicator reading should be between
0.004 and 0.009 inch. Repair or replace shaft assembly if readings do not fall within
limits.
(20) Check shaft radial movement as follows:
(a) Bolt dial indicator adaptor (35) to oil drain tube mounting pad.
(b) Mount dial indicator (36) on dial indicator adaptor (35).
(c) Place dial indicator tip against indicator adaptor rod.
4-182
TM9-2815-202-34
Insure adaptor rod does not contact sides of center housing or readings are invalid.
(d) Grasp ends of rotating assembly and apply equal pressure at each end, moving rotating
shaft toward and away from dial indicator. Crosswise movement must be between 0.003
and 0.007 inch. If not within limits, disassemble and repair or replace rotating assembly.
(21) Aline match marks on turbine housing (3) with marks on center housing (2). Secure with four
clamps (14), four locking plates (12), and eight bolts (13). Apply antiseize compound to bolts
(13). Torque bolts to 100-130 lb-in (11-15 N-m) and bend locking plate tangs over side of
bolt heads.
(22) Aline match marks on compressor housing (1) with marks on center housing (2). Secure
compressor housing to backplate (5) with V-band clamp (4). Lubricate threads on toggle bolt
with engine oil and torque nut on toggle bolt to 110-130 lb-in (12-15 N-m).
(23)
Install adaptor bushing (11) in oil inlet hole in center housing (2).
NOTE
On model 7083-7396, install angle bracket (9) with bolt (6) away from turbine inlet.
(24) Install gasket (10), oil drain tube (8), two Iockwashers (7), and two bolts (6) on oil outlet of
center housing (2). Torque bolts to 30-35 Ib-ft (41-47 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-2
Turbocharger
Turbocharger
5-2
removed (7083-7395)
removed (7083-7396)
C h a n g e
1 4-183
TM 9-2815-202-34
4-38. CYLINDER HEAD REPAIR
This task covers:
a. Disassembly
d. Inspection/Repair
b. Cleaning
e. Assembly
c. Pressure Check
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395 7083-7398
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Valve insert remover (App B, Item 80
Bridge guide installer (App B, Item 49)
Injector tube installer - new style (App B, Item 54)
Valve spring compressor (App B, Item 13)
Cylinder head pressure testing kit (App D, Item 10)
Valve guide remover (App B, Item 79)
Spring tester (App B, Item 93)
Valve bridge guide remover set (App B, Item 74)
Valve insert installer (App B, Item 61 )
Slide hammer (App B, Item 39)
Reamer (App B, Item 47)
Depth gage (App B, Item 28)
Valve guide installer (App B, Item 60)
Fuel nut wrench (App B, Item 99)
Reamer (App B, Item 47)
Upsetting die (App B, Item 47)
Injector tube pilot (App B, Item 47)
Micrometer 0-1 inch (App B, Item 65)
Cam follower holding fixture (App B, Item 18)
Injector protrusion gage (App B, Item 32)
Injector tube tip refinisher (App B, Item 47)
Insert runout dial gage (App B, Item 29)
Magnetic base dial indicator (App B, Item 45)
Bridge guide remover - broken (App B, Item 75)
Adaptor kit - insert grinding (App B, Item 3)
Valve insert grinder (App B, Item 38)
Telescoping gage (App B, Item 25)
Injector tube installer - old style
(App B, Item 47)
Torque wrench (App B, Item 100)
4-184
8
2
8
18
4
16
2
8
8
8
Gaskets (App F, Item 71)
Cup plugs (App F, Item 11)
Gaskets (App F, Item 49)
Lockwashers (App F, Item 93)
Bushings (App F, Item 6)
Lockwashers (App F, Item 91 )
Cup plugs (App F, Item 8)
Injector tube kits (App F, Item 158)
Fuel lines (App F, Item 18)
Fuel lines (App F, Item 19)
EXPENDABLE/DURABLE SUPPLIES
Sealant (App C, Item 40)
Engine oil (App C, Item 16)
Cindol 1705 oil (App C, Item 8)
Sulphurized oil - E.P. type (App C, Item 45)
Cutting oil (App C, Item 13)
Sealant (App C, Item 38)
Fuel oil (App C, Item 21)
Crocus cloth (App C, Item 12)
Prussian blue (App C, Item 32)
EQUIPMENT CONDITION
Para Description
4-7
Lifting brackets removed
4-27 Cylinder head removed
TM 9-2815-202-34
a. Disassembly
NOTE
Immediately after removing fuel lines, cover each
injector opening with caps to keep out dirt.
(1) Remove four inlet fuel lines (1) and four outlet
fuel lines (2) from fuel injectors (3) and fuel
connectors (4). Discard fuel lines.
NOTE
●
Tag rocker arms, shafts, brackets,
valves, cam followers, and
associated hardware so they can
be installed in their original
position.
●
On model 7083-7395, one rocker
arm shaft bracket on right cylinder
head contains throttle delay
housing (5).
(2) Remove eight bolts (6) securing
rocker arm shafts (7) and brackets (8)
to cylinder head.
NOTE
Inspect throttle delay check valve for
leakage. Fill throttle delay cylinder
with fuel oil and watch check valve
leakage while moving engine
throttle from idle to full fuel position.
If more than a drop of leakage
occurs, replace check valve.
(3) Remove four rocker arm shafts (7)
and eight rocker shaft brackets (8)
from cylinder head. If necessary,
remove check valve (9) and oil supply
fitting (10) from throttle delay housing
(5) used on model 7083-7395.
(4) Swing rocker arms (11 ) away from
injector and valves. Remove four
injector clamp bolts (12), four washers
(13), and four clamps (14).
(5) Remove four fuel injectors (4) from
cylinder head.
(6) Loosen twelve locknuts (15) at upper
end of push rods (16) next to rocker
arm clevis. Unscrew twelve rocker
arms (11 ) from push rods.
(7) Remove eight valve bridges (17) from
bridge guides (18).
4-185
TM 9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
(8) Rest cylinder head on its side and
remove eight cam follower guide bolts
(19), eight Iockwashers (20), and four
cam follower guides (21). Discard
lockwashers.
(9) Remove twelve cam follower spring
retainers (22) from cam follower bores
in cylinder head.
(10) Pull twelve cam followers (23) and
twelve push rods (16) assemblies
from bottom of cylinder head. Remove
twelve push rod nuts (15), twelve
upper spring seats (25), twelve cam
follower springs (24), and twelve
lower spring seats (26) from twelve
push rods.
NOTE
Mark location of valve for
reinstallation. With used valves,
valves must go back in original
location.
(11) Remove sixteen exhaust valves as
follows:
(a) Position cylinder head on its side.
(b) Using valve spring compressor
(27), compress valve spring (28).
Remove two-piece tapered valve
locks (29).
(c) Remove upper spring seat (30),
valve spring (28), lower spring
seat (31) , and exhaust valve (32).
NOTE
•l Model 7083-7395 contains four
bolts (33), four flat washers (34),
two cover plates (35), and two
gaskets (36) per head.
• Model 7083-7398 contains six
bolts, six flat washers, three cover
plates, and three gaskets per
head.
4-186
TM
9-2815-202-34
(12) Remove bolts (33), flat washers (34), cover plates (35) and gaskets (36) from corners of
cylinder head. Discard gaskets.
(13)
If necessary, remove support bracket (37), two bolts (38), and two Iockwashers (39) from
right cylinder head. Discard Iockwashers.
(14) Remove two bolts (40), two flat washers (41), adaptor (42), and gasket (43) from inboard
corner or cylinder head. Discard gasket.
(15) Remove eight fuel connectors (4) and eight washers (44) from cylinder head.
NOTE
If the cylinder head is to be pressure checked, do not remove parts in steps (16) thru
(21).
(16) Remove eight nuts (45), eight Iockwashers (46), four cover plates (47), and four gaskets (48)
from outboard side of cylinder head. Discard gaskets and Iockwashers.
(17) Remove eight studs (49) from outboard side of cylinder head.
(18) Remove five studs (50) from outboard side of cylinder head.
(19) Remove cup plug (51 ) from rear of cylinder head. Discard plug.
(20) Remove fuse plug (52) from outboard side of cylinder head.
4-187
TM 9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
(21)
Remove two each of pipe plugs (53 and
54) from ends of head.
(22)
Remove fuel spill crossover elbow (55)
from cylinder head.
(23)
Remove twelve pipe plugs (56) from inboard side and ends of cylinder head.
(24)
Remove six threaded plugs (57) from left cylinder head or four plugs from right cylinder head.
(25)
If necessary, remove two cup plugs (58) from front rear of cylinder head. Discard plugs.
(26) If necessary, remove two threaded plugs (59) from front of right cylinder head or one plug
from front of left cylinder head.
4-188
C h a n g e
1
TM9-2815-202-34
(27) Remove elbow (60) from front of left cylinder head or two elbows (60) from front of right
cylinder head.
(28) Remove adaptor bushing (61 ) and restrictive fitting (62) from front of left cylinder head.
(29) If necessary, remove two bushings (63) from cylinder head bolt holes.
b. Cleaning
(1) Thoroughly clean cylinder head and cylinder head components (refer to Para 3-2).
(2) Clean galleries in cylinder head using probes and brushes.
(3) If water passages are heavily coated with scale, remove injector tubes and water nozzles
and thoroughly clean water jacket areas.
Change
1 4-189
TM 9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
c. Pressure Check
NOTE
Before pressure checking cylinder
head, insure four cover plates (47),
cup plug (54), two pipe plugs (54),
fuse plug (52), and five exhaust
manifold studs (50) are in position.
(1) Install scrap or dummy injectors to
properly seal injector tubes. Torque
injector clamp bolts to 20-25 Ib-ft
(27-34 N-m).
(2) Using cylinder head pressure testing
kit, install fabricated end plate (64)
and gasket over hole in front of
cylinder head. Secure with bolts from
kit. Torque bolts to 30-35 Ib-ft
(41-47 N-m).
(3) Using cylinder head pressure test kit,
install fabricated blocking plates (65)
and rubber gaskets to seal off ten water
holes on fire deck. Secure with bolts,
flat washers, and nuts from kit. Torque
bolts to 50-60 Ib-ft (71-85 N-m).
(4) Attach a regulated air supply to end
plate (64) and gradually apply
pressure of 40 psi (276 kPa) to water
jacket.
4-190
TM 9-2815-202-34
head in a tank of water
(5) Immerse cylinder
o
o
o
o
heated to 180 -200 F (82 -93 C) for
twenty minutes to heat head. Observe
water in tank for bubbles which indicate a
leak or crack. Check for leaks at top and
bottom of injector tubes, oil gallery,
exhaust ports, fuel galleries, and at top
and bottom of cylinder head.
(6) Relieve air pressure and remove cylinder
head from water tank. Remove regulated
air supply, end plate, injectors, and
blocking plates from cylinder head.
d. Inspection/Repair
NOTE
If warpage exceeds limits, reface cylinder
head. Do not remove more metal from fire
deck than minimum distance of 3.536
inches from top of deck to bottom of fire
deck.
(1) Cylinder head
(a) Check fire deck surface of cylinder
head for flatness. Using a straight
edge (66) and a set of feeler gages
(67), check lengthwise (six places)
and crosswise (five places) warpage.
Maximum lengthwise warpage is
0.008 inch and maximum crosswise
warpage is 0.004 inch.
(b) Inspect cam follower bores in
cylinder head for scoring and wear.
Clean light score marks with crocus
cloth wet with fuel oil. Measure
diameter of cam follower body and
cam follower bore to determine
clearance. Maximum clearance is
0.006 inch. Replace cylinder head if
bores are excessively worn or
scored.
(2) Water nozzles
Check water hole nozzles (68 and 69) for
looseness. If necessary, replace nozzles
as follows:
(a) Remove old nozzle (68 or 69) and
clean bore in cylinder head.
4-191
TM9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
(b) Position nozzles (68) in end bore or nozzles (69) in inner bore as shown.
(c) Press nozzles (68 or 69) 0.003 inch above to 0.010 inch below surface of cylinder head.
(3) Exhaust valve guides
Inspect valve guides for fractures,
chipping, scoring, or excessive wear.
Measure inside diameter of valve
guide and diameter of valve stem to
determine clearance between guide
and valve stem. If clearance exceeds
0.005 inch, replace valve guide.
Replace valve guide as follows:
(a) Support cylinder head, bottom
side up, on three inch thick wood
blocks.
(b)
Drive valve guide (70) out of
cylinder head with valve guide
remover (71 ).
(c)
Place cylinder head right side up in arbor press.
(d)
Position valve guide squarely in bore. Using valve guide installer tool (72), press guide
into position until tool contacts cylinder head.
4-192 C h a n g e
1
TM9-2815-202-34
(4) Valve bridge guides
(a) Inspect valve bridge guides for wear. If necessary, replace guides as follows:
1.
File or grind two opposite notches 0.06 inch deep in side of bridge guide (18)
approximately 1.25 inches from top.
2. Using bridge guide remover tool set, place spacer (73) over guide.
3. Slide guide remover (74) over guide and aline set screws with notches ground in
guide. Tighten set screws to secure tool in place.
4. Place spacer (75) over guide remover (74).
5. Thread nut (76) on guide remover and turn clockwise to withdraw guide from
cylinder head.
(b)
Remove broken valve bridge
guides as follows:
1. Center punch end of valve
bridge guide (18).
2. Drill hole 0.5 inch deep in
end of guide (18) with No. 3
(0.2130 inch) drill bit.
3. Tap guide with 1/4-28
bottoming tap.
4-193
TM 9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
4. Thread bridge guide remover
(77) into tapped hole.
5. Attach slide hammer (78) to
guide remover (77) and remove
guide.
(c) Install valve bridge guides as follows:
1. Apply a coat of sealant to bridge
guide (18).
2. Start guide (18) in cylinder head
with undercut end first.
guide installer (79)
3. Place bridge
over guide (l 8) and drive into
place. Installer will position
guide to correct height (2.040
inches) in cylinder head.
(5) Valve inserts
Inspect valve inserts for excessive wear,
pitting, cracking, or improper seat angle.
Replace inserts as follows:
(a) Place cylinder head on wood blocks
with bottom side up.
(b) Using valve seat insert remover (80),
remove valve insert (81 ).
(c)
Clean valve seat insert counterbore
in cylinder head and inspect for
concentricity, flatness, and cracks.
4-194 C h a n g e
1
TM9-2815-202-34
NOTE
Insert counterbore has a diameter of 1.2600 to 1.2610 inches and a depth of 0.3380 to
0.3520 inch. Counterbores must be concentric with valve guides within 0.003 inch total
indicator reading.
o
o
o
(d) Immerse cylinder head in water heated to 180 -200 F (82°-93 C) for 30 minutes or cool
insert with liquid nitrogen.
NOTE
Install insert in cylinder head while head is still hot and insert is at room temperature or
when insert is chilled and head is at room temperature.
(e) Place cylinder head on a bench with bottom side up. Place insert in counterbore with
valve seat side facing up.
(9
Using insert installer (82), drive insert in place until it seats solidly in cylinder head.
(9) Check exhaust valve seat inserts for concentricity in relation to valve guides using insert
runout gage (83).
NOTE
Exhaust valve seat inserts are prefinished. Only check for concentricity after
installation. Grind insert only if runout exceeds 0.002 inch.
4-195
TM9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
(6) Valve seat insert grinding
Use a valve seat grinder (84) and valve seat grinder adapter kit to grind inserts. Grind valve
inserts as follows:
CAUTION
Do not permit grinding wheel to contact cylinder head when grinding insert. If an insert
has been ground until grinding wheel contacts cylinder head, then install new insert.
(a) Apply 31-degree grinding wheel on valve seat insert.
(b) Grind throat of insert using 60-degree grinding wheel.
(c) Grind top surface of insert with 15degree grinding wheel to narrow seat width to
dimensions shown in figure. The 31-degree face (85) of insert maybe adjusted relative
to center of valve face (86) with 15 and 60-degree grinding wheels.
NOTE
Maximum amount exhaust valve should protrude beyond cylinder head and still
maintain proper piston to valve clearance is shown. Grinding will reduce thickness of
valve seat insert and cause valve to recede into cylinder head. Replace valve seat
insert if valve recedes beyond limits.
4-196
TM9-2815-202-34
(d) After grinding is completed, clean valve seat insert thoroughly. Measure concentricity of
insert in relation to valve guide. If runout exceeds 0.002 inch, check for bent or worn
valve guide before regrinding insert.
(e) Determine position of contact area between valve and valve seat insert as follows:
1. Apply a light coat of Prussian blue or equivalent to valve seat insert.
2. Lower stem of valve in valve guide and bounce valve on seat. Do not rotate valve.
3. Remove valve and observe area of contact on valve face. Most desirable area of
contact is at center of valve face.
(7) Exhaust valves and springs
(a) Insure valve stems are free from
scratches or scuff marks. Valve
faces must be free of ridges,
cracks, or pitting.
(b) Replace valves if warped,
excessively worn, or pitted.
(c) Using spring tester (87), replace
valve spring (28) when a load of
less than 25 Ibs will compress it
to 1.80 inches.
CAUTION
Replace both springs under an
exhaust valve bridge together.
Mating a new spring with a used
spring can cause unbalanced valve
operation.
(8) Cam followers and cam follower
springs.
(a) Examine cam follower springs
(24) for wear or damage. Using
spring tester (87), check spring
load. Replace spring when a load
of less than 172 Ibs will compress
it to a length of 2.125 inches.
4-197
TM 9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
CAUTION
Do not use fuel oil to clean cam followers. Lubricating oil will be washed away and
cause scoring of cam roller bushing at startup.
(b) Wash cam followers with engine oil and wipe dry. Examine cam follower rollers for
pitting, scoring, and flat spots. Rollers (88) must turn freely on their pins (89).
(c) Using a dial indicator and holding fixture, measure total diametric clearance on cam
follower roller. Secure cam follower assembly in a vise or other holding device and
place dial indicator needle against outside diameter of roller. Obtain total clearance by
moving roller in crosswise direction. Maximum clearance is 0.010 inch.
(d) Using a feeler gage, measure side clearance on cam follower. Insert gage between end
of roller and leg of cam follower body. Side clearance must be 0.015 to 0.023 inch.
(e) If necessary, install new cam follower rollers and pins as follows:
1, Clamp cam follower holding fixture (90) in a vise and place cam follower in groove
at top of assembly with cam follower pin resting on top of small plunger in holding
assembly.
4-198
TM 9-2815-202-34
WARNING
Restrain cam follower body and roller during removal from cam follower
holding fixture (90). Follower pin is seated on top of spring-loaded
plunger in holding fixture and a sudden release could eject cam follower
and cause injury to personnel.
CAUTION
Remove any burrs on cam follower surfaces at pin holes prior to installing roller and pin
to prevent scoring of roller bushing and pin.
2. Drive pin (89) from roller (88) with a drift.
3. Position follower body in groove of holding assembly with small plunger extending
through roller pin hole in one leg of follower body.
4. Coat pin and roller with engine oil.
5. Position roller (88) in cam follower body (91). Plunger will extend into roller bushing
and assure accurate alinement of bushing with roller pin holes in follower body.
6. Start pin (89) squarely into follower body (91 ) and drive into position until pin is
centered in legs of follower.
7. Check side clearance between roller (88) and follower body (91). Clearance must
be between 0.011 and 0.023 inch.
(9) Rocker arms and shafts
Inspect rocker arm shafts and bushings for wear. Maximum shaft to bushing clearance is
0.004 inch.
4-199
TM 9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
(10) Injector tube
Replace injector tubes if found
leaking during pressure test. Replace
injector tubes as follows:
(a) Place injector tube installer (92)
in injector tube (93).
(b) Insert pilot (94) through small
hole in injector tube (93) and
thread pilot in threaded hole of
installer (92).
(c) Tap end of pilot (94) to loosen
injector tube (93). Lift injector
tube, pilot, and installer (92) from
cylinder head. Discard injector
tube and seal ring (95).
(d) Thoroughly clean injector tube hole in cylinder head to remove dirt, burrs, or foreign
material preventing tube from seating properly.
(e) Lubricate injector tube seal (95) with engine oil and place in counterbore of cylinder
head.
NOTE
●
There are two injector tube installation tools, a fixed tool for the old style tube and an
adjustable tool the current injector tube. The current tube has “606” stamped on
top flange.
●
For proper installation of current injector tube, adjustable installation tool must
contact bottom of injector tube before it touches flange at top. Clearance at top,
between flange and tool, should be 0.001 to 0.010 inch.
(f)
4-200
Place installer (92) in injector tube (93). Insert pilot (94) through small hole in injector
tube and thread into tapped hole at end of installer.
TM9-2815-202-34
(9) Slip injector tube (93), installer (92), and pilot (94), into injector bore and drive into
place.
(h) Upset lower end of injector tube as follows:
1. Turn cylinder head bottom up and remove insert pilot (94). Thread upsetting die
(96) into tapped hole of installer (92).
2. Using socket and torque wrench, apply 30 Ib-ft (41 N-m) torque to upsetting die
(96).
3. Remove upsetting die (96) and installer (92) from injector tube.
NOTE
Reamer does not contact large inside
diameter of current injector tube. Ream only
at small inside diameter and injector nut
seat.
(i) Ream injector tube as follows:
1. Clean injector tube (93) and
place cylinder head right side
up.
2. Apply a few drops of cutting oil
on reamer flutes and carefully
position reamer (97) in injector
tube (93).
4-201
TM 9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
CAUTION
Turn reamer only in clockwise direction, both when inserting and removing reamer.
Movement in opposite direction will dull cutting edges on flutes.
3. Turn reamer (97) clockwise (withdraw reamer frequently to remove chips) until
lower shoulder of reamer contacts injector tube (93). Clean out all chips.
4. Rotate cylinder head to bottom up position. Insert pilot of cutting tool (98) into small
hole of injector tube (93).
5. Apply a few drops of cutting oil on tool (98). Using a socket and speed handle,
remove excess stock so lower end of injector tube (93) is from flush to 0.005 inch
below finished surface of cylinder head.
6. Install injector gage (99) in injector tube. Using dial indicator gage (100),
premeasure distance from fire deck to gage. Reading must be within +/-0.014 inch
of fire deck.
7. Wash interior of injector tube (93) to prepare for second reaming operation.
4-202
TM9-2815-202-34
8. Apply a few drops of cutting oil on bevel seat of injector tube (93). Lower reamer
(101 ) carefully into injector tube until it contacts bevel seat.
9. For trial cut, turn reamer (101) steadily without applying any downward force.
Remove reamer, clean out chips, and observe bevel seat to see what portion of
seat was cut.
10. Proceed with reaming and withdraw tool occasionally to observe progress.
11. Continue reaming until shoulder of spray tip is within +/- 0.014 inch of fire deck. Use
gages (99 and 100) to measure distance.
12. Wash interior of injector tube (93).
4-203
TM 9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
e. Assembly
(1) If necessary, install two bushings (63) in cylinder head bolt holes. Press flush to 0.02 inch
below surface.
(2) Install adaptor bushing (61) and restrictive fitting (62) in front of left cylinder head.
(3) Install elbow (60) to front of left cylinder head or two elbows (60) to front of right cylinder head.
(4) If necessary, install threaded plugs (59) - two in right head or one in left head. Coat cup plug
(58) with gasket cement and install in front of cylinder head.
4-204 C h a n g e
1
TM 9-2815-202-34
(5) If necessary, install six threaded plugs (57) in left cylinder head and four plugs in right
cylinder head.
-
(6) Install twelve pipe plugs (56) in inboard side and ends of cylinder head.
(7) Install fuel spill crossover elbow (55) at inboard side of cylinder head.
(8) Install two each of pipe plugs (53 and 54) in ends of cylinder head. Plugs must be flush to
0.18 inch below surface.
C h a n g e
1 4-205
TM9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
(9) Install fuse plug (52) in outboard side of cylinder head. Plug must be flush to 0.16 inch below
surface.
(10) Coat cup plug (51 ) with gasket cement and install in rear of cylinder head.
(11) Install five exhaust manifold studs (50) in outboard side of cylinder head. Torque studs to
25-40 Ib-ft (34-54 N-m).
(12) Install eight water manifold studs (49) in cylinder head. Torque studs to 10-25 Ib-ft
(14-34 N-m).
(13) Install four gaskets (48), four cover plates (47), eight Iockwashers (46), and eight nuts (45) to
cylinder head. Torque nuts to 20-25 Ib-ft (27-34 N-m).
(14) Install eight washers (44) and eight fuel connectors (4) to cylinder head. Torque connectors
to 40-45 Ib-ft (54-61 N-m).
(15) Install gasket (43), adaptor (42), two flat washers (41), and two bolts (40) to front inboard
corner of cylinder head. Torque bolts to 7-9 Ib-ft (10-12 N-m).
4-206 C h a n g e 1
TM9-2815-202-34
N O T E
● Model
7083-7395 contains four bolts (33), four flat washers (34), two cover plates
(35), and two gaskets (36) per head and no cover plate on inboard rear corner.
● Model
7083-7398 contains six bolts (33), six flat washers (34), three cover plates
(35), and three gaskets (36) per head.
(16) Install gaskets (36), cover plates (35), flat washers (34), and bolts (33) to remaining corners
of cylinder head. Torque bolts to 7-9 Ib-ft (10-12 N-m).
(17) If necessary, install support bracket (37), two Iockwashers (39), and two bolts (38) to right
cylinder head. Torque bolts to 30-35 Ib-ft (41-47 N-m).
(18) Install sixteen exhaust valves as follows:
(a) Position cylinder head on its side. Lubricate valve stems with sulphurized oil (E.P. type)
and slide valves (32) all the way into guides (70).
NOTE
With used valves, install valves in their original location.
(b) Install lower spring seat (31 ), valve spring (28), and upper spring seat (30) over valve
stem.
CAUTION
Avoid scoring valve stem with valve
seat when compressing spring.
(c) Using valve spring compressor
(27), compress valve spring (28)
and install two piece tapered
valve locks (29).
(d) Release pressure on valve spring
compressor (27) and remove tool.
(e) Repeat steps (a) thru (d) for
remaining valves.
(f) Support cylinder head on wood
blocks at both ends (right side
up). Give end of valve stems a
sharp tap with soft-headed
hammer to seat valve locks (29).
4-207
TM9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
(9) Using depth gage (100), measure
exhaust valve protrusion beyond
fire deck. If out of limits, regrind or
replace insert.
NOTE
● Before
installing cam followers,
immerse in Cindol 1705 oil
o
heated to 100 F-125°F (38°Co
52 C) for one hour for initial
lubrication of cam roller pins and
bushings. Rotate cam rollers
during soaking period to purge
air from bushing and roller area.
●
Install used cam followers and
push rods in their original
locations.
(19) Assemble lower spring seat (26), cam
follower spring (24), upper spring seat
(25), and locknut (15) on push rod
(16).
(20) Install twelve cam follower spring
retainers (22) in cam follower bores
from top of cylinder head.
(21) Slide twelve push rod (16)
assemblies in position from bottom of
cylinder head.
NOTE
Install cam followers with oil hole
directed away from exhaust valves.
(22) Slide twelve cam followers (23) in
position from bottom of cylinder head.
4-208
TM9-2815-202-34
CAUTION
Insure cam follower is not cocked in
cam follower bore. With cam
follower guide installed, bottom of
cam follower body must be flush
with fire deck.
(23) . Attach four cam follower guides (21) to
cylinder head using eight Iockwashers
(20) and eight bolts (19). Torque bolts
to 12-15Ib-ft (16-20 N-m).
(24) Measure clearance between cam
follower guide (21 ) and cam follower
legs using feeler gages (102).
Clearance must beat least 0.005
inch.
(25) If clearance is insufficient, slightly
loosen bolts (19) and tap corners of
guide (21) with brass rod. Retorque
bolts with proper clearance.
4-209
TM9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
NOTE
● Injector rocker arm is different than exhaust valve rocker arms. Boss for rocker arm
shaft on right and left hand exhaust valve rocker arms is longer on one side.
Extended boss of each rocker arm must face toward injector rocker arm.
● If a new rocker arm is installed, also install a new push rod.
● Refer to Chapter 8 for push rod locknut adjustment during engine tune-up.
(26) Thread each rocker arm (11) on its push rod (16) until end of push rod is flush with inner side
of clevis yoke.
NOTE
Adjust valve bridges after cylinder head disassembly or extended engine operation.
4-210
TM9-2815-202-34
(27) Adjust bridges as follows:
CAUTION
Do not loosen or tighten locknut with
bridge installed in cylinder head.
Bent bridge guide or rear valve stem
may result.
(a) Place valve bridge (17) in a vise
or bridge holding fixture and
loosen locknut (103)on bridge
adjusting screw (104).
(b) Install valve bridge (17) on valve
bridge guide (18).
(c) While firmly pressing straight
down on pallet surface of valve
bridge (17), turn adjusting screw
(104) clockwise until it just
touches valve stem. Then turn
screw an additional 1/8 to 1/4 turn
and tighten locknut (103) finger
tight.
(d) Remove valve bridge (17) and
place in a vise or holding fixture.
Hold adjustment screw (104) from
turning with screwdriver and
torque locknut (103) on
adjustment screw to 20-25 Ib-ft
(27-34 N-m).
(e) Lubricate valve bridge (17) and
valve bridge guide (18) with
engine oil and install bridge in
original position.
(f) Place 0.0015 inch feeler gage
under each end of valve bridge
(17). When pressing down on
pallet surface of valve bridge,
both gages must be tight. If both
feeler gages are not tight,
readjust screw as outlined in
steps (a) thru (e).
4-211
TM 9-2815-202-34
4-38. CYLINDER HEAD REPAIR (Cont)
CAUTION
Seat slot in valve bridges over
inboard exhaust valve stem to
prevent valve damage.
(28) Position eight valve bridges (17) on
bridge guides (18) with adjustment
screw (104) toward outboard side of
engine.
CAUTION
Insure injector hold down clamp
does not contact exhaust valve
spring.
(29) Install four fuel injectors (3) in cylinder
head and secure in place with four
clamps (14), four washers (13), and
four bolts (12) putting curved side of
washer against clamp. Torque bolts to
20-25 Ib-ft (27-34 N-m).
NOTE
Install special rocker arm shaft
bracket (5) containing throttle delay
housing at right bank No. 1 cylinder
on model 7083-7395.
(30) If necessary, install check valve (9)
and oil supply fitting (10) into throttle
delay housing (5).
(31) Apply engine oil to rocker arm shafts
(7) and slide shaft through rocker
arms (11). Place rocker shaft bracket
(8) over each end of shaft with
finished face of bracket toward rocker
arm.
(32) Insert eight rocker arm bracket bolts
(6) through eight brackets (8) and four
shafts (7). Swing rocker arms, shafts,
and brackets into position and thread
bolts into cylinder head. Torque bolts
to 90-100 Ib-ft (122-136 N-m).
4-212
TM 9-2815-202-34
CAUTION
•
Do not bend fuel lines and do not exceed specified torque on fuel line nuts.
Excessive tightening will twist or fracture flared end of fuel line and result in leaks.
•
Never reuse fuel lines regardless of their appearance. Always use new fuel lines.
Reused fuel lines may not seal properly and result in leaks.
(33) Remove caps from fuel injectors (3) and connect four inlet fuel lines (1) and four outlet fuel
lines (2) to injectors and fuel connectors (4). Using special socket, torque fuel lines to 130-160
lb-in (14.7-18.3 N-m).
END OF TASK
4-27 Install cylinder head
4-7
Install Iifting brackets
C h a n g e
1 4-213
TM9-2815-202-34
4-39. OIL COOLER ASSEMBLY REPAIR
This task covers:
a. Cleaning prior to Disassembly
c. Cleaning/Inspection
b.Disassembly
d. Assembly
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
■ All
Cleaning solvent (App C, Item 10)
Cleaning solution (App C, Item 9)
Engine oil (App C, Item 16)
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Air nozzle plate kit (App D, Item 7)
Universal puller (App B, Item 71)
Bar tool (App D, Item 4)
Spring tester (App B, Item 93)
Torque wrench (App B, Item 101
Plate kit (App D, Item 6)
Para Description
3-6
Oil cooler removed
MANDATORY REPLACEMENT PARTS
39
5
1
1
4
1
2
Lockwashers (App F, Item 93)
Gaskets (App F, Item 51)
Gasket (App F, Item 52)
Gasket (App F, Item 57)
Seals (App F, Item 149)
Gasket (App F, Item 64)
Preformed packings (App F, Item 107)
a. Cleaning Prior to Disassembly
NOTE
Do not clean oil cooler if an engine or transmission failure caused metal particles (from
worn or broken parts) to enter lubricating oil. Replace tube bundle.
(1) Clean engine oil section of oil cooler as follows:
(a) Remove two bolts (1) two Iockwashers (2), flange (3) and gasket (4) from oil cooler
assembly (5).
(b) Remove two bolts (6) and two Iockwashers (2) securing flange (3), oil cooler bypass (7)
assembly, and two gaskets (4) to oil cooler assembly (5).
(c)
Remove metal tube (8), flange (3), and oil cooler bypass (7) assembly.
(d) Remove screw (9) securing retainer (1 O), spring (1 1), and valve (12) from oil cooler
bypass (7).
(e) Install tube (8) with two flanges (3), three gaskets (4), and oil cooler bypass (7) to oil
cooler assembly (5). Secure with four bolts (1 and 6) and four Iockwashers (2).
4-214 C h a n g e
1
TM9-2815-202-34
(f) Install plate kit (13) blocking inlet from oil filter and outlet from oil cooler to filter. Secure
two plates and two gaskets with eight bolts and eight lockwashers from kit.
(g) Attach air nozzle plate kit (14) to front cover at oil outlet to block. Secure plate and
gasket with two bolts, two flat washers, two Iockwashers and two nuts from kit.
WARNING
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid contact
with skin, eyes, and clothes and don’t breathe vapors. oDo not use near
open flames or excessive heat. The flash point is 100 F-138°F (38°C50°C). If you become dizzy while using cleaning solvent, get medical aid.
If contact with eyes is made, wash your eyes with water and get medical
aid Immediately.
(h) Place oil cooler assembly (5) in a barrel or suitable container with tube bundles laying
horizontal. Fill oil cooler with cleaning solvent at oil inlet opening on front cover.
WARNING
Compressed air used for debris removal will not exceed 100 psi. Increase
pressure gradually. Use only with effective chip guarding and personal
protective equipment (goggles/shield, gloves, etc.).
(i) Gradually apply up to 100 psi of air pressure to air nozzle plate kit (14) until all cleaning
solvent and sludge is blown out.
4-215
TM 9-2815-202-34
4-39. OIL COOLER ASSEMBLY REPAIR (Cont)
(j) Move air nozzle plate kit (14) to front cover of oil cooler assembly at oil inlet opening.
Attach with two bolts, two Iockwashers, two flat washers and two nuts from kit.
(k) Fill oil cooler assembly (5) with cleaning solvent, at front cover at oil outlet. Gradually
apply up to 100 psi of air pressure to air nozzle plate kit (14) until all cleaning solvent
and sludge is blown out.
(1) Repeat steps (g) thru (k) until cleaning solvent comes out clean.
(m) Remove four bolts (1 and 6) and four Iockwashers (2) securing tube (8), two flanges (3),
oil cooler bypass (7), and three gaskets (4) to oil cooler assembly (5). Remove two
preformed packings (15) from flange (3) and tube (8).
(2) Clean transmission oil section of the oil cooler as follows:
(a) Attach plate kit (13), with air connection in tapped hole, at transmission outlet using four
bolts, four flat washers, four Iockwashers, and four nuts from kit.
WARNING
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid contact
with skin, eyes, and clothes and don’t breathe vapors. Do not use near
o
open frames or excessive heat. The flash point is 100 F-138°F (38 °Co
50 C). If you become dizzy while using cleaning solvent, get medical aid.
If contact with eyes is made, wash your eyes with water and get medical
aid immediately.
4-216
TM9-2815-202-34
(b) Place oil cooler assembly (5) in a barrel or suitable container with tube bundles
horizontal. Fill oil cooler with cleaning solvent at transmission inlet.
WARNING
Compressed air used for debris removal will not exceed 100 psi. Increase
pressure gradually. Use only with effective chip guarding and personal
protective equipment (goggles/shield, gloves, etc.).
(c) Gradually apply up to 100 psi of air pressure to plate kit (13) until all cleaning solvent
and sludge is blown out.
(d) Move plate kit (13) to transmission inlet opening.
(e) Fill oil cooler assembly (5) with cleaning solvent at transmission outlet. Gradually apply
up to 100 psi of air pressure to plate kit (13) until all cleaning solvent and sludge is
blown out.
(f)
Repeat steps (a) thru (e) until cleaning solvent comes out clean.
WARNING
Cleaning solution is an acid. Wear protective goggles and equipment.
Avoid contact with skin, eyes and clothing. If contact Is made, flush with
water and seek medical aid or Injury may result.
(3) Clean coolant side of oil cooler assembly (5) by circulating cleaning solution through coolant
inlet and outlet passages of oil cooler assembly, front cover.
CAUTION
Cleaning solution is an acid. Thoroughly rinse oil coolant passages with water after
using the cleaning solution, or corrosion of tube bundles may result.
(4) Remove oil cooler assembly (5) from barrel or container.
(5) Remove plate kit (13), and air nozzle plate kit (14) from front and rear of oil cooler assembly.
4-217
TM9-2815-202-34
4-39. OIL COOLER ASSEMBLY REPAIR (Cont)
b. Disassembly
(1) Remove four bolts (16), four Iockwashers (2), two access covers (17), and two gaskets (4)
from oil cooler assembly (5). Discard Iockwashers and gaskets.
(2) Remove ten bolts (18), ten Iockwashers (2), front cover (19), and gasket (20) from oil cooler
assembly (5). Discard Iockwashers and gaskets.
(3) Remove ten bolts (18), ten Iockwashers (2), rear cover (21), and gasket (22) from oil cooler
assembly (5). Discard lockwashers and gaskets.
4-218
TM9-2815-202-34
(4) Support one end of oil cooler
assembly (5) on blocks. Attach puller
(23) to oil cooler assembly and place
bar tooI (24) on upper tube bundle
(25).
(5) Press upper tube bundle (25) down
enough to remove seal (26) from oil
cooler assembly (5). Remove puller
(23) and bar tool (24). Discard seal.
(6) Invert oil cooler assembly (5). Using
puller (23) and bar tool (24), press
upper tube bundle (25) down enough
to remove remaining seal (26) from oil
cooler shell. Remove puller, bar tool,
and upper tube bundle. Discard seal.
(7) Repeat steps (4, 5, and 6) for lower
tube bundle (27).
(8) Remove seven bolts (28), seven Iockwashers (2), oil return junction (29), and gasket (30)
from rear cover (21). Remove oil return junction. Discard Iockwasher and gasket.
(9) If necessary, remove two plugs (31) and seven plugs (32) from cooler shell (33).
(10) If necessary, remove drain cock (34) from rear cover (21).
(11) If necessary, remove four bolts (28), four Iockwashers (2), and support bracket (35) from rear
cover (21). Discard Iockwashers.
c. Cleanlng/inspection
(1) Inspect front and rear oil cover, access cover, and oil cooler shell for cracks or damage.
(2) Using spring tester (36), check valve spring (11) load. Replace spring if it compresses to a
length of 0.813 inch (20.65 mm) with a 6.5 lb load.
(3) Inspect retainer for cracks, warps, or damage.
(4) Inspect tube bundles for damaged baffles, cracks, or plugged tubes.
d. Assembly
(1) If removed, instaIl support bracket (35) to rear cover (21). Secure with four bolts (28) and four
Iockwashers (2). Torque bolts to 30-35 Ib-ft (41-47 N-m).
(2) If removed, install drain cock (34) into rear cover (21).
(3) Secure gasket (30) and oil return junction (29) to rear cover (21) with seven bolts (28) and
seven Iockwashers (2). Torque bolts to 30-35 Ib-ft (41-47 N-m).
(4) If removed, install two plugs (31) and seven plugs (32) into oil cooler assembly (5). Tighten
securely.
(5) Support one end of oil cooler assembly (5) on blocks.
4-219
TM9-2815-202-34
4-39. OIL COOLER ASSEMBLY REPAIR (Cont)
CAUTION
Seal ring grooves must be free of burrs and foreign material or damage to seals will occur.
(6) Install first seal (26) into seal ring groove at bottom end of lower oil cooler shell (33).
Lubricate seal with engine oil.
NOTE
Oil cooler shell and tube bundles are marked with numbers. Match and a line numbers when
installing tube bundles.
(7) Insert lower tube bundle (27) into end of lower oil cooler shell (33) without any seal (26) in
top seal ring groove. Attach puller (23) to oil cooler shell and place bar tool (24) on tube.
Carefully press tube bundle past top seal ring groove.
(8) Remove puller (23) and bar tool (24). Install seal (26) into top seal ring groove of oil cooler
(5). Lubricate seal with engine oil.
(9) Invert oil cooler shell (5). Using puller (23) and bar tool (24), carefully press tube bundle (27)
until ends are flush with shell.
(10) Repeat steps (5) thru (9) for installing
upper tube bundle (25).
(11) Install gasket (20) and front cover (19)
to oil cooler assembly (5) securing
with ten bolts (18) ten Iockwashers
(2). Torque bolts to 30-35 Ib-ft
(41-47 N-m).
(12) Install gasket (22) and rear cover (21)
to oil cooler assembly (5) securing
with ten bolts (20) and ten
Iockwashers (2). Torque bolts to
30-35 Ib-ft (41-47 N-m).
4-220
TM9-2815-202-34
(13)
Install two gaskets (4) and two access covers (17) to oil cooler assembly (5), securing with
four bolts (16) and four Iockwashers (2). Torque bolts to 30-35 Ib-ft (41-47 N-m).
(14)
Install two preformed packings (15) and two gaskets (4) on flange (3).
(15)
Install valve (12), spring (11), and retainer (10) into oil cooler bypass (7). Secure retainer
with screw (9). Tighten securely.
(16)
Install oil cooler bypass (7), gasket (4), and tube (8) on oil cooler shell (5). Secure with two
bolts (1 and 6) and four Iockwashers (2). Torque bolts to 30-35 Ib-ft (41-47 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
3-6
Oil Cooler Installed
4-221
TM 9-2815-202-34
4-40. FUEL INJECTOR ASSEMBLY REPAIR
This task covers:
a. Disassembly
d. Lapping
b. Cleaning
e. Assembly
c. Inspection/Measurements
f. Testing
INITIAL SETUP
MODELS
Wire rotary brush (App B, Item 9)
Spray tip carbon remover (App B, Item 95)
Diesel fuel tester (App B, Item 91)
Micrometer (1-2”) (App B, Item 65)
Micrometer (0-1”) (App B, Item 65)
TOOLS AND SPECIAL TOOLS
MANDATORY REPLACEMENT PARTS
General mechanics tooI kit (App B, Item 96)
Injector holding fixture (App B, Item 20)
Spray tip remover (App B, Item 95)
Rack hole cleaning brush (App B, Hem 95)
Pin vise (App B, Item 95)
Spray tip wire (App B, Item 95)
Fuel hole cleaning brush (App B, Item 95)
Injector body reamer (App B, Item 95)
Nut reamer (App B, Item 95)
Nut reamer - tip hole (App B, Item 95)
Spring tester (App B, Item 93)
Needle valve height gage (App B, Item 35)
Torque wrench (App B, Item 101)
Lapping blocks (App B, Item 7)
Diesel test fixture (App B, Item 89)
Injector nut socket (App B, Item 95)
Injector tip concentricity gage and
rack freeness tester (App B, Item 92)
1 Seal ring (App F, Item 141)
2 Gaskets (App F, Item 77)
1 Filter (App F, Item 14)
EXPENDABLE/DURABLE SUPPLIES
Fuel oil (App C, Item 21)
Cleaning solvent (App C, Item 10)
Lapping compound (App C, Item 25)
Engine oil (App C, Item 16)
EQUIPMENT CONDITION
Para Description
4-38 Injectors removed (7083-7395 and
7083-7398)
5-37 Injectors removed (7083-7391,
7083-7396 and 7083-7399)
a. Disassembly
(1) Place injector upright in injector holding fixture
(2) Remove two shipping caps (2), two
fuel line connectors (3), two gaskets
(4), and fuel filter (5) from injector.
Discard filter and gaskets.
(3) Rotate spring until spring end is clear
of pin (6). Compress follower spring
(7) by pressing down on follower (8).
Then raise follower spring above stop
pin (6) with a screwdriver and
withdraw stop pin. Allow spring to rise
gradually by releasing pressure on
follower.
(4) Remove follower (8), follower spring
(7), and plunger (9) from injector as
an assembly.
4-222
Change 1
.
TM9-2815-202-34
(5) Invert injector on fixture. Using
injector nut socket (10), loosen nut
(11) on injector body.
NOTE
When injector has been in
service for an extended period,
spray tip may not be easily
pushed from nut. In this case,
support nut on a wood block and
drive tip out with special tool (12).
Do not dislodge spray tip and
valve parts during injector nut
removal.
(6) Lift injector nut (11) straight up.
(7) Remove spray tip assembly (13),
spring cage (14), spring seat (15),
valve spring (16), check valve cage
(17), and check valve (18).
(8) Remove spill deflector (19).
(9) Lift bushing (20) straight out of
injector body (21).
(10) Remove injector body from fixture.
Turn body upside down and catch
gear retainer (22) and gear (23) in
hand as they fall from body.
(11) Remove injector control rack (24) from
body (21).
(12) Remove seal ring (25) from body.
Discard seal ring.
4-223
TM9-2815-202-34
4-40. FUEL INJECTOR ASSEMBLY REPAIR (Cont)
b. Cleaning
WARNING
● Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. oDo not
use near open flame or excessive heat. The flash point is 100 F-138°F
o
o
(38 -50 C). If you become dizzy while using cleaning solvent, get fresh
air immediately and get medical aid. If contact with eyes is made, wash
your eyes with water and get medical aid immediately.
● Compressed air used for cleaning purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
Wash all parts with cleaning solvent and dry with clean, filtered compressed air. Use lint free
towels to wipe off parts. Clean out passages, drilled holes and slots in all injector parts.
(1) Injector spray tip
(a) Soak spray tip in cleaning solvent
to loosen carbon.
CAUTION
Do not contact needle valve seat
with carbon removing tool during
spray tip insertion or-valve seat
could be damaged.
(b) Insert carbon removing tool (26)
and clean.
(c) Clean spray tip orifices with pin
vise (27) and cleaning wire (28).
CAUTION
Do not buff spray tip area
excessively. Do not use a steel wire
buffing wheel or spray tip holes may
be distorted.
(d) Clean exterior of spray tip with
brass wire buffing wheel.
4-224
TM9-2815-202-34
(2) Injector body
(a) Clean and brush all passages in
injector body using fuel hole
cleaning brush and rack hole
cleaning brush.
(b) Ream injector body ring using
reamer (29). Insert reamer in body
and turn in clockwise direction a few
turns. Then remove reamer and
check face of ring for reamer contact.
Repeat operation until reamer makes
contact with entire face of ring. Clean
opposite side of ring in same
manner.
(3) Injector nut
(a) Using injector nut reamer (30), turn
clockwise to remove carbon deposits
from lower end of nut.
CAUTION
Carbon deposits on spray tip
seating surfaces of injector nut will
cause poor seating and may result
in fuel leakage around spray tip.
(b)
. Using injector nut reamer (31),
turn clockwise to remove carbon
deposits from bottom of tip seat to
produce a clean uniform seat for
spray tip.
●
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. oDo not
useo near
open flame or excessive heat. The flash point is 100 F-138°F
o
(38 -50 C). If you become dizzy while using cleaning solvent, get fresh
air immediately and get medical aid. If contact with eyes is made, wash
your eyes with water and get medical aid immediately.
●
Compressed air used for cleaning- purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
(c) Wash nut in clean solvent and blow dry.
(d) If necessary, repeat steps (a thru c) until all carbon is removed.
4-225
TM9-2815-202-34
4-40. FUEL INJECTOR ASSEMBLY REPAIR (Cont)
(4) Injector plunger and bushing
CAUTION
Make sure high pressure bleed hole in side of bushing is not plugged. If hole is
plugged, fuel oil will leak into engine and cause oil dilution.
NOTE
Keep plunger and bushing together as they are matched sets. Keep parts of each
injector assembly together.
Wash with cleaning solvent and dry with compressed air.
c. Inspection/Measurements
(1) Follower
(a) Measure distance between top of
follower (8) and slot. Dimension
must be 1.645 to 1.649 inches.
stop pin groove in side of
(b) Inspect
.
follower to make sure it is smooth
and not damaged. Do not reuse
follower if there is more than
0.002 inch wear on top or there is
other visual damage or wear.
(2) Follower spring
(a) Examine outside diameter of
follower spring coils (7) for wear
caused by rocker arms contacting
coils. Replace if worn.
(b) Inspect follower springs for rust,
pitting, nicks, or notches in coils,
broken coils, broken coil ends,
and notches under coil ends.
(c) Check spring tension with spring
tester. Replace spring when a
load of less than 78 Ibs will
compress it to 1.028 inches.
4-226
TM9-2815-202-34
(3) Injector body
Inspect injector body (21) threads, bushing seating surface, and fuel connector gasket
sealing surfaces for damage. Inspect rack hole, body seal ring sealing surface, clamp radius,
and dowel pin. Replace if necessary.
(4) Fuel connectors
Check condition of jumper line sealing surfaces, copper gasket sealing surfaces, and fuel
connector (3) threads. Replace if necessary.
(5) Control rack
(a) Check injector control rack (24) for straightness, rack teeth for damage, and notch in
clevis for wear. Check rack for nicks, burrs, rust, and hardness.
(b) Notch in clevis should be 0.3125 to 0.3145 inch.
(6) Gear and gear retainer
Inspect gear (23) and gear retainer (22) for nicks, burrs, or rust. Check gear teeth for wear.
(7) Bushing
Check bushing lapped sealing surface for scratches and bushing internal diameter for
scoring. Observe condition of dowel pin. Check for corrosion and varnish. Replace if
necessary.
(8) Plunger
Check plunger (9) for corrosion or varnish, scoring, scratching or wear, and chips along
edge of helix.
(9) Check valve and check valve cage
(a) Inspect for cracks and scratches on lapped surfaces. Also inspect for corrosion, varnish,
and wear.
(b) Measure thickness of check valve (18) and check valve cage (17). Minimum cage
thickness is 0.163 inch and minimum check valve thickness is 0.022 inch.
(10) Valve spring
Check valve spring (16) for wear on coil ends, broken coil ends, and notches under coil
ends. Check for corrosion, nicks, and erosion on inside at armroximatety 1 1/2 coils from
end. Replace if necessary.
(11) Spring seat
Check spring seat (15) surfaces for wear. Replace
if necessary.
(12) Spring cage
(a) Inspect spring gage (14) for
cracks, corrosion or varnish, and
scratches on lapped sealing
surfaces. Inspect spring set
surface and needle valve seating
surface for wear.
(b) Measure thickness of spring cage. Minimum thickness is 0.602 inch.
4-227
TM 9-2815-202-34
4-40. FUEL INJECTOR ASSEMBLY REPAIR (Cont)
(13) Spray tip
(a) Check spray tip (33) for cracks,
enlarged spray holes, corrosion
on outside diameter taper, and
oxide scale on spray hole end.
Check nut to tip sealing surface
and lapped sealing surface for
scratches. Do not reuse if there is
scale, cracks, or enlarged spray
holes.
(b) Measure thickness of spray tip
shoulder. Minimum thickness is
0.199 inch.
(14) Needle valve
Check spray tip needle valve for
erosion at seat shoulder, scratches,
and overheating.
(15) Needle valve lift
Using needle valve height gage (32),
measure needle valve lift as follows:
(a) Zero indicator by placing bottom
surface of plunger assembly on a
flat surface and zero indicator
dial.
(b) Place spray tip and needle valve
assembly (13) tight against
bottom of gage with quill of
needle valve in hole in plunger.
(c)While holding spray tip and needle
valve assembly (13) tight against gage
(32), read needle valve lift indicator. Lift
should be 0.008 to 0.018 inch. If tip
assembly exceeds 0.018 inch, replace
it. If less than 0.008 inch, inspect tip
assembly for foreign material between
needle valve and tip seat.
(16) Nut
Check nut (11 ) for damaged threads, condition of seal ring seating area, and condition of
spray tip seating area. Check spray tip hole for corrosion.
(17) Spill deflector
Inspect ends of deflector (19) for sharp edges or burrs.
4-228
Change 1
TM 9-2815-202-34
d. Lapping
NOTE
Check valve only requires one lapped side. Turn over to utilize unused side.
New parts do not require lapping prior to use. Following list of used parts may require lapping:
check valve cage (17), bushing (20), valve spring cage (14), and spray tip (33). Lap components
using following procedure:
WARNING
Compressed air used for cleaning purposes will not exceed 30 PSI. Use only
with effective chip guarding and personal protective equipment (goggles/shield,
gloves, etc.)
(1) Clean lapping block set (34) with compressed air. Do not use cloth or any other-material for this
purpose.
(2) Spread 600 grit dry lapping powder on lapping block (34).
CAUTION
Ensure no lapping compound is accidently placed on the lapped surfaces located higher
up in the spray tip. The slightest lapping action on these surfaces can alter the near
perfect fit between the needle valve and tip.
(3) Place part flat on lapping block (34). Using figure-eight motion, move part back and forth across
block. Do not press on part. Apply only enough pressure to keep part flat on block. Keep part
flat on block at all times.
(4) After five passes, draw part across a clean
piece of tissue placed on flat surface and
clean lapping powder from it.
(5) Inspect part and continue lapping if
necessary. Do not lap excessively.
WARNING
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles
and gloves and use in a well-ventilated area. Avoid contact with skin, eyes, and
clothes. Do not breathe vapors. Do not use near open flame or excessive heat.
o
The flash point is 100-138°F (38-50 C). If you become dizzy while using cleaning
solvent, get fresh air immediately and seek medical aid. If contact with eyes is
made, wash with water and get medical aid immediately.
(6) When part is flat, wash in cleaning solvent and dry with compressed air.
(7) Place part on second block (34). Apply 600 grit lapping powder to block and repeat steps (3)
and (6).
(8) Place part on third block (34). Do not apply lapping powder to this block and repeat steps (3)
and (6).
Change 1
4-229
TM 9-2815-202-34
4-40. FUEL INJECTOR ASSEMBLY REPAIR (Cont)
e. Assembly
(1) Secure injector body (21) infolding fixture(1).
(2) install filter (5) in inlet port of body (located above injector rack). Position filter with dimple end
down and slotted end up. No filter is required at outlet port.
(3) Install two gaskets (4) and two fuel connectors (3) to injector body. Lubricate connector threads
with engine oil before installation. Torque connectors to 70 Ib-ft (95 N-m) (blued components)
or to 62 Ib-ft (84 N-m) (mixed and nonblued components).
(4) Install two shipping caps (2) to connectors (3) to prevent dirt from entering injector.
(5) Support injector body assembly, bottom
end up, in holding fixture.
(6) Install seal ring (25) onto shoulder of
injector body (21 ).
(7) Slide injector control rack (24) into injector
body (21 ).
(8) Look into injector body bore and move
control rack (24) until you see two drill
marks on rack. Hold rack in this position.
(9) Place gear (23) in injector body so that
marked tooth on gear is engaged between
two marked teeth on control rack (24).
(10) Place gear retainer (22) on top of gear (23).
(11) Aline locating pin in bushing (20) with slot in
injector body (21). Slide end of bushing into
place.
(12) Install spill deflector (19) over barrel of
bushing (20).
NOTE
Perform needle valve opening
pressure test [ref. step f.(5)] at this
time before completing assembly.
(13) Place check valve (18) centrally on top of
bushing (20).
(14) Place check valve cage (17), flat side up,
over check valve (18) and against bushing
(20). Check valve cage must not rest on
check valve.
(15) Insert spring seat (15) in valve spring (16).
Install assembly on check valve cage (17)
with seat up.
4-230
Change 1
TM9-2815-202-34
(16) Place spring cage (14) over spring seat (15) and spring (16).
(17) Insert needle valve (35) into spray tip (33) with tapered end down. Place spray tip assembly
(13) on top of spring cage (14) with quill end of needle valve in hole in spring cage.
(18) Lubricate threads on injector nut (11) with engine oil and carefully thread nut on injector
body. Tighten nut as tight as possible by hand.
(19) Turn injector over and push rack (24) all way in.
(20) Place follower spring (7) on injector body (21).
(21) Slide head of plunger (9) into follower
(8).
(22) Aline slot in follower (8) with stop pin
hole in injector body (21).
(23) Aline flat side of plunger (9) with flat in
gear.
(24) Insert free end of plunger (9) in
injector body (21).
(25) Place stop pin (6) in slot on injector
body (21 ). Rotate spring (7) so flat
part of end coil is clear of pin (6).
Then push pin in place while pressing
down on follower (8). Once in place,
rotate spring (7) so flat on end coil is
positioned over pin.
CAUTION
Do not exceed specified torque. Otherwise,
nut may be stretched and result in improper
sealing of lapped surfaces in overhauled
injector.
NOTE
After assembling fuel injector,
always check area between nut and
body. If seal is still visible after nut is
torqued, try another nut and seal.
(26) With injector in holding fixture (1) and
using injector nut socket (10), torque
injector nut (11) to 80 Ib-ft (108 N-m)
for blued components or 50 Ib-ft
(68 N-m) for nonblued components or
65 Ib-ft (88 N-m) for mixed
components.
4-231
TM9-2815-202-34
4-40. FUEL INJECTOR ASSEMBLY REPAIR (Cont)
f. Testing
NOTE
Injectors that were disassembled
must pass all tests outlined below
prior to installation in engine.
Injectors which were removed from
engine should be checked prior to
any disassembly to avoid
unnecessary repair.
(1) Injector control rack freeness
(a) Place injector in fixture (36).
(b) Hold injector control rack (24) in
NO FUEL position. (Rack all the
way extended).
(c)
Using handle, depress follower to
bottom of its stroke.
(d)
Slowly release pressure on
handle while moving control rack
in and out until follower reaches
top of its travel. Injector passes
test if rack falls freely.
(e) If rack binds, loosen injector nut,
turn tip, and then torque nut to
80 Ib-ft (108 N-m) for blued
components, 50 Ib-ft (68 N-m)
for nonblued components, or 65
Ib-ft (88 N-m) for mixed
components. Loosen and torque
nut a couple of times if
necessary. If rack still binds,
change injector nut. Finally, if
rack binds, disassemble injector
to eliminate cause of misaligned
parts or to remove dirt.
(2) Spray tip concentricity
(a) Place injector in fixture (36).
(b) Adjust dial indicator (37) to zero.
(c)
Rotate injector 360 degrees and note total runout as indicated on dial.
(d) If total runout exceeds 0.008 inch, remove injector from fixture. Loosen injector nut,
center spray tip, and retorque nut. Recheck sprav tip concentricity. If, after several
attempts, spray tip cannot be positioned satisfactorily, replace injector nut.
4-232
Change 1
TM9-2815-202-34
(3) High pressure leak test
WARNING
Fuel injector may contain residual fuel oil and can emit a high pressure
jet of fuel oil from spray tip when bumped. Always hold injector so that tip
will spray away from skin. Fuel oil which enters blood stream may cause
serious infection.
(a) Place fuel injector (37) in injector
test fixture (38).
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
(b) Thoroughly dry injector with
compressed air.
(c)
Check fuel connections for leaks.
If leaks have occurred, tighten
connections, dry injector, and
recheck.
(d)
With injector rack in FULL FUEL
position (fully depressed) and popping
handle (39) locked in downward
position, operate pump handle (40) to
build up and maintain pressure.
(e) Pump up injector tester and
maintain pressure of 1600 to
2000 psi. Inspect for leaks at fuel
connector gaskets, injector body
plugs, and injector nut seal ring.
(4) Spray pattern
(a) Place fuel injector (37) in injector test
(b) Place injector rack in FULL FUEL position (fully depressed).
(c)
Operate pump handle (40) to build up slight pressure (10 psi minimum) in system.
(d)
Pop fuel injector several times with popping handle (39). Observe spray pattern emitted
from fuel injector spray tip. If spray tip does not produce uniform pattern, dirty or
damaged spray tip orifice is indicated.
Change 1
4-233
TM 9-2815-202-34
4-40. FUEL INJECTOR ASSEMBLY REPAIR (Cont)
NOTE
If needle valve opening
pressure check was previously
preformed, bypass this step.
(5) Needle Valve Opening Pressure
(a) Operate pump handle (40) on diesel
fuel injector nozzle tester (41) until a
clear flow of test oil comes out of
mounting pedestal (42).
(b) Place check valve (18) centrally on
pedestal (42).
(c) Place check valve cage (17), flat side
up, and check valve (18) on pedestal
(42) with check valve in recess of check
valve cage.
(d) Insert spring seat (15) in valve spring
(16) and install on check valve cage
(17) with seat up.
(e) Place spring cage (14) over spring seat
(15) and spring (16).
(f)
Insert needle valve (35) into spray tip
(33) with tapered end down. Place
assembly on spring cage (14) with quill
end of needle valve in hole in spring
cage.
(9) Lubricate threads on injector nut (11)
with engine oil and carefully thread nut
on pedestal (42). Tighten nut as tight as
possible by hand.
(h) Using injector nut socket, torque injector
nut (11) to 75-85 Ib-ft (102-115 N-m) for
blued components, 45-55 Ib-ft (61-75
N-m) for steel gray components, or
60-70 Ib-ft (81-95 N-m) for mixed
components.
4-234
Change 1
TM 9-2815-202-34
WARNING
Do not operate diesel fuel
injector nozzle tester without
shield. Fuel spray can penetrate
skin. Fuel oil entering blood
stream may cause serious
infection.
(i)
(j)
Place shield (43) on diesel fuel injector
nozzle tester (41). Operate pump
handle (40) with smooth even strokes
and record fuel injector needle valve
opening pressure (pop pressure).
Needle valve opens when fuel sprays
from tip. Pop needle valve several times
to purge air from system. Record test
gage (44) opening pressure. Final
needle valve opening pressure must be
3450-4050 PSI.
Remove injector nut (11), spray tip (33),
needle valve (35), spring (16), spring
seat (15), spring cage (14), check valve
cage (17), and check valve (18) from
mounting pedestal (42).
NOTE
After needle valve opening
pressure test is complete, continue
injector assembly [ref. step e.(13)].
(6) Needle Valve Holding Pressure
(a) Place fuel injector in fixture (38).
(b) Operate pump handle (39) to bring pressure up to 2200 PSI.
NOTE
Pop fuel injector several times with popping handle (39) until no pressure is observed
on injector test fixture (41) before removing injector from test fixture to avoid fuel spray
as injector is removed from fixture.
(c) Close fuel shut off valve. Start timing when pressure reaches 2000 PSI and stop at 1500
PSI. Minimum time is 20 seconds.
(d) If pressure drops in less than 20 seconds, check for leaks around spray tip, seal ring, and
fuel connectors.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
5-37 Install injectors (7083-7391, 7083-7396, and 7083-7399)
4-38 Install injectors (7083-7395 and 7083-7398)
Change 1
4-234.1/4-234.2 Blank
TM 9-2815-202-34
4-41. BLOWER REPAIR
This task covers:
a. Disassembly
b. Cleaning
c. Inspection
d. Assembly
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
All
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Gear and bearing puller (App B, Item 94)
Oil seal installer App B, Item 94)
Seal ring carrier adaptor (App B, Item 94)
Oversized seal pilot (App B, Item 94)
Seal ring installer (App B, item 94)
Gage set (App B, Item 26)
Torque wrench (App B, Item 101)
Dial indicator (App B, Item 44)
Tachometer drive alignment tools
(App B, Item 5)
16
12
1
1
4
1
Lockwashers (App F, Item 92)
Lockwashers (App F, Item 91)
Gasket (App F, Item 56)
Key washer (App F, Item 166)
Seals ** (App F, Item 145)
Seal set* (App F, Item 156)
EXPENDABLE/DURABLE SUPPLIES
5 Bolts 5/16-24 x 1 1/2 inch (App C, Item 3)
2 Wood blocks (App C, Item 46)
Engine oil (App C, Item 16)
4 Bolts 5/16-18 x 1 7/8 (App C, Item 2)
4 Washers 5/16 (App C, Item 18)
Form-A-Gasket sealant (App C, Item 39)
EQUIPMENT CONDITION
Lip type oil seal (replacement part)
● * Ring type oil seal (replacement part)
●
4-12 Fuel pump removed
4-17 Governor cover and throttle control
rod removed
4-18 Governor and blower assembly
removed
a. Disassembly
NOTE
Matchmark blower housing to front
and rear end plates before
disassembly.
(1) Remove ten bolts (1), ten lockwashers
(2), and ten special washers (3) from
blower end plate cover (4). Discard
Iockwashers.
(2)
Remove blower end plate cover (4)
and gasket (5). Discard gasket.
Change 1
4-235
TM 9-2815-202-34
4-41. BLOWER REPAIR (Cont)
(3) Place clean folded wiping rag
between rotors (6 and 7). Remove six
bolts (8) and six Iockwashers (9)
securing blower drive coupling (10)
and retainer (11) to gear (12). Discard
Iockwashers.
(4) Remove bolt (13), shaft (14), deflector
(15), and spacer (16).
(5) Place flanges of two gear and bearing
pullers (with center screw backed out)
against faces of gears(12 and 17).
Aline flange holes with tapped holes
in gears.
(6) Secure pullers to gears (12 and 17)
with 5/1 6-24 x 1 1/2-inch bolts. Install
two bolts on gear (17) and three bolts
on gear (12).
(7) Turn two pullers uniformly and
remove gears (12 and 17) from shafts
of rotors (6 and 7). Remove pullers
from gears.
NOTE
Secure shims to matching gears to
insure identical number and size of
replacement shims during
reassembly.
(8) Remove shims (18) from shafts of
rotors (6 and 7).
(9) Remove twelve bolts (19), twelve
Iockwashers (20), and four retainers
(21 ) from blower end plates (22 and
23). Discard Iockwashers.
4-236
TM 9-2815-202-34
(10) Remove fuel pump drive bolt (24), key
washer (25), disc (26), and spacer
(27) from shaft of rotor (6). Discard
key washer.
(11) Remove four fillister head screws (28)
securing end plates (22 and 23) to
blower housing (29).
(12) Place flanges of gear and bearing
pullers (with center backed out) flat
against face of rear end plate (22).
CAUTION
Bolts must be threaded all the way
into tapped holes of end plate to
provide maximum anchorage for
pullers and to eliminate possible
damage to end plate.
(13) Aline holes in puller flanges with
tapped holes in end plate (22).
Secure pullers to end plate with six
1/4-24 x 11/4-inch bolts.
(14) Turn two pullers uniformly and
remove rear end plate (22) from
blower housing (29) and shafts of
rotors (6 and 7). Remove pullers and
rag from rotors.
CAUTION
To avoid damage to rotors, handle
them with care. Do not force rotors
out of housing and pull out slowly
and evenly.
(15) To remove front end plate (23), repeat
steps (12) thru (14).
(16) Remove rotors (6 and 7) from blower
housing (29).
(17) Support outer face of rear end plate
(22) on two wood blocks. Place long
end of oil seal installer through oil
seal ring collar (30) or lip-type seal
(31). Tap two rear roller bearings (32)
and two collars or seals from end
plate. If unit has oil seals, discard
seals.
4-237
TM9-2815-202-34
4-41. BLOWER REPAIR (Cont)
(18) Apply step (16) to front end plate (23)
and remove two front bearings (33)
and two seal ring collars (30) or two
lip-type seals (31).
(19) Clamp lobe of rotor (6) in soft-jawed
vise just tight enough to hold rotor
stationary.
CAUTION
To avoid breakage or distortion, do
not spread or twist oil ring seals
more than necessary to remove.
NOTE
Steps (20) thru (23) provide
information to remove oil seal rings
(34) and carriers (35) from rotor
shafts if original oil seals are
installed.
(20) Remove oil ring seal (34) from seal
ring carrier (35) with snap-ring pliers.
(21) Place seal ring carrier adapter over
carrier (35) for seal. Secure adaptor
to flange of gear puller (with center
screw backed out) with two supplied
bolts.
(22) Turn puller screw and pull oil seal
ring carrier (34) from shaft of rotor (6).
(23) To remove remaining oil seal ring
carriers from shafts of rotors (6 and 7),
repeat steps (20) thru (22).
(24) If necessary, remove two oil strainers
(36) and two sleeve bushings (37)
from blower end plates (22 and 23).
(25) Remove two plugs (38) from top of
blower end plate covers (22 and 23).
(26) If necessary, remove two dowel pins
(39) from each end plate (22 or 23).
Discard dowel pins.
4-238
TM9-2815-202-34
b. Cleaning
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves etc).
Wash all blower parts In clean fuel oil and dry with compressed air.
c. Inspection
(1) Examine bearings for indications of corrosion and pitting. Lubricate each ball bearing with
clean engine oil. Hold bearing inner race from turning and revolve outer race slowly by
hand, checking for rough spots.
(2) Check oil seal rings, carriers, and collars for wear and scoring. When replacement of an oil
seal ring or carrier is necessary, replace both parts together.
(3) Inspect blower lobes and sealing ribs for burrs and scoring. If rotors are slightly scored or
burred, clean up with emery cloth.
(4) Examine rotor shaft serrations for wear, burrs, or peening. Inspect bearing and oil seal
contact surfaces of shafts for wear and scoring.
(5) Inspect inside surface of blower housing for burrs and scoring. Inside surface must be
smooth for efficient operation. If inside surface is slightly scored or burred, clean up with
emery cloth.
(6) Check finished ends of blower housing for flatness and burrs. End plates must be flat against
blower housing.
CAUTION
Use care not to remove metal at joint face between end plates and housing. Air or oil
leaks could develop after assembly.
(7) Finished inside face of each end plate must be smooth and flat. If finished face is slightly
scored or burred, clean up with emery cloth.
NOTE
When required, replace blower gears as a set.
(8) Examine serrations in blower timing gears for wear and peening. Check gear teeth for wear,
chipping, or damage. Gear backlash between gear teeth must not exceed 0.004 inch.
WARNING
Compressed air used for cleaning purposes will not exceed 30 PSI. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves etc).
(9) Clean oil strainer in vertical oil passage at bottom of each blower end plate and blow out all
oil passages with compressed air.
(10) Examine blower drive support, coupling seats, spring seats, and springs for cracks and
broken parts.
4-239
TM 9-2815-202-34
4-41. BLOWER REPAIR (Cont)
d. Assembly
NOTE
Dowel pins must project 0.320 inch
(8.23 mm) from flat face of front end
plate to assure proper alinement of
end plate with housing.
(1) If removed, install two dowel pins (39)
in each end plate (22 or 23). Pins
must project 0.320 inch (8.23 mm)
above face of plate.
(2) If removed, install two oil strainers
(36) and two sleeve bushings (37) in
bottom of end plates (22 and 23).
Strainer must be flush to 0.015 inch
(0.38 mm) below surface.
(3) Install two plugs (38) in top of end
plates (22 and 23).
NOTE
Steps (4) thru (6) provide
information to install oversized
replacement lip-type oil seals on
rotor shafts and end plates. If the
ring-type oil seals, carriers, and
collars are still available from
existing stock, proceed to steps (9)
thru (16).
(4) Support blower rear end plate (22),
finished surface facing up, on two
wooden blocks.
(5) Start oil seal (31 ) straight into bore of
end plate with part number facing up
(away from bore).
(6) Place short end of oil seal installer in
oil seal (31 ). Tap oil seal into end
plate (22) until shoulder of installer
contacts end plate.
(7) To install remaining oil seals (31) in
end plates (22 and 23), repeat steps
(4) thru (6).
(8) Position rotor on two wood blocks
under arbor press. Using oversized
seal pilot, press oil seal sleeves (40)
on rotor shaft until sleeve contacts
rotor.
4-240
TM 9-2815-202-34
NOTE
Steps (9) thru (16) provide information to install oil seal rings, carriers, and collars (old
style) on rotor shafts and end plates. These three parts are only available from existing
stock and have been superseded.
(9) Support rotor assembly on wood block in arbor press.
(10) Lubricate inside diameter of oil seal ring carrier (35) with engine oil. Start carrier over end of
rotor shaft with chamfered inside diameter end facing rotor.
NOTE
A step under shoulder of installer will position collar 0.005 inch (0.12 mm) below
finished face of end plate.
(11) Place oil seal ring carrier installer over end of rotor shaft and against carrier (35). With
installer under ram of press, press carrier down tight against rotor.
(12) To install remaining oil seal ring carriers (35) on shafts of rotors (6 and 7), repeat steps (9)
thru (11).
NOTE
To avoid breakage or distortion, do not spread or twist oil seal rings more than
necessary to install.
(13) Install ring-type oil seal (34) in ring groove of carrier (35) with snap ring pliers.
(14) Support one blower end plate, inner face up, on two wood blocks in arbor press.
(15) Lubricate outside diameter of oil seal ring collar (29) with engine oil. Start chamfered outside
diameter end of collar straight into bore of end plate using short end of oil seal installer.
(16) To install remaining ring-type oil seals (34) on rotors and oil seal ring collars (29) in end
plates, repeat steps (13) thru (15).
4-241
TM 9-2815-202-34
4-41. BLOWER REPAIR (Cont)
NOTE
Top of front end pIate is identified
by three bolt holes and one oil
hole. Bottom of end plate has
three bolt holes and three oil
holes. Dowel pins extend from
both sides of front end plate.
The horizontal oil passage in top
of front end plate intersecting the
vertical oil passages is plugged.
Do not install this end plate on
rear of blower housing.
Mating surfaces between blower
end plates and blower housing
must be flat and smooth. No
gasket is used.
(17) Apply light coating of Form-A-Gasket
sealant to mating surfaces of end
plate and blower housing. Sealant
must not protrude into housing.
(18) Position front end plate (23) on two
wood blocks, finished side up. Install
blower housing (29), with match
marks alined, on two dowel pins (39).
NOTE
Right hand helix rotor is marked
“GEAR END” on one end. Gear end
of left hand rotor has serrated shaft.
(19) Place rotors (6 and 7) in mesh with
missing teeth in rotor shafts in
position and facing to left as viewed
from gear end.
(20) For replacement lip-type oil seal set
only, install two oversized oil seal
pilots over underrated end of each
shaft of rotors (6 and 7).
(21) Insert rotors (6 and 7) straight into housing (29) and through bores of front blower end plate
(25). If installed, remove oversized oil seal pilots.
(22) For replacement lip-type seal set only, install two oversized oil seal pilots over serrated end
of each shaft of rotors (6 and 7).
4-242
TM 9-2815-202-34
NOTE
Mating surfaces between blower end plates and blower housing must be flat and
smooth. No gasket is used.
(23) Apply light coating of Form A Gasket sealant to mating surfaces of end plate and blower
housing. Sealant must not protrude into housing.
(24) Aline match marks on rear end plate (22) and blower housing (29). Install rear end plate with
flat finished surface towards blower housing. Slide end plate down over oil seal pilots. Aline
dowel pins (39) with holes in blower housing. Push end plate against blower housing. If
installed, remove oil seal pilots.
(25) Install two screws (28) through rear end plate (22) into blower housing (29). Invert blower
housing and install two screws through front end plate (23). Torque screws to 5-10 Ib-ft
(7-14 N-m).
CAUTION
Check relationship of blower end plates to blower housing on the bottom face.
Protrusion must not be more than 0.0005 above or 0.0065 inch below end plate.
Excessive protrusion could distort blower housing when end plate mounting bolts are
tightened and could cause rotor to housing contact.
(26) Lubricate rear ball bearings (32) with light engine oil. Position two bearings, numbered end
up, on rear end plate (22) and straight on shafts of rotors (6 and 7).
(27) Place seal and rear bearing installer on top of rear ball bearings (32). Tap bearings straight
and onto shafts of rotors (6 and 7) into rear end plate (22).
NOTE
Position retainer with word “OUT”
away from end plate.
(28) Position two bearing retainers (21) on
rear end pIate (22). Install six bolts
(19) and six Iockwashers (20). Torque
bolts to 7-9 Ib-ft (9-12 N-m).
(29) Invert blower housing (29). To install
two front roller bearings (32) and two
retainers (21) on front end plate (23),
repeat steps (24) thru (26) using front
bearing installer.
Place blower housing (29) in upright
position with gear end up on two
wood blocks.
NOTE
Rotors must turn freely for proper
assembly.
4-243
TM9-2815-202-34
4-41. BLOWER REPAIR (Cont)
(31) Rotate rotors (6 and 7) to bring flat in
spline on shafts in alinement and
facing left.
(32) Install original number and thickness
of shims (18) on shafts of rotors (6
and 7) that were removed at
disassembly.
(33) Lubricate serrations of shafts of rotors
(6 and 7) with engine oil.
(34) Place teeth of rotor gears (12 and 17)
so missing teeth on inside of gears
are alined and facing same direction
as missing teeth on shafts of rotors (6
and 7).
(35) Using a soft-headed hammer, drive
gear (12) on shaft of rotor (7) and
gear (17) on shaft of rotor (6).
(36) Install bolt (13) into end in shaft of
rotor (7). Install spacer (16), shaft (14)
and deflector (15) in shaft of rotor (6).
Place folded rag between rotors to
prevent gears (12 and 17) from
turning. Torque bolt and shaft to
100-110 Ib-ft (136-150 N-m).
(37) Reverse blower assembly. Install
spacer (27), disc (26), key washer
(25) and bolt (24) to rotor (7). Aline
tang on key washer with groove in
disc. Torque bolt to 55-65 Ib-ft
(75-88 N-m). Bend one tang of key
washer into groove in disc and two
tangs against side of bolt head.
Remove rag from rotors.
(38) Install four 5/16-18x1 7/8-inch bolts
with flat washers through holes in
each end plate (top and bottom) to
blower housing. Torque bolts to
13-17 Ib-ft (18-23 N-m) (bolts are
temporarily securing blower housing
to end plates to determine clearance
between rotors and end plates).
4-244
TM 9-2815 -202-34
NOTE
When measuring clearances between rotor lobes, 1/2-inch wide feeler gages are
recommended. When measuring clearances of more than 0.005 inch, laminated
feeler gages made up of 0.002, 0.003 or 0.005-inch feeler stock are recommended.
Rotor to rotor measurement should be taken one inch from each end and at center of
blower.
(39) Measure clearance between trailing edge of right hand helix rotor and left hand helix rotor,
(CC) clearance, from both inlet and outlet sides. Clearance must be 0.004 to 0.008 inch.
(40) Measure clearance between leading edge of right hand helix rotor and trailing edge of left
hand helix rotor, (C) clearance. Minimum clearance is 0.010 inch.
4-245
TM 9-2815-202-34
NOTE
When different shims are required, always remove both gears from rotors. Placing a
0.003-inch shim in back of a right hand helix rotor gear (11 ) will decrease (CC)
clearance 0.001 inch.
(41) Remove blower gears (12 and 17) and install required thickness of shims in back of proper
gear. Install gears and check clearance as outlined in steps (37) and (38).
(42) Check clearances at points (A) and (B). Insert feeler gages between end plates (22 and 23)
and ends of rotors (6 and 7). Measure clearance for each lobe end (total of twelve). Minimum
clearance at (A) is 0.007 inch and at (B) is 0.014 inch.
4-246
TM9-2815-202-34
(43) Check clearances at points (D) and (E). Insert feeler gages between lobes of rotors (6 and 7)
and blower housing (29). Measure clearance for each lobe at both inlet and outlet side (total
of twelve). Minimum clearance at (D) is 0.015 inch and at (E) is 0.004 inch.
(44) Place blower assembly on end on two wood blocks with gear end up. Place blower drive
coupling (1 O) on gear (12) with groove inside coupling next to gear. Install coupling, retainer
(11 ), six bolts (8), and six Iockwashers (9) to gear(11 ). Insert folded rag between rotors (6
and 7). Torque bolts to 20-25 Ib-ft (27-34 N-m). Remove rag.
(45) Using dial indicator, measure cam spline runout. Maximum runout must not exceed 0.020
inch total indicator reading.
(46) Remove four bolts and four flat washers holding each end plate to blower housing (installed
to check blower clearances).
(47) Position gasket (5) on blower rear end plate cover (4) and loosely secure cover and gasket
to rear end plate (22) with ten bolts (1), ten Iockwashers (2), and ten special washers (3).
NOTE
Whenever installing a tachometer drive cover assembly or drive adaptor, maintain
proper alinement between cover and tachometer drive shaft. Correct alinement is when
no binding occurs between drive shaft and inside diameter of alinement tool when
rotating blower rotors.
(48)
. . Using tachometer drive alinement set (41), aline cover (4) with tachometer drive shaft (14) by
selecting tool with best fit. Torque bolts (1) to 13-17 Ib-ft (1 8-23 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-12 Install fuel pump
4-17 Install governor cover and throttle
control rod
4-18 Install governor and blower assembly
4-247
TM9-2815-202-34
4-42. GOVERNOR REPAIR
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
7083-7395 7083-7398
Grease (App C, Item 22)
Sealant (App C, Item 40)
Engine oil (App C, Item 16)
Cleaning solvent (App C, Item10)
Bolt 5/1 6-24 x 3 (App C, Item 4)
Sealant (App C, Item 38)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Governor cover bushing remover
(App B, Item 78)
Governor cover bearing installer (App B, Item 77)
Governor cover bushing installer
(App B, Item 53)
Torque wrench (App B, Item 101)
MANDATORY REPLACEMENT PARTS
1 Seal ring (App F, Item 131)
1 Seal ring (App F, Item 132)
2 Lockwashers (App F, Item 92)
2 Gaskets (App F, Item 78)
1 Seal ring (App F,ltem 135)
1 Gasket (App F,ltem 82)
1 Key washer (App F, Item 165)
1 Expansion plug (App F, Item 113)
a. Disassembly
NOTE
●
Before and during disassembly of
governor, clean entire unit and
visually inspect for worn or
damaged parts which may be
repaired or replaced without
complete disassembly.
●
If remote control levers are on
governor cover, remove prior to
disassembly of cover.
(1) Remove eight bolts (1) securing
governor cover (2) to governor (3).
Remove cover and gasket (4).
Discard gasket.
4-248
EQUIPMENT CONDITION
Para Description
4-17 Throttle control rods removed
4-18 Governor removed from blower
TM9-2815-202-34
(2) Remove retaining ring (5) and two washers (6) from stop lever shaft (7).
(3) Remove stop lever shaft (7) and return spring (8) from governor cover (2).
(4) Remove seal ring (9) from governor cover (2). Discard seal ring.
(5) Remove spacer (10), retaining ring (11 ), and two washers (12) from speed control shaft (13).
(6) Remove speed control shaft (13) from governor cover (2).
(7) Remove seal ring (14) from governor cover (2). Discard seal ring.
(8) Support governor cover (2) on wooden blocks in an arbor press, top facing down.
(9) Using bushing remover tool (15), remove two control shaft bushings (16) from governor
cover (2).
4-249
TM 9-2815-202-34
4-42. GOVERNOR REPAIR (Cont)
(10) Place governor housing (3)in soft-jawed vise.
(11) Remove setscrew (17), locking nut (18), and washer (19) from access cover (20).
NOTE
When removing governor high speed spring housing, do not lose shims located inside
housing.
(12) Remove two bolts (21) and two Iockwashers (22) securing access cover (20), two gaskets
(23), and housing (24) to governor housing (3). Discard gaskets and Iockwashers.
4-250
TM9-2815-202-34
NOTE
Record quantity and thickness of shims (26) for reinstallation.
(13) Remove sleeve (25), shims (26), and piston (27) from housing (24).
(14) Remove seal ring (28) from piston (27). Discard seal ring.
(15) Remove high speed spring retainer (29) and plunger (30) assembly from governor housing
(3).
(16) Remove low speed spring cap (31), low speed spring (32) spring seat (33), and adjusting pin
(34) from plunger (30).
(17) Using a socket head wrench, hold screw (35) and loosen nut (36).
WARNING
High speed spring is under pressure and personal injury could occur if
downward pressure is not applied to retainer.
(18) While applying pressure to high speed spring (37), remove screw (35) from plunger (30).
(19) Remove high speed spring (37) and seat (38) from plunger (30).
(20) Remove plug (39) and gasket (40) from governor housing (3). Discard gasket.
(21) Bend tang of key washer (41) away from
retainer bolt (42).
(22) While holding weight carrier
assembly (43), remove retainer bolt
(42), flat washer (44), and key washer
(41). Discard key washer.
(23) Thread a 5/16-24 x 3 inch bolt (45) into
hole for retainer bolt (42).
(24) Remove governor housing (3) from
vise and place on a flat surface with
bolt (45) facing up. Tap weight carrier
assembly (43) out of bearing (46) with
a soft headed hammer.
(25) Slide riser bearing (47) and riser (48)
off weight carrier assembly (43).
NOTE
Inspect weight carrier bearing in
governor housing to determine
need for removal.
(26) If necessary, remove weight carrier
bearing (46) from governor housing
(3). Use a small brass rod and
hammer to tap bearing from inside
housing.
4-251
TM 9-2815-202-34
4-42. GOVERNOR REPAIR (Cont)
(27) Matchmark two high speed and two low speed weights (49 and 50) to weight carrier (51).
(28) Remove four retaining rings (52).
(29) Press two pins (53) from weight carrier (51) and remove four washers (54), two high speed
weights (49), and two low speed weights (50).
(30) Using bearing remover tool (55), sleeve (56), and arbor press, remove needle bearing (57)
from one high speed weight (49). Repeat procedure for other high speed weight.
(31) Using an arbor press, remove carrier shaft (58) from weight carrier (51) by placing spline end
into a sleeve (59) having a one inch hole.
(32) Remove retaining clip (60) and flat washer (61 ) from differential lever pin (62) and remove
operating lever connecting link (63).
(33) Remove retaining clip (64) and flat washer (65) from operating lever pin (66). Remove
differential lever (67) from operating lever (68).
(34) If damaged, remove pin (62) from differential lever (67).
(35) For model 7083-7395 only, remove two springs (69) and retainer clips (70). Separate
governor links (71 and 72) and remove pin (73).
4-252
TM
9-2815-202-34
(36) Loosen locknut (74) and remove buffer screw assembly (75).
(37) Remove screw and washer assembly (76) and locking clip (77) securing operating lever
shaft (78) to governor housing (3).
(38) Remove operating lever shaft (78), control link operating lever (79), and two washers (80).
(39) If bearings are damaged, support control link operating lever (79) on sleeve and rest sleeve
on bed of arbor press. Place bearing remover (55) on top of bearing (81) and press two
bearings (81 ) out of operating lever (79).
(40) Remove expansion plug (82) from
bottom of governor housing (3).
Discard expansion plug.
(41) Remove operating shaft upper
bearing retainer screw and washer
assembly (83) and flat washer (84)
securing bearing in governor housing
(3).
(42) Place governor housing (3) in press,
bottom side up.
(43) Press operating shaft (85) out of lower
bearing (86) located in governor
housing (3).
(44) Place a 9/16 inch open end wrench
(87) under operating fork (88) and
press fork off operating shaft (85).
4-253
TM 9-2815-202-34
4-42. GOVERNOR REPAIR (Cont)
(45) Remove spacer (89), operating shaft
(85), upper operating lever bearing
(90), and operating lever (68) from
governor housing (3). Slide spacer
(89) from shaft (85).
CAUTION
When pressing operating shaft from
operating lever and bearing, catch
shaft by hand to prevent it from
falling and being damaged.
(46) Press operating shaft (85) from upper
bearing (90) and operating lever (68).
(47) Loosen locknut (91 ) and remove
adjusting screw (92).
(48) If damaged, remove pin (66) from
operating lever (68).
(49) Press lower bearing (86) from
governor housing (3).
(50) For model 7083-7395 only, hold
starting aid screw (93) and remove
nut (94) from governor housing (3).
CAUTION
External starting aid screw can only be removed by screwing inward through governor
housing. Removing the screw outward through the governor housing will damage the
threads in the housing due to oversize button on end.
(51 ) Remove external starting aid screw (93) through governor housing (3) by turning screw
clockwise.
b. Cleaning/Inspection
WARNING
● Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do not
o
use nearo open flame or excessive heat. The flash point is 100 F-138°F
(38°C-50 C). If you become dizzy while using cleaning solvent, get
fresh air immediately and get medical aid. If contact with eyes is made,
wash your eyes with water and get medical aid immediately.
● Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves, etc.).
4-254
TM
9-2815-202-34
(1) Clean all parts with dry cleaning solvent and dry with compressed air. Inspect all parts.
(2) Inspect all bearings and shafts for corrosion, pitting, rough spots, and excessive wear.
(3) Inspect governor housing and cover for cracks, warpage, and damaged threads.
(4) Inspect governor weights after assembly for free movement.
c. Assembly
(1) For model 7083-7395 only, install
starting aid screw (93) through inside
of governor housing (3) and secure
with nut (94) on outside of governor
housing.
(2) If removed, install pin (66) in
operating lever (68).
(3) Install adjusting screw (92) and
locknut (91) in operating lever (68).
(4) Coat inside diameter of operating
shaft upper bearing (90) with engine
oil. Using an arbor press, install upper
bearing (90), numbered side up, on
large end of operating shaft (85).
(5) Using an arbor press, install
operating lever (68), with pin (66)
facing up, onto operating shaft (85),
alining flat on lever with flat on shaft,
until flush with operating shaft (85).
(6) Install spacer (89) onto operating shaft (85).
(7) Insert end of governor operating shaft (85), bearing (90), spacer (89), and operating lever
(68) through upper bearing bore in governor housing (3) with operating fork (88) facing rear
of governor housing.
(8) Place governor housing (3) in arbor press with top facing down.
(9) Place a support (95) under operating shaft (85) and press operating fork (88) until spacer
(89) does not move up or down.
(10) Lubricate operating lever bearing (90) with engine oil and seat bearing in governor housing
(3). Install screw and washer assembly (83), and washer (84) to secure bearing.
(11) Lubricate lower bearing (86) with engine oil and start bearing into governor housing (3) on
operating shaft (85).
(12) Place a 7/16 inch inside diameter sleeve on inner race of lower bearing (86). Using arbor
press, install bearing on operating shaft (85) until bearing seats on shoulder in governor
housing (3).
4-255
TM 9-2815-202-34
4-42. GOVERNOR REPAIR (Cont)
(13) Apply a thin coat of sealant to edge of
expansion plug (82).
(14) Using a ballpeen hammer, tap
expansion plug (82), convex side up,
into governor housing (3).
(15) If removed, lubricate outside of two
control link operating lever bearings
(81) with engine oil and lubricate
inside of bearings with grease. Using
bearing installing tool (55), press one
bearing (81), numbered side up, into
control link operating lever (79) until
flush with top of lever. Reverse
operating lever and install second
bearing in same manner.
(16) Insert control link operating lever (79) and two washers (80) between two bosses inside
governor housing (3).
(17) Install operating lever shaft (78) with grooved end up.
4-256
TM9-2815-202-34
(18) Install locking clip (77) and screw and washer assembly (76) securing operating lever shaft
(78) in governor housing (3). Tighten screw and washer assembly.
(19) Install buffer screw (75) and locknut (74).
(20) Place governor housing (3) in soft-jawed vise.
(21) For model 7083-7395 only, assemble pin (73), governor link (71), and link (72) together.
Install two retainer clips (70) and two springs (69).
(22) If removed, install pin (62) into differential lever (67).
(23) Install differential lever (67), washer (65), and spring clip (64) on operating lever (68) with
slot facing rear of governor housing (3).
(24) If removed, install operating lever connecting link (63) on differential lever (67) and secure
with washer (61 ) and retaining clip (60) to pin (62).
(25) Using an arbor press and one-inch inside diameter sleeve, press weight shaft (58) into
weight carrier (51 ) until shoulder of weight shaft is seated in carrier.
NOTE
When installing weights, insure
matchmarks made at disassembly
are alined.
(26) Lubricate outside diameter of needle
bearing (57) with engine oil and
inside diameter with grease. Using
bearing installer tool (55), sleeve (56),
and arbor press, install needle
bearing (57) into high speed weight
(49). Repeat procedure for other high
speed weight.
Maintain 0.004-0.012 inches
clearance between carrier and low
speed weight; otherwise, low speed
weight will bind causing erratic
operation of governor.
(27) Install retaining clip (52) on one end
of weight pin (53). Slide weight pin
consecutively through weight carrier
(51 ), washer (54), high speed weight
(49), and second washer (54). Place
low speed weight (50) in position and
then insert a 0.004- 0.012-inch shim
between low speed weight and
carrier. Press pin through weight
carrier until retaining clip bottoms
against carrier.
(28) Remove shim and install second
retaining clip (52).
(29) Repeat steps (27) and (28) to install
opposite side weights in carrier (51).
4-257
TM9-2815-202-34
4-42. GOVERNOR REPAIR (Cont)
(30) Install riser (48) on shaft of weight carrier assembly (43).
NOTE
Incorrect installation of riser thrust bearing will result in erratic operation of governor.
(31 ) Install riser bearing (47) with smaller inside diameter against riser (48) on weight carrier
assembly (43).
(32) Insert weight carrier assembly (43) in governor housing (3). Support spline end of shaft and
governor housing on arbor press bed.
(33) Place weight carrier bearing (46) in governor housing (3) with number side up. Place a 1/2
inch diameter sleeve on top of inner race of bearing (46) and press into governor housing (3)
and against shoulder of shaft on weight carrier assembly (43).
(34) Clamp spline end of weight carrier
assembly (43) in soft-jawed vise.
(35) Place key washer (41 ) on end of
weight carrier assembly (43) with tang
on inner diameter of washer in notch
in end of carrier shaft.
(36) Install washer (44) and retaining bolt
(42), Torque bolt to 15-19 Ib-ft (20-26
N-m). Bend tang on key washer (41)
against head of bolt.
(37) Install washer (40) against bearing
(46).
(38) Apply sealant to threads of plug (39)
and install in governor housing (3).
Torque plug to 45 Ib-ft (61 N-m).
(39) Place seat (38) and high speed
spring (37) on plunger (30).
(40) Thread screw (35) one-half inch into
threaded end of plunger (30) and
install nut (36) onto screw until it
contacts end of plunger,
(41) Place low speed spring (32) into low
speed spring cap (31).
(42) Place small end of spring seat (33) into low speed spring (32). Place adjusting pin (34) into
spring seat.
(43) Install adjusting pin (34), spring seat (33), low speed spring (32), and low speed spring cap
(31) into plunger (30).
4-258
TM
9-2815-202-34
(44) Install high speed spring retainer (29) and plunger (30) assembly into governor housing (3).
Tighten spring retainer in governor housing.
(45) Place seal ring (28) in groove of piston (27).
(46) Apply a thin coat of grease on inside diameter of housing (24). Insert solid end of piston (27)
in housing.
NOTE
Quantity and thickness of shims installed must match quantity and thickness removed.
(47) Install shims (26) down inside piston (27). Insert piston sleeve (25) against shims (26) in
bore of piston (27).
(48) Affix a gasket (23) to governor housing (3) and another to access cover (20).
(49) Attach housing (24) with piston (27), shims (26), sleeve (25), and access cover (19) to
governor housing (3) with two bolts (21 ) and Iockwashers (22). Tighten bolts.
(50) Install set screw (17), locking nut (18), and washer (19) in access cover (20) one inch from
locking nut.
4-259
TM 9-2815-202-34
4-42. GOVERNOR REPAIR (Cont)
(51 ) Place governor cover (2) in press with top facing up.
(52) Using bushing installer tool (98), press two bushings (16), numbered side up, into governor
cover (2) until flush.
(53) Lubricate inside diameter of two bushings (16) with grease.
(54) Place stop lever return spring (8) over boss on inner face of governor cover (2).
(55) Insert stop lever shaft (7) part way through hole in governor cover (2) and hook end of return
spring (8) over end of lever. Push shaft up in cover.
(56) Position stop lever (7) against stop pin (95), opposite spring (8).
4-260
TM 9-2815-202-34
(57)
Install seal ring (9), two washers (6), and retaining ring (5) securing stop lever to governor
cover (2).
(58)
Install speed control shaft (13) into governor cover (2) with guide pin (96) between two pins
(97) in cover.
(59)
Install seal ring (14), two washers (12), and retaining ring (11) securing speed control shaft
to governor cover (2).
(60)
Install spacer (10) on speed control shaft (1 3).
(61)
Install governor cover (2) and gasket (4) on governor (3). Secure with eight bolts (1) and
tighten bolts.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-18 Install governor on blower
4-261
TM 9-2815-202-34
4-43. WATER PUMP REPAIR
This task covers :
a. Disassembly
b. Cleaning/Inspection
c. Assembly
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
All
Cleaning solvent (App C, Item 10)
Engine oil (App C, Item 16)
Sealant (App C, Item 38)
Compound (App C, Item 24)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Puller combination leg (App B, Item 68)
Installer water pump drive gear (App B, Item 62)
Adaptor (App D, Item 5)
Torque wrench (App B, Item 101)
MANDATORY REPLACEMENT PARTS
1
1
1
1
Gasket (App F, Item 38)
Locknut (App F, Item 88)
Seal (App F, Item 151)
Seal (App F, Item 155)
a. Disassembly
(1) Remove five bolts (1) securing pump
cover (2) and gasket (3) to pump body
(4). Discard gasket.
CAUTION
When securing gear in vise, use
care to prevent damaging gear
teeth.
(2) Secure gear (5) in vise. Remove
locknut (6) and flat washer (7) from
shaft (8). Remove locknut
(3) Using puller (9), remove pump
impeller (10) from shaft (8).
(4) Insert snap ring pliers through gear
(5). Remove lock ring (11) from
groove on shaft (8). Remove gear and
shaft as an assembly from pump body
(4).
(5) Support gear (5) on arbor press.
Place shaft (8) with threaded end
facing downward.
(6) Using a 5/8 inch diameter bar, press
shaft (8) off gear (5). Remove gear.
4-262
Change 1
EQUIPMENT CONDITION
Para Description
4-9
Water pump removed (7083-7395 and
7083-7398)
Water pump removed (7083-7391,
5-7
7083-7396, and 7083-7399)
TM 9-2815-202-34
CAUTION
When removing bearings, support inner race only, or damage to bearing may result.
(7) Support shaft (8) on inner race of inner bearing (12). Remove inner bearing.
(8) Invert shaft (8) in arbor press. Support shaft on inner race of outer bearing (13). Press shaft
off outer bearing. Remove outer bearing.
(9) Remove oil seal (14) from pump body
(4). Discard oil seal.
(10) Remove water pump seal (15) from
pump body (4). Discard seal.
NOTE
Step (11 ) is for models 7395 and 7398.
(11) If necessary, remove two pipe plugs
(16) and pipe plug (17) from pump
body (4).
b. Cleaning/Inspection
Dry cleaning solvent P-D-680 is toxic
and flammable. Wear protective
goggles and gloves and use only in a
well-ventilated area. Avoid contact with
skin, eyes and clothes and don’t breath
vapors. Do not use near open flames or
excessive
heat. The
flash point is
o
o
o
o
100 F-138 F (38 -50 C). If you become
dizzy while using cleaning solvent, get
fresh air immediately and get medical
aid. If contact with eyes is made, wash
your eyes with water and get medical
aid immediately.
4-263
TM 9-2815-202-34
4-43. WATER PUMP REPAIR (Cont)
WARNING
Compressed air used for cleaning
purposes will not exceed 30 PSI.
Use only with effective chip guarding
and personal protective equipment
(goggles/shield, gloves, etc.).
(2) Dry all parts with compressed air.
(3) Inspect pump impeller for cracks, burrs, or
damage. If ceramic insert is damaged,
replace pump impeller.
(4) Inspect housing and cover for cracks,
wear, or damage.
(5) Inspect shaft for scores, discoloration, or
damage.
(6) Inspect inner and outer bearings for pits,
discoloration, or damage.
c. Assembly
(1) Lubricate bearings (12 and 13) inner
surfaces and shaft (8) bearing surfaces
with engine oil.
CAUTION
When installing bearings, support inner
race only or damage to bearing may result.
(2) Using installer (18), press inner bearing
(12) and outer bearing (13) onto shaft (8).
(3) Support pump body (4) with cover side
down, and press bearings and shaft into
pump body.
(4) Install lock ring (11) in groove of shaft (8).
(5) Using installer (18), press gear (5) onto
impeller end of shaft (8) until gear is flush
with end of shaft.
(6) Lubricate new oil seal (14) and shaft (8)
seal surface with engine oil.
4-264
TM 9-2815-202-34
NOTE
Use correct size sleeve to press seal into pump body. Sleeve should only contact metal
part of seal.
(7) Install new oil seal (14) into pump body (4).
NOTE
Oil seal must be flush with the water pump seal counter bore in pump body.
(8) Invert pump body (4) on arbor press.
(9) Apply sealant to outer diameter of new water pump seal (15).
NOTE
Use correct size sleeve to press seal into pump body. Sleeve should only contact metal
part of seal.
(10) Press water pump seal (15) into pump body (4). Remove from arbor press.
When securing gear in soft-jawed vise, hold gear securely. Use care to prevent
damaging gear teeth.
(11) Hold gear (5) securely. Apply compound to threads on shaft (8). Place pump impeller (10),
flat washer (7), and lock nut (6) on shaft (8).
4-265
TM 9-2815-202-34
4-43. WATER PUMP REPAIR (Cont)
(12) Tighten lock nut (6) to install pump impeller (10) on shaft (8). Torque lock nut (6) to 35-40 Ib-ft
(47-54 N-m).
(13) Before installing pump assembly, check the slip torque as follows:
a. Scribe a line across gear (5) and shaft (8).
b. Scribe a line across pump impeller (10), lock nut (6), and shaft (8).
c. Attach adaptor (19) onto a torque wrench.
CAUTION
When securing gear in vise, hold gear securely. Use care to prevent damaging gear
teeth.
d. Hold gear (5) securely. Insert adapter (19) into pump impeller (10), and apply 80 Ib-ft
(108 N-m) of torque.
e. If slippage occurs, examine scribed marks to determine if gear (5) or pump impeller (1 O)
has turned on shaft (8).
f.
If slippage occurred, replace shaft (8) and part that turned.
g. After replacing necessary parts, retest pump assembly.
(14) Insert feeler gage into water outlet opening of pump body (4). Measure clearance between
pump impeller (1 O) and pump body (4). Clearance must be 0.015 inch minimum.
(15) Install new gasket (3) and pump cover (2) to pump body (4). Secure with five bolts (1).
Torque bolts to 13-17 Ib-ft (18-23 N-m).
NOTE
Step (16) is for models 7395 and 7398.
(16) If removed, install two pipe plugs (16) and pipe plug (17) into pump body (4). Remove pump
from vise.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
5-7 Install water pump (7083-7391, 7083-7396, and 7083-7399)
4-9 Install water pump (7083-7395 and 7083-7398)
4-266
Change 1
TM9-2815-202-34
4-267/4-268 Blank
TM 9-2815-202-34
CHAPTER 5
REPAIR PROCEDURES FOR MAJOR COMPONENTS OF
ENGINE MODEL 7083-7396
Contents
Para
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Turbocharger Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Exhaust Manifold and Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
.
Fuel Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Engine Lifting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Engine Water Manifolds Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Water Pump Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Air Box Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Engine Rocker Arm Cover and Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Air Inlet Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
.
Tachometer Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Block Mounted Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Accessory Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Blower Drive Shaft and Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. -15
Governor Cover and Throttle Control Rod Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Governor and Blower Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Blower Drive Gear and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Camshaft Front Gear Cover and Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Rear Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
Idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Injector Control Tube and Throttle Delay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Cylinder Head Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Engine Lower Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Camshaft and Gear Assemblies Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Cylinder Block End Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Oil Pressure Regulator and Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Piston and Connecting Rod Maintenance (Cross. head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Cylinder Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Crankshaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Cylinder Block Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Turbocharger Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-36
Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 5-37
Oil Cooler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Fuel Injector Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Page
5-2
5-3
5-5
5-8
5-10
5-12
5-14
5-15
5-15
5-15
5-15
5-15
5-15
5-16
5-20
5-23
5-23
5-23
5-23
5-24
5-27
5-27
5-27
5-27
5-27
5-27
5-28
5-33
5-33
5-33
5-33
5-33
5-33
5-33
5-33
5-33
5-35
5-64.1
5-64.1
5-64.1
5-64.2
5-74
Change
1
5-1
TM9-2815-202-34
Section I. INTRODUCTION
5-1. GENERAL. This chapter provides the repair procedures performed on engine model 7083-
7396 after the engine has been installed on the maintenance stand. Component replacement
typically consists of removal, disassembly, cleaning/inspection, repair, assembly, and installation of
the component. Next, the engine block maintenance consists of disassembly, inspection, repair, and
assembly of the block components. For major components, the repair is handled separately from
removal and installation. Component repair usually consists of disassembly, cleaning/inspection, and
assembly.
This chapter deals with model 7083-7396. However, if a model in a previous chapter has identical or
nearly identical components, this chapter will refer to the previous chapter. If models in subsequent
chapters have identical or nearly identical components, this chapter will also cover those models.
5-2
TM 9-2815-202-34
Section II. GENERAL ENGINE MAINTENANCE
5-2. TURBOCHARGER REMOVAL/lNSTALLATION
This task covers:
a. Removal
b. Cleaning/Inspection
c. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7391 7083-7396
4 Locking nuts (App F, Item 105)
1 Gasket (App F, Item 79)
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Para Description
3-8
Starter removed
3-10 Turbocharger oil return line removed
3-12 Turbocharger oil supply line removed
3-14 Air inlet manifold removed
a. Removal
(1)
Loosen four clamps (1) and two
hoses (2) connecting air inlet tube (3)
to turbocharger (4) and air inlet
housing (5).
(2) Slide two hoses (2) and four clamps
(1) onto air inlet tube (3) and remove
tube. Remove hoses and clamps from
tube.
CAUTION
Tape all openings of turbocharger
after removal to keep foreign
particles from entering and
damaging turbocharger blades.
(3) Remove four locking nuts (6) and four
washers (7) securing turbocharger (4)
to exhaust manifold (8). Discard
locking nuts.
(4) Remove turbocharger (4) and gasket
(9). Discard gasket.
C h a n g e
1 5-3
TM9-2815-202-34
5-2. TURBOCHARGER REMOVAL/lNSTALLATION (Cont)
b. Cleanlng/inspection
(1) Inspect hoses for cuts, cracks, and
brittleness.
(2) Replace all parts failing inspection.
c. Installation
(1) Install gasket (9) over studs (10) on
exhaust manifold (8).
(2) Install turbocharger (4) over studs
(10); secure with four washers (7) and
four locking nuts (6). Torque locking
nuts to 35-39 Ib-ft (47-53 N-m).
(3) Slide two hoses (2) and four clamps
(1) onto air inlet tube (3).
(4) Position air inlet tube (3) between
turbocharger (4) and air inlet housing
(5).
(5) Slide hoses (2) and clamps (1) onto
turbocharger (4) and air inlet housing
(5). Tighten hose clamps.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
3-14 Install air inlet manifold
3-12 Install turbocharger oil supply line
3-10 Install turbocharger oil return line
3-8 Install starter
5-4
.
TM 9-2815-202-34
5-3. EXHAUST MANIFOLD AND TUBE REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
EQUIPMENT CONDITION
7083-7391 7083-7396
TOOLS AND SPECIAL TOOLS
General Mechanics Tool Set (App B, Item 96)
Torque wrench (App B, Item 101)
MANDATORY REPLACEMENT PARTS
2 Gaskets App F, Item 29)
2 Gaskets (App F, Item 172)*
13 Locking Nuts (App F, Item 173)
14 Locking nuts (App F, Item 173) *
Para Description
3-10 Turbocharger oil return line removed
3-12 Turbocharger oil supply line removed
3-14 Air inlet manifold removed
5-2 Turbocharger removed
* Used on model 7083-7391
■
a. Removal
(1) Remove two nuts (1) from two clamps (2) securing exhaust crossover tube (3) to right exhaust
manifold (4) and left exhaust manifold (5). Slide clamps onto manifolds.
(2) Loosen five locking nuts (6) securing
right exhaust manifold (4) to side of
cylinder head.
C h a n g e
1 5-5
TM 9-2815-202-34
5-3. EXHAUST MANIFOLD AND TUBE REPLACEMENT (Cont)
(3) Remove exhaust crossover tube (3) from exhaust manifolds (4 and 5). Slide right exhaust
manifold (4) upward and off cylinder head. Remove clamp (2) from manifold.
NOTE
Model 7083-7391 has five beveled washers and no end retainers.
(4) Remove five locking nuts (6), three beveled washers (7), and two end retainers (8) from studs
(9) on right cylinder head. Discard locking nuts.
(5) Remove exhaust manifold gasket (10). Discard gasket.
(6) For model 7083-7396 remove eight locking nuts (6), six beveled washers (7), and two end
retainers (8) from studs (9) on left cylinder head. Remove exhaust manifold and discard locking
nuts.
(7) For model 7083-7391, remove nine locking nuts (6), and nine beveled washers (7) from studs
(9 and 11) on left cylinder head. Remove exhaust manifold and discard locking nuts.
(8) Remove exhaust manifold gasket (10). Discard gasket.
5-6 C h a n g e
1
TM 9-2815-202-34
b. Installation
NOTE
Model 7083-7391 has an
unidirectional exhaust manifold
gasket which must be installed
with embossed word “TOP”
facing outward and at the top.
(1) Position gasket (10) over exhaust
manifold studs (9) on left cylinder head.
NOTE
• Position
beveled washers with
crown facing nut.
• Insure
locating pads on exhaust
manifold rest on cylinder block
locating pads.
• For
model 7083-7391, install
glow plugs prior to installing
exhaust manifolds. (Refer to
Para 5.1-8.)
(2) For model 7083-7396, position left
exhaust manifold (5) over studs (9) on
cylinder head and secure with six
beveled washers (7), two end retainers
(8) and eight locking nuts (6). Torque
nuts to 30-35 Ib-ft (41-47 N-m) starting
from center and working outward
alternately toward either end.
(3) For model 7083-7391, position left
exhaust manifold (5) over studs (9 and
11) on cylinder head and secure with
nine beveled washers (7), and nine
locking nuts (6). Torque nuts to 43-48
lb-ft (59-67 N-m) starting from the
center and working outward alternately
toward either end.
NOTE
Model 7083-7391 has an
unidirectional exhaust manifold
gasket which must be installed
with the embossed word “TOP”
facing outward and at the top.
(4) Position gasket (10) over exhaust
manifold studs (9) on right cylinder
head.
Change 1
5-7
TM 9-2815-202-34
5-3. EXHAUST MANIFOLD AND TUBE REPLACEMENT (Cont)
NOTE
• Position beveled washers with crown facing nut.
• Model 7083-7391 has five beveled washers and no end retainers.
(5) Install three beveled washers (7), two end retainers (8), and five locking nuts (6) on right
exhaust manifold studs (9).
CAUTION
Use care when sliding exhaust manifold down pass exhaust gasket so not to bend or
damage gasket or exhaust leaks will result.
NOTE
• Do not tighten or torque exhaust manifold nuts until crossover tube has been
installed.
• Insure locating pads on exhaust manifold rest on cylinder block locating pads.
(6) Install right exhaust manifold (4) onto cylinder head by sliding downward between gasket and
retainers.
(7) Position two clamps (2) on crossover tube (3). Install exhaust crossover tube between exhaust
manifolds (4 and 5).
(8) Secure exhaust manifolds (4 and 5) to crossover tube (3) with two clamps (2) and two nuts (1).
Tighten nuts.
(9) For model 7083-7396, torque five
locking nuts (6) securing right exhaust
manifold (4) to cylinder head to 30-35
Ib-ft (41-47 N-m) starting from center
and working outward alternately toward
either end. For model 7083-7391,
torque five locking- nuts to 43-48 Ib-ft
(59-67 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
5 - 2 Install turbocharger
3-14 Install air inlet manifold
3-12 Install turbocharger oil supply line
3-10 Install turbocharger oil return line
5-8
Change 1
TM9-2815-202-34
5-4. FUEL LINES REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
TOOLS AND SPECIAL TOOLS
7083-7396 7083-7399
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
a. Removal
(1) Remove bolt (1) and flat washer (2) securing fuel crossover return line clamp (3) to front of
governor cover (4). Reinstall bolt and flat washer in governor cover.
(2) Disconnect fuel return crossover line (5) at elbows (6) on front of right and left cylinder
heads. Remove crossover return line.
(3) Remove two bolts (7) and two flat washers (8) attaching fuel supply crossover line clamps (9)
to rear of governor cover (4). Reinstall bolts and flat washers in governor cover.
(4) Disconnect fuel supply crossover line (10) at elbow (11) on front of left cylinder head and at
tee (12) on front of right cylinder head. Remove supply crossover line.
b. Installation
(1) Connect one end of fuel supply crossover line (10) to elbow(11 ) at front of left cylinder head
and connect other end to tee (12) at front of right cylinder head. Tighten connections.
NOTE
Drape and clip lines around governor cover. Do not mount lines over top of cover.
(2) Secure fuel line clamps (9) on fuel supply crossover line (10) to rear of governor cover (4) by
installing two bolts (7) and two flat washers (8) from governor cover. Torque bolts to 7-9 Ib-ft .
(10-12 N-m).
(3) Connect fuel return crossover line (5) to elbow connectors (6) at front of right and left cylinder
heads. Tighten connections.
(4) Secure fuel line clamps (3) on fuel return crossover line (5) to front of governor cover (4) by
installing two bolts (1) and two flat washers (2) from governor cover. Torque bolts to 7-9 Ib-ft
(10-12 N-m).
END OF TASK
5-8.1 Blank/5-8.2 Change 1
TM9-2815-202-34
5-9
TM 9-2815-202-34
5-5. ENGINE LIFTING BRACKETS REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MANDATORY Replacement PARTS
MODELS
■ 7083-7391 7083-7396 7083-7399
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
8 Lockwashers (App F, Item 94)
4 Gaskets (App F,ltem 34)
EQUIPMENT CONDITION
Para Description
5-8 Air box heater line removed (Except
7083-7391)
a. Removal
(1) Remove two bolts (1) and two Iockwashers (2) securing engine lifting bracket (3) to front of
right cylinder head. Remove bracket and discard Iockwashers.
(2) Remove gasket (4) from front of cylinder head. Discard gasket.
(3) Remove two bolts (5) and two Iockwashers (6) securing engine lifting bracket (7) to rear of
right cylinder head. Remove bracket and discard Iockwashers.
(4) Remove gasket (8) from rear of cylinder head. Discard gasket.
(5) Repeat steps (1) thru (4) for removal of left cylinder head lifting brackets.
b. Installation
(1) Install two bolts (5), two Iockwashers (6), and gasket (8) securing rear engine lifting bracket
(7) to right cylinder head. Torque bolts to 46-50 Ib-ft (62-68 N-m).
(2) Install two bolts (1), two Iockwashers (2), and gasket (4) securing front engine lifting bracket
(3) to right cylinder head. Torque bolts to 46-50 Ib-ft (62-68 N-m).
(3) Repeat steps 1 and 2 for installation of left engine lifting brackets.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
5-8 Install air box heater line (Except 7083-7391)
5-10 C h a n g e
1
TM9-2815-202-34
5-11
TM9-2815-202-34
5-6. ENGINE WATER MANIFOLDS REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
■ 7083-7396 7083-7399
MANDATORY REPLACEMENT PARTS
16 Lockwashers (App F,ltem 93)
8 Gaskets (App F, Item 71 )
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Para Description
3-7 Oil level gauge rod removed
3-14 Air inlet manifold removed (7083-7396)
3-15 Air inlet manifold removed (7083-7399)
5-2 Turbocharger removed (7083-7396)
5-3 Exhaust manifolds removed (7083-7396)
7-3 Turbocharger removed (7083-7399)
7-4 Exhaust manifolds removed (7083-7399)
a. Removal
(1) Disconnect tube assembly (1) at upper fitting (2) on right water manifold (3) and at elbow
fitting (4) on top of water pump (5). Remove tube assembly.
(2) Disconnect tube assembly (6) at lower fitting (7) on right water manifold (3) and at elbow
fitting (8) on front of right cylinder head (9). Remove tube assembly.
(3) Remove eight nuts (10) and eight Iockwashers (11) securing water manifold (3) to right
cylinder head (9). Discard Iockwashers and remove water manifold.
(4) Remove four gaskets (12) from bottom of water manifold or top of cylinder head. Discard
gaskets.
(5) If necessary, remove four fittings (2,7,13, and 14) from end of right water manifold (3), and
two plugs (15) from top of water manifold.
(6) Repeat steps (2) thru (4) above for left water manifold.
(7) If necessary, remove two fittings (7 and 14) and three plugs (15) from left bank water
manifold (3).
b. Installation
(1) If removed, install four fittings (2,7,13, and 14) in the front of right water manifold (3) and two
plugs (15) in top of manifold.
(2) Install four gaskets (12) over studs (16) on right cylinder head.
(3) Install water manifold (3) on right cylinder head and secure with eight Iockwashers (11) and
eight nuts (10). Torque nuts to 20-25 Ib-ft (27-34 N-m).
5-12 Change 1
TM 9-2815-202-34
(4) Connect tube assembly (1) at elbow fitting (4) on water pump (5) and at upper fitting (2) on
water manifold (3). Tighten connections.
(5)
Repeat steps (2) and (3) above for left water manifold.
(6)
If removed, install two fittings (7 and 14) and three plugs (15) in left water manifold (3).
(7) Connect tube assembly (6) at elbow fitting (8) on cylinder head (9) and at lower fitting (7) on
each water manifold (3). Tighten connections.
END OF TASK
FOLLOW-ON MAINTENANCE
Para
5-3
5-2
7-4
7-3
3-14
3-15
3-7
Description
Install exhaust manifolds (7083-7396)
Install turbocharger (7083-7396)
Install exhaust manifolds (7083-7399)
Install turbocharger (7083-7399)
Install air inlet manifold (7083-7396)
Install air inlet manifold (7083-7399)
Install oil level gauge rod
C h a n g e
1 5-13
TM9-2815-202-34
5-7. WATER PUMP REMOVAL/lNSTALLATION
This task covers:
a. Removal
b. Installation
c. Gear-Backlash Adjustment
INITIAL SETUP
MANDATORY REPLACEMENT PARTS
MODELS
3 LockWashers (App F, Item 94)
1 Seal ring (App F, Item 133)
7083-7391 7083-7396 7083-7399
EQUIPMENT CONDITION
TOOLS AND SPECIAL TOOLS
General mechanics tool Kit (App B, Item 96)
Magnetic base dial indicator (App B, Item 45)
Torque wrench (App B, Item 101)
Para Description
3-6 Water outlet removed
5-6 Water manifold tube assembly removed
(7083-7396 and 7083-7399)
5.1-6 Water manifold tube assembly removed
(7083-7391)
a. Removal
(1) Remove bolt (1), two bolts (2), three Iockwashers (3), and flat washer (4) securing water
pump (5) to engine front cover (6). Discard Iockwashers.
CAUTION
Use care when removing water pump to prevent damage to gear teeth.
(2) Remove water pump (5) from engine front cover (6). Remove seal ring (7) and discard.
5-14 C h a n g e
1
TM 9-2815-202-34
b. Installation
(1) Affix seal ring (7) to back of water pump (5).
(2) Install water pump (5), alining gear teeth with drive gear in engine front cover (6).
(3) Install bolt (1), two bolts (2), three Iockwashers (3), and flat washer (4) securing water pump
(5) to front cover (6). Torque bolts to 46-50 Ib-ft (62-68 N-m).
c. Gear Backlash Adjustment
(1) Remove five bolts (8), pump cover (9), and gasket (10) from water pump (5).
(2) Check gear backlash by installing a bolt or equivalent in impeller puller hole. Measure
backlash with a dial indicator at this point. Backlash setting should be between 0.001 and
0.006 inch. If setting is not correct, loosen bolts (1 and 2) and pivot water pump until properly
set. Retorque bolts (1 and 2).
(3)
Install gasket (10), pump cover (9) and five bolts (8) to water pump (5). Torque bolts to 13-17
Ib-ft (1 8-23 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
5-6 Install water manifold tube assembly (7083-7396 and 7083-7399)
5.1-6 Install water manifold tube assembly (7083-7391 )
3-6 Install water outlet
5-8.
AIR BOX HEATER REPLACEMENT
5-9.
ENGINE ROCKER ARM COVER AND CRANKCASE
BREATHER REPLACEMENT
(See Para 4-10)
(See Para 4-11)
5-10. FUEL PUMP REPLACEMENT
(See Para 4-12)
5-11. AIR INLET HOUSING REPLACEMENT
(See Para 4-13)
5-12. TACHOMETER DRIVE REPLACEMENT
(See Para 4-14)
5 - 1 3 . BLOCK MOUNTED CRANKCASE BREATHER REPLACEMENT
(See Para 4-15)
Change 1
5-15
TM9-2815-202-34
5-14. ACCESSORY DRIVE REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning/Inspection
INITIAL SETUP
MANDATORY REPLACEMENT PARTS
MODELS
7083-7391 7083-7396 7083-7399
TOOLS AND SPECIAL TOOLS
6 Lockwashers (App F,ltem 93)
1 Gasket (App F,ltem 26)
1 Seal (App F, Item 148)
1 CUP plug (App F, Item 12)
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
EXPENDABLE/DURABLE SUPPLIES
Fuel oil (App C, Item 21)
Sealant (App C, Item 38)
Engine oil (App C, Item 16)
a. Removal
(1) Remove bolt (1), nut (2), flat washer (3), and Iockwasher (4) from accessory drive assembly
(5) and flywheel housing (6). Discard Iockwasher.
(2) Remove three bolts (7) and three lockwashers (4) securing accessory drive assembly (5) to
flywheel housing (6). Discard Iockwashers.
(3) Remove two bolts (8), two Iockwashers (4), and accessory drive assembly (5) from flywheel
housing (6). Discard Iockwashers.
(4) Remove fiber coupling (9) from blower drive hub (10).
(5) Remove gasket (11) from accessory drive assembly (5). Discard gasket.
b. Disassembly
(1) If necessary, remove six studs (12) from accessory drive housing (13).
(2) Using arbor press, press shaft coupling half assembly (14) from accessory drive housing
(13).
(3) If necessary, remove seal (15) from accessory drive housing (13) using a brass drift. Discard
seal.
(4) Using arbor press, press shaft coupling half (16) from bearing (17) and sleeve (18).
(5) If necessary, remove cup plug (19) from shaft coupling half (16). Discard cup plug.
5-16 C h a n g e
1
TM 9-2815-202-34
5-17
TM 9-2815-202-34
5-14. ACCESSORY DRIVE REPLACEMENT (Cont)
c. Cleanlng/inspection
(1) Clean all parts with fuel oil except
bearing.
WARNING
Compressed air used for
cleaning purposes will not
exceed 30 PSI. Use only with
effective chip guarding and
personal protective equipment
(goggles/shield, gloves, etc.).
(2) Dry all parts with compressed air.
(3) Inspect fiber coupling and shaft
coupling half for cracks, wear, or
damage.
(4) Inspect bearing and sleeve for scores,
pitting, or wear.
d. Assembly
(1) If removed, install cup plug (19) into
shaft coupling half (16).
(2) Apply lubricant to each side of
bearing (17) prior to installing on shaft
coupling half (16).
(3) Apply sealant to inner diameter of
bearing (17). Using arbor press, press
bearing onto shaft coupling half (16).
(4) Apply sealant to inner diameter of
sleeve (18). Using arbor press, press
sleeve onto shaft coupling half (16).
Sleeve must be flush with end of
shaft.
(5) Apply sealant to outer diameter of
bearing (17). Using arbor press, press
shaft coupling half assembly (14) into
accessory drive housing (13).
(6) If removed, install seal (15), part
number out, into accessory drive
housing (13).
(7) If removed, install six studs (12) into
accessory drive housing (13). Torque
studs to 12-17 Ib-ft (1 6-23 N-m).
5-18
TM9-2815-202-34
e. Installation
(1) Install gasket (11) onto accessory drive assembly (5).
(2) Install fiber coupling (9) onto blower drive hub (10). Aline accessory drive assembly (5) with
slots in fiber coupling.
(3) Install accessory drive assembly (5) onto flywheel housing (6). Install two bolts (8) and two
Iockwashers (4).
(4) Install three bolts (7) and three Iockwashers (4).
(5) Install bolt (1), flat washer (3), Iockvvasher (4), and nut (2).
(6) Torque two bolts (8) to 30-35 Ib-ft (41-47 N-m). Torque three bolts (7) and bolt (1) to
35-39 Ib-ft (47-53 N-m).
END OF TASK
5-19
TM9-2815-202-34
5-15. BLOWER DRIVE SHAFT AND HUB REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning/Inspection
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
1Bolt, 10-32 x1-inch (App C, Item 33)
Dry cleaning solvent (App C, Item 10)
7083-7396 7083-7399
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Para Description
5-14 Accessory drive removed
a. Removal
(1) Install 10-32 x 1 inch bolt (1) in blower drive shaft (2). Remove snap ring (3) and extract
blower drive shaft.
NOTE
Place a rag below the hub and spring plate assembly to prevent bolts from falling into
flywheel housing.
(2) Remove three bolts (4) securing hub and spring plate assembly (5) to blower drive gear (6).
Remove hub and spring plate assembly.
b. Disassembly
Remove three bolts (7) securing two spring plates (8) to blower drive hub (9).
c. Cleanlng/inspection
WARNING
●
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do noto
useo nearo open flame or excessive heat. The flash point is 100°F-138 F
(38 C-50 C). If you become dizzy while using cleaning solvent, get
fresh air immediately and get medical aid. If contact with eyes Is made,
wash your eyes with water and get medical aid immediately.
●
Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves, etc.).
(1) Clean all parts with dry cleaning solvent and dry with compressed air.
5-20
TM9-2815-202-34
(2) Examine blower drive shaft. Replace blower drive shaft if splines are worn, cracked, or
otherwise damaged.
(3) Examine blower drive hub. Replace hub if cracked or damaged or if spline is cracked, worn,
or otherwise damaged.
(4) Examine spring plates. Replace if cracked, kinked, or if bolt holes show signs of distortion.
d. Assembly
Attach two spring plates (8) to blower drive hub (9) using three bolts (7). Torque bolts to
35-39 lb-ft (47-53 N-m).
5-21
TM9-2815-202-34
5-15. BLOWER DRIVE SHAFT AND HUB REPLACEMENT (Cont)
e. Installation
NOTE
Place a rag below the hub and spring plate assembly to prevent bolts from falling into
flywheel housing.
(1) Attach drive hub and spring plate assembly (5) to blower drive gear (6) using three bolts (4).
Torque bolts to 35-39 Ib-ft (47-53 N-m).
(2) Thread 10-32 x 1 inch bolt (1) in blower drive shaft (2).
(3) Insert drive shaft (2) through blower drive gear (6). If binding occurs, refer to blower
alinement procedure in Para 4-18.
(4) Install snap ring (3) in blower drive hub (9). Remove 10-32 x 1 inch bolt.
END OF TASK
FOLLOW-ON MAINTENANCE
Para 5-14
5-22
TM 9-2815-202-34
5-16. GOVERNOR COVER AND THROTTLE CONTROL
ROD REMOVAL/lNSTALLATION
(See Para 4-17)
5-17. GOVERNOR AND BLOWER ASSEMBLY
REMOVAL/lNSTALLATION
(See Para 4-18)
5-18. BLOWER DRIVE GEAR AND SUPPORT REPLACEMENT
(See Para 4-19)
5-19. OIL PAN REPLACEMENT
(See Para 4-20)
5-23
TM 9-2815-202-34
5-20. CAMSHAFT FRONT GEAR COVER AND DAMPER REPLACEMENT
This task covers:
a. Removal
b. Inspection
c. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7391 7083-7396 7083-7399
9
1
1
1
1
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B,Item 96)
Mechanical 2-jaw puller (App B, Item 70)
Torque wrench (App B, Item 101)
Balance weight cover seal installer
(App B, Item 48)
Lockwashers (App F, Item 93)
Jam nut (App F, Item 86)
Lockwasher (App F, Item 95)
Gasket (App F, Item 48)
Seal (App F, Item 153)
EQUIPMENT CONDITION
Para Description
Water pump removed
5-7
a. Removal
(1) Remove bolt (1), Iockwasher (2), and flat washer (3) securing damper (4) to shaft pulley drive
(5). Discard Iockwasher.
(2) Using mechanical puller (6), remove damper (4) from shaft pulley drive (5). Remove woodruff
key (7).
NOTE
Bolts securing front gear cover vary in length and diameter. For ease of assembly, note
location of bolts, washers, and nuts when removing.
(3) Remove bolt (8) and flat washer (9).
(4) Remove five bolts (10), four nuts (11), five Iockwashers (2), and five flat washers (12) from
top of front gear cover (1 3). Remove bolt (10), flat washer (12), Iockwasher (2), and jam nut
(14) from lower left corner of gear cover. Discard Iockwashers.
(5) Remove bolt (15), Iockwasher (16), and flat washer (17). Discard Iockwasher.
(6) Remove two bolts (18), two lockwashers (2), and two flat washers (12). Discard Iockwashers.
(7) Remove two bolts (19) and two flat washers (20).
(8) Remove front gear cover (13) and gasket (21) from front end plate (22). Discard gasket.
(9) If necessary, remove seal (23) from front gear cover (13).
5-24 Change 1
TM
9-2815-202-34
5-25
TM 9-2815-202-34
5-20. CAMSHAFT FRONT GEAR COVER AND DAMPER REPLACEMENT (Cont)
b. Inspection
Inspect front gear cover and damper for cracks, pitting, or damage.
c. Installation
(1) If removed, install seal (23) into front gear cover (13). Position seal with lip facing inward.
Using seal installer, drive seal into cover until installer is flush with cover.
NOTE
Assemble top three bolts with nuts toward front of engine.
(2) Position front gear cover (13) and gasket (21) on front end plate (22). Secure with five bolts
(10), five flat washers (12), five Iockwashers (2), and four nuts (11) at top of cover.
(3) Install bolt (10), flat washer (12), Iockwasher (2), and jam nut (14) at lower left corner of
cover.
(4) Install bolt (15), Iockwasher (16), and flat washer (17).
(5) Install two bolts (18), two Iockwashers (2), and two flat washers (12).
(6) Install two bolts (19) and two flat washers (20).
(7) Install bolt (8) and flat washer (9).
(8) Torque two bolts (18) to 30-35 Ib-ft (41 -47 N-m). Torque six bolts (10) to 35-39 Ib-ft
(47-53 N-m). Torque bolt (15) and bolt (8) to 71-75 Ib-ft (96-102 N-m). Torque two bolts (19)
to 137-147 Ib-ft (186-200 N-m).
(9) Install woodruff key (7) into shaft pulley drive (5). Aline keyway in damper (4) with woodruff
key on shaft pulley drive and install damper.
(lo) Secure damper (4) to shaft pulley drive (5) with bolt (1), Iockwasher (2), and flat washer (3).
Torque bolt to 30-35 Ib-ft (41-47 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
Install water pump
5-7
5-26
TM 9-2815-202-34
5-21. FLYWHEEL ASSEMBLY REPLACEMENT
(See Para 4-22)
5-22. REAR OIL SEAL REPLACEMENT
(See Para 4-23)
5 - 2 3 . FLYWHEEL HOUSING REPLACEMENT
(See Para 4-24)
5-24. IDLER GEAR REPLACEMENT
(See Para 4-25)
5-25. INJECTOR CONTROL TUBE AND THROTTLE
DELAY REPLACEMENT
(See Para 4-26)
5 - 2 6 . CYLINDER HEAD ASSEMBLY REMOVAL/lNSTALLATION
(See Para 4-27)
5-27
TM 9-2815-202-34
5-27. ENGINE LOWER FRONT COVER REPLACEMENT
This task covers:
a. Removal
d. Installation
b. Cleaning/Inspection
c. -Repair
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7391 7083-7396 7083-7399
1 Gasket (App F,ltem 42)
2 Lockwashers (App F,ltem 93)
6 Lockwashers (App F, Item 94)
6 Lockwashers (App F, Item 95)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Oil seal installer (App B, Item 50)
Universal puller (App B, Item 71)
Torque wrench (App B, Item 102)
EXPENDABLE/DURABLE SUPPLIES
Grease (App C, Item 22)
Nonhardening sealant (App C, Item 38)
Emery cloth (App C, Item 15)
Crocus cloth (App C, Item 12)
EQUIPMENT CONDITION
Para Description
5-19 Oil pan removed
a. Removal
NOTE
Secure gear train in place to
prevent crankshaft from turning
during removal of front crankshaft
bolt.
(1) Remove bolt (1) and spacer (2) from
front of crankshaft.
(2) Reinstall bolt (1) on crankshaft.
(3) Attach universal puller (3) to vibration
damper hub (4) with two long bolts
threaded into tapped holes in hub.
CAUTION
Do not pound or pry on vibration
damper during removal. Dents in
damper outer case may cause it to
function ineffectively. Damper
cannot be repaired.
5-28 Change 1
TM9-2815-202-34
(4) Pull damper assembly (5) and outer
cone (6) until cone is loose on
crankshaft.
(5) Remove universal puller (3) from
damper hub (4).
(6) Remove bolt (1) from crankshaft.
(7) Slide outer cone (6), damper
assembly (5), and inner cone (7) from
end of crankshaft by hand.
(8) Remove six bolts (8) and six
Iockwashers (9); then, separate
damper (10) from hub (4). Discard
Iockwashers.
(9) Remove four bolts (11), two bolts (12),
six Iockwashers (13), two bolts (14),
and two Iockwashers (15) from lower
front cover (16). Discard Iockwashers,
(10) Strike edges of cover (16) alternately
on each side with a soft-head
hammer to free it from dowels. Pull
cover straight off end of crankshaft.
(11) Remove dirt deflector (17) from end of
crankshaft.
(12) Remove gasket (18) from cylinder
block. Discard gasket.
----
5-29
TM 9-2815-202-34
5-27. ENGINE LOWER FRONT COVER REPLACEMENT (Cont)
b. Cleaning/inspection
WARNING
●
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do
not
o
useo nearo open flame or excessive heat. The flash point is 100 F-138°F
(38 C-50 C). If you become dizzy while using cleaning solvent, get
fresh air immediately and get medical aid. If contact with eyes is made,
wash your eyes with water and get medical aid immediately.
●
Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves, etc.).
(1) Clean front cover with dry cleaning solvent and dry with compressed air.
(2) Inspect front cover sealing and mating surfaces for cracks, nicks, and damage that would
prevent proper sealing.
(3) Check inside of spacer and crankshaft for burrs and nicks. Clean up burrs using crocus cloth
in circular motion.
(4) Inspect spacer ring for nicks or burrs that would prevent proper sealing.
(5) Inspect damper for dents, nicks, bulges or leakage in outer case. Replace damper if any of
above conditions are present.
NOTE
Regardless of condition, replace damper at time of normal periodic major engine
overhaul.
(6) Inspect inner cone, outer cone, and damper hub for galling or burrs. Remove sight scratches
or burrs with emery cloth.
c. Repair (seal replacement)
(1) Support outer face of front cover (16)
on two wooden blocks and drive seal
(19) out of front cover. Discard seal.
(2) Clean seal bore.
NOTE
if new oil seal is not precoated,
apply nonhardening sealant to outer
edge of metal casing.
(3) Position seal (19) in front cover (16)
with seal lip pointed toward inner face
of cover.
5-30
TM 9-2815-202-34
(4) Drive seal (19) into front cover (16)
with seal installer tool (20).
(5) Remove any excess sealant.
d. Installation
(1) Affix gasket (18) to inner face of front
cover (16).
(2) Position dirt deflector (17) onto
crankshaft with flat surface toward
engine.
(3) Coat lip of oil seal lightly with grease
or vegetable shortening.
(4) Position front cover (16) over two
alinement pins (21) and tap cover
until it contacts cylinder block.
(5)
Install four bolts (11), two bolts (12),
six lockwashers (13), two bolts (14),
and two Iockwashers (15) to lower
front cover (16).
(6) Torque bolts (14) to 25-30 Ib-ft
(34-41 N-m) and bolts (11 and 12) to
80-90 Ib-ft (108-122 N-m).
5-31
TM 9-2815-202-34
5-27. ENGINE LOWER FRONT COVER REPLACEMENT (Cont)
(7) Place vibration damper (10)against hub (4) with dished side of damper towards inner side of
hub flange.
CAUTION
When attaching damper hub (4) to vibration damper (10), insure two dowels in hub aline
with two smaller holes in vibration damper. Incorrect assembly will allow for movement
between hub and damper and serious engine damage will result.
(8) Attach vibration damper (10) to hub (4) with six bolts (8) and six Iockwashers (9). Torque
bolts to 57-61 lb- ft (77-83 N-m).
(9) Slide inner cone (7), damper assembly (5), outer cone (6), and spacer (2) on end of
crankshaft.
(10) Install bolt (1) in end of crankshaft,
NOTE
Secure gear train in place to
prevent crankshaft from turning
during installation of front
crankshaft bolt.
(11 ) Tighten crankshaft end bolt (1) as follows:
(a) Torque bolt to 180 Ib-ft (244 N-m).
(b) Strike end of bolt a sharp blow
three times with 3 pound softhead hammer.
(c) Torque bolt to 300 lb-ft (407 N-m)
and strike bolt again three times.
(d) Torque bolt to 290-310 Ib-ft (393421 N-m). Do not strike bolt after
final torque has been applied.
END OF TASK
Para Description
5-19 Install oil pan
5-32 C h a n g e
1
TM9-2815-202-34
5-28. CAMSHAFT AND GEAR ASSEMBLIES
REPLACEMENT
(See Para 4-29)
5-29. CYLINDER BLOCK END PLATES REPLACEMENT
(See Para 4-30)
5-30. OIL PRESSURE REGULATOR AND
RELIEF VALVE REPLACEMENT
(See Para 4-31)
5-31. OIL PUMP REPLACEMENT
(See Para 4-32)
Section Ill. ENGINE DISASSEMBLY/ASSEMBLY
5-32. PISTON AND CONNECTING ROD
MAINTENANCE (CROSS-HEAD)
(See Para 4-33)
5-33. CYLINDER LINER MAINTENANCE
(See Para 4-34)
5-34. CRANKSHAFT MAINTENANCE
(See Para 4-35)
5-35. CYLINDER BLOCK MAINTENANCE
(See Para 4-36)
Section IV. COMPONENT REPAIR
(See Para 4-37)
5-36. TURBOCHARGER REPAIR
Change
1 5-33/5-34 Blank
TM 9-2815-202-34
5-37. CYLINDER HEAD REPAIR
This task covers:
a. Disassembly
d. Inspection/Repair
b. Cleaning
e. Assembly
c. Pressure check
INITIAL SETUP
MODELS
7083-7391 7083-7396 7083-7399
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Valve insert remover (App B, Item 80)
Bridge guide installer (App B, Item 49)
Injector tube installer - new style (App B, Item 54)
Valve spring compressor (App B, Item 13)
Cylinder head pressure test kit (App D, Item 10)
Valve guide remover (App B, Item 79)
Spring tester (App B, Item 93)
Valve bridge guide remover set (App B, Item 74)
Valve insert installer (App B, Item 61)
Slide hammer (App B, Item 39)
Reamer (App B, Item 47)
Depth gage (App B, Item 28)
Valve guide installer (App B, Item 60)
Fuel nut wrench (App B, Item 99)
Reamer (App B, Item 47)
Upsetting die (App B, Item 47)
Injector tube pilot (App B, Item 47)
Micrometer 0-1 inch (App B, Item 65)
Cam follower fixture (App B, Item 18)
Injector protrusion gage (App B, Item 32)
Injector tube tip refinisher (App B, Item 47)
Insert runout dial gage (App B, Item 29)
Magnetic base dial indicator (App B, Item 45)
Bridge guide remover (App B, Item 75)
Adaptor kit - insert grinding (App B, Item 3)
Valve insert grinder (App B, Item 38)
Telescoping gage (App B, Item 25)
Injector tube installer - old style tube
(App B, Item 47)
Torque wrench (App B, Item 100)
Installer, exhaust seal (App D, Item 14)
MANDATORY REPLACEMENT PARTS
8
2
16
2
8
8
8
6
4
2
Gaskets (App F, Item 49)
Lockwashers (App F, Item 93)
Bushings (App F, Item 6)
Lockwashers (App F, Item 91)
Cup plugs (App F, Item 8)
Injector tube kit (App F, Item 158)
Fuel lines (App F, Item 18)
Fuel lines (App F, Item 19)
Gaskets (App F, Item 71)
Cup plugs (App F, Item 174)
Plugs (App F, Item 175)
EXPENDABLE/DURABLE SUPPLIES
Engine oil (App C, Item 16)
Cindol 1705 oil (App C, Item 8)
Sulphurized oil - E.P. type (App C, Item 45)
Cutting oil (App C Item 38)
Sealant (App C,Item 38)
Four cover plates (App C, Item 11)
Fuel oil (App C, Item 21)
Crocus cloth (App C, Item 12)
Sealant (App C, Item 40)
Prussian blue (App C, Item 32)
Teflon pipe sealant (App C, Item 49)
Gasket cement (App C, Item 50)
EQUIPMENT CONDITION
Para Description
4-27 Cylinder head removed
5-5 Lifting brackets removed
5-6 Water manifolds removed (7083-7396 and
7083-7399)
5.1-6 Water manifolds removed (7083-7391)
5.1-8 Glow plugs removed (7083-7391)
Change
1 5-35
TM 9-2815-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
a. Disassembly
NOTE
Immediately after removing fuel lines,
cover each injector opening with cap
to keep out dirt.
(1) Remove four inlet fuel lines (1) and four
outlet fuel lines (2) from fuel injectors (3)
and fuel connectors (4). Discard fuel lines.
NOTE
● Tag
rocker arms, shafts, brackets, valves, cam followers, and associated hardware
so they can be installed in their original position.
● On
models 7083-7396 and 7083-7391, one rocker arm shaft bracket on right cylinder
head contains throttle delay housing (5).
(2) Remove eight bolts (6) securing rocker arm shafts (7) and brackets (8) to cylinder head.
NOTE
■
On model 7083-7396, inspect throttle
delay check valve for Ieakage. Fill
throttle delay cylinder with fuel oil and
watch check valve for leakage while
moving engine throttle from idle to full
fuel position. If more than a drop of
leakage occurs, replace check valve.
(3) Remove four rocker arm shafts (7) and
eight rocker shaft brackets (8) from
cylinder head. If necessary, remove check
valve (9) used on model 7083-7396 and oil
supply fitting (10) from throttle delay
housing (5) used on models 7083-7396
and 7083-7391.
5-36 C h a n g e
1
TM 9-2815-202-34
(4) Swing rocker arms (11) away from injector
and valves. Remove four injector clamp
bolts (12), four washers (13), and four
clamps (14).
(5) Remove four fuel injectors (3) from cylinder
head.
(6) Loosen twelve lock nuts (15) at upper end
of push rods (16) next to rocker arm clevis.
Unscrew twelve rocker arms (11) from
push rods.
(7) Remove eight valve bridges (17) from
bridge guides (18).
(8) Rest cylinder head on its side and remove
eight cam follower guide bolts (19), eight
Iockwashers (20), and four cam follower
guides (21 ). Discard Iockwashers.
(9) Remove twelve cam follower spring
retainers (22) from cam follower bores in
cylinder head.
(10) Pull twelve cam followers (23) and twelve
push rod (16) assemblies from bottom of
cylinder head. Remove twelve push rod
nuts (15), twelve upper spring seats (25),
twelve cam follower springs (24), and
twelve lower spring seats (26) from twelve
push rods.
NOTE
Mark location of valve for
reinstallation. With used valves,
valves must go in original location.
Remove sixteen exhaust valves as follows:
(a) Position cylinder head on its side.
(b) Using valve spring compressor (27),
compress valve spring (28). Remove
two piece tapered valve locks (29).
(c) Release compressor (27) and remove
upper spring seat (30), valve spring
(28), lower spring seat (31), and
exhaust valve (32).
Change 1 5-37
TM 9-2815-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
NOTE
■
• Models 7083-7396 and 7083-7391 contain four bolts (33), four flat washers (34), two
cover plates (35), and two gaskets (36) per head.
• Model 7083-7399 contains six bolts (33), six flat washers (34), and three cover plates
(35), and three gaskets (36)per head.
(12) Remove bolts (33), flat washers (34), cover plates (35), and gaskets (36) from corners of
cylinder head. Discard gaskets.
(13) If necessary, for models 7083-7396 and 7083-7399, remove support bracket (37), two bolts
(38), and two Iockwashers (39) from right cylinder head. Discard lockwashers.
(14) Remove two bolts (40), two flat washers (41), adaptor (42), and gasket (43) from inboard
corner of cylinder head. Discard gasket.
(15) Remove eight fuel connectors (4) and eight washers (44) from cylinder head.
NOTE
If the cylinder head is to be pressure checked, do not remove parts in steps (16) thru
(21).
(16) For models 7083-7396 and 7083-7399, remove eight studs (45) from outboard side of cylinder
head.
(16.1) For model 7083-7391, remove six studs (45) from outboard side of cylinder head.
(17) For models 7083-7396 and 7083-7399, remove five exhaust manifold studs (46) from right
cylinder head or eight exhaust manifold studs (46) from left cylinder head.
(17.1) For model 7083-7391, remove five exhaust manifold studs (46) from right exhaust manifold or
five studs (46) and four studs (46.1 ) from left exhaust manifold.
(18) For models 7083-7396 and 7083-7399, remove three pipe plugs (47) from outboard side of left
cylinder head.
(18.1) For model 7083-7391, remove four pipe plugs (47) from outboard side of right cylinder head.
NOTE
Model 7083-7391 has eight exhaust port seals in each cylinder head which seal the
exhaust gases from the air gap built within the head. These seals are reusable and
only need to be removed and replaced if damaged.
(18.2) For model 7083-7391, if necessary, remove eight exhaust port seals (47.1) from cylinder head.
(19) Remove cup plug (48) from rear of cylinder head. Discard plug.
(20) Remove fuse plug (49) from outboard side of cylinder head.
(21) Remove two pipe plugs (50) from ends of cylinder head.
5-38 Change 1
T M 9 - 2 8 1 5 - 2 0 2 - 3 4
5-39
Change
1
5-39
TM 9-2815-202-34
5-37.
CYLINDER HEAD REPAIR (Cont)
(22) Remove two pipe plugs (51) from ends of
cylinder head.
(23) Remove elbow (53) from solid plug (52) on
front of cylinder head.
(23.1) Using adaptor and slide hammer, remove
solid plug (52) from front of cylinder head.
Discard solid plug.
NOTE
•
Model 7083-7396 has restrictive
fitting on rear inboard side of left
cylinder head.
•
Model 7083-7399 has restrictive
fitting on rear inboard side of right
cylinder head.
•
Model 7083-7391 has restrictive fitting on front of right cylinder head.
(24) For models 7083-7396 and 7083-7399, remove restrictive fitting (54) from cylinder head.
(24.1)
5-40 Change
1
TM 9-2815-202-34
(25) For right cylinder head of model 7083-7396
and left cylinder head of model 7083-7399,
remove twelve pipe plugs (55) from
inboard side and ends of cylinder head.
For left cylinder head of model 7083-7396
and right cylinder head of model
7083-7399, remove thirteen pipe plugs (55)
from inboard side and ends of cylinder
head.
(25.1 ) For model 7083-7391, remove thirteen
pipe plugs (55) from inboard side and ends
of right cylinder head or fourteen from left
cylinder head.
■ (26) For models 7083-7396 and 7083-7399,
remove eight threaded plugs (56) from left
cylinder head or six plugs (56) from right
cylinder head.
(26.1) For model 7083-7391, remove six threaded plugs (56) from cylinder head.
(27) Remove elbow (57) from front of right cylinder head or two elbows (57) from front of left
cylinder head.
(28) Remove fitting (58) from front of right cylinder head or reducer (59) from front of left cylinder
(29) If necessary, remove two bushings (60) from cylinder head bolt holes.
(30) If necessary, remove two cup plugs (61) from front and rear of cylinder head. Discard cup
Change 1 5 - 4 1
TM9-2815-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
b. Cleaning
(1) Thoroughly clean cylinder head and cylinder head components (refer to Para 3-2).
(2)
Clean galleries in cylinder head using probes and brushes.
(3) If water passages are heavily coated with scale, remove injector tubes and water nozzles and
thoroughly clean water jacket areas.
c. Pressure Check Cylinder Head
NOTE
Before pressure checking cylinder head, cup plug (48), water manifold studs (45), two
pipe plugs (50), fuse plug (49), exhaust manifold studs (46), four exhaust manifold studs
(46.1) (left head only model 7083-7391, and three pipe plugs (47) (left head only
models 7083-7396 and 7083-7399) or our pipe plugs (47) (right head only model
7083-7391 ) must be in position.
(1) For models 7083-7396 and 7083-7399, position four gaskets (62) and four cover plates (63)
over studs (45) and secure with eight Iockwashers (64) and eight nuts (65). Torque nuts to
20-25 lb-ft (27-34 N-m).
(1.1) For model 7083-7391, position three gaskets (62) and three cover plates (63) over studs (45)
and secure with six washers (64) and six nuts (65). Torque nuts to 20-25 Ib-ft (27-34 N-m).
(2) Install scrap or dummy injectors to properly
seal injector tubes. Torque injector clamp
bolts to 20-25 Ib-ft (27-34 N-m).
5-42 C h a n g e
1
TM 9-2815-202-34
(3) Using cylinder head pressure testing kit,
install fabricated blocking plates (66) and
rubber gaskets to seal ten water holes on
fire deck. Secure with bolts, flat washers,
and nuts from kit. Torque bolts to 50-60
Ib-ft (71-47 N-m).
(4) Using cylinder head pressure testing kit,
install fabricated end plate (67) and gasket
over hole in front of cylinder head. Secure
with bolts from kit. Torque bolts to 30-35
Ib-ft (41-47 N-m).
(5) Attach a regulated air supply to end of
plate (67) and gradually apply pressure of
40 psi (276 kPa.1 ) to water jacket.
o
o
(6) Immerse cylinder head in a tank of water heated to 180 F-200 F (82oC-93oC) for twenty
minutes to heat head. Observe water in tank for bubbles which indicate a leak or crack. Check
for leaks at top and bottom of injector tubes, oil gallery, exhaust ports, fuel galleries, and at top
and bottom of cylinder head.
(7) Relieve air pressure and remove regulated air supply, injectors, end plate, and blocking plates
from cylinder head.
C h a n g e
1 5-43
TM 9-2815-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
d. Inspection/Repair
NOTE
If warpage exceeds limits, reface
cylinder head. Do not remove more
metal from fire deck than minimum
distance of 3.536 inches from top of
deck to bottom of fire deck.
(1) Cylinder head
(a) Check fire deck surface of cylinder
head for flatness. Using a straight edge
(68) and a set of feeler gages (69),
check lengthwise (six places) and
crosswise (five places) warpage.
Maximum lengthwise warpage is 0.008
inch and maximum crosswise warpage
is 0.004 inch.
(b) Inspect cam follower bores in cylinder
head for scoring and wear. Clean up
light score marks with crocus cloth wet
with fuel oil. Measure diameter of cam
follower body and cam follower bore to
determine clearance. Maximum
clearance is 0.006 inch. Replace
cylinder head if bores are excessively
worn or scored.
(2) Water nozzles
Check water hole nozzles (70 and 71) for
looseness. If necessary, replace nozzles
as follows:
(a) Remove old nozzle (70 or 71 ) and
clean bore in cylinder head.
(b) Position nozzle (70) in end bore or
nozzle (71 ) in inner bore as shown.
(c) Press nozzle (70 or 71 ) 0.003 inch
above to 0.010 inch below surface of
cylinder head.
5-44
Change 1
TM 9-2815-202-34
(3) Exhaust valve guides
Inspect valve guides for fractures, chipping, scoring, or excessive wear. ‘Measure inside
diameter of valve guide and diameter of valve stem to determine clearance between guide and
valve stem. If clearance exceeds 0.005 inch, replace valve guide, Replace valve guide as
follows:
(a) Support cylinder head, bottom side up,
on three inch thick wood blocks.
(b) Drive valve guide (72) out of cylinder
head with valve guide remover (73).
(c) Place cylinder head right side up on
bed of an arbor press.
(d) Position valve guide squarely in bore.
Using valve guide installer (74), press
into position until tool contacts cylinder
head.
(4) Valve bridge guides
(a) Inspect valve bridge guides for wear.
Replace guides as follows:
1. File or grind two opposite notches
0.06 inch deep in side of bridge
guide (18) approximately 1.25 inches
from top.
2. Using bridge guide remover set,
place spacer (75) over guide.
3. Slide guide remover (76) over guide
and aline set screws with notches
ground in guide. Tighten set screws
to secure guide remover in place.
4. Place spacer (77) over guide remover (76).
5. Thread nut (78) on guide remover and turn clockwise to withdraw guide from cylinder
head.
Change 1
5-45
TM 9-2815-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
(b) Remove broken valve bridge guides as
1. Center punch end of valve bridge
guide (18).
2. Drill hole 0.5 inch deep in end of
guide (18) with No. 3 (0.2130 inch)
drill bit.
3. Tap guide with 1/4-28 bottoming tap.
4. Thread bridge guide remover (79)
into tapped hole.
5. Attach slide hammer (80) to guide
remover (79) and remove guide.
(c) Install valve bridge guides as follows:
1. Apply a coat of sealant to bridge
guide (18).
2. Start guide (18) in cylinder head with
undercut end first.
3. Place bridge guide installer (81) over
guide (18) and drive into place.
Installer will position guide to correct
height (2.040 inches) in cylinder
head.
5-46 Change 1
TM9-2815-202-34
(5) Valve inserts
Inspect valve inserts for excessive wear, pitting, cracking, or improper seat angle. Replace
inserts as follows:
(a) Place cylinder head on wood blocks
with bottom side up.
(b) Using valve seat insert remover (82),
remove valve seat insert (83).
(c) Clean valve seat insert counterbore in
cylinder head and inspect for
concentricity, flatness, and cracks.
NOTE
Insert counterbore has a diameter of
1.2600 to 1.2610 inches and a depth
of 0.3380 to 0.3520 inch.
Counterbores must be concentric with
valve guides within 0.003 inch total
indicator reading.
(d) Immerse cylinder head in water heated
o
o
o
to 180 F-200 F (82°C-93 C) for 30
minutes or cool insert with liquid
nitrogen.
NOTE
Install insert in cylinder head while
head is still hot and insert is at room
temperature or when insert is chilled
and head is at room temperature.
(e) Place cylinder head on a bench with
bottom side up. Place insert in
counterbore with valve seat side facing
up.
(f)
Using valve seat insert installer (84),
drive insert in place until it seats solidly
in cylinder head.
C h a n g e
1 5-47
TM 9-2815-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
NOTE
Exhaust valve seat inserts are
prefinished. Only check inserts for
concentricity after installation. Grind
inserts only if runout exceeds 0.002
inch.
(g) Check exhaust valve seat inserts for
concentricity in relation to valve guides
using dial indicator (85).
(6) Valve seat insert grinding
Grinding inserts requires a valve seat
grinder (86) and valve seat grinder adapter
kit. Grind valve inserts as follows:
CAUTION
Do not permit grinding wheel to contact cylinder head when grinding insert. If an insert
has been ground until grinding wheel contacts cylinder head, then instaIl new insert.
(a) Apply 31 degree grinding wheel on valve seat insert.
(b) Grind throat of insert using 60 degree grinding wheel.
(c) Grind top surface of insert with 15 degree grinding wheel to narrow seat width to
dimensions shown in figure. If required, adjust the 31 degree face (87) of insert relative to
center of valve face (88) with 15 and 60 degree grinding wheels.
5-48 C h a n g e
1
TM 9-2815-202-34
NOTE
Maximum amount exhaust valve should protrude beyond cylinder head” and still
maintain proper piston to valve clearance is shown. Grinding reduces thickness of valve
seat insert and valve recedes into cylinder head. Replace valve seat insert if valve
recedes beyond limits.
(d) After grinding is completed, clean valve seat insert. Measure concentricity of insert in
relation to valve guide. If runout exceeds 0.002 inch, check for bent or worn valve guide
before regrinding insert.
(e) Determine position of contact area between valve and valve seat insert as follows:
1. Apply a light coat of Prussian blue or equivalent to valve seat insert.
2. Lower stem of valve in valve guide and bounce valve on seat, Do not rotate valve.
3. Observe area of contact on valve face. Most desirable area of contact is at center of
valve face.
(7) Exhaust valves and springs
(a) insure valve stems are free from
scratches or scuff marks. Valve faces
must be free of ridges, cracks, or
pitting.
(b) Replace valves if warped, excessively
worn, or pitted.
(c) Using spring tester (89), replace valve
spring (28) when a load of less than 25
pounds will compress it to 1.80 inches.
CAUTION
Replace both springs under an
exhaust valve bridge together. Mating
a new spring with a used spring can
cause unbalanced valve operation.
(8) Cam followers and cam follower springs.
(a) Examine cam follower springs (24) for
wear or damage. Using spring tester
(89), check spring load. Replace springwhen a load of Iess than 172 pounds
will compress it to a length of 2.125
inches.
Change 1
5-49
TM 9-2815-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
CAUTION
Do not use fuel oil to clean cam followers. It will wash away lubricating oil and cause
scoring of cam roller bushing at startup.
(b) Wash cam followers with engine oil and wipe dry. Examine cam follower rollers for pitting,
scoring, and flat spots. Rollers (90) must turn freely on their pins (91).
(c) Using a dial indicator and holding fixture, measure total diametric clearance on cam follower
roller. Secure cam follower assembly in a vise or other holding device and place dial
indicator needle against outside diameter of roller. Obtain total clearance by moving roller in
crosswise direction. Maximum clearance is 0.010 inch.
(d) Using a feeler gage, measure side clearance on cam follower. Insert gage between end of
roller and leg of cam follower body. Side clearance must be 0.015 to 0.023 inch.
(e) If necessary, install new cam follower rollers and pins as follows:
1. Clamp cam follower holding fixture (92) in a vise and place cam follower in groove at top
of assembly with cam follower pin resting on top of small plunger in holding assembly.
5-50
C h a n g e
1
TM9-2815-202-34
Restrain cam follower body and roller during removal from holder assembly
(92). Follower pin is seated on top of spring loaded plunger in holder
assembly and a sudden release could eject cam follower and cause injury to
personnel.
Remove any burrs on cam follower surfaces at pin holes prior to installing roller and pin
to prevent scoring of roller bushing and pin.
2. Drive pin (91) from roller (90) with a drift.
3. Position follower body in groove of holding assembly with small plunger extending
through roller pin hole in one leg of follower body.
4. Coat pin and roller with engine oil.
5. Position roller (90) in cam follower body (93). Plunger will extend into roller bushing and
assure accurate alinement of bushing with roller pin holes in follower body.
6. Start pin (91) squarely into follower body (93) and drive into position until pin is centered
in legs of follower.
7. Check side clearance between roller (90) and follower body. (93).
. . Clearance must be
between 0.011 and 0.023 inch.
(9) Rocker arms and shafts
Inspect rocker arm shafts and bushings for wear. Maximum shaft to bushing clearance is 0.004
inch.
Change
1 5-51
TM9-2815-202-34
5-37.
CYLINDER HEAD REPAIR (Cont)
(10) Injector tube
Replace injector tubes if cylinder head
leaked at injector tube during pressure test.
Replace injector tubes as follows:
(a) Place injector tube installer (94) in injector
tube (95).
(b) Insert pilot (96) through small hole in
injector tube and thread pilot in threaded
hole at end of installer (94).
(c) Tap end of pilot (96) to loosen injector
tube. Lift injector tube, pilot, and installer
from cylinder head. Discard injector tube
(95) and seal ring (97).
(d) Thoroughly clean injector tube hole in cylinder head to remove dirt, burrs, or foreign
material preventing tube from seating properly.
(e) Lubricate injector tube seal (97) with engine oil and place in counterbore of cylinder head.
NOTE
There are two injector tube installers, a fixed installer for the old style tube and an
adjustable installer for the current injector tube. The current tube has “606” stamped on
top flange.
For proper installation of current injector tube, the installer must contact bottom of
injector tube before it touches flange at top. Clearance at top, between flange and tool,
should be 0.001 to 0.010 inch.
(f)
Place installer (94) in injector tube (95).
Then insert pilot (96) through small hole in
injector tube and thread into tapped hole at
end of installer.
(g) Slip injector tube (95), installer (94), and
pilot (96) into injector bore and drive in
place.
5-52 C h a n g e
1
TM9-2815-202-34
(h) Upset lower end of injector tube as follows:
1. Turn cylinder head bottom side up and remove insert pilot (96). Thread upsetting die (98)
into tapped hole of installer (94).
2. Using socket and torque wrench,
apply 30 Ib-ft (41 N-m) torque to
upsetting die (98).
3. Remove upsetting
installer (94) from
NOTE
Reamer does not contact large diameter of current injector tube. Ream only at small
inside diameter and injector nut seat.
(i)
Ream injector tube as follows:
1. Clean injector tube and place
cylinder head right side up.
2. Apply few drops of cutting oil on
reamer flutes and carefully position
reamer (99) in injector tube (95).
Change 1
5-53
TM9-281-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
CAUTION
Turn reamer in clockwise direction only, both when inserting and when removing
reamer. Movement in opposite direction will dull cutting edges on flutes.
3. Turn reamer (99) clockwise (withdraw reamer frequently to remove chips) until lower
shoulder of reamer contacts injector tube (95). Clean out all chips.
4. Rotate cylinder head to bottom side up position. Insert pilot of tube tip refinisher (100) into
small hole of injector tube (95).
5. Apply few drops of cutting oil on refinisher (100). Using a socket and speed handle,
remove excess stock so lower end of injector tube is from flush to 0.005 inch below
finished surface of cylinder head.
6. Install gage (101) in injector tube. Using dial indicator gage (102), premeasure distance
from fire deck to gage. Reading must be within +/- 0.014 inch of fire deck.
7. Wash interior of injector tube (95) to prepare for second reaming operation.
5-54
C h a n g e
1
TM 9-2815-202-34
8. Apply few drops of cutting oil on bevel seat of injector tube (95). Lower reamer (103)
carefully into injector tube until it contacts bevel seat.
9. For the trial cut, turn reamer (103) steadily without applying any downward force on
reamer. Remove reamer, clean out chips, and observe bevel seat to see where seat was
cut.
10. Proceed with reaming and withdraw
tool occasionally to observe
progress.
11. Continue reaming until shoulder of
spray tip is within +/- 0.014 inch of
fire deck. Use gages (101 ) and (102)
to measure distance.
12. Wash interior of injector tube (95).
C h a n g e 1 5-55
TM 9-2815-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
e. Assembly
(1) If necessary, install two bushings (60) in
cylinder head bolt holes. Press flush to
0.02 inch below surface.
(1.1 ) Apply gasket cement to cup plug (61) and
install in front and rear of cylinder head.
(2) Apply gasket cement to solid plug (52) and
install at a 32 degree angle to the right of
perpendicular in front of right cylinder head
or 32 degrees to the left of perpendicular in
front of left cylinder head as shown.
(2.1 ) Install elbow (53) in solid plug (52) for right
cylinder head or left cylinder head.
(3) Install fitting (58) to front of right cyIinder
head or reducer (59) to front of left cylinder
head.
(4) Install elbow (57) to front of right cylinder
head or two elbows (57) to front of left
cylinder head.
(5) For models 7083-7396 and 7083-7399, install eight threaded plugs (56) in left cylinder head or
six plugs (56) in right cylinder head.
(5.1) For model 7083-7391, install six threaded plugs (56) in left or right cylinder head.
(6) For right cylinder head of model 7083-7396 and left cylinder head of model 7083-7399, install
twelve pipe plugs (55) in inboard side and ends of cylinder head. For left cylinder head of
model 7083-7396 and right cylinder head of model 7083-7399, install thirteen pipe plugs (55) in
inboard side and ends of cylinder head.
5-56 C h a n g e
1
TM 9-2815-202-34
(6.1) For model 7083-7391, install thirteen pipe
plugs (55) in inboard side and ends of right
cylinder head and fourteen pipe plugs (55)
in left cylinder head.
(7) Install two each of pipe plugs (50 and 51)
in ends of cylinder head. Plugs must be
flush to 0.18 inch below surface.
NOTE
Model 7083-7396 has restrictive
fitting on rear inboard side of left
cylinder head.
●
Model 7083-7399 has restrictive
fitting on rear inboard side of right
cylinder head.
●
Model 7083-7391 has restrictive fitting on front of right cylinder head.
50
(8) Install restrictive fitting (54) in cylinder head.
(8.1) For model 7083-7391, install fitting (54.1) in restrictive fitting (54) at fornt of right cylinder head.
Change
1 5-57
TM 9-2815-202-34
5-37.
CYLINDER HEAD REPAIR (Cont)
(9) Install fuse plug (49) in outboard side of cylinder head. Plug must be flush to 0.16 inch below
surface.
(10) Apply pipe sealant with teflon to cup plug (48) and install in rear of cylinder head.
(11) For models 7083-7396 and 7083-7399, install five exhaust manifold studs (46) in right cylinder
head or eight exhaust manifold studs (46) in left cylinder head. Torque studs to 25-40 Ib-ft
(34-54 N-m).
(11.1) For model 7083-7391, install five exhaust manifold studs (46) in right head or five exhaust
manifold studs (46) and four studs (46.1) in left cylinder head. Torque studs to 25-40 Ib-ft
(34-54 N-m).
(12) For models 7083-7396 and 7083-7399, install three pipe plugs (47) in outboard side of left
cylinder head.
(12.1) For model 7083-7391, install four pipe plugs (47) in outboard side of right cylinder head.
(13) For models 7083-7396 and 7083-7399, install eight water manifold studs (45) in cylinder head.
Torque studs to 10-25 Ib-ft (14-34 N-m).
(13.1) For model 7083-7391, install six water manifold studs (45) in cylinder head. Torque studs to
10-25 Ib-ft (14-34 N-m).
(14) Install eight washers (44) and eight fuel connectors (4) to cylinder head. Torque connectors to
40-45 Ib-ft (54-61 N-m).
(15) Install gasket (43), adaptor (42), two flat washers (41 ), and two bolts (40) to front inboard
corner of cylinder head. Torque bolts to 7-9 Ib-ft (10-12 N-m).
5 - 5 8
C h a n g e
1
TM 9-2815-202-34
(15.1) For model 7083-7391 only, if necessary, install eight exhaust port seals (47.1) in cylinder head.
Using hammer and exhaust seal installer (103.1), carefully tap seal in place.
NOTE
●
Models 7083-7396 and 7083-7391
contain four bolts (33), four flat
washers (34), two cover plates
(35), and two gaskets (36) per
head and no cover plate on rear
inboard corner.
●
Model 7083-7399 contains six
bolts (33), six flat washers (34),
three cover plates (35), and three
gaskets (36) per head.
(16) Install gaskets (36), cover plates (35), flat washers (34), and bolts (33) to remaining corners of
cylinder head. Torque bolts to 7-9 Ib-ft (10-12 N-m).
(17) If necessary for models 7083-7396 and 7083-7399, install support bracket (37), two
Iockwashers (39), and two bolts (3$) to right cylinder head. Torque bolts to 30-35 Ib-ft (41-47
N-m).
(18) Install sixteen exhaust valves as follows:
(a) Position cylinder head on its side. Lubricate valve stems with sulphurized oil (E. P. type) and
slide valves (32) all the way into guides (72).
NOTE
With used valves, install in their original location.
(b) Install lower spring seat (31 ), valve spring (28), and upper spring seat (30) over valve stem.
CAUTION
Avoid scoring valve stem with valve seat when compressing spring.
(c) Using valve spring compressor (27),
compress valve spring (28) and install
two piece tapered valve locks (29).
(d) Release pressure on valve spring
compressor (27) and remove tool.
(e) Repeat steps (a) thru (d) for remaining
valves.
(f)
Support cylinder head on wood blocks
at both ends (right side up). Give end of
valve stems a sharp tap with soft
headed hammer to seat valve locks
(29).
Change 1
5-59
TM 9-2815-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
(9) Using depth gage (102), measure
exhaust valve protrusion beyond fire
deck of cylinder head. If out of limits,
regrind or replace insert.
NOTE
●
Before installing cam followers,
immerse in Cindol 1705 oil heated
o
to 100°F-125°F (38 °C-52 C) for
one hour to insure initial lubrication
of cam roller pins and bushings.
Rotate cam rollers during soaking
period to purge air from bushing
and roller area.
●
Install used cam followers and
push rods in their original
locations.
(19) Assemble lower spring seat (26), cam
follower spring (24), upper spring seat (25),
and locknut (15) on twelve push rods (16).
(20) Install twelve cam follower spring retainers
(26) in cam follower bores from top of
cylinder head.
(21) Slide twelve push rod (16) assemblies in
position from bottom of cylinder head.
NOTE
Install cam followers with oil hole
directed away from exhaust valves.
(22) Slide twelve cam followers (23) in position
from bottom of cylinder head.
5-60 C h a n g e
1
TM 9-2815-202-34
CAUTION
Insure cam follower is not cocked in
cam follower bore. With cam follower
guide installed, bottom of cam
follower body must be flush with fire
deck.
(23) Attach four cam follower guides (21) to
cylinder head using eight Iockwashers (20)
and eight bolts (19). Torque bolts to 12-15
Ib-ft (16-20 N-m).
(24) Measure clearance between cam follower
guide (21) and cam follower legs using
feeler gages (104). Clearance must be at
least 0.005 inch.
(25) If clearance is insufficient, slightly loosen
bolts (19) and tap corners of guide (21)
with brass rod. Retorque bolts with proper
clearance.
C h a n g e 1 5-61
TM 9-281-202-34
5-37. CYLINDER HEAD REPAIR (Cont)
NOTE
• Injector rocker arm is different than exhaust valve rocker arms. Boss for rocker arm
shaft on right and left hand valve rocker arms is longer on one side. Extended boss
of each rocker arm must face toward injector rocker arm.
• If a new rocker arm is installed, also install a new push rod.
• Refer to Chapter 8 for push rod locknut adjustment during engine tune-up.
(26) Thread each rocker arm (11 ) on its push
rod (16) until end of push rod is flush with
inner side of clevis yoke.
Adjust valve bridges after cylinder
head disassembly or extended engine
operation.
(27) Adjust bridges as follows:
Do not loosen or tighten locknut with
bridge installed in cylinder head. Bent
bridge guide or rear valve stem may
result.
(a) Place valve bridge (17) in a vise or
bridge holding fixture and loosen
locknut (105) on bridge adjusting screw
(106).
5-62 Change 1
TM 9-2815-202-34
(b) Install valve bridge (17) on valve bridge
guide (18).
(c) While firmly pressing straight down on
pallet surface of valve bridge (17), turn
adjusting screw (106) clockwise until it
just touches valve stem. Then turn
screw an additional 1/8 to 1/4 turn and
tighten locknut (105) finger tight.
(d) Remove valve bridge and place in a
vise or holding fixture. Hold adjustment
screw (106) from turning with
screwdriver and torque locknut (105)
on adjusting screw to 20-25 Ib-ft (27-34
N-m).
(e) Lubricate valve bridge (17) and valve
bridge guide (18) with engine oil and
install bridge in original position.
(f)
Place 0.0015 inch feeler gage under
each end of valve bridge (17). When
pressing down on pallet surface of
valve bridge, both gages must be tight.
If both feeler gages are not tight,
readjust screw as outlined in steps (a)
thru (e).
Seat slot in valve bridges over
outboard exhaust vale stem to
prevent valve damage.
(28) Position eight valve bridges (17) on bridge
guides (18) with adjusting screw (106)
toward outboard side of engine.
Insure injector hold-down clamp does
not contact exhaust valve spring.
(29) Install four fuel injectors (3) in cylinder
head and secure in place with four clamps
(14), four washers (13), and four bolts (12).
Torque bolts to 20-25 Ib-ft (27-34 N-m).
Change
1 5-63
TM9-2815-202-34
5-37.
CYLINDER HEAD REPAIR (Cont)
CAUTION
Insure oil supply fitting (10) is installed
in throttle delay housing (5) or low oil
pressure will result in engine failure.
NOTE
Install special rocker arm shaft
bracket (5) containing throttle delay
housing at right bank No. 1 cylinder
on models 7083-7396 and
7083-7391. Model 7083-7391 does
not require an operational throttle
delay system.
(30) if necessary, install check valve (9) used
on model 7083-7396 and oil supply fitting
(1 O), used on models 7083-7396 and
7083-7391, into throttle delay housing (5).
(31) Apply engine oil to rocker arm shafts (7)
and slide shaft through rocker arms (11).
Place rocker shaft bracket (8) over each
end of shaft with finished face of bracket
toward rocker arm.
(32) Insert eight rocker arm bracket bolts (6)
through eight brackets (8) and four shafts
(7). Swing rocker arms, shafts, and
brackets in position and thread bolts in
cylinder head. Torque bolts to 90-100 Ib-ft
(122-136 N-m).
5-64
Change 1
TM 9-2815-202-34
CAUTION
• Do not bend fuel lines and do not
exceed specified torque on fuel
line nuts. Excessive tightening will
twist or fracture flared end of fuel
line and result in leaks.
• Never reuse fuel lines regardless
of their appearance. Always use
new fuel lines. Reused fuel lines
may not seal properly and result in
leaks.
(33) Remove caps from fuel injectors (3) and
connect four inlet fuel lines (1) and four
outlet fuel lines (2) to injectors and fuel
connectors (4). Using special socket,
torque fuel lines to 130-160 lb-in (14.7 -18.3
N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
5-6 Install water manifolds (7083-7396 and 7083-7399)
5.1-6 Install water manifolds (7083-7391)
5-5 Install lifting brackets
4-27 Install cylinder head
5.1-8 Install glow plugs (7083-7391)
5-38. OIL COOLER ASSEMBLY REPAIR
(See Para 4-39)
5-39. FUEL INJECTOR ASSEMBLY REPAIR
(See Para 4-40)
5-40. BLOWER REPAIR
(See Para 4-41)
C h a n g e 1 5-64.1
TM 9-2815-202-34
5-41. GOVERNOR REPAIR
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. -Assembly
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
7083-7391 7083-7396 7083-7399
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Governor cover bushing remover (App B, Item 78)
Governor cover bearing installer (App B, Item 77)
Governor cover bushing installer (App B, Item 53)
Torque wrench (App B, Item 101)
Sealant (App C, Item 38)
Grease (App C, Item 22)
Sealant (App C, Item 40)
Engine oil (App C, Item 16)
Cleaning solvent (App C, Item 10)
Bolt 5/1 6-24 x 3 (App C, Item 4)
EQUIPMENT CONDITION
Para Description
5-17 Governor removed from blower
MANDATORY REPLACEMENT PARTS
1 Seal ring (App F, Item 131)
1 Seal ring (App F, Item 132)
1 Gasket (App F, [tern 78)
1 Gasket (App F, Item 82)
1 Key washer (App F, Item 165)
1 Expansion plug (App F, Item 113)
1 Washer (App F, Item 161)
a. Disassembly
NOTE
● Before
and during disassembly of
governor, clean entire unit and
visually inspect for repairs of
worn or damaged parts not
requiring complete disassembly.
● If
remote control levers are on
governor cover, remove prior to
disassembly of cover.
(1) Remove eight screws (1) securing
governor cover (2) to governor (3).
Remove cover and gasket (4).
Discard gasket.
(2) Remove retaining ring (5) and two
washers (6) from stop lever shaft (7).
(3) Remove stop lever shaft (7) and
return spring (8) from governor cover
(2).
(4) Remove seal ring (9) from governor
cover (2). Discard seal ring (9).
5-64.2
Change 1
TM 9-2815 -202-34
(5) Remove spacer (10), retaining ring
(11), and two washers (12) from
speed control shaft (13).
(6) Remove speed control shaft (13) from
governor cover (2).
(7) Remove seal ring (14) from governor
cover (2). Discard seal ring (14).
(8) Support governor cover (2) on
wooden blocks in a press, top facing
down.
(9) Using bushing remover (15), remove
two control shaft bushings (16) from
governor cover (2).
(10) Place governor housing (3) in softjawed vise.
(11) Remove two bolts (17) and two flat
washers (18) securing access cover
(19) and gasket (20) to governor
housing (3). Discard gasket.
(12) Loosen retainer nut (21) and remove
high speed spring retainer (22),
retainer nut (21), and plunger (23)
assembly from governor housing (3).
(13) Remove low speed spring cap (24),
low speed spring (25) spring seat
(26), and adjusting pin (27) from
plunger (23).
(14) Using a socket head wrench, hold
screw (28) and loosen nut (29).
WARNING
High speed spring is under
pressure, and personal injury
could occur if downward
pressure Is not applied to
retainer.
(15) While applying pressure to high
speed spring (30), remove screw (28)
from plunger (23).
(16) Remove high speed spring (30) from
plunger (23).
5-65
TM 9-2815-202-34
5-41. GOVERNOR REPAIR (Cont)
(17) Remove plug (31) and gasket (32).
Discard gasket.
(18) Bend tang of key washer (33) away
from retainer bolt (34).
(19) While holding weight carrier (35),
remove retainer bolt (34), washer (36)
and key washer (33). Discard key
washer.
(20) Thread a 5/16-24 x 3 inch bolt (37)
into hole for retainer bolt (34).
(21) Remove governor housing (3) from
vise.
(22) Place governor housing (3) on a flat
surface with bolt (37) facing up. Tap
weight carrier shaft (38) out of bearing
(39) with a soft-headed hammer.
(23) Slide riser bearing (40) and riser (41 )
off weight carrier shaft (38).
NOTE
Inspect weight carrier bearing in
governor housing to determine
need for removal.
(24) If necessary, remove weight carrier
bearing (39) from governor housing
(3). Use a small brass rod and
hammer to tap bearing from inside
housing.
(25) Matchmark two high speed and two
low speed weights (42 and 43) to
weight carrier (44).
(26) Remove four retaining rings (45).
(27) Press two pins (46) from weight
carrier (44) and remove two washers
(47), two high speed weights (42),
and low speed weights (43).
(28) Using bearing remover (48), sleeve
(49) and arbor press, remove needle
bearing (50) from one high speed
weigh{; Repeat procedure for
other high speed weight.
5-66
TM 9-2815 -202-34
(29) Using an arbor press, remove carrier shaft (51) from weight carrier (44) by placing spline end
into a sleeve (52) having a one-inch hole.
(30) Remove retaining clip (53) and washer (54) from differential lever pin (55) and remove
operating lever connecting link (56).
(31) Remove retaining clip (57) and washer (58) from operating lever pin (59). Remove
differential lever (60) from operating lever (61).
(32) If damaged, remove pin (55) from differential lever (60).
(33) For models 7083-7391 and 7083-7396, remove two springs (62) and two retainer clips (63).
Separate governor links (64 and 65) and remove pin (66).
(34) Loosen locknut (67) and remove buffer screw assembly (68).
(35) Remove screw and washer assembly (69) and locking clip (70) securing operating lever
shaft (71) to governor housing (3).
(36) Remove operating lever shaft (71), control link operating lever (72) and two washers (73).
(37) If bearings are damaged, support control link operating lever (72) on sleeve and rest sleeve
on bed of arbor press. Place bearing remover (48) on top of bearing (74) and press two
bearings (74) out of operating lever (72).
Change
1 5-67
TM 9-2815-202-34
5-41. GOVERNOR REPAIR (Cont)
(38) Remove expansion plug (75) from bottom of governor housing (3). Discard expansion plug.
(39) Remove operating shaft upper bearing retainer screw and washer assembly (76) and flat
washer (77) securing bearing in governor housing (3).
(40) Place governor housing (3) in press, bottom side up.
(41) Press operating shaft (78) out of lower bearing (79) located in governor housing (3).
(42) Place a 9/16-inch open end wrench (80) under operating fork (81) and press fork off
operating shaft (78).
(43)
Remove spacer (82), operating shaft (78), upper operating lever bearing (83), and operating
Iever (61) from governor housing (3). Slide spacer (82) from shaft (78).
When pressing operating shaft from operating lever and bearing, catch shaft by hand to
prevent it from falling and being damaged.
(44) Press operating shaft (78) from upper bearing (83) and operating lever (61).
(45) Loosen locknut (84) and remove
adjusting screw (85).
(46) If damaged, remove pin (59) from
operating lever (61 ).
(47) Press lower bearing (79) from
governor housing (3).
(48)
For models 7083-7391 and 7083-7396
---only, hold starting aid screw (86) and
remove nut (87) from governor housing (3).
External starting aid screw is
removed by screwing inward
through governor housing.
Removing the screw outward
through the governor housing will
damage the threads in the housing
due to oversize button on end.
(49) For models 7083-7391 and 7083-7396
only, remove external starting aid screw
(86) through governor housing (3) by
turning screw clockwise.
5-68 C h a n g e 1
TM 9-2815-202-34
b.
Cleaning/Inspection
WARNING
●
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do
not
o
useo nearo open flame or excessive heat. The flash point is 100 F-138°F
(38 C-50 C). If you become dizzy while using cleaning solvent, get
fresh air immediately and get medical aid. If contact with eyes is made,
wash your eyes with water and get medical aid immediately.
●
Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves, etc.).
(1) Clean all parts with dry cleaning solvent and dry with compressed air. Inspect all parts.
(2) Inspect all bearings and shafts for corrosion, pitting, rough spots and excessive wear.
(3) Inspect governor housing for cracks, warpage, and damaged threads.
(4) Inspect governor weights after assembly for free movement.
(5) Inspect governor cover for cracks, wear on pins, or shaft deflection.
c. Assembly
(1)
For models 7083-7391 and 7083-7396
only, install external starting aid screw (86)
through inside of governor housing (3) and
secure nut (87) on outside of governor
housing.
(2) If removed, install pin (59) in
operating lever (61).
(3) Install adjusting screw (85) and
locknut (84) in operating lever (61).
(4) Coat inside diameter of operating
shaft upper bearing (83) with engine
oil. Using an arbor press, install upper
bearing (83), numbered side up, on
large end of operating shaft (78).
(5) Using an arbor press, install
operating lever (61 ), with pin (59)
facing up, onto operating shaft (78),
alining flat on lever with flat on shaft,
until flush with operating shaft (78).
(6) Install spacer (82) onto operating
shaft (78).
Change
1 5-69
TM 9-2815-202-34
5-41. GOVERNOR REPAIR (Cont)
(7) Insert end of governor operating shaft
(78), bearing (83), spacer (82),and
operating lever (61) through upper
bearing bore in governor housing (3)
with operating fork (81) facing rear of
governor housing.
(8) Place governor housing (3) in press
with top facing down.
(9) Place a support (88) under operating
shaft (78) and press operating fork
(81 ) until spacer (82) does not move
up or down.
(10) Lubricate operating shaft upper
bearing (83). with engine oil and seat
bearing in governor housing (3).
Install screw and washer assembly
(76), and washer (77) to secure
bearing.
(11) Lubricate lower bearing (79) with
engine oil and start bearing into
governor housing (3) on operating
shaft (78).
(12) Place a 7/16-inch inside diameter
sleeve on inner race of lower bearing
(79). Using arbor press, install
bearing on operating shaft (78) until
bearing seats on shoulder in
governor housing (3).
(13) Apply a thin coat of sealant to edge of
expansion plug (75).
(14) Using a ballpeen hammer, tap
expansion plug (75), convex side up,
into governor housing (3).
(15) If removed, lubricate outside of two control
link operating lever bearings (74) with
engine oil and lubricate inside bearings
with grease. Using bearing installer (48),
press one bearing into control link
operating lever (72) until flush with top
lever. Reverse operating lever (72) and
install second bearing (74) in same
manner.
5-70
Change 1
TM 9-2815-202-34
(16) Insert control link operating Iever (72)
and two washers (73) between two
bosses inside governor housing (3).
(17) Install operating lever shaft (71) with
grooved end up.
(18) Install locking clip (70) and screw and
washer assembly (69) securing
operating lever shaft in governor
housing (3). Tighten screw (69)
securely.
(19) Install buffer screw assembly (68) and
locknut (67).
(20) Place governor housing (3) in softjawed vise.
(21) For models 7083-7391 and 7083-7396
only, assemble pin (66), governor link (64),
and link (65) together. Install two retainer
clips (63) and two springs (62).
(22) If removed, install pin (55) into
differential lever (60).
(23) Install differential lever (60), washer
(58), and spring clip (57) on operating
lever (61 ) with slot facing rear of
governor housing (3).
(24) Install operating lever connecting link
(56) on differential lever (60) and
secure with washer (54) and retaining
clip (53) to pin (55).
(25) Using an arbor press and one-inch
inside diameter sleeve, press weight
shaft (51) into weight carrier (44) until
shoulder of weight shaft is seated in
carrier.
NOiTE
When installing weights, insure
matchmarks made at disassembly
are alined.
(26) Lubricate outside diameter of needle
bearing (50) with engine oil and
inside diameter with grease. Using
bearing installer (48), sleeve (49) and
arbor press, install needle bearing
(50) into high speed weight (42).
Repeat procedure for other high
speed weight (42).
C h a n g e 1 5-71
TM 9-2815-202-34
5-41. GOVERNOR REPAIR (Cont)
CAUTION
Maintain 0.004- 0.012-inch clearance between carrier and low speed weight;
otherwise, low speed weight will bind causing erratic operation of governor.
(27)
Install retaining clip (45) on one end of weight pin (46). Slide weight pin through weight
carrier (44), washer (47), and high speed weight (42). Place low speed weight (43) in
position, insert a 0.004 - 0.012-inch shim between low speed weight and weight carrier
while pressing weight pin through weight carrier. Press until retaining clip bottoms against
carrier.
(28) Remove shim and install second retaining clip (45).
(29) Repeat steps (27) and (28) to install opposite side weights in carrier (44).
(30)
Install riser (41) on weight carrier
shaft (38).
NOTE
Incorrect installation of riser thrust
bearing will result in erratic
operation of governor.
(31) Install riser bearing (40) with smaller
inside diameter against riser (41) on
weight carrier shaft (38).
(32) Insert weight carrier assembly (35) in
governor housing (3). Support
splined end of shaft and governor
housing on arbor press bed.
(33) Place weight carrier bearing (39) in
governor housing (3) with number
side up. Place a 0.5-inch diameter
sleeve on top of inner race of weight
carrier bearing (39) and press into
governor housing (3) and against
shoulder on carrier shaft (38).
(34) Clamp spline end of weight shaft (38)
in soft-jawed vise.
5-72
TM
9-2815-202-34
(35) Place key washer (33) on end of
carrier shaft (38) with tang on inner
diameter of washer in notch in end of
carrier shaft (38).
(36) Install washer (36) and retaining bolt
(34). Torque bolt to 15-19 Ib-ft (20-26
N-m). Bend tang on key washer (33)
against head of bolt.
(37) Install washer (32) against bearing
(39).
(38) Apply sealant to threads of plug (31)
and install in governor housing (3).
Torque plug to 45 Ib-ft (61 N-m).
(39) Thread retainer nut (21 ) onto retainer
(22) 1.5 inches. Install high speed
spring (30) on plunger (23) and insert
into retainer (22).
(40) Thread screw (28) 0.5 inch, through
retainer (22), into threaded end of
plunger (23) and install nut (29) onto
screw (28) until it contacts end of
plunger.
(41) Insert low speed spring (25) into low
speed spring cap (24).
(42) Place small end of spring seat (26)
into low speed spring (25). Place
adjusting pin (27) into spring seat.
(43) Install adjusting pin (27), spring seat
(26), low speed spring (25), and low
speed spring cap (24) into plunger
(23).
(44) Place gasket (20) on shoulder of
retainer nut (21 ) and install high
speed spring retainer (22) and
plunger (23) assembly into governor
housing (3) 1.0 inch. Tighten retainer
nut.
(45) Fasten access cover (19) to governor
(3) with two bolts (17) and two flat
washers (18). Tighten bolts.
(46) Place governor cover (2) in press with
top facing up.
(47) Using bushing installer (90), press
two bushings (16), numbered side up,
into governor cover (2) until flush.
5-73
TM 9-2815-202-34
5-41. GOVERNOR REPAIR (Cont)
(48) Lubricate inside of two bushings (16)
with grease.
(49) Place stop lever return spring (8) over
boss on inner face of governor cover
(2).
(50) Insert stop lever shaft (7) part way
through hole in governor cover (2)
and hook end of return spring (8) over
end of lever. Push shaft up in cover.
(51) Position stop lever (7) against stop
pin (91 ), opposite spring (8).
(52) Install seal ring (9), two washers (6),
and retaining ring (5) securing stop
lever to governor cover (2).
(53) Install speed control shaft (13) into
governor cover (2) between two pins
(92).
(54) Install seal ring (14), two washers
(12), and retaining ring (11) securing
speed control shaft to governor cover
(2).
(55) Install spacer (10) on speed control
shaft (13).
NOTE
If remote control levers were
removed during disassembly of
governor cover, reinstall levers.
(56) Install governor cover (2) and gasket
(4) on governor (3). Secure with eight
screws (1) and tighten screws.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
5-17 Install governor on blower
5-42. WATER PUMP REPAIR
5-74
(See para 4-43)
TM 9-2815-202-34
CHAPTER 5.1
REPAIR PROCEDURES FOR MAJOR COMPONENTS OF
ENGINE MODEL 7083-7391
Contents
Para
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-1
Turbocharger and Oil Line Removal/lnstalIation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-2
Exhaust Manifold and Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1-3
Fuel Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-4
Engine Lifting Brackets Repacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-5
Engine Water Manifolds Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-6
Water Pump Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1-7
Glow Plug Controller and Harnesses Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-8
Engine Rocker Arm Cover and Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-9
Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-10
Air Inlet Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-11
Tachometer Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-12
Block Mounted Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-13
5.1-14
Accessory Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Shaft and Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-15
Governor Cover and Throttle Control Rod Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-16
Governor and Blower Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-17
Blower Drive Gear and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-18
Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-19
Camshaft Front Gear Cover and Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-20
Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-21
Rear Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-22
Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-23
Idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-24
Injector Control Tube and Throttle Delay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-25
Cylinder Head Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-26
Engine Lower Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-27
Camshaft and Gear Assemblies Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-28
Cylinder Block End Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-29
Oil Pressure Regulator and Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-30
Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-31
Piston and Connecting Rod Maintenance (Cross-Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-32
Cylinder Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-33
Crankshaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-34
Cylinder Block Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-35
Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-36
Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-37
Oil Cooler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-38
Fuel Injector Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-39
Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-40
Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-41
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-42
Change 1
Page
5-76
5-77
5-77
5-78
5-81
5-82
5-83
5-84
5-86
5-86
5-87
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-92
5-93
5-93
5-93
5-93
5-94
5-102
5-102
5-102
5-102
5-102
5-102
5-75
TM 9-2815-202-34
Section I. INTRODUCTION
5.1-1. GENERAL. This chapter provides the repair procedures performed on engine model 7083-7391
after the engine has been installed on the maintenance stand. Component replacement typically
consists of removal, disassembly, cleaning/inspection, repair, assembly, and installation of the
component. Next, the engine block maintenance consists of disassembly, inspection, repair, and
assembly of the block components. For major components, the repair is handled separately from
removal and installation. Component repair usually consists of disassembly, cleaning/inspection, and
assembly.
This chapter deals with model 7083-7391. However, if a model in a previous chapter has identical or
nearly identical components, this chapter will refer to that previous chapter. If a model in a subsequent
chapter has identical or nearly identical components, this chapter will also cover that models.
5-76 C h a n g e
1
TM 9-2815-202-34
Section Il. GENERAL ENGINE MAINTENANCE
5.1-2. TURBOCHARGER REMOVAL/INSTALLATION
(See Para 5-2)
5.1-3. EXHAUST MANIFOLD AND TUBE REPLACEMENT
(See Para 5-3)
C h a n g e
1 5-77
TM 9-2815-202-34
5.1-4. FUEL LINES REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
TOOLS AND SPECIAL TOOLS
7083-7391
General Mechanics Tool Set (App B, Item 96)
Torque wrench (App B, Item 100)
Torque wrench (App B, Item 101)
a. Removal
(1) Remove bolt (1) and flat washer (2) securing fuel supply line clip (3) to front of governor cover
(4). Reinstall bolt and flat washer in governor cover.
(2) Disconnect fuel supply line (5) at elbow (6) on front of left cylinder head.
(3) Remove nut (7), Iockwasher (8), flat washer (9), and bolt (10) securing fuel supply line clamp
(11 ) at right side rear of front cover and remove fuel line. Reinstall bolt, flat washer, Iockwasher
and nut in front cover.
(4) If necessary, remove clamp (11 ), clip (3), and coupling (12) from fuel supply line (5).
(5) Remove bolt (13) and flat washer (14) attaching fuel crossover line clip (15) to front of governor
cover (4). Reinstall bolt and flat washer in governor cover. If necessary remove clip from
crossover line.
5-78
Change 1
TM 9-2815-202-34
(6) Disconnect fuel crossover line (16) at
outboard elbow (17) on front of left
cylinder head and at outboard elbow
(18) on front of right cylinder. Remove
fuel crossover line.
(7) Remove bolt (19) and flat washer (20)
attaching fuel return line clip (21) to
rear of governor cover (4). Reinstall bolt
and flat washer in governor cover.
(8) Remove bolt (22) and Iockwasher (23)
securing fuel return clamp (24) to
engine lifting bracket at rear of left
cylinder head. Reinstall bolt and
Iockwasher in lifting bracket.
(9) Disconnect fuel return line (25) at adaptor fitting (26) on front of right cylinder head. Remove
fuel return line.
(10) Remove bolt (27) and Iockwasher (28) securing clip (29) on fuel return line (25) to left side
by-pass valve cover (30). Remove fuel return line and reinstall bolt and Iockwasher.
(11) If necessary, remove clamp (24) and clips (21 and 29) from fuel return line (25).
C h a n g e
15-79
TM 9-2815-202-34
5.1-4. FUEL LINES REPLACEMENT (Cont)
b. Installation
(1) Connect end of fuel return line (25) to adaptor fitting (26) at front of right cylinder head and
tighten connection.
(2) lf removed, install clips (21 and 29) and clamp (24) on fuel return line (25).
NOTE
● For
all lines attached to governor cover, drape and clip lines around governor cover.
Do not mount lines overtop of cover.
● Route
fuel return line under turbocharger air inlet tube between blower and left
cylinder head toward rear of engine.
(3) Secure clip (21) on fuel return line (25) to rear of governor cover (4) by removing bolt (19) and
flat washer (20) from governor cover. Torque bolt to 7-9 Ib-ft (1 0-12 N-m).
(4) Secure clip (29) to left side by-pass valve cover (30) by removing bolt (27) and Iockwasher (28)
from by-pass valve cover. Torque bolt to 84-108 lb-in (9-12 N-m).
(5) Secure clamp (24) of fuel return line (25) to lifting bracket at rear of left cylinder head by
removing bolt (22) and Iockwasher (23) from lifting bracket. Torque bolt to 40-50 Ib-ft (62-68
N-m).
5-80
Change 1
TM 9-2815-202-34
(6) If removed, install clip (15) on fuel crossover line (16). Connect fuel crossover line to outboard
elbows (18) and (17) at front of right and left cylinder heads. Tighten connections.
(7) Secure clip (15) on fuel crossover line (16) to front of governor cover (4) by removing bolt (13)
and flat washer (14) from governor cover. Torque bolt to 7-9 Ib-ft (10-12 N-m).
(8) If removed, install pipe coupling (12), clamp(11) and clip (3) on fuel supply line (5).
(9) Connect fuel supply line (5) to elbow (6) at front of left cylinder head. Tighten connection.
(10) Secure clamp (11) on fuel supply line (5) to right side rear of front cover by removing nut (7),
Iockwasher (8), flat washer (9), and bolt (10). Torque bolt to 30-35 Ib-ft (41-47 N-m).
(11 ) Secure clip (3) on fuel supply line (5) to front of governor cover (4) by removing bolt (1) and flat
washer (2) from governor cover. Torque bolt to 7-9 Ib-ft (10-12 N-m).
END OF TASK
5.1-5. ENGINE LIFTING BRACKETS REPLACEMENT
(See Para 5-5)
Change
1 5-81
TM
9-2815-202-34
5.1-6. ENGINE WATER MANIFOLDS REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7391
12 Lockwashers (App F, Item 93)
6 Gaskets (App F, Item 71 )
EQUIPMENT CONDITION
TOOLS AND SPECIAL TOOLS
General Mechanics Tool Set (App B, Item 96)
Torque wrench (App B,Item 101)
Para Description
3-7 Oil level gauge rod removed
3-14 Air Inlet manifold removed
5.1-2 Turbocharger removed
5.1-3 Exhaust manifolds removed
5.1-8 Glow plug harness clips removed
a. Removal
(1) Disconnect tube assembly (1) at upper fitting (2) on right water manifold (3) and at elbow fitting
(4) on top of water pump (5). Remove tube assembly.
(2) Disconnect tube assembly (6) at lower fitting (7) on right water manifold (3) and at elbow fitting
(8) on front of right cylinder head. Remove tube assembly.
(3) Remove six nuts (9) and six Iockwashers (10) securing water manifold (3) to right cylinder
head. Discard lockwashers and remove water manifold.
(4) Remove three gaskets (11 ) from bottom of water manifold or top of cylinder head. Discard
gaskets.
(5) If necessary, remove four fittings (2, 7, 12, and 13) from end of water manifold (3) and three
plugs (14) and plug (15) from water manifold.
(2) thru (4) move for left water manifold (3). If necessary, remove two fittings (7
(6) Repeat
.-. steps
.
and 13), four plugs (14) and plug (15) from left water manifold.
b. Installation
(1) If removed, install four fittings (2, 7, 12, and 13) in front of right water manifold (3) and three
plugs (14) and plug (15) at rear of manifold.
(2) Install three gaskets (11 ) over studs (16) on right cylinder head.
(3) Install water manifold (3) on right cylinder head and secure with six Iockwashers (10) and six
nuts (9). Torque nuts to 20-25 Ib-ft (27-34 N-m).
(4) Connect tube assembly (1) at elbow fitting (4) on water pump (5) and at upper fitting (2) on
right water manifold (3). Tighten connections.
(5) Connect tube assembly (6) at elbow fitting (8) on front of cylinder head and at lower fitting (7)
on right water manifold (3). Tighten connections.
5-82
Change 1
TM 9-2815-202-34
5.1-7
14
●
●
IGHT BANK
FRONT
●
*
14
14
LEFT
RE
(6] if removed, install two fittings (7 and 13), four plugs (14) and plug (15) in left water manifold (3).
#
(7) Repeat steps (2) and (3) above for left water manifold.
&
(8) Connect tube assembly (6) at elbow fitting (8) on front of cylinder head and at lower fitting (7)
on left water manifold (3). Tighten connections.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
8 Install glow plug harness clips
Install exhaust manifolds
e2 Install turbocharger
3-14 Install air inlet manifold
3-7 Install oil level gauge rod
@
. WATER PUMP REMOVAIJINSTALLATION
(See Para 5-7)
Change 1
5-83
TM 9-2815-202-34
5.1-8. GLOW PLUG CONTROLLER AND HARNESSES REMOVAL/iNSTALLATION
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7391
5 Lockwashers ((App F,ltem 92)
2 Lockwashers (App F,ltem 91)
1 Lockwasher (App F,ltem 93)
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 100)
Para Description
3-8 Glow plug power harness disconnected
from starter
a. Removal
(1) Remove nut (1), Iockwasher (2) and flat washer (3), securing clip (4) and glow plug power
harness (5) to bolt (6) on flywheel housing (7). Discard lockwasher. If necessary, remove clip
from harness.
(2) Disconnect and remove glow plug power harness (5) from rear left side of glow plug controller
(8).
(3) Remove three bolts (9), three
Iockwashers (10), and three flat
washers (11) securing three clips (12)
on glow plug harness (13) to left side
water manifold (14). Discard
Iockwashers.
(4) Disconnect four plug ends (15) of glow
plug harness (13) at glow plugs (16) in
left cylinder head.
(5) Remove four glow plugs (16) from left
cylinder head.
(6) Remove two bolts (9), two Iockwashers
(10), and two flat washers (11) securing
two clips (12) on glow plug harness (13)
to right side water manifold (14).
Discard Iockwashers.
(7) Repeat steps 4 and 5 above for
opposite side.
(8) Disconnect and remove glow plug
harness (13) from rear right side of glow
plug controller (8).
(9) If necessary, remove five clips (12) from
glow plug harness (13).
5-84
Change 1
TM9-2815-202-34
(10) Remove two bolts (17), two Iockwashers (18), two flat washers (19), and glow plug controller
(8) from rear of air inlet housing (20). Discard Iockwashers.
b. Installation
(1) Secure glow plug controller (8) to rear of air inlet housing (20) with two flat washers (1 9), two
Iockwashers (18), and two bolts (17). Torque bolts to 84-108 lb-in (9-12 N-m).
(2) If removed, install three clips (12) on left side or two clips on right side of glow plug harness
(13).
(3) Attach plug connection end of glow plug harness (13) to rear right side connector on glow plug
controller (8). Tighten securely.
(4) Install four glow plugs (16) in left cylinder head. Torque glow plugs to 11-13 Ib-ft (15-18 N-m).
Glow plug harness leads are identified with location near ends of wires. Correct
installation of wires is necessary for proper diagnostics to aid in locating a failed glow
plug.
(5) Install four plug ends (15) of glow plug harness (13) to corresponding glow plug (16) locations
in cylinder head.
(6) Attach glow plug harness (13) to left side water manifold (14) by securing three clips (12) with
three flat washers (11), three Iockwashers (10), and three bolts (9). Torque bolts to 13-17 Ib-ft
(18-23 N-m).
(7) Attach glow plug harness (13) to right side water manifold (14) by securing two clips (12) with
two flat washers (11 ), two Iockwashers (10), and two bolts (9). Torque bolts to 13-17 Ib-ft
(18-23 N-m).
(8) Repeat steps (4) and (5) above for opposite side.
Change 1
5-85
TM9-2815-202-34
5.1-8.
GLOW PLUG CONTROLLER AND HARNESSES REMOVAL/INSTALLATION (Cont)
(9) Attach plug connection end of glow plug power harness (5) to left side connector on glow plug
controller (8). Tighten securely.
(10) Attach glow plug power harness (5) to left side rear of flywheel housing (7) by securing clip (4)
to bolt (6) with flat washer (3), Iockwasher (2), and nut (1). Torque nut to 25-30 Ib-ft (34-41
N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
3-8 Connect glow plug power harness to starter
5.1-9. ENGINE ROCKER ARM COVER AND CRANKCASE BREATHER
REPLACEMENT
(See Para 4-11)
5.1-10. FUEL PUMP REPLACEMENT
(See Para 4-12)
5-86 C h a n g e
1
TM9-2815-202-34
5.1-11. AIR INLET HOUSING REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning/Inspection
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
7083-7391
Cleaning solvent (App C, Item 10)
Hex nut 3/8-1 6 (App C, Item 47)
Flat washer 3/8 (App C, Item 48)
Engine oil (App C, Item 16)
Teflon pipe sealant (App C, Item 49)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 100)
Torque wrench (App B, Item 101)
Piston ring compressor (App B, Item 103)
Threaded rod (App D, Item 13)
MANDATORY REPLACEMENT PARTS
8 LockWashers (App F, Item 91 )
12 LockWashers (App F, Item 94)
2 Gaskets (App F, Item 176)
1 Gasket (App F, Item 177)
EQUIPMENT CONDITION
Para Description
3-3 Air inlet tube removed
5.1-4 Fuel return line clip removed from
by-pass valve cover
5.1-8 Glow plug controller removed
(1)
(2)
(3)
C h a n g e 1 5-87
TM9-2815-202-34
5.1-11. AIR INLET HOUSING REPLACEMENT (Cont)
b. Disassembly
(1) Secure air inlet housing assembly (5) in soft-jawed vise with side of by-pass valve cover (9)
facing upward.
(2) Remove elbow fitting (2) from by-pass valve cover (9).
Firmly secure spring-loaded mechanisms during disassembly. The spring can
eject parts at high speed if released in an uncontrolled manner. Personal injury
may result.
(3) Insert threaded rod (10) through hole in
by-pass valve cover (9), then thread rod
into by-pass valve assembly (11)
located in air inlet housing. Install 5/16
inch flat washer (12) and 5/1 6-18 inch
hex nut (13) on threaded rod and
tighten to compress spring (14) between
cover and by-pass valve assembly.
(4) Remove four bolts (15) and four
Iockwashers (16) securing cover (9) to
air inlet housing (5). Discard
Iockwashers.
(5) Remove cover (9) and valve assembly
(11), while under compression with
threaded rod (10).
(6) Remove nut (13), flat washer (12),
cover (9), gasket (17), and spring (14)
from by-pass valve assembly (11 ).
Remove threaded rod (10) from by-pass
valve.
(7)
Place by-pass valve assembly (11) on
bench with ring side up and remove ring
(18).
(8) Repeat steps 1 thru 7 above for
opposite side of air inlet housing (5).
5-88
Change 1
TM 9-2815-202-34
c. Cleaning/Inspection
•
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles
and gloves and use in a well-ventilated area. Avoid contact with skin, eyes, and
clothes. Do not breathe vapors. Do not use near open flame or excessive
heat. The flash point is 100-138°F (38-50°C). If you become dizzy while using
cleaning solvent, get fresh air immediately and seek medical aid. If contact
with eyes is made, wash with water and get medical aid immediate y.
• Compressed air used for cleaning purposes will not exceed 30 PSI. Use only
with effective chip guarding and personal protective equipment (goggles/
shield, gloves, etc.)
(1) Clean air inlet housing and valve with
cleaning solvent and dry with
compressed air.
(2) Inspect air inlet housing for cracks,
warpage, scoring or other damage.
(3) Check by-pass valve for scores or ring
groove damage. Replace any valve
severely scored or damaged.
(4) Check ring for chips or scoring. Replace
any ring chipped, scored or severely
damaged.
d. Assembly
(1) Install ring (18) in groove of by-pass
valve (11). Lubricate by-pass valve, ring
and by-pass valve bore with engine oil.
(2) Secure one side of air inlet housing (5),
in soft-jawed vise, with valve bore facing
upward.
(3) Use a piston ring compressor (19) to
compress ring (18) on by-pass valve
assembly (11). Install valve, with ring
side facing up, in bore of air inlet
housing (5) by lightly tapping valve with
handle end of hammer.
Change 1
5-89
TM9-2815-202-34
5.1-11. AIR INLET HOUSING REPLACEMENT (Cont)
(4) Screw threaded rod (10) into by-pass
valve (11). Install spring (14) in valve,
and place gasket (17) over valve bore
on air inlet housing (5). Place hole in
cover (9) over threaded rod , with words
“OUT” facing outward. Install 5/1 6 inch
flat washer (12) over rod. Using 5/1 6-18
hex nut (13) compress spring so cover
is within 1/4 inch of air inlet housing.
(5) Aline gasket (17) and cover (9) with four
holes in air inlet housing (5). Install four
bolts (15) and four Iockwashers (16)
and secure cover and gasket to
housing. Torque bolts to 84-108 lb-in
(9-12 N-m).
(6) Remove nut (13), flat washer (12) and
threaded rod (10) from cover (9).
(7) Apply sealant to threads of elbow fitting
(2) and install in by-pass valve cover (9)
so end of fitting faces rear and
downward at approximately 7:00
O’clock position for the right side cover.
(8) Repeat steps (1) thru (6) for opposite
side.
(9) Apply sealant to threads of elbow fitting
(2) and install in by-pass valve cover (9)
so end of fitting faces rear and
downward at approximately 4:00
O’clock position for the left side cover.
(10) Remove air inlet housing assembly (5)
from soft-jawed vise.
5-90 C h a n g e
1
TM 9-2815-202-34
e. Installation
(1) Install air inlet housing assembly (5) and gasket (8) on blower. Secure with twelve bolts (6) and
twelve Iockwashers (7). Torque bolts to 42-48 Ib-ft (57-65 N-m).
(2) Install two clamps (1) on hose (4). Attach one end of hose to elbow fitting (2) on right side
bypass valve cover (9) and attach other end of hose to fitting (3) on cylinder head. Slide clamps
onto fittings and secure hose.
(3) Repeat step (2) above for opposite side.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
3-3 Air inlet tube installed
5.1-8 Glow plug controller installed
5.1-4 Fuel return line clip installed on by-pass valve cover
Change
15-91
TM9-2815-202-34
5.1-12.
TACHOMETER DRIVE REPLACEMENT
(See Para 4-14)
5.1-13.
BLOCK MOUNTED CRANKCASE BREATHER REPLACEMENT
(See Para 4-15)
5.1-14.
ACCESSORY DRIVE REPLACEMENT
(See Para 5-14)
5.1-15.
BLOWER DRIVE SHAFT AND HUB REPLACEMENT
(See Para 5-15)
5.1-16.
GOVERNOR COVER AND THROTTLE CONTROL ROD REMOVAL
INSTALLATION
(See Para 4-17)
5.1-17.
GOVERNOR AND BLOWER ASSEMBLY REMOVAL/INSTALLATION
(See Para 4-18)
5.1-18.
BLOWER DRIVE GEAR AND SUPPORT REPLACEMENT
(See Para 4-19)
5.1-19.
OIL PAN REPLACEMENT
(See Para 4-20)
5.1-20.
CAMSHAFT FRONT GEAR COVER AND DAMPER REPLACEMENT
(See Para 5-20)
5.1-21.
FLYWHEEL ASSEMBLY REPLACEMENT
(See Para 4-22)
5.1-22.
REAROILSEALREPLACEMENT
(See Para 4-23)
5.1-23.
FLYWHEEL HOUSING REPLACEMENT
(See Para 4-24)
5.1-24.
IDLER GEAR REPLACEMENT
(See Para 4-25)
5.1-25.
INJECTOR CONTROL TUBE AND THROTTLE DELAY REPLACEMENT
(See Para 4-26)
5.1-26.
CYLINDER HEAD ASSEMBLY REMOVAL/lNSTALLATION
(See Para 4-27)
5.1-27.
ENGINE LOWER FRONT COVER REPLACEMENT
(See Para 5-27)
5.1-28.
CAMSHAFT AND GEAR ASSEMBLIES REPLACEMENT
(See Para 4-29)
5.1-29.
CYLINDER BLOCK END PLATES REPLACEMENT
(See Para 4-30)
5.1-30.
OIL PRESSURE REGULATOR AND RELIEF VALVE REPLACEMENT
(See Para 4-31)
5.1-31.
OIL PUMP REPLACEMENT
(See Para 4-32)
5-92 C h a n g e
1
TM 9-2815-202-34
Section Ill. ENGINE DISASSEMBLY/ASSEMBLY
5.1-32. PISTON AND CONNECTING ROD MAINTENANCE (CROSS-HEAD)
(See Para 4-33)
5.1-33. CYLINDER LINER MAINTENANCE
(See Para 4-34)
5.1-34. CRANKSHAFT MAINTENANCE
(See Para 4-35)
5.1-35. CYLINDER BLOCK MAINTENANCE
(See Para 4-36)
C h a n g e
1 5-93
TM 9-2815-202-34
SECTION IV. COMPONENT REPAIR
5.1-36. TURBOCHARGER REPAIR
This task covers:
a. Disassembly
d. Assembly
b. Cleaning
c. Inspection
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
7083-7391
TOOLS AND SPECIAL TOOLS
General mechanics tool set (App B, Item 96)
Torque wrench (App B, Item 100)
Dial indicator adaptor (App B, Item 4)
Turbocharger holding fixture (App B, Item 21 )
Magnetic base dial indicator (App B, Item 45)
Torque wrench (App B, Item 101)
Impeller Nut Box Wrench (App B, Item 104)
MANDATORY REPLACEMENT PARTS
Engine oil (App C, Item 16)
Cleaning solvent (App C, Item 10)
Crocus cloth (App C, Item 12)
Silicone carbide cloth (App C, Item 41)
Antiseize compound (App C, Item 1)
Silicone lubricant (App C, Item 42)
EQUIPMENT CONDITION
Para Description
5-2 Turbocharger removed
Piston ring (App F, Item 178)
Seal ring (App F, Item 179)
Piston rings (App F, Item 180)
Thrust washer (App F, Item 181)
Bearings (App F, Item 182)
Washers (App F, Item 183)
Retaining rings (App F, Item 184)
LockWashers (App F, [tern 93)
Gasket (App F, Item 74)
Self-locking screws (App F, Item 185)
Self-locking nut (App F, Item 186)
a. Disassembly
(1) Mark relative position of compressor housing (1), center housing (2), and turbine housing (3)
with a marking pen to assure reassembly in same relative location.
CAUTION
Exercise care when removing compressor housing and turbine housing to prevent damage
to compressor and turbine wheels.
(2) Loosen V-band coupling (4) securing compressor housing (2) to backplate assembly (5).
Remove coupling and housing.
5-94
Change 1
TM 9-2815-202-34
(3) Remove two bolts (6) and two
Iockwashers (7) securing turbocharger
drain tube (8) to center housing (2).
Remove bracket (9), drain tube (8), and
gasket (10) from center housing.
Discard Iockwashers and gasket.
(4) Remove adaptor bushing (11) from top
of center housing (2).
(5) Loosen V-band coupling (12) securing
turbine housing (3) to center housing
(2). Remove clamp.
(6) Remove turbine housing (3) from center housing (2).
Remove compressor wheel nut from shaft with a double universal socket and tee handle to
prevent bending turbine wheel shaft.
(7) Position turbine wheel assembly (13) in
turbocharger holding fixture. Remove
self-locking nut (14) from compressor
wheel (15) end of shaft. Discard nut.
Change 1
5-95
TM9-2815-202-34
5.1-36. TURBOCHARGER REPAIR (Cont)
CAUTION
Catch wheel shroud before it falls
from press. Wheel shroud (16) will
fall free when wheel shaft
assembly is removed.
(8) Remove compressor wheel (15) from
turbine wheel shaft assembly (13) by
using a press.
(9) Withdraw turbine wheel shaft assembly
(13) and wheel shroud (16) from center
housing (2).
NOTE
If groove in turbine wheel shaft
(13) is not present, turbocharger
does not require a piston ring (17)
near turbine wheel.
(10) Remove piston ring (17) from turbine
wheel shaft assembly (13). Discard
piston ring.
(11) Remove four bolts (18) securing
backplate (5) to center housing (2).
(12) Remove backplate (5) from center housing (2) by tapping it lightly.
(13) Remove seal ring (19) from groove in center housing (2). Discard seal ring.
(14) Remove thrust spacer (20) with two piston rings (21 ) from backplate (5). Remove two piston
rings from thrust spacer. Discard piston rings.
(15) Remove three self-locking screws (22) securing thrust collar (23) and thrust washer (24) to
center housing (2). Discard thrust washer and self-locking screws.
(16) Remove bearing (25), bearing washer (26) and retaining ring (27) from compressor end of
center housing (2). Discard retaining ring, bearing washer, and bearing.
(17) Remove outer retaining ring (28), bearing (29), bearing washer (30) and inner retaining ring
(31) from compressor end of center housing (2). Discard retaining rings, bearing washer, and
bearing.
5-96 C h a n g e
1
TM 9-2815-202-34
b. Cleaning
●
Compressed air used for cleaning purposes will not exceed 30 PSI. Use only
with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc.)
●
Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles
and gloves and use in a well-ventilated area. Avoid contact with skin, eyes, and
clothes. Do not breathe vapors. Do not use near open flame or excessive
heat. The flash point is 100-138°F (38-50°C). If you become dizzy while using
cleaning solvent, get fresh air immediately and seek medical aid. If contact
with eyes is made, wash with water and get medical aid immediately.
Never use caustic cleaning solution for cleaning. Do not use wire brush or steel blade
scraper to clean parts. Such cleaning will damage finished surfaces of turbocharger.
NOTE
• Before cleaning, inspect parts for signs of burning, rubbing, or other damage which
might not be evident after cleaning.
• Insure compressor and turbine wheel blades are thoroughly clean. Deposits left on
blades will affect balance of rotating assembly.
(1) Soak all parts in cleaning solvent for 25 minutes. After soaking, use a stiff bristle brush to
remove all dirt particles. Using compressed air, dry all parts thoroughly.
(2) Clean all internal cavities and oil passages in center housing thoroughly with compressed air.
(3) Clean oil passage in center housing thrust plate with compressed air.
Change
1 5-97
TM9-2815-202-34
5.1-36. TURBOCHARGER REPAIR (Cont)
CAUTION
When polishing surfaces, use silicone carbide abrasive cloth for aluminum parts and crocus
cloth for steel parts.
(4) Minor surface damage may be burnished or polished away.
c. Inspection
(1) Inspect all parts for signs of damage, corrosion, or deterioration. Check for nicked, crossed, or
stripped threads.
(2) Check turbine wheel for nicks, rubbing, and wear.
(3) Inspect shaft for signs of scoring, scratches, or bearing seizure.
(4) Check compressor wheel for signs of rubbing or blade damage. Check to see wheel bore is not
galled.
(5) Inspect seal parts for signs of rubbing or
scoring of running faces.
(6) Inspect backplate for wear or damaged
bore.
(7) Inspect center housing for contact with
rotating parts.
d. Assembly
(1) Lubricate bearing (25) and bearing (29) with engine oil.
(2) Install inner retaining ring (31), bearing washer (30), bearing (29), and outer retaining ring (28)
in compressor end of center housing (2).
(3) Install retaining ring (27), bearing washer (26), and bearing (25) in compressor end of center
housing (2).
(4) Lubricate thrust collar (23) and thrust washer (24) with engine oil.
(5) Insert thrust collar (23) into thrust washer (24) and install thrust collar, thrust washer, and three
self-locking screws (22) in center housing (2). Torque screws to 30-35 lb-in (3.4-3.9 N-m).
(6) Install seal ring (19) in groove at compressor end of center housing (2).
5-98
Change 1
TM 9-2815-202-34
CAUTION
Do not cock or force piston rings (21) into grooves. Rings are brittle and will snap easily.
(7) Install two piston rings (21 ) on thrust spacer (20).
(8) Lubricate thrust spacer (20) and piston rings (21 ) with engine oil. Gently insert thrust spacer
with rings into bore in backplate (5).
(9) Aline oil feed hole in center housing (2) and backplate assembly (5). Attach backplate to center
housing with four bolts (1 8). Torque bolts to 110-130 lb-in (12.4 -14.7 N-m)
CAUTION
Do not cock or force piston ring (17) into groove. Ring is brittle and will snap easily.
NOTE
Piston ring (17) is used on some turbochargers. If there is no groove in shaft (1 3), ring is not
required.
(10) Fill piston ring groove with high vacuum
silicone lubricant and install piston ring
(17) on wheel shaft assembly (13).
CAUTION
Do not scuff or scratch bearings
when installing shaft or bearing
will seize during operation.
(11) Lubricate turbine wheel shaft assembly
(13) with engine oil. Position wheel
shroud (16) against center housing (2).
Insert turbine wheel shaft assembly
through wheel shroud and into center
housing.
Change 1
5-99
TM 9-2815-202-34
5.1-36. TURBOCHARGER REPAIR (Cont)
(12) Place turbine wheel shaft assembly
(13), shroud (16), center housing (2),
and backplate (5) upright in
turbocharger holding fixture.
(13) With compressor wheel (15) at room
temperature, position it over turbine
wheel shaft assembly (13).
CAUTION
When torquing compressor
wheel nut on shaft, use two
universal joints connected in
tandem or a single universal joint
and a universal socket to
prevent bending turbine wheel
shaft.
(14) Lubricate shaft threads of turbine wheel
shaft assembly (13) and wheel face on
compressor wheel (15) with engine oil.
Install self-locking nut (14). Torque nut
to 125-150 lb-in (14-17 N-m) to seat
compressor wheel against thrust
spacer.
(15) Loosen self-locking nut (14) and inspect
nut face and front face of compressor
wheel to insure they are smooth and
clean.
(16) Torque self-locking nut (14) to 35-55
lb-in (4-6 N-m).
(17) Attach magnetic base dial indicator (32)
to center housing.
(18) Place impeller nut box wrench (33) on
impeller nut (14) and position dial
indicator on tip of turbine shaft
assembly (13). Set dial indicator to zero.
Tighten nut to obtain shaft stretch of
0.009-0.010 inch.
5-100
Change 1
TM 9-2815-202-34
(19) Check bearing axial end play as follows:
(a) Clamp center housing assembly in
soft-jawed vise.
(b) Fasten magnetic base dial indicator
(32) to center housing with indicator
tip resting on end of rotating shaft
on compressor side.
(c) Move shaft axially back and forth by
hand. Total indicator reading should
be between 0.003 and 0.010 inch.
Repair or replace shaft assembly if
readings do not fall within limits.
(20) Install turbine housing (3) on center
housing (2) and align match marks.
(21) Install V-band coupling (12) on turbine
housing (3) and center housing (2) so
T-bolt end does not interfere with
turbine housing. Apply antiseize
compound to threads on T-bolt and
tighten nut to 160 lb-in (18 N-m).
Loosen to 50 lb-in (5.6 N-m) and
retorque to 152-168 lb-in (17.2-19.0
N-m).
(22) Check shaft radial movement as
follows:
(a) Position magnetic base dial indicator
(32) on flat surface of turbine
housing inlet flange.
(b) Insert dial indicator tip extension rod
into oil drain hole with rod touching
shaft and perpendicular.
NOTE
Insure adaptor rod does not
contact sides of center housing or
readings are invalid.
(c) Grasp ends of rotating assembly
and apply equal pressure at each
end, moving rotating shaft toward
and away from dial indicator.
Crosswise movement must be
between 0.003 and 0.007 inch.
Change
1 5-101
TM 9-2815-202-34
5.1-36. TURBOCHARGER REPAIR (Cont)
(23) Aline match marks on compressor housing (1) with marks on center housing (2). Secure
compressor housing to backplate (5) with V-band coupling (4). Lubricate threads on T-bolt with
engine oil and torque nut to 110-130 lb-in (12-15 N-m).
(24) Install adaptor bushing (11) in oil inlet hole in center housing (2).
(25) Install gasket (10), oil drain tube (8), bracket (9), two Iockwashers (7), and two bolts (6) on oil
outlet of center housing (2). Torque bolts to 30-35 Ib-ft (41-47 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-2 Install turbocharger
5.1-37.
CYLINDER HEAD REPAIR
(See Para 5-37)
5.1-38.
OIL COOLER ASSEMBLY REPAIR
(See Para 4-39)
5.1-39.
FUEL INJECTOR ASSEMBLY REPAIR
(See Para 4-40)
5.1-40.
BLOWER REPAIR
(See Para 4-41)
5.1-41.
GOVERNOR REPAIR
(See Para 5-41)
5.1-42.
WATER PUMP REPAIR
(See Para 4-43)
5-102
Change 1
TM9-2815-202-34
CHAPTER 6
REPAIR PROCEDURES FOR MAJOR COMPONENTS OF
ENGINE MODEL 7083-7398
Contents
Para
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-1
Turbocharger Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Turbocharger RemovaI/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Exhaust Manifold and Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Fuel Strainer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Fuel Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Engine Lifting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Thermostat Housing and Crossover Tubes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Water Pump Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Air Box Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Engine Rocker Arm Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Air Inlet Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Tachometer Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Blower Drive Shaft and Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Governor Cover and Throttle Control Rod Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Governor and Blower Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Blower Drive Gear and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
..
Oil Pan Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Camshaft Front Gear Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Rear Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Injector Control Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Cylinder Head Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Engine Lower Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Camshaft and Gear Assemblies Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Cylinder Block End Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Oil Pressure Regulator and Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Piston and Connecting Rod Maintenance (Trunk Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Cylinder Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Crankshaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Cylinder Block Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Turbocharger Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Oil Cooler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Fuel Injector Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-42
6-43
Governor Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Page
6-2
6-3
6-6
6-10
6-13
6-13
6-13
6-13
6-13
6-13
6-14
6-25
6-25
6-25
6-25
6-26
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-29
6-30
6-43
6-43
6-43
6-44
6-54
6-54
6-54
6-54
6-54
6-54
6-1
TM 9-2815-202-34
Section I. INTRODUCTION
6-1. GENERAL. This chapter provides the repair procedures performed on engine model 7083-
7398 after the engine has been installed on the maintenance stand. Component replacement
typically consists of removal, disassembly, cleaning/inspection, repair, assembly, and installation of
the component. Next, the engine block maintenance consists of disassembly, inspection, repair, and
assembly of the block components. For major components, the repair is handled separately from
removal and installation. Component repair usually consists of disassembly, cleaning/inspection, and
assembly.
This chapter deals with engine model 7083-7398. However, if a model in previous chapters has
identical or nearly identical components, this chapter will refer to the previous chapter. If a model in
the subsequent chapter has identical or nearly identical components, this chapter also covers that
model.
A
6-2
TM9-2815-202-34
Section Il. GENERAL ENGINE MAINTENANCE
6-2. TURBOCHARGER REGULATOR REPLACEMENT
This task covers:
a. Removal
b. Test
c. Installation
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-73987083-7399
4 Lockwashers (App F,ltem 93)
1 Gasket (App F,ltem 73)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
a. Removal
(1) Disconnect line (1)at eIbow (2) on air
inlet housing (3) and at elbow (4) on
regulator valve (5).
NOTE
Model 7083-7399 uses an elbow
instead of an adaptor at the
regulator valve connection.
(2) Disconnect line (6) from turbocharger
(7) and at adaptor (8) on regulator
valve (5).
(3) Remove four bolts (9) and four
Iockwashers (1O) securing regulator
valve (5) to exhaust adaptor (11).
Discard Iockwashers.
(4) Remove regulator valve (5) and
gasket (12) from exhaust adaptor
(11 ). Discard gasket.
6-3
TM 9-2815-202-34
6-2. TURBOCHARGER REGULATOR REPLACEMENT (Cont)
b. Test
ApplV air pressure to regulator valve inlet port at elbow (4). Valve should move 0.30 inch
(0.76 cm) with 12.7-13.6 PSI (87.6-89.8 kPa). If valve is out of limits, replace valve.
c. Installation
NOTE
● Outlet
flange on turbocharger regulator valve must face rear of engine on model
7083-7398
● Outlet
flange on turbocharger regulator valve must face left side of engine on model
7083-7399.
(1) Position gasket (12) and regulator valve (5) on exhaust adaptor (11).
(2) Install four Iockwashers (10) and four bolts (9) securing regulator valve (5) to exhaust
adaptor (11). Torque bolts to 30-35 Ib-ft (41-47 N-m).
NOTE
Model 7083-7399 uses an elbow instead of an adaptor at the regulator valve
connection.
(3) Connect line (6) to turbocharger (7) and to adaptor (8) on regulator valve (5). Tighten line
connections.
(4) Connect line (1) at elbow (2) on air inlet housing (3) and to elbow (4) on regulator valve (5).
Tighten line connections.
END OF TASK
6-4
TM9-2815-202-34
6-5
TM9-2815-202-34
6-3. TURBOCHARGER REMOVAL/lNSTALLATION
This task covers:
a. Removal
b. Inspection
c. Installation
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
7083-7398
Tape (App C, Item 27)
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Para Description
3-11 Turbocharger oil supply line removed
Turbocharger air regulator line
6-2
removed
MANDATORY REPLACEMENT PARTS
6 Locking nuts (App F, Item 104)
1 Gasket (App F, Item 40)
PERSONNEL REQUIRED: 2
a. Removal
(1) Loosen two clamps (1) and slide rubber connector (2) onto turbocharger oil drain tube (3).
(2) Loosen two clamps (4) on hose connector (5) connecting air inlet housing (6) to
turbocharger (7). Slide hose and two clamps onto air inlet housing.
(3) Remove six locking nuts (8) securing turbocharger (7) to exhaust tee (9). Discard locking
nuts.
WARNING
Engine components are heavy. To prevent personal injury, use extreme
caution when removing large components from engine.
CAUTION
● Turbocharger
is heavy. Use two persons or lifting device to prevent dropping and
damage to turbocharger.
● Tape
all openings of turbocharger after removal to keep foreign particies from
entering and damaging turbocharger blades.
(4) Remove turbocharger (7) and gasket (10). Discard gasket.
6-6
TM 9-2815 -202-34
(5) Remove rubber connector (2) and two clamps (1) from drain tube (3). Remove hose (5) and
two clamps (4) from air inlet housing (6).
InspectIon
(1) Inspect hoses and rubber connector for cuts, cracks, and brittleness.
(2) Replace all parts failing inspection.
6-7
TM 9-2815-202-34
6-3. TURBOCHARGER REMOVAL/lNSTALLATION (Cont)
c. Installation
(1) install gasket (10)on exhaust tee (9).
(2) Slide hose (5) and two clamps (4) onto air inlet housing (6). Slide rubber connector (2) and
two clamps (1) onto oil drain tube (3).
WARNING
Engine components are heavy. To prevent personal injury, use extreme
caution when removing large components from engine.
CAUTION
Turbocharger is heavy. Use two persons or lifting device to prevent dropping and
damage to turbocharger.
(3) Install turbocharger (7) on exhaust tee (9) and secure with six locking nuts (8). Torque nuts to
83-93 Ib-ft (113-126 N-m).
(4) Slide hose (5) and two clamps (4) from air inlet housing (6) onto turbocharger (7). Tighten
clamps.
(5) Slide rubber connector (2) and two clamps (1) on turbocharger oil drain tube (3) onto
flywheel housing cover (11 ). Tighten clamps.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
6-2 Install turbocharger regulator air line
3-11 Install turbocharger oil supply line
6-8
TM9-2815-202-34
6-9
TM 9-2815-202-34
6-4. EXHAUST MANIFOLD AND TUBE REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP
MODELS
EQUIPMENT CONDITION
7083-7398
TOOLS AND SPECIAL TOOLS
Para
3-7
6-2
6-3
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
PERSONNEL REQUIRED: 2
Description
Oil level gauge removed
Turbocharger regulator removed
Turbocharger removed
MANDATORY REPLACEMENT PARTS
10 Locking nuts (App F, Item 103)
3 Locking nuts (App F, Item 102)
4 Gaskets (App F, Item 28)
4 Gaskets (App F, Item 41 )
4 Locking nuts (App F, Item 104)
1 Gasket (App F, Item 50)
4 Lockwashers (App F, Item 94)
a. Removal
(1) Remove four nuts (1) from four clamps (2) securing exhaust tubes (3 and 4) to exhaust
housing (5), exhaust manifold (6), and adaptor (7), Slide clamps onto tubes and reinstall
nuts on clamps.
(2) Loosen four nuts (8) securing exhaust housing (5) to bracket (9) to aid in removal of exhaust
tubes (3 and 4).
(3) Remove exhaust tubes (3 and 4), four clamps (2), and four gaskets (10). Discard gaskets and
remove clamps from tubes.
(4) Remove four bolts (11 ), four flat washers (1 2), and four locking nuts (8) securing housing (5)
to bracket (9). Remove housing. Discard locking nuts.
(5) Remove four bolts (13), four Iockwashers (14), and four flat washers (15) securing bracket (9)
to flywheel housing. Remove bracket and discard Iockwashers,
(6) Remove three locking nuts (16) from studs (17) securing adaptor (7) to left exhaust manifold
(18). Discard locking nuts and remove adaptor.
(7) Remove gasket (19) from end of left manifold (18) and discard.
(8) Loosen five locking nuts (20) securing right exhaust manifold (6) to cylinder head.
(9) Slide exhaust manifold (6) up and off cylinder head.
6-10
TM 9-2815 -202-34
(10) Remove five locking nuts (20), three beveled washers (21 ), and two end retainers (22).
Discard locking nuts.
(11) Remove two exhaust manifold gaskets (23). Discard gaskets.
(12) Repeat steps (8) thru (11) above for left exhaust manifold.
b. Installation
NOTE
When installing metal clad exhaust manifold gaskets, place crimped side of gasket
against cylinder head.
(1) Position two gaskets (23) over right exhaust manifold studs (24).
6-11
TM 9-2815-202-34
6-4. EXHAUST MANIFOLD AND TUBE REPLACEMENT (Cont)
NOTE
Position beveled washers with crown facing nut.
(2) install three beveled washers (21), two end retainers (22) and five locking nuts(20).
NOTE
Insure locating pads on exhaust manifold rest on cylinder block locating pads.
(3) Install right exhaust manifold (6) onto cylinder head by sliding downward between gaskets
and retainers.
(4) Repeat steps (1) thru (3) above for left exhaust manifold.
(5) Position gasket (19) over studs (17) on rear of left exhaust manifold (18).
(6) Install adaptor (7) on studs (17) and secure with three locking nuts (16). Torque nuts to
57-61 lb-ft (77-83 N-m),
(7) Attach bracket (9) to rear of flywheel housing with four bolts (13), four Iockwashers (14), and
four flat washers (15). Torque bolts to 46-50 Ib-ft (62-68 N-m).
(8) Position exhaust housing (5) on top of bracket (9) and loosely secure with four bolts (11),
four flat washers (12), and four locking nuts (8).
(9) Slide two clamps (2) on left exhaust tube (4). Affix one gasket (10) on end of adaptor (7) and
one on end of exhaust housing (5).
(10) Install left exhaust tube (4) between adaptor (7) and housing (5) and secure with two clamps
(2).
(11) Slide two clamps (2) on right exhaust tube (3). Affix one gasket (10) to housing (5) and one
gasket on end of exhaust manifold (6).
(12) Install right exhaust tube (3) between housing (5) and exhaust manifold (6) and secure with
two clamps (2).
(13) Torque ten nuts (20) to 30-35 Ib-ft (41-47 N-m) starting from center and working outward
alternately toward either end.
(14) Torque four nuts (8) to 46-50 Ib-ft (62-68 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para
6-3
6-2
3-7
6-12
Description
Turbocharger installed
Turbocharger regulator installed
Liquid level gauge installed
TM9-2815-202-34
6-5.
FUEL FILTER REPLACEMENT
(See Para 4-4)
6-6.
FUEL STRAINER REPLACEMENT
(See Para 4-5)
6-7.
FUEL LINES REPLACEMENT
(See Para 4-6)
6-8.
ENGINE LIFTING BRACKETS REPLACEMENT
(See Para 4-7)
6-9. THERMOSTAT, THERMOSTAT HOUSING, AND
(See Para 4-8)
CROSSOVER TUBES REPLACEMENT
6-10. WATER PUMP REMOVAL\lNSTALLATION
(See Para 4-9)
6-13
TM9-2815-202-34
6-11. AIR BOX HEATER REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Test/Adjustment
c. Cleaning/Inspection
f. Installation
INITIAL SETUP
MANDATORY REPLACEMENT PARTS
MODELS
7083-7398 7083-7399
1
2
1
1
2
3
2
2
4
TOOLS AND SPECIAL TOOLS
General mechanics tools kit (App B, Item 96)
Torque wrench (App B, Item 101)
Lockwasher (App F, Item 95)
Lockwashers (App F, Item 91 )
LockWashers (App F, Item 92)
Gasket (App F, Item 61)
Gasket (App F, Item 77)
Gaskets(App F, Item 45)
LockWashers (App F, Item 93)
Lockwashers (App F, Item 98)
Lockwashers (App F, Item 90)
LockWashers (App F, Item 89)
EXPENDABLE/DURABLE SUPPLIES
Cleaning solvent (App C, Item 10)
Fuel oil (App C, Item 21)
PUMP AND MOTOR ASSEMBLY
a. Removal
NOTE
If present, remove safety wire from connector.
(1) Disconnect wiring harness connector (1) from terminal on pump and motor assembly (2).
(2) Remove nut (3) and Iockwasher (4) securing wiring harness lead (5) to pump. Discard
Iockwasher.
(3) Disconnect tube (6) from elbow (7) on pump.
(4) Disconnect hose (8) from elbow (9) on pump.
(5) For model 7083-7398 only, disconnect hose (8) from elbow (1 O) on fuel strainer.
(6) Disconnect wiring harness connector (11 ) from ignition coil (12).
(7) Remove nut (13) and Iockwasher (14) securing two wiring harness leads (15) to stud (16)
mounted in cylinder head. Remove leads. Discard Iockwasher.
(8) Disconnect tube (17) from elbow (18) on solenoid valve.
6-14
TM9-2815-202-34
(9) For model 7083-7399 only, remove bolt (19), Iockwasher (20), and flat washer (21), securing
clamp (22) and hose (8) to upper front cover.
(10) Remove two bolts (23) and two Iockwashers (24) securing bracket (25) and clamp (22) to
support (26). Remove hose (8). If necessary, remove clamp. Discard Iockwashers.
(11) Remove bolt (27), retainer (28), and clamp (29) securing wiring harness (30) to blower.
(12) Remove two bolts (31), two Iockwashers (32), and four flat washers (33) securing bracket
(25) assembly to governor. Remove bracket assembly. Discard Iockwashers and install bolts
into governor.
(13) Remove four bolts (34), four nuts (35), four Iockwashers (36), and four flat washers (37)
securing pump and motor assembly (2) to bracket (25). Remove assembly. Discard
Iockwashers.
b. Disassembly
Remove elbows (7 and 9) from pump and motor assembly (2).
6-15
TM9-2815-202-34
6-11. AIR BOX HEATER REPLACEMENT (Cont)
c. Cleanlng/inspection
WARNING
● Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only In a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do
not o
o
use near open flames or excessive heat. The flash point is 100 F-138 F
o
o
(38 C-50 C). If you become dizzy while using cleaning solvent, get
fresh air immediately and get medical aid. If contact with eyes Is made,
wash your eyes with water and get medical aid immediately.
● Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves, etc).
(1) Clean outside surface of pump with dry cleaning solvent and dry with compressed air.
(2) Inspect pump and motor for cracks, dents, or damage.
(3) Inspect electrical terminals for damage or corrosion.
(4) Inspect wiring harness for cuts, tears, burns, or other damage.
(5) Inspect hose for cuts, tears, or other damage.
d. Assembly
Install elbows (7 and 9) onto pump and motor assembly (2).
6-16
TM9-2815-202-34
e. Test/Adjustment
(1) Connect end of hose (8) to inlet port and hose (6) to outlet port of pump.
(2) Attach a 24 V dc power source to pump and motor assembly (2). After pump is primed and
fuel flow established, flow with no restrictions is 0.2 GPM.
(3) Connect a pressure gage and cutoff valve to hose (6) and power up pump. Pressure with
outlet shut off must be 40 PSI minimum.
(4) Connect a vacuum gage and cutoff valve to hose (8) and power up pump. Suction with inlet
shut off must be 18 inches of mercury minimum.
(5) Disconnect 24 V dc power source.
(6) Remove gages, valves, and hoses (6 and 8) from pump and motor assembly (2).
6-17
TM9-2815-202-34
f. Installation
(1) Secure pump and motor assembly (2) to bracket (25) with four bolts (34), four flat washers
(37), four Iockwashers (36), and four nuts (35). Torque bolts to 7-9 Ib-ft (1 0-12 N-m).
(2) Install wiring harness lead (5) to terminal on pump and secure with nut (3) and Iockwasher
(4).
(3) Connect wiring harness connector (1) to terminal on pump and motor assembly (2).
(4) For model 7083-7399 only, route hose (8) to front of engine. If removed, install clamp (22)
onto hose (8) and secure hose to upper front cover with bolt (19), Iockwasher (20), flat
washer (21 ), and clamp. Torque bolt to 71-75 Ib-ft (96-102 N-m).
NOTE
When positioning wiring harness (30) on engine, route harness to prevent cuts,
chaffing, burns, or interference with components,
(5) Install bracket (25) assembly onto governor. Secure with two bolts (31 ), two Iockwashers
(32), and four flat washers (33).
(6) If removed, install clamp (22) onto hose (8). Install two bolts (23) and two Iockwashers (24),
securing bracket (25) and clamp to support (26). Torque bolts (23) to 35-39 Ib-ft (47-53 N-m).
Torque bolts (31 ) to 7-9 Ib-ft (1 0-12 N-m).
(7) Install bolt (27), retainer (28), and clamp (29) securing wiring harness (30) to blower. Torque
bolt to 30-35 Ib-ft (41-47 N-m).
(8) Connect tube (6) to elbow (7) on pump.
(9) For model 7083-7398 only, connect hose (8) to elbow (10) on fuel strainer,
(10)
Connect tube (17) to elbow (18) on solenoid valve (38).
(11) Connect hose (8) to elbow (9) on pump and motor assembly (2).
(12) Install wiring harness connector (11 ) onto ignition coil (12).
(13) Install two wiring harness leads (15) to stud (16). Secure with Iockwasher (14) and nut (13).
6-18
TM 9-2815 -202-34
6-19
TM 9-2815-202-34
6-11. AIR BOX HEATER REPLACEMENT (Cont)
AIR BOX HEATER
a. Removal
(1) Disconnect wire (39) from terminal nut pin (40).
NOTE
Disconnect tube (17) from solenoid during pump and motor assembly removal.
(2) Disconnect tube (17) from adapter (41) on air box heater assembly (42). Remove tube.
(3) Remove two bolts (43) and two Iockwashers (44) securing air box heater assembly (42) and
gasket (45) to block. Remove heater assembly and gasket. Discard Iockwashers and gasket.
b. Disassembly
(1) Remove adapter (41), gasket (46), and filter element (47) from heater body (48). Discard ring
spacer.
(2) Unscrew insulator nut (49) from heater body (48).
(3) Remove electrode (50) and two gaskets (51 ). Discard ring spacers.
(4) Unscrew terminal nut pin (40) from electrode (50).
(5) Remove spray nozzle (52) and flat washer (53) from heater body (48).
c. Cleaning/Inspection
(1) Inspect electrode and filter element for cracks, corrosion, or damage.
(2) Inspect spray nozzle and insure orifice is not plugged. If necessary, clean orifice.
(3) Inspect ignition wire for cuts, tears, burns, or other damage.
(4) Inspect tube bends or other damage.
d. Assembly
(1) Install spray nozzle (52) and flat washer (53) into heater body (48).
(2) Screw terminal nut pin (40) onto electrode (50).
(3) Install electrode (50) and two gaskets (51) into heater body (48).
6-20
TM
9-2815-202-34
(4) Screw insulator nut (49) into heater body (48).
(5) Install filter element (47), gasket (46), and adapter (41) into heater body (48).
e. Test/Adjustment
Using feeler gage set, adjust gap between electrode (50) and wire (54) to 0.080 inch.
f. Installation
NOTE
Do not install ignition coil if air box heater assembly testing is required.
(1) Install air box heater assembly (42) and gasket (45) into block. Secure with two bolts (43)
and two Iockwashers (44). Torque bolts to 15-19 Ib-ft (20-26 N-m).
NOTE
Connect tube (17) to solenoid during pump and motor assembly installation.
(2) Connect tube (17) to adapter (41) on air box heater assembly (42).
(3) Connect wire (39) to terminal nut pin (40).
6-21
TM9-2815-202-34
6-11. AIR BOX HEATER REPLACEMENT (Cont)
IGNITION COIL
a. Removal
NOTE
Remove wire (39) from air box heater during air box heater removal.
(1) Disconnect wire (39) from ignition coil (12).
NOTE
Remove nut, Iockwasher, and harness leads from stud (16) and remove connector (11)
from coil (12) during pump and motor assembly removal.
(2) Remove Iockwasher (55), flat washer (56), ignition coil (12) with tension clip (57), and
spacer (58) from stud (16). Discard Iockwasher.
(3) Remove ignition coil (12) from tension clip (57).
(4) If necessary, remove stud (16) from cylinder head.
c. Cleaning/Inspection
WARNING
● Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do not
use near oopen oframes or excessive heat. The flash point is 100°F138°F (38 C-50 C). If you become dizzy while using cleaning solvent,
get fresh air immediately and get medical aid. If contact with eyes is
made, wash your eyes with water and get medical aid immediately.
● Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves, etc).
(1) Clean outside surface of ignition coil with cleaning solvent and dry with compressed air.
(2) Inspect ignition coil for cracks, oil seepage, or damage to electrical connectors.
e. Test/Adjustment
(1) Connect wire (39) to ignition coil (12) and terminal nut pin (40) on air box heater assembly
(42).
(2) Connect air box heater assembly (42) to common ground.
WARNING
Do not touch ignition coil or air heater assembly while performing test.
High voltage is present. Personal injury may result.
6-22
TM9-2815-202-34
CAUTION
● Do
not apply voltage to ignition coil without a coil to air heater connection. Coil and
air heater must be grounded.
● Apply
positive lead to pin (A) and negative lead to pin (B) or damage to coil will
result.
(3) Connect a 24 V dc power source to the coil input side of ignition coil (12). Observe electric
arc between electrode (48) and wire (54). Arc may be steady or intermittent (about ten to
thirty pulses a second) with a popping noise.
f. Installation
(1) If removed, install stud (16) into cylinder head.
(2) Install tension clip (57) on ignition coil (12).
NOTE
Install nut, Iockwasher, and harness leads on stud during pump and motor assembly
installation.
(3) Install spacer (58), ignition coil (12), with tension clip (57), Iockwasher (55), and flat washer
(56) onto stud (16).
NOTE
Install ignition wire from air box heater during air box heater installation.
(4) Install wire (39) onto ignition coil (12).
6-23
TM9-2815-202-34
6-11. AIR BOX HEATER REPLACEMENT (Cont)
SOLENOID VALVE
a. Removal
NOTE
Remove pump, motor, and bracket assembly before removing solenoid.
(1) Disconnect wiring harness terminal (59) from solenoid (38).
(2) Remove four screws (60), four nuts (61), and four Iockvvashers (62) securing wiring harness
connector (63) to bracket (25). Remove connector from bracket. Discard Iockwashers.
(3) Remove wiring harness (30). If necessary, remove clamp (29) from harness.
NOTE
Disconnect tube (17) during pump and motor assembly removal.
(4) Disconnect tube (6) from elbow (64) on solenoid (38). Remove tube.
(5) Remove two screws (65), two nuts (66), two Iockwashers (67), and two flat washers (68),
securing solenoid (38) to bracket (25). Remove solenoid.
b . Disassembly
(1) Remove elbow (64) from solenoid (38).
(2) Remove elbow (18) from bushing (69).
(3) Remove bushing (69) from solenoid (38).
c. Inspection
Inspect solenoid for cracks, damage, or
valve leakage.
d. Assembly
(1) Install bushing (69) into solenoid (38).
(2) Install elbow (18) into bushing (69).
(3) Install elbow (64) into solenoid (38).
e. Test/Adjustment
(1) Attach 24 V dc power source to
solenoid (38) and listen to confirm
solenoid valve is opening and
closing. If no indication of movement,
replace solenoid valve.
(2) Disconnect and remove 24 V dc
power source from solenoid (38).
6-24
TM9-2815-202-34
f. Installation
(1) install solenoid (38), two screws (65), two flat washers (68), two Iockwashers (67), and two
nuts (66) on bracket (25). Tighten securely.
(2) Secure wiring harness connector (63) to bracket (25) with four screws (60), four Iockwashers
(62), and four nuts (61). Tighten securely.
(3) Connect wiring harness terminal (59) to solenoid (38).
NOTE
Connect tube (6) to pump during pump and motor assembly installation.
(4) Connect tube (6) onto elbow (64) on solenoid (38).
NOTE
Install pump and motor assembly.
END OF TASK
6-12. ENGINE ROCKER ARM COVER REPLACEMENT
(See Para 4-11)
6-13. FUEL PUMP REPLACEMENT
(See Para 4-12)
6-14. AIR INLET HOUSING REPLACEMENT
(See Para 4-13)
6-15. TACHOMETER DRIVE REPLACEMENT
(See Para 4-14)
6-25
TM9-2815-202-34
6-16. CRANKCASE BREATHER REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning/Inspection
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
7083-7398
Cleaning solvent (App C, Item 10)
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Para Description
6-14 Air Inlet housing removed
MANDATORY REPLACEMENT PARTS
11 Lockwashers (App F,Item 93)
1 Gasket (App F, Item 26)
1 Gasket (App F, Item 36)
1 Gasket (App F, Item 44)
FLYWHEEL HOUSING CRANKCASE BREATHER
a. Removal
Remove two bolts (1), bolt (2), three bolts (3), and six Iockwashers (4) securing breather
assembly (5) and gasket (6) to flywheel housing. Remove breather assembly. Discard
Iockwashers and gasket.
h. Disassembly
(1) Remove bolt (7), flat washer (8), and spacer (9) securing filter element (10) and shell (11) to
adaptor (12). Remove shell from element.
(2) Remove two bolts (13) and two Iockwashers (14) securing breather pipe (15) and gasket
(16) to adaptor (1 2). Discard gasket and Iockwashers.
6-26
TM9-2815-202-34
c. Cleaning/Inspection
WARNING
● Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do not
use near open frames or excessive heat. The flash point is 100°F-138°F
o
(38°C-50 C). If you become dizzy while using cleaning solvent, get
medical aid. If contact with eyes is made, wash your eyes with water
and get medical aid immediately.
● Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
(1) Clean all parts with dry cleaning solvent and dry with compressed air.
(2) Inspect adaptor, pipe, and shell for cracks, pitting, or damage.
(3) Inspect filter element for cuts, tears, or damaged.
d. Assembly
(1) Install gasket (16) and breather pipe (15) onto adaptor (12). Secure with two lockwashers
(14) aid two bolts (1 3). Torque bolts to 30-35 lb-ft (41-47 N-m).
(2) Install filter element (10) and shell (11) onto adaptor (12) and secure with spacer (9), fiat
washer (8), and bolt (7). Torque bolt to 30-35 lb-ft (41-47 N-m).
e. installation
(1) Install gasket (6) onto breather assembly (5).
(2) Position breather assembly (5) onto flywheel housing
and secure with two bolts (1), bolt (2), three bolts (3),
and six lockwashers (4). Torque bolts to 30-35 lb-ft
(41-47 N-m).
6-27
TM9-2815-202-34
6-16. CRANKCASE BREATHER REPLACEMENT (Cont)
CRANKCASE BREATHER TUBE REPLACEMENT
a. Removal
(1) Remove bolt (17), nut (18), and lockwasher (19) securing clip (20) and tube (21) to flywheel
housing. lf necessary, remove clip from tube. Discard lockwasher.
(2) Remove twobolts (22), two clockwashers (19), and flatwasher (23) securing tube (21) and
gasket (24) to cylinder block. Remove tube from block. Discard Iockwashers and gasket.
NOTE
Do not remove breather pipe unless damaged. Removal of pipe will destroy it and
require its replacement.
(3) If necessary, remove breather pipe (25) from cylinder block,
b. Inspection
Inspect tube and breather pipe for cracks, holes, or damage.
c. Installation
(1) If removed, drive new breather pipe (25) into cylinder block with a collar and soft-headed
hammer until flush with counterbore.
6-28
TM9-2815-202-34
(2) Install gasket (24) and tube (21 ) onto block. Secure with two bolts (22), two Iockwashers
(19), and flat washer (23). Torque bolts to 30-35 Ib-ft (41 -47 N-m).
(3) If removed, install clip (20) onto tube (21). Secure clip and tube on flywheel housing with bolt
(17), Iockwasher (19), and nut (18). Torque bolt to 30-35 Ib-ft (41-47 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
6-14 Install air inlet housing
6-17. BLOWER DRIVE SHAFT AND HUB REPLACEMENT
(See Para 4-16)
6-18. GOVERNOR COVER AND THROTTLE CONTROL
ROD REMOVAL/lNSTALLATION
(See Para 4-17)
6-19. GOVERNOR AND BLOWER ASSEMBLY REMOVAL/lNSTALLATION
(See Para 4-1 8)
6-20. BLOWER DRIVE GEAR AND SUPPORT REPLACEMENT
(See Para 4-19)
6-21. OIL PAN REPLACEMENT
(See Para 4-20)
6-22. CAMSHAFT FRONT GEAR COVER REPLACEMENT
(See Para 4-21)
6-23. FLYWHEEL ASSEMBLY REPLACEMENT
(See Para 4-22)
6-24. REAR OIL SEAL REPLACEMENT
(See Para 4-23)
6-25. FLYWHEEL HOUSING REPLACEMENT
(See Para 4-24)
6-26. IDLER GEAR REPLACEMENT
(See Para 4-25)
6-27. INJECTOR CONTROL TUBE REPLACEMENT
(See Para 4-26)
6-28. CYLINDER HEAD ASSEMBLY REMOVAL/lNSTALLATION
(See Para 4-27)
6-29. ENGINE LOWER FRONT COVER REPLACEMENT
(See Para 4-28)
6-30. CAMSHAFT AND GEAR ASSEMBLIES REPLACEMENT
(See Para 4-29)
6-31. CYLINDER BLOCK END PLATES REPLACEMENT
(See Para 4-30)
6-32. OIL PRESSURE REGULATOR AND RELIEF VALVE
REPLACEMENT
(See Para 4-31)
6-33. OIL PUMP REPLACEMENT
(See Para 4-32)
6-29
TM9-2815-202-34
Section Ill. ENGINE
DISASSEMBLY\ASSEMBLY
6-34. PISTON AND CONNECTING ROD MAINTENANCE (TRUNK TYPE)
This task covers:
a. Removal
d. Inspection
g. Assembly
b. Disassembly
c. Cleaning
f. Fitting Piston Rings
e. Fitting Piston
h. Installation - Cylinder Kit Assembly
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7398 7083-7399
1 Ring Set (App F, Item 127)
1 Ring Set (App F, Item 126)
1 Ring (App F, Item 121)
3 Rings (App F, Item 123)
2 Piston pin retainers (App F, Item 119)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Piston ring pliers (App B, Item 12)
Ball attachment (App B, Item 6)
Piston pin retainer installer (App B, Item 57)
Piston pin retainer leak detector (App B, Item 63)
Piston ring compressor (App B, Item 12)
Cylinder liner hold down clamps (App B, Item 11)
Spring scale (App B, Item 24)
Feeler gage set (App B, Item 24)
Torque wrench (App B, Item 101)
Micrometer 0-1 inch (App B, Item 65)
Micrometer 4-5 inch (App B, Item 65)
Micrometer 1-2 inch (App B, Item 65)
Ridge reamer (App B, Item 72)
EXPENDABLE/DURABLE SUPPLIES
Flat Stone (App C, Item 43)
Engine oil (App C, Item 16)
Wood block (App C, Item 46)
Carbon removing compound (App C, Item 7)
Plastic gage (App C, Item 30)
Crocus cloth (App C, Item 12)
Fuel oil (App C, Item 21)
EQUIPMENT CONDITION
Para Description
6-21 Oil pan removed
6-28 Cylinder head removed
6-32 Oil pressure regulator and relief valve
removed
6-33 Oil pump removed
●
a. Removal
CAUTION
Piston ring breakage can occur if
carbon deposits at top of liner are
not removed.
(1) Using a ridge reamer, remove carbon
deposits from upper inner surface of
cylinder liner (1).
6-30
Applies to engines thru
serial number 8VA-294356
TM9-2815-202-34
(2) Remove two nuts (2), cap (3), and
lower bearing shell (4) from piston
and connecting rod assembly (5).
NOTE
Tag piston assembly with cylinder
number for matching during
reassembly.
(3) Push piston and connecting rod
assembly (5) out through top of
cylinder block (6).
NOTE
Reassemble cap with stamped
number on same side as connecting
rod to assure cap is not rotated 180
degrees.
(4) Reassemble bearing cap (3) and
lower bearing shell (4) to piston and
connecting rod assembly (5) using
two nuts (2).
b. Disassembly
(1) Secure piston and connecting rod
assembly (5) in a soft-jawed vise and
remove piston rings (7) with piston
ring pliers (8). Discard piston rings.
CAUTiON
Do not damage piston or bushings
during removal of piston pin
retainers.
(2) Punch a hole through center of one
piston pin retainer (9) with narrow
chisel or punch and pry retainer from
piston (10). Discard retainer.
(3) Withdraw piston pin (11 ) from piston
(1 0) and remove connecting rod
assembly (12).
(4) Drive remaining piston pin retainer (9)
out from inside with a brass rod.
Discard retainer.
6-31
TM9-2815-202-34
6-34. PISTON AND CONNECTING ROD MAINTENANCE (TRUNK TYPE) (Cont)
c. Cleaning
WARNING
●
Use goggles, rubber gloves, and rubber apron when cleaning parts in
carbon-removing corn-pound. Provide adequate ventilation. Avoid
inhaling fumes and contact with skin. If compound is splashed on skin,
flush with water and wash with alcohol. Alcohol containing 2 or 3
percent camphor is preferable. If contact with eyes is made, flush eyes
with water and get medical aid immediately.
●
Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only with effective chip guarding and personal protective
equipment (goggles/shield, gloves, etc).
(1) Clean piston components with fuel oil and dry with compressed air. If fuel oil does not
remove carbon deposits, use carbon-removing compound which will not harm bushings or
tin plating on piston.
CAUTION
Do not damage tin plating on piston skirt. Upper section of piston, including
compression ring lands and grooves, is not tin-plated. Wire brush upper section only to
remove any hard carbon.
(2) Clean ring grooves with suitable tool or a piece of an old compression ring ground to a
beveled edge.
(3) Clean inside surfaces of piston and oil drain holes in piston skirt. Do not enlarge holes while
cleaning them.
d. Inspection
(1) Piston
CAUTION
Do not remove bushings in piston or connecting rod. These parts are not serviced.
(a) Check cylinder liner and block bore for excessive out of round, taper, or high spots
which could cause failure of piston (see Para 4-34).
NOTE
Overheating or burned spots on piston may indicate an obstruction in connecting rod
oil passage.
6-32
TM9-2815-202-34
(b) Examine piston for score marks, cracks, damaged ring grooves, loss of tin plating, or
indications of overheating. Using a crocus cloth, remove light score marks from piston.
Replace any piston severely scored or overheated. Discard piston if cracks are found
across internal struts.
(2) Piston Pin
CAUTION
Do not polish or refinish piston pin. Hand polishing will destroy precision finish
required against bushing and result in rapid bushing wear.
(a) Inspect piston pin for signs of fretting. Discard pin if fretting is present.
(b) Measure piston pin diameter. New pin must be 1.4996 to 1.5000 inches in diameter.
Replace used pin if diameter is 1.4980 inches or less.
6-33
TM9-2815-202-34
6-34. PISTON AND CONNECTING ROD MAINTENANCE (TRUNK TYPE) (Cont)
(3) Connecting Rod
(a) Check connecting rod for visual damage. Scrap rod if bent, had previous bearing failure,
was overheated (blued) at top or bottom end, or fretted at split line between rod and cap.
(b) Check for cracks by the magnetic particle method.
NOTE
Overheated bushings may become loose and creep together, thus blocking off supply
of lubricating oil to piston pin and spray nozzle.
(c) Check connecting rod bushings for indications of scoring, overheating, or other damage.
Compressed air used for cleaning purposes will not exceed 30 PSI. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
(d) Check spray nozzle at upper end of connecting rod for plugged holes. Blow compressed
air through drilled oil passage in rod to insure spray nozzle holes are open.
(e) Inspect connecting rod bearing bores for burrs or foreign particles. Clean up minor burrs
with crocus cloth using circular motion.
6-34
TM9-2815-202-34
(9) When installing a new connecting
rod assembly, stamp cylinder
number on connecting rod (5)
and cap (3).
(4) Connecting Rod Bearings
(a) Inspect bearing shells for scoring,
pitting, flaking, etching, and dirt
grooving. If defective, discard
bearing shells.
TABLE 6-1.
(b) Discard bearing shells with bright
spots on backs indicating
movement in bearing caps or
supports.
NOTE
If one bearing shell is less than
minimum thickness shown in Table
6-1, replace both bearing shells
(upper-and lower).
(c) Using a micrometer and ball
attachment, measure thickness of
lower bearing shell (4) and upper
bearing shell (13) at point “C”, 90
degrees from parting line.
e. Fitting Piston
NOTE
Fit new or used piston to
corresponding cylinder liner and
retain as matched set for assembly
in engine.
(1) Using a micrometer, measure piston
skirt outside diameter parallel to and
perpendicular with piston
pino bore at
o
room temperature, 70 F (21 C).
Diameter must be 4.2428 to 4.2450
inches. Taper and out of round must
not exceed 0.0005 inch.
6-35
TM9-2815-202-34
6-34. PISTON AND CONNECTING ROD MAINTENANCE (TRUNK TYPE) (Cont)
NOTE
•
Use feeler gage to check piston to
liner clearance. Use a spring scale
attached to feeler gage to measure
amount of force in pounds required
to withdraw feeler gage from
between piston and liner. Select
feeler gage with thickness requiring
six pounds pull to move. Piston to
liner clearance is 0.001 inch greater
than thickness of feeler gage used.
For example, a 0.004 inch feeler
gage indicates 0.005 inch clearance
when withdrawn with a six pound
pull.
•
Feeler gage must be perfectly flat
and free of nicks and bends.
(2) With cylinder liner (1) installed in
cylinder block (6), hold piston (10)
upside down in liner and measure
clearance in four places, 90 degrees
apart. Clearance must be 0.0045 to
0.0083 inch with new parts. Allow a
maximum clearance of 0.0120 inch
for used parts.
(3) If binding occurs between piston and
liner, remove piston and examine
piston and liner for burrs. Remove
burrs on piston with a fine stone.
Remove burrs in liner with fine flat
hone and recheck clearance.
f. Fitting Piston Rings
(1) Insert ring inside cylinder liner in
normal area of ring travel. Using
piston to push ring down, measure
ring gap with feeler gage. Refer to
Table 6-2 for ring gap specifications.
Repeat procedure for balance of
compression and oil rings.
File or stone both ends of
compression ring from outer surface
to inner surface to prevent chipping
or peeling of chrome plating on ring.
(2) File ends of compression ring if ring
gap is too small. Ends of ring must
remain square, and chamfer on outer
edge must be approximately 0.015
inch.
6-36
TABLE 6-2
TM9-2815-202-34
(3) Using feeler gage, measure ring side
clearance. Refer to Table 6-2 for ring
side clearance specifications.
g. Assembly
(1) Connecting Rod Assembly to Piston
(a) Apply clean engine oil to piston
pin and piston pin bushings.
Do not drive piston pin retainer in
too far. Retainer may move piston
bushing inward and result in reduce
piston pin end clearance.
(b) Insert one piston pin retainer (9)
in position. Then place crowned
end of installer (14) against
retainer and strike installer just
hard enough to deflect retainer
and seat it evenly in piston (10).
NOTE
Since loading on the piston pin is
downward, it must have free
movement to secure perfect
alinement and uniform wear.
Therefore, the piston pin has a full
floating fit in connecting rod and
piston bushings. Large clearances
of 0.010 inch maximum are allowed.
(c)
Place upper end of connecting
rod assembly (12) between
piston pin bosses and in line with
piston pin holes. Then slide
piston pin (11) in place.
(d) Install second piston pin retainer
(9) as directed in step (b).
(e) Check for piston pin end
clearance by cocking connecting
rod and shifting pin in bushings.
6-37
TM9-2815-202-34
6-34. PISTON AND CONNECTING ROD MAIN TENANCE (TRUNK TYPE) (Cont)
(f) Check each piston pin retainer for
proper sealing with leak detector
(15). Place suction cup over
retainer and hand operate lever
to pull a vacuum of ten inches of
mercury on gage. A drop in gage
reading indicates air leakage at
retainer.
(2) Installation - Piston Rings
NOTE
Before installing piston rings,
assemble piston and rod as directed
in previous section.
(a) Lubricate piston rings and piston
with engine oil before installing
rings.
CAUTION
● Do not overlap ends of oil control ring expanders. An overlapped expander will
cause oil control ring to protrude beyond allowable limits and result in breakage
when inserting piston in ring compressor.
● Do not cut or grind ends of expanders to prevent overlapping. Cutting or grinding
ends will decrease expanding force on oil control rings and result in high-lubricating
oil consumption.
NOTE
Scraper edges of all oil control rings must face downward (toward bottom of piston) for
proper oil control.
(b) Install two ring expanders (16) in oil control ring grooves in piston (10). Install oil ring
expanders with legs of free ends toward top of piston.
WARNING
Do not grasp or graze sharp edges of oil control rings with bare hands.
Rings are extremely sharp and can cut personnel when mishandled.
NOTE
● Upper oil control ring groove requires a one-piece ring, and lower groove requires a
two-piece ring (upper and lower halves).
● Install upper and lower oil control rings by hand.
Scraper edges of all oil control rings must face downward (toward bottom of piston)
for proper oil control.
6-38
TM9-2815-202-34
(c)
Install lower half of lower oil control ring (17) with gap 90 degrees from gap in expander.
Then install upper half of lower oil control ring (18) with gap 180 degrees from gap in
expander.
(d) Install upper oil control ring (19) over upper groove. Aline gap in oil ring 180 degrees
from gap in expander (1 6). Press ring against gap side of expander to prevent ends of
expander from overlapping.
CAUTION
Do not spread rings more than necessary to slip over piston. Ring breakage and
overstressing will result.
NOTE
Compression rings have no marks on top or bottom of rings. Fire ring has one mark
(indentation near gap) on top of ring.
(e) Starting with bottom compression ring (20), install three compression rings using piston
ring pliers. Install fire ring (21 ) with identification mark toward top of piston (10).
(f)
Stagger ring gaps around piston a minimum of 90 degrees from each other.
6-39
TM9-2815-202-34
6-34. PISTON AND CONNECTING ROD MAINTENANCE (TRUNK TYPE) (Cont)
(3) Piston and Connecting Rod Assembly
to Cylinder Liner
(a) Apply clean engine oil to piston,
rings, and inside surface of piston
ring compressor.
NOTE
Inspect ring compressor for nicks or
burrs, especially at nontapered
inside diameter end. Nicks or burrs
on inside diameter of compressor
will result in damage to piston rings.
(b) Place piston ring compressor (22)
on a wood block with tapered end
of ring compressor facing up.
(c) Stagger piston ring gaps 90
degrees apart on piston. Make
sure ends of oil control ring
expanders do not overlap.
(d) Start top of piston and connecting
rod assembly (5) straight into ring
compressor (22). Then push
piston down until it contacts wood
block.
(e) Place cylinder liner (1) with
flange end down on wood block.
NOTE
Numbers on side of connecting rod
and cap identify rod with cap and
indicate cylinder where used.
6-40
TM9-2815-202-34
(f)
Place ring compressor (22) and
piston and connecting rod
assembly (5) on liner (1) with
numbers on side of connecting
rod and cap alined with
matchmark on liner.
(g) Push piston and connecting rod
assemblv (5) down into liner until
piston is-free of ring compressor
(22).
CAUTION
Do not force piston into liner.
Expanders apply considerable force
on oil rings; therefore, take care
during loading operation to prevent
ring breakage.
(h) Remove connecting rod cap and
ring compressor. Then push
piston down until compression
rings pass cylinder liner ports.
h. Installation - Cylinder Klt Assembly
NOTE
If any pistons and liners are already
in engine, use hold down clamps
(23) to retain liners (1) in place
when rotating crankshaft.
(1) Install cylinder liner insert (24) in
block counterbore.
(2) Rotate crankshaft (25) until
connecting rod journal (26) of cylinder
is at bottom of its travel. Wipe journal
clean and lubricate with clean engine
oil.
6-41
TM9-2815-202-34
6-34. PISTON AND CONNECTING ROD MAINTENANCE (TRUNK TYPE) (Cont)
NOTE
Tang on bearing shell must fit in
indentation on connecting rod.
(3)
Install upper bearing shell (13)
(without continuous oil groove) in
connecting rod. Lubricate bearing
shell with clean engine oil.
NOTE
Distance from vertical center line of
connecting rod bolts to edges of rod
are not equal. Therefore, when
installing piston and connecting rod
assembly, insure narrow side of two
adjoining connecting rods are
together to avoid cocking of rod.
(4) Position piston, rod, and liner
assembly (27) above cylinder block
bore. Aline identification number and
letter on rod with outer edge of
cylinder block and matchmarks on
Iliner. Guide end of connecting rod
assembly (12) through block bore
carefully to avoid damaging or
dislodging bearing shell. Then slide
piston, rod, and liner assembly
straight into block bore until liner
flange rests against insert in block
counterbore (6).
(5) Push piston and connecting rod into
liner until upper bearing shell seats
firmly on crankshaft journal.
(6) Place lower bearing shell (4) (with
continuous oil groove) in connecting
rod cap (3).
NOTE
6-42
•
Tang on bearing shell must fit in
indentation in connection rod
cap.
•
Insure connecting rod bolt has
not turned in connecting rod
before torquing nut.
TM9-2815-202-34
(7) To check bearing to crankshaft
journal clearance, place a plastic
gage strip (28) between crankshaft
journal (26) and connecting rod cap
(3). Tighten connecting rod nuts (2) to
60-70 Ib-ft (81-95 N-m). Remove
connecting rod nuts and cap, and
measure width of plastic gage with
measuring strip (29). Maximum
clearance with used parts is 0.0056
inch.
(8) Lubricate bearing with clean engine
oil and install bearing cap (3) and
lower bearing shell (4) on connecting
rod (5) with identification numbers on
cap and rod adjacent to each other.
Install two connecting rod bolt nuts (2)
and torque to 60-70 lb-ft (81-95 N-m).
NOTE
If necessary, pry connecting rods
apart before measuring side
clearance.
(9) Using feeler gage (30), measure side
clearance between each pair of
connecting rods. Clearance limits are
0.008 to 0.016 inch.
(10) Repeat steps (1) thru (9) to install
additional liners, pistons, and rod
assemblies. Use hold-down clamps to
hold each installed liner in place.
(11) Remove all liner hold down clamps.
END OF TASK
FOLLOW-ON MAINTENANCE
Para
6-33
6-32
6-28
6-21
Description
Install oil pump
Install oil pressure regulator and relief
valve
Install cylinder head
Install oil pan
6-35. CYLINDER LINER MAINTENANCE
(See Para 4-34)
6-36. CRANKSHAFT MAINTENANCE
(See Para 4-35)
6-37. CYLINDER BLOCK MAINTENANCE
(See Para 4-36)
6-43
TM9-2815-202-34
Section IV. COMPONENT REPAIR
6-38. TURBOCHARGER REPAIR
This task covers:
a. Disassembly
d. Assembly
b. Cleaning
c. Inspection
INITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
7083-7398 7083-7399
Engine oil (App C, Item 16)
Cleaning solvent (App C, Item 10)
Crocus cloth (App C, Item 12)
Silicone carbide cloth (App C, Item 41)
Silicone lubricant (App C, Item 42)
Sealing compound (App C, Item 40)
Sealant (App C, Item 39)
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
Magnetic base dial indicator (App B, Item 45)
Turbocharger holding fixture (App D, Item 8)
Micrometer depth gage (App B, Item 23)
Sleeve (App D, Item 12)
Back plate torquing tool (App D, Item 9)
Torque wrench, (App B, Item 100)
EQUIPMENT CONDITION
Para Description
Turbocharger removed
6-2
MANDATORY REPLACEMENT PARTS
Lockwashers (App F, Item 93)
Gasket (App F, Item 21 )
Gasket (App F, Item 60)
Locking plates (App F, Item 111)
Gaskets (App F, Item 20)
Locking plates (App F, Item 11O)
Piston ring (App F, Item 128)
Seal ring (App F, Item 139)
Gasket (App F, Item 76)
Bearings (App F, Item 1)
Snap ring (App F, Item 143)
Locking nut (App F, Item 187)
a. Disassembly
(1) Remove oil inlet elbow (1) from cover plate(2).
(2) Remove two bolts (3) and two Iockwashers (4) securing cover plate (2) to turbocharger
assembly (5). Remove cover plate and gasket (6). Discard gasket and Iockwashers.
(3) Remove two bolts (7) and two Iockwashers (8) securing oil drain tube (9) to turbocharger
assembly (5). Remove drain tube and gasket (10). Discard Iockwashers and gasket.
CAUTION
Do not nick compressor and turbine wheels when removing compressor and turbine
housings. These wheels are highly balanced and can become unbalanced by small
nicks.
6-44 Change 1
TM 9-2815-202-34
NOTE
Mark relative position of compressor
housing (11), center housing
assembly (12), and turbine housing
(13) with a scribe to insure
assembly in same location.
(4) Remove twelve bolts (14) securing
compressor housing (11) to center
housing assembly (12). Remove
compressor housing.
NOTE
Mark location of lifting bracket (15)
to insure assembly in same location.
(5) Bend locking plates (16) away from
nuts (17). Remove eight nuts, four
locking plates, and lifting bracket (15).
Discard locking plates.
(6) Remove turbine housing (13) and
shims (18).
(7) Remove three nuts (19), three gaskets
(20), and three bolts (21) securing
turbine nozzle (22) to turbine housing
(13). Remove turbine nozzle and
discard gaskets.
NOTE
Mark location of two long studs (23)
to insure assembly in same location.
(8) If necessary, remove two studs (23)
and six studs (24).
(9) Remove four nuts (25) and four
Iockwashers (26) securing diffuser
(27) to center housing assembly (12).
6-45
TM9-2815-202-34
6-38. TURBOCHARGER REPAIR (Cont)
(10) Place center housing assembly (12)
in holding fixture to prevent rotating
assembly (28) from turning.
CAUTION
Use a wrench with a doubleuniversal joint to remove impeller
nut. A fixed wrench or ratchet can
side load impeller and bend shaft.
(11) Remove impeller locking nut (29) and
washer (30) from rotating assembly (28).
Discard nut.
■
WARNING
Use heat-resistant gloves
when handling heated parts.
Metal components will
dissipate heat quickly. Burns
to personnel will result.
(12) Heat center housing assembly (12) at
temperature
of 350-375°F (177o
190 C) for period of not longer than
10 minutes.
(13) Using arbor press, press rotor
assembly (31) from impeller (32). Lift
center housing assembly (5) from
rotor assembly.
NOTE
Retain original shims for use during
reassembly to obtain proper size
and quantity for rotor clearance.
(14) Remove impeller (32), diffuser (27),
and shims (33) from center housing
assembly (12).
(15) Bend locking plates (34) away from
heads of bolts (35). Remove six bolts
and three locking plates securing
thrust plate assembly (36) to center
housing assembly (5). Discard
locking plates.
(16) Remove thrust plate assembly (36),
thrust plate (37), thrust ring (38), and
thrust washer (39) from center
housing assembly (12).
(17) Remove piston ring (40) from thrust
ring (38). Discard piston ring.
6-46
Change 1
TM9-2815-202-34
CAUTION
Do not scuff bearing journal
surfaces of shaft. Journal surfaces
are machined to high tolerances.
(18) Remove snap ring (41) and two
bearings (42) from center housing
assembly (12). Discard snap ring and
bearings.
(19) Install center housing assembly (12)
in a soft-jawed vise. Unscrew back
plate (43) from center housing
assembly. Remove shims (44),
diaphragm (45), and gasket (46).
Discard gasket.
(20) Remove seal ring (47) from center
housing assembly (12). Discard seal
ring.
(21) If necessary, remove two pins (48)
from center housing assembly (12).
b. Cleaning
WARNING
Dry cleanIng solvent P-D-680
is toxic and flammable. Wear
protective goggles and gloves
and use only in a wellventilated area. Avoid contact
with skin, eyes, and clothes
and don’t breathe vapors. Do
not use near open flame or
excessive heat.
The flash
o
point is 100 F-138°F (38 °C50°C). If you become dizzy
while using cleaning solvent,
get fresh air immediately and
get medical aid. If contact with
eyes is made, wash your eyes
with water and get medical aid
immediately.
CAUTION
•
Do not use a caustic solution to clean aluminum components. A caustic solution will
erode aluminum parts.
•
Do not use wire brush or steel-bladed scraper to clean bearing surfaces or
aluminum parts. Metal to metal contact will mar bearing finishes and deform
aluminum parts.
•
Clean compressor and turbine wheel blades thoroughly. Deposits left on blades will
affect balance of rotating assembly.
6-47
TM9-2815-202-34
6-38. TURBOCHARGER REPAIR (Cont)
NOTE
Before cleaning, inspect parts for signs of burning, rubbing, or other damage which
might not show after cleaning.
(1) Soak all part is in dry cleaning solvent for 25 minutes. Using a stiff bristle brush, remove all
dirt particles. Dry all parts thoroughly.
WARNING
Compressed air used for cleaning purposes will not exceed 30 PSI. Use
only with effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
(2) Using compressed air, blow clean all internal cavities and oil passages in center housing.
c. inspection
(1) Inspect all parts for signs of damage, corrosion, or deterioration. Check for nicked, crossed,
or stripped threads.
(2) Check turbine wheel for signs of rubbing or wear.
(3) Inspect shaft for signs of scoring, scratches, or bearing seizure,
(4) Check impeller for signs of rubbing or blade damage. Check wheel bore for galling.
(5) Inspect seal parts for signs of rubbing or scoring of running faces.
(6) Inspect turbine nozzle for erosion and bent vanes.
(7) Inspect diffuser for dirt and foreign matter.
(8) Inspect center housing, compressor housing, and turbine housing for contact with rotating
parts.
(9) Replace thrust washer if faces are worn unevenly or scratched excessively.
(10) Smooth or polish minor surface damage. Use silicone carbide abrasive cloth for aluminum
parts and crocus cloth for steel parts.
d. Assembly
(1)If removed, install two pins (48) in compressor end of center housing assembly (1 2). Pins
must extend 0.075 to 0.085 inch above surface.
(2) Install gasket (46) and diaphragm (45) on center housing assembly (12). Aline holes in
diaphragm (45) to holes in center housing.
NOTE
Place four bolts through diaphragm and center housing holes to prevent diaphragm
from turning when torquing back plate.
6-48
TM9-2815-202-34
(3) Install shims (44) and back plate (43)
on center housing assembly (12).
Using fabricated back plate torquing
tool, torque back plate to 25-30 Ib-ft
(34-41 N-m).
(4) Lubricate bearing (42) with engine oil.
Install bearing in turbine side of
center housing assembly (12). Install
snap ring (41 ) in center housing
assembly.
(5) Turn center housing assembly (12) so
compressor side is up. Install second
bearing (42).
(6) Lightly coat seal ring (47) with
silicone lubricant. Install ring in center
housing assembly (12).
CAUTION
Do not scuff or score inner surface
of bearings while pushing shaft
through bearings. Turbocharger will
not operate long with damaged
bearing surfaces.
(7) Lubricate bearing journals of rotor
assembly (31 ) with engine oil. Lower
center housing assembly (12), with
back plate (43) down, over rotor
assembly.
(8) Install thrust washer (39) on shaft of
rotor assembly (31 ). Position holes
and cutout in thrust washer over pins
(48). Seat thrust washer flat against
center housing assembly (12).
(9) Install piston ring (40) on thrust collar
(38).
(10) Install thrust plate washer (37) and
thrust collar (38) in thrust plate (36).
6-49
TM9-2815-202-34
6-38. TURBOCHARGER REPAIR (Cont)
(11) Slide thrust plate assembly (50) over
rotor assembly (31 ). Aline holes in
thrust plate assembly with holes in
center housing assembly (12).
(12) Install three locking plates (34) and
six bolts (35) securing thrust plate
assembly (50) to center housing
assembly (12). Torque bolts to
80-100 lb-in (9-11.4 N-m).
NOTE
Back plate shim comes in a 0.010
inch thickness.
(13) Push rotor assembly (31) toward
compressor end of turbocharger.
Using feeler gage, measure
clearance between rotor assembly
and back plate (43). Repeat steps (2)
thru (12) to add or remove shims (44)
until clearance is between 0.020 to
0.030 inch.
(14) Bend up tangs on locking plates (34)
against heads of bolts (35).
(15) Install fabricated sleeve (51) over
shaft of rotor assembly (31) and
against face of thrust collar (38).
Sleeve length is 2.125 inches.
Secure rotor assembly and center
housing assemblv (12) in place with
washer (30) and nut (29). Tighten nut
securely.
(16) Using dial indicator (52), measure
axial play of rotor assembly (31). Play
should be 0.005 to 0.010 inch.
(17) Remove nut (29), washer (30), and
sleeve (51).
(18) Install diffuser shims (33) and diffuser
(27) on center housing assembly (12)
and secure with four nuts (25) and
four Iockwashers (26). Torque nuts to
150-200 lb-in (17-22 N-m).
6-50
TM9-2815-202-34
(19) Determine quantity of diffuser shims
(33) as follows:
(a) Place center housing assembly
(12) upright with turbine wheel
resting on flat surface.
(b) Place flat bar (53) across diffuser
vanes (54).
(c) Measure distance from top of bar
(53) to face of thrust collar (38)
with depth gage (55).
(d) Measure distance from top of bar
(53) to face of diffuser vanes (54).
(e) Subtract two readings. Difference
is height of diffuser vanes above
face of thrust collar.
(f)
Rotate bar (53) 180 degrees and
repeat measurements. Results
should agree within 0.001 inch.
(9) Place impeller (32), blades up, on
flat surface and measure height
of impeller blades from flat
surface. Measure at least 1/8 inch
back from blade tip edge.
(h) Rotate impeller 180 degrees and
repeat measurement. Results
should agree within 0.001 inch.
NOTE
Diffuser shims come in 0.005,0.010,
and 0.020 inch thicknesses.
(i) Subtract impeller blade tip height
from diffuser vane height. Answer
is height difference diffuser is
higher than impeller blade tips.
Add or remove shims (33), as
directed in step (18), to attain a
height difference of 0.013 to
0.017 inch.
Wear heat-resistant gloves
when handling heated parts.
Metal components will
dissipate heat quickly. Burns
to personnel will result.
6-51
TM 9-2815-202-34
6-38. TURBOCHARGER REPAIR (Cont)
(20) Heat impeller (32) o temperature of
350-375°F (177-191 C) for 10
minutes maximum.
(21) Install impeller (32) on rotor assembly
(31)
CAUTION
Use a wrench with a doubleuniversal joint to tighten impeller
nut. A fixed wrench or ratchet can
side load rotor assembly and bend
shaft.
(22) While impeller (32) is still hot, install
washer (30) and nut (29). Torque nut to
30-35 Ib-ft (41-47 N-m).
(23) Aftero impeller (32) has cooled to less than
150 F (66°C), torque nut (29) to 40-45
Ib-ft (54-61 N-m).
(24) Apply thin coat of sealing compound to
diffuser face (27) mating with compressor
housing (11). Apply sealing compound
around bolt holes in compressor housing.
(25) Install compressor housing (11) on
diffuser (27). Aline scribe marks on
compressor housing and center housing,
(26) Secure compressor housing (11) in place
with twelve bolts (14). Torque bolts to
150-200 lb-in (17-22.6 N-m).
NOTE
Nozzle bolts are not symmetrical,
Sides of bolt heads must press
firmly against nozzle. If the bottom of
any bolt head contacts the turbine
housing, rotate that bolt 180
degrees.
(27) Install nozzle (22) in turbine housing (13) and secure with three bolts (21), three gaskets
(20), and three nuts (19). Torque nuts to 35-45 lb-in (4-5.1 N-m).
(28) If removed, install studs (23 and 24) into original locations as marked.
(29) Place shims (18) over studs (23 and 24) in turbine housing (13).
NOTE
Aline scribe marks on center housing assembly and turbine housing.
(30) Place turbine housing (13) on center housing assembly (12).
(31) Place lifting bracket (15) over studs (23) where marked.
6-52
TM 9-2815 -202-34
(32) Secure lifting bracket (15) and turbine housing (13) to center housing assembly (12) with
four locking plates (16) and eight nuts (17). Torque nuts to 20-25 Ib-ft (34-41 N-m).
(33) Adjust turbine housing to turbine wheel clearance as follows:
(a) Place turbine housing (13) flat on bench resting on exhaust flange.
NOTE
When turning rotor assembly during adjustment, turbine should rub just lightly enough
to hear a soft contact noise but not heavy enough to feel any binding.
(b) Check impeller (32) for free spin. Rotor assembly (31 ) should rub lightly on turbine
housing (13).
NOTE
Turbine housing shims come in 0.010 and 0.042 inch thicknesses.
(c)
If turbine wheel does not rub lightly on turbine housing (13), remove housing and add or
remove shims (18) until light rubbing is achieved.
(d) Remove turbine housing (13) from center housing assembly (12). Add shims (18) to
provide an additional clearance of 0.019 to 0.029 inch.
(e) Reinstall turbine housing according to steps (30) thru (32).
(34) Bend four locking plates (16) over sides of eight nuts (17).
6-53
TM9-2815-202-34
6-38. TURBOCHARGER REPAIR (Cont)
(35) Install gasket (6) and adaptor plate (2)
to oil inlet port in turbocharger
assembly (5) and secure with two
bolts (3) and two Iockwashers (4).
Torque bolts to 30-35 Ib-ft
(41-47 N-m).
(36) Install elbow (1) in adaptor plate (2).
(37) Install gasket (10) and drain tube (9)
to oil outlet port in turbocharger
assembly (5) and secure with two
bolts (7) and two Iockwashers (8).
Torque bolts to 30-35 Ib-ft
(41-47 N-m).
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
6-2
Install turbocharger
6-39. CYLINDER HEAD REPAIR
(See Para 4-39)
6-40. OIL COOLER ASSEMBLY REPAIR
(See Para 4-39)
6-41. FUEL INJECTOR ASSEMBLY REPAIR
(See Para 4-40)
6-42. BLOWER REPAIR
(See Para 4-41)
6-43. GOVERNOR REPAIR
6-44. WATER PUMP REPAIR
* Dual-range limiting speed governor for M578
**Single-range limiting speed governor for M110.
6-54
(See Para 4-42*) (See Para 5-41)
(See Para 4-43)
TM 9-2815-202-34
CHAPTER 7
REPAIR PROCEDURES FOR MAJOR COMPONENTS OF
ENGINE MODEL 7083-7399
Contents
Para
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . ...7-1
Turbocharger Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Turbocharger Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Exhaus Manifold and Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7-4
Fuel Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7-5
Engine Lifting Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Engine Water Manifolds Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7’-7
Water Pump Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Air Box Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7-9
Engine Rocker Arm Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 1
Air Inlet Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Tachometer Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
Accessory Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Blower Drive Shaft and Hub Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Governor Cover and Throttle Control Rod Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
Governor and Blower Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
Blower Drive Gear and Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2O
Camshaft Front Gear Cover and Damper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Rear Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24
Idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 -25
Injector Control Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Cylinder Head Assembly Removal/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Engine Lower Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
Camshaft and Gear Assemblies Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
Cylinder Block End Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
Oil Pressure Regulator and Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7-32
Piston and Connecting Rod Maintenance (Trunk Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Cylinder Liner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34
Crankshaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..7-35
Cylinder Block Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36
Turbocharger Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38
Oil Cooler Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7-39
Fuel Injector Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40
Blower Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
7-2
7-2
7-3
7-6
7-10
7-10
7-10
7-10
7-10
7-10
7-10
7-10
7-10
7-11
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-15
7-16
7-16
7-16
7-16
7-16
7-16
7-16
7-16
7-16
7-16
7-16
Change 1
7-1
TM9-2815-202-34
Section I. INTRODUCTION
7-1. GENERAL. This chapter provides the repair procedures performed on engine model 7083-
7399 after the engine has been installed on the maintenance stand. Component replacement
typically consists of removal, disassembly, cleaning /inspection, repair, assembly, and installation of
the component. Next, the engine block maintenance consists of disassembly, inspection, repair, and
assembly of the block components. For major components, the repair is handled separately from
removal and installation. Component repair usually consists of disassembly, cleaning/inspection, and
assembly.
This chapter deals with model 7083-7399. However, if a model in previous chapters has identical or
nearly identical components, this chapter will refer to the previous chapter.
Section II. GENERAL ENGINE MAINTENANCE
7-2. TURBOCHARGER REGULATOR REPLACEMENT
7-2
(See Para 6-2)
TM9-2815-202-34
7-3. TURBOCHARGER REMOVAL/lNSTALLATION
This task covers:
a. Removal
b. Inspection
c. Installation
INITIAL SETUP
MODELS
EQUIPMENT CONDITION
7083-7399
Para Description
3-10 Turbocharger oil return line removed
3-13 Turbocharger oil supply line removed
3-15 Air inlet manifold removed
6-2 Regulator air line removed
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
PERSONNEL REQUIRED: 2
MANDATORY REPLACEMENT PARTS
6 Locking nuts (App F, Item 104)
1 Gasket (App F, Item 40)
a. Removal
(1) Loosen two clamps (1) and slide hose
(2) and clamps onto air inlet housing
(3).
(2) Remove six locking nuts (4) from
exhaust manifold studs (5) securing
turbocharger (6) to exhaust manifold
(7). Discard locking nuts.
WARNING
Engine components are heavy.
To prevent personal injury,
use extreme caution when
removing large components
from engine.
7-3
TM9-2815-202-34
7-3. TURBOCHARGER
REMOVAL/lNSTALLATION (Cont)
CAUTION
•
Turbocharger is heavy. Use two persons or lifting device to prevent dropping or
damage to turbocharger.
•
Tape all openings of turbocharger after removal to keep foreign particles from
entering and damaging turbocharger blades.
(3) Remove turbocharger (6) and gasket (8). Discard gasket.
(4) Remove hose (2) and two clamps (1) from air inlet housing (3).
b. Inspection
(1) Inspect hoses for cuts, cracks, and brittleness.
(2) Replace all parts failing inspection.
c. Installation
(1) Install hose (2) and two clamps (1) on air inlet housing (3).
(2) Install gasket (8) over studs (5) on exhaust manifold (7).
7-4
TM9-2815-202-34
WARNING
Engine components are heavy. To prevent personal injury, use extreme
caution when removing large components from engine.
CAUTION
Turbocharger is heavy. Use two persons or lifting device to prevent dropping or
damage to turbocharger.
(3) Install turbocharger (6) over studs (5) and secure with six locking nuts (4). Torque locking
nuts to 83-93 Ib-ft (113-126 N-m).
(4) Slide hose (2) and two clamps (1) from air inlet housing (3) onto turbocharger (6). Tighten
clamps.
END OF TASK
FOLLOW ON MAINTENANCE
Para Description
6-2 Install regulator air line
3-15 Install air inlet manifold
3-13 install turbocharger oil supply line
3-10 Install turbocharger oil return line
7-5
TM9-2815-202-34
7-4. EXHAUST MANIFOLD AND TUBE REPLACEMENT
This task covers:
INITIAL
a. Removal
b. Installation
SETUP
MODELS
EQUIPMENT CONDITION
7083-7399
Para Description
3-10 Turbocharger oil return line removed
3-13 Turbocharger oil supply line removed
3-15 Air inlet manifold removed
7-2 Turbocharger regulator removed
7-3 Turbocharger removed
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
PERSONNEL REQUIRED: 2
MANDATORY REPLACEMENT PARTS
17 Locking nuts (App F, Item 103)
1 Gasket (App F, Item 62)
2 Gaskets (App F,ltem29)
a. Removal
(1) Remove two nuts (1) from two clamps (2) securing exhaust crossover tube (3) to right
exhaust manifold (4) and adaptor (5) on left exhaust manifold (6). Slide clamps onto
crossover tube.
(2) Loosen five locking nuts (7) securing right exhaust manifold (4) to cylinder head.
(3) Remove exhaust crossover tube (3) and clamps (2) from exhaust manifold (4) and adaptor
(5). Remove clamps from tube.
(4) Slide exhaust manifold (4) upward and off cylinder head. Remove five locking nuts (7), three
beveled washers (8), and two end retainers (9) from studs (10) on right cylinder head.
Discard locking nuts.
(5) Remove exhaust manifold gasket (11). Discard gasket.
(6) Remove four locking nuts (12) securing adaptor (5) to left exhaust manifold (6). Discard
locking nuts.
(7) Remove adaptor (5) and gasket (13) from exhaust manifold. Discard gasket.
WARNING
Use a second person to hold or secure exhaust manifold when loosening
self-locking nuts to prevent manifold from slipping or falling. Injury to
personnel can occur if manifold is not secured.
7-6
TM 9-2815-202-34
(8) Loosen eight locking nuts (7) securing left exhaust manifold (6) to cylinder head.
(9) Slide exhaust manifold (6) upward and off cylinder head.
(10) Remove eight locking nuts (7), six beveled washers (8), and two end retainers (9) from studs
(10) on left cylinder head. Discard locking nuts.
(11) Remove exhaust manifold gasket (11). Discard gasket.
Change
1
7-7
TM 9-2815-202-34
7-4. EXHAUST MANIFOLD AND TUBE REPLACEMENT (Cont)
b. Installation
(1) Position gasket (11) over exhaust manifold studs (10) on left cylinder head.
NOTE
Position beveled washers with crown facing nut.
(2) Install six beveled washers (8), two end retainers (9), and eight locking nuts (7) on left
exhaust manifold studs (10).
WARNING
Use a second person to hold or secure exhaust manifold when installing
self-locking nuts to prevent manifold from slipping or falling. Injury to
personnel can occur if manifold is not secured.
NOTE
Insure locating pads on exhaust manifold rest on cylinder block locating pads.
(3)
Install left exhaust manifold (6) onto cylinder head by sliding downward between gasket (11)
and retainers (9) and beveled washers (8).
(4) Torque eight locking nuts (7) on exhaust manifold (6) to 30-35 Ib-ft (41-47 N-m) starting from
center and working outward alternately toward either end.
(5)
Install gasket (13) and adaptor (5) on exhaust manifold (6) and secure with four locking nuts
(12). Torque nuts to 30-35 Ib-ft (41-47 N-m).
(6) Position gasket (11 ) over exhaust manifold studs (1 O) on right side of cylinder head.
NOTE
Position beveled washers with crown facing nut.
(7)
Install three beveled washers (8), two end retainers (9), and five locking nuts (7) on right
exhaust manifold studs (10).
NOTE
● Do
not tighten or torque exhaust manifold nuts until crossover tube has been
installed.
● Insure
7-8
locating pads on exhaust manifold rest on cylinder block locating pads.
TM 9-2815-202-34
6
LEFT SIDE
(8) Install right exhaust manifold (4) onto cylinder head by sliding downward between gasket
and retainers and beveled washers.
(9) Install exhaust crossover tube (3) between exhaust manifold (4) and adaptor (5). Position
two clamps (2) on crossover tube (3).
(10) Torque five locking nuts (7), securing right exhaust manifold (4) to cylinder head, to 30-35
Ib-ft (41-47 N-m) starting from center and working outward alternately toward either end.
Install two nuts (1) on two clamps (2) and tighten nuts.
END OF TASK
FOLLOW-ON MAINTENANCE
Para
7-3
7-2
3-15
3-13
3-10
Description
Install turbocharger
Install turbocharger regulator
Install air inlet manifold
Install turbocharger oil supply line
Install turbocharger oil return line
Change 1
7-9
TM 9-2815-202-34
7-5
Fuel Lines Replacement
(See Para 5-4),
7-6
Engine Lifting Brackets Replacement
(See Para 5-5)
7-7
Engine Water Manifolds Replacement
(See Para 5-6)
7-8
Water Pump Removal/installation
(See Para 5-7)
7-9
Air Box Heater Replacement
(See Para 6-11)
7-10
Engine Rocker Arm Cover Replacement
(See Para 4-11)
7-11
Fuel Pump Replacement
(See Para 4-12)
7-12
Air Inlet Housing Replacement
(See Para 4-13)
7-13
Tachometer Drive Replacement
(See Para 4-14)
7-10 C h a n g e
1
TM9-2815-202-34
7-14. CRANKCASE BREATHER REPLACEMENT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning/Inspection
INITIAL SETUP
MODELS
7083-7399
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Torque wrench (App B, Item 101)
MANDATORY REPLACEMENT PARTS
8 LockWashers (App F,Item 93)
1 Gasket (App F, Item 26)
1 Gasket (App F, Item 36)
1 LockWasher (App F, Item 92)
EXPENDABLE/DURABLE SUPPLIES
Cleaning solvent (App C, Item 10)
FLYWHEEL HOUSING CRANKCASE BREATHER
a. Removal
Remove two bolts (1), bolt (2), three bolts (3), and six Iockwashers (4) securing
breather assembly (5) and gasket (6) to flywheel housing. Remove breather assembly.
Discard Iockwashers and gasket.
7-11
TM9-2815-202-34
7-14. CRANKCASE BREATHER REPLACEMENT (Cont)
b. Disassembly
(1) Remove bolt (7), flat washer (8), and spacer (9) securing filter element (10) and shell (11) to
adaptor (12). Remove shell from element.
(2) Remove two bolts (13) and two Iockwashers (14) securing breather pipe(15) and gasket
(16) to adaptor (12). Discard gasket and Iockwashers.
c. Cleanlng/Inspection
WARNING
● Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only In a well-ventilated area. Avoid
contact with skin, eyes, and clothes and don’t breathe vapors. Do
not
o
useo nearo open flames or excessive heat. The flash point is 100 F-138°F
(38 C-50 C). If you become dizzy while using cleaning solvent, get
medical aid. If contact with eyes is made, wash your eyes with water
and get medical aid immediately.
● Compressed air used for cleaning purposes will not exceed 30 PSI.
Use only effective chip guarding and personal protective equipment
(goggles/shield, gloves, etc).
(1) Clean all parts with dry cleaning solvent and dry with compressed air.
(2) Inspect adaptor, pipe, and shell for cracks, pitting, or damage.
(3) Inspect filter element for cuts, tears, or damage.
7-12
TM9-2815-202-34
d. Assembly
(1) Install gasket (16) and breather pipe (15) onto adaptor (12). Secure with two Iockwashers
(14) and two bolts (13). Torque bolts to 30-35 Ib-ft (41 -47 N-m).
(2) Install filter element (10) and shell (11) onto adaptor (12) and secure with spacer (9), flat
washer (8), and bolt (7). Torque bolt to 30-35 Ib-ft (41-47 N-m).
e. Installation
(1) Install gasket (6) onto breather assembly (5).
(2) Position breather assembly (5) onto flywheel housing and secure with two bolts (1), bolt (2),
three bolts (3), and six Iockwashers (4). Torque bolts to 30-35 Ib-ft (41-47 N-m).
7-13
TM9-2815-202-34
7-14. CRANKCASE BREATHER REPLACEMENT (Cont)
CRANKCASE BREATHER TUBE REPLACEMENT
a. Removal
(1) Remove bolt (17), nut (18), and
Iockwasher (19) securing clip (20)
and tube (21 ) to bracket (22). Remove
tube. If necessary, remove clip from
tube. Discard Lockwasher.
(2)
Loosen two clamps (23) securing
hose (24) to tube (21) and breather
pipe (25). Remove tube from hose.
(3) Remove two clamps (23) from hose
(24). Remove hose from breather pipe
(25).
(4)
If necessary, remove nut (26) and
Iockwasher (27) from bolt (28)
securing bracket (22) to flywheel
housing. Discard Iockwasher.
NOTE
Do not remove breather pipe unless
damaged. Removal of pipe will
destroy it and require its
replacement.
(5) If necessary, remove breather pipe
(25) from cylinder block.
b. Inspection
(1) Inspect breather pipe and tube for
cracks, holes, or other damage.
(2) Inspect hose for cuts, cracks, or
brittleness.
c. Installation
(1) If removed, secure bracket (22) to bolt (28) with nut (26) and Iockwasher (27) to flywheel
housing. Torque bolt 25-30 Ib-ft (34-41 N-m).
(2) If removed, drive new breather pipe (25) into cylinder block with a piece of wood and softheaded hammer until distance from surface of block to top of pipe is 5.75 inches (14.6 cm).
7-14
TM9-2815-202-34
(3) Install hose (24) and two clamps (23) onto breather pipe (21). Install tube (25) into hose and
tighten two clamps.
(4) If removed, install clip (20) onto tube (21).
(5)
. Iockwasher (19), and nut (18).
. , Secure clip (20) and tube (21) to bracket (22) with bolt (1. 7),
Torque bolt to 13-17 Ib-ft (18-23 N-m).
END OF TASK
7-15. ACCESSORY DRIVE REPLACEMENT
(See Para 5-14)
7-16. BLOWER DRIVE SHAFT AND HUB REPLACEMENT
(See Para 5-15)
7-17. GOVERNOR COVER AND THROTTLE CONTROL
(See Para 4-17)
ROD REMOVAL/lNSTALLATION
7-18. GOVERNOR AND BLOWER ASSEMBLY
(See Para 4-18)
REMOVAL/lNSTALLATION
7-19. BLOWER DRIVE GEAR AND SUPPORT REPLACEMENT
(See Para 4-19)
7-20. OIL PAN REPLACEMENT
(See Para 4-20)
7-21. CAMSHAFT FRONT GEAR COVER AND
(See Para 5-20)
DAMPER REPLACEMENT
7-22. FLYWHEEL ASSEMBLY REPLACEMENT
(See Para 4-22)
7-23. REAR OIL SEAL REPLACEMENT
(See Para 4-23)
7-24. FLYWHEEL HOUSING REPLACEMENT
(See Para 4-24)
7-25. IDLER GEAR REPLACEMENT
(See Para 4-25)
7-26. INJECTOR CONTROL TUBE REPLACEMENT
(See Para 4-26)
7-27. CYLINDER HEAD ASSEMBLY REMOVAL/lNSTALLATION
(See Para 4-27)
7-28. ENGINE LOWER FRONT COVER REPLACEMENT
(See Para 5-27)
7-29. CAMSHAFT AND GEAR ASSEMBLIES
(See Para 4-29)
REPLACEMENT
7-30. CYLINDER BLOCK END PLATES REPLACEMENT
(See Para 4-30)
7-31. OIL PRESSURE REGULATOR AND RELIEF
(See Para 4-31)
VALVE REPLACEMENT
7-32. OIL PUMP REPLACEMENT
(See Para 4-32)
7-15
TM9-2815-202-34
Section Ill. ENGINE DISASSEMBLY\ASSEMBLY
7-33. PISTON AND CONNECTING ROD MAINTENANCE
(See Para 6-34)
7-34. CYLINDER LINER MAINTENANCE
(See Para 4-34)
7-35. CRANKSHAFT MAINTENANCE
(See Para 4-35)
7-36. CYLINDER BLOCK MAINTENANCE
(See Para 4-36)
Section IV. COMPONENT REPAIR
7-37. TURBOCHARGER REPAIR
(See Para 6-38)
7-38. CYLINDER HEAD REPAIR
(See Para 5-37)
7-39. OIL COOLER ASSEMBLY REPAIR
(See Para 4-39)
7-40. FUEL INJECTOR ASSEMBLY REPAIR
(See Para 4-40)
7-41 . BLOWER REPAIR
(See Para 4-41)
7-42. GOVERNOR REPAIR
(See Para 5-41)
7-43. WATER PUMP REPAIR
(See Para 4-43)
7-16
TM9-2815-202-34
CHAPTER 8
TESTING AND INSPECTION PROCEDURES
Contents
Para
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . ..... 8-1
Engine Preparation for Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
intervals and Adjustment Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. -3
Exhaust Valve Clearance Adjustment (Hot or Cold Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Fuel Injector Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Governor Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
.
Fuel Injector Control Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Throttle Delay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Starting Aid Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Maximum No-Load Speed Adjustment (Dual Range Limiting Speed Governor) . . . . . . . 8-11
Maximum No-Load Speed Adjustment (Limiting Speed Governor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Governor Buffer Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Cylinder Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Fuel Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 8-1 5
Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Crankcase Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 7
Air Box Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Preparation for Run-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Run-in Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Page
8-1
8-2
8-5
8-6
8-8
8-10
8-16
8-20
8-22
8-24
8-26
8-30
8-32
8-34
8-39
8-40
8-42
8-44
8-46
8-48
SECTION I. INTRODUCTION
8-1. GENERAL. This chapter provides the necessary instructions for engine preparation,
adjustments, tests, and run-in required following any major repair.
Whenever work is done which allows air in the fuel system, purge the fuel system to help start the
engine.
After an engine is overhauled or in storage, prelubricate the turbocharger and rocker arm
mechanisms to insure against inadequate lubrication at start-up.
Whenever a major repair involves the governor, blower, cylinder head, or fuel injector controls,
adjustment the fuel control system prior to issue.
Prior to release for issue to user, test the engine condition and performance characteristics.
Whenever a major repair involves the installation of piston rings, pistons, cylinder liners, or bearings,
run-in the engine.
8-1
TM 9-2815-202-34
SECTION Il. ENGINE PREPARATION
8-2. ENGINE PREPARATION FOR START-UP
This task covers:
a. Priming Fuel System
b. Prelubrication of Oil Gallery (with Pressure Lubricator)
c. Prelubrication of Oil Gallery (without Pressure Lubricator)
d. Prelubrication of Turbocharger
e. Initial Start-up
INITIAL SETUP
.
TOOLS AND SPECIAL TOOLS
MODELS
All
General mechanics tool kit (App B, Item 96)
●
a. Priming Fuel System
NOTE
Prime and/or purge engine fuel system after any major repair or overhaul.
(1) Block or disconnect line from fuel pump.
(2) Apply fuel under pressure, 60-80 PSI (41 3-552 kPa), to inlet on secondary filter with external
fuel source. Allow fuel to flow freely from fuel return line until a steady stream without air
bubbles is observed.
CAUTION
Prelubricate any stored or repaired engine prior to start-up. Oil gallery and associated
components will have insufficient oil during the time lag following start-up. Bearing
damage from lack of lubrication could result.
b. Prelubrication of Oil Gallery (With Pressure Lubricator)
(1) Remove plug from engine main oil gallery and attach lubricator hose.
(2) Remove rocker arm covers.
(3) Pump in lubricating oil until oil flows from rocker arms.
8-2
Change 1
TM9-2815-202-34
8-2. ENGINE PREPARATION FOR START-UP (Cont)
(4) Disconnect lubricator hose and install oil gallery plug.
(5) Install rocker arm covers.
(6) Check and fill crankcase to proper level.
CAUTION
Prelubricate any stored or repaired engine prior to start-up. Oil gallery and associated
components will have insufficient oil during the time Iag following start-up. Bearing
damage from lack of lubrication could result.
c. Prelubrication of Oil Gallery (Without Pressure Lubricator)
(1) Remove rocker arm covers.
(2) Pour lubricating oil on rocker arm assemblies.
(3) Install rocker arm covers.
(4) Check and fill crankcase to proper level.
d. Prelubrication of Turbocharger
(1)
Disconnect oil supply line at turbocharger bearing (center) housing.
(2) Fill bearing housing cavity with oil while rotating assembly by hand to coat internal bearing
surfaces with oil.
(3) Connect turbocharger oil supply line.
8-3
TM9-2815-202-34
8-2. ENGINE PREPARATION FOR START-UP (Cont)
CAUTION
Do not energize starter for more than 30 seconds at one time. Allow starter motor to
cool for two to three minutes between operations to prevent overheating and damage.
NOTE
Following any repair involving the exhaust valve or injector operating mechanisms,
reset exhaust valve clearance (Para 8-4.) and injector timing (Para 8-5.) before starting
engine.
e. Initial Start-up
(1) Crank engine with governor in NO FUEL position until an oil pressure reading registers on
gage.
(2) Start and run engine at idle. Oil pressure gage should read 10 PSI (69 kPa) for adequate
lubrication.
END OF TASK
8-5
TM9-2815-202-34
SECTION Ill. ADJUSTMENT SEQUENCE
8-3. INTERVALS AND ADJUSTMENT SEQUENCE
a. Intervals. Following any engine repair, the adjustments specified in Para 8-4.b must be performed.
b. Adjustment Sequence. Normally, when performing adjustments on an engine in service, check
various settings for possible changes from previous adjustments. However, if the cylinder head,
governor, or fuel injectors have been removed or replaced, also check specific preliminary
adjustments before starting engine. The preliminary adjustments consist of the first four steps in
the following sequence. The remaining items complete the list of engine adjustments to be
performed.
(1) Exhaust Valve Clearance (Cold Engine or Hot Engine)
(2) Fuel Injector Timing Adjustment
(3) Governor Gap Adjustment
(4) Fuel Injector Control Lever Adjustment
(5) Throttle Delay Adjustment
(6) Starting Aid Screw Adjustment (External Starting Aid Screw)
(7) Idle Speed Adjustment
(8) Maximum No-Load Speed Adjustment (Dual Range Limiting Speed Governor)
(9) Maximum No-Load Speed Adjustment (Limiting Speed Governor)
(10) Governor Buffer Screw Adjustment
8-5
TM9-2815-202-34
8-4. EXHAUST VALVE CLEARANCE ADJUSTMENT (HOT OR COLD ENGINE)
This taskcovers: Adjustment
INITIAL SETUP
MODELS
EQUIPMENT CONDITION
All
Para Description
4-11 Rocker arm covers removed
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Adjustment
a. Place governor speed control lever (1) in
NO-FUEL position.
CAUTION
Do not turn engine in
counterclockwise direction as
crankshaft bolt will be loosened.
b. Rotate crankshaft clockwise, by turning
crankshaft end bolt, until fuel injector
follower (2) is fully depressed on cylinder to
be adjusted.
c. Hold push rod (3) in position and loosen
push rod locknut (4).
8-6
TM9-2815-202-34
8-4. EXHAUST VALVE CLEARANCE ADJUSTMENT (HOT OR COLD ENGINE) (Cont)
NOTE
Normal engine coolant operating
temperature
is 160-185°F
o
(71.1-85.0 C).
d. Place a 0.015 inch (0.381 mm) feeler gage
(5) (cold engine) or a 0.013 inch (0.330
mm) feeler gage (5) (hot engine) between
valve bridge (6) and rocker arm (7).
e. Turn push rod (3) in or out of clevis (8) until
a smooth pull is obtained on feeler gage
(5).
f.
Remove feeler gage (5). Hold push rod (3)
and tighten locknut (4).
NOTE
A 0.015 inch (0.381 mm) feeler
gage (5) (cold engine) or a 0.013
inch (0.330 mm) feeler gage (hot
engine) must pass freely between
valve bridge (6) and rocker arm (7).
A 0.017 inch (0.432 mm) feeler
gage (5) (cold engine) or a 0.015
inch (0.381 mm) feeler gage (hot
engine) must not pass through
bridge clearance.
g.
i.
8-7
TM9-2815-202-34
8-5. FUEL INJECTOR TIMING ADJUSTMENT
This taskcovers: Adjustment
INITIAL SETUP
MODELS
EQUIPMENT CONDITION
All
Para Description
4-11 Rocker arm covers removed
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Injector timing gage (App B, Item 46)
injector timing gage (App B, Item 105)*
Adjustment
a. Place governor speed control lever (1) in
NO-FUEL position.
CAUTION
Do not turn engine in
counterclockwise direction as
crankshaft bolt will be loosened.
b. Rotate crankshaft clockwise, by turning
crankshaft end bolt, until exhaust valves (2)
are fully depressed on cylinder to be timed.
NOTE
Ail fuel injectors should be timed
during one full revolution of
crankshaft. Firing order: 1L, 3R, 3L,
4R, 4L, 2R, 2L, 1R.
c. Place drop of oil from cylinder head on
injector follower (3).
d. Place small end (5) of fuel injector timing
gage (4), 1.484 inches (for model
7083-7391 only, use 1.460 inches), in
opening (6) in top of fuel injector body (7)
with flat of timing gage on fuel injector
follower (3).
8-8 Change 1
* 7083-7391
TM9-2815-202-34
NOTE
Proper adjustment is when rotating
injector timing gage wipes a thin
even film of oil on injector follower
behind flat of injector timing gage.
Rotate injector timing gage (4). Flat of
timing gage should wipe oil from follower
(3).
Adjust injector timing as follows:
(1) Hold fuel injector push rod (8) in
position and loosen locknut (9).
NOTE
Turn push rod in clockwise direction
(as viewed from above) to lower fuel
injector follower. Turn push rod in
counterclockwise direction to raise
fuel injector follower.
(2) Turn push rod (8) to adjust fuel
rocker arm (10) until top of
follower (3) is flush with flat of
gage (4).
(3) Hold push rod (8) and tighten
locknut (9).
g. Recheck injector timing adjustment, repeat
steps c thru e.
h. If adjustment is needed, repeat steps c thru
f.
i.
Time remaing seven fuel injectors as
outlined in stess a thru h above.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-11 Install rocker arm covers
Change
18-9
TM9-2815-202-34
8-6. GOVERNOR GAP ADJUSTMENT
This task covers: Adjustment
INITIAL SETUP
MANDATORY REPLACEMENTS PARTS
MODELS
■ All
1 Gasket (App F,ltem 82)
2 Gaskets (App F, Item 78)
2 Lockwashers (App F,ltem 92)
TOOLS AND SPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Turbocharger inlet shield (App B, Item 81)
Adjustment
.
NOTE
Before proceeding with governor
adjustments, disconnect cables from
governor cover lever.
a. For models 7083-7395 and 7083-7396,
loosen two nuts (1) on throttle delay U-bolt
(2) on right bank injector control tube (3).
Injector control tube must move freely in Ubolt.
■ b. For models 7083-7391 ,7083-7395, and
7083-7396, loosen and hold starting aid nut
(4). Back out starting aid screw (5) to make
it ineffective.
8-10 Change
1
4-11 Rocker arm covers removed
TM9-2815-202-34
WARNING
●
Avoid contact with hot
manifolds, pulleys, and
other moving parts to avoid
personal injury.
●
Wear proper ear protection
when running engine. Noise
volume of engine can cause
hearing loss or injury.
●
Protective turbocharger air
inlet shield must be
installed prior to doing
maintenance when engine is
running and air inlet has
been removed. Contact with
rotating blades will cause
injury to personnel.
CAUTION
Run engine in clean area when air
intake ducting is removed. Dirt, dust,
and particles in unfiltered air can
enter engine and damage parts or
cause mechanical failure.
NOTE
Start and operate engine to attain a
coolant operating temperature of
160-185°F (71.1-85.0oC) before
adjusting governor gap.
c. For models 7083-7395 and 7083-7398,
remove two bolts (6), two Iockwashers (7),
access cover (8), and spring housing (9)
from governor housing. Discard two
gaskets (1O) and Iockwashers.
For models 7083-7391, 7083-7396, and
7083-7399, remove two bolts (11 ) and two
flat washers (12) from access cover (13).
Remove cover and gasket (14) from
governor housing. Discard gasket.
e. Hold buffer screw locknut (15) and back out
buffer screw (16) until it extends 0.63 inch
from locknut. Snug locknut to governor
housing (17).
f.
Hold idle speed screw (18) and loosen idle
screw locknut (19). Adjust idle speed screw
to obtain idle speed of 625+/-25 RPM. Hold
idle speed screw and tighten locknut.
g. Stop engine using engine stop lever (20).
Change
1 8-11
TM9-2815-202-34
8-6. GOVERNOR GAP ADJUSTMENT (Cont)
h. For all models except 7083-7391. remove
two bolts (21) and two lockwashers (22)
securing bracket (23) to support (24).
■ i. For all models except 7083-7391, remove
two screws (25) and four flat washers (26)
and move bracket (23) away from governor
cover (27).
j. For all models except 7083-7391, remove
remaining six screws (25) from governor
cover (27). For model 7083-7391, remove
eight screws (25) from governor cover.
Remove cover and gasket (28). Discard
gasket.
WARNING
8-12
•
Avoid contact with hot
manifolds, pulleys, and
other moving parts to avoid
personal injury.
•
Wear proper ear protection
when running engine. Noise
volume of engine can cause
hearing loss or injury.
•
Protective turbocharger air
inlet shield must be
installed prior to doing
maintenance when engine is
running and air inlet has
been removed. Contact with
rotating blades will cause
injury to personnel.
Change 1
TM9-2815-202-34
CAUTION
Run engine in clean area when air intake ducting is removed. Dirt, dust, and
particles in unfiltered air can enter engine and damage parts or cause mechanical
failure.
Do not exceed engine speed required to set governor gap adjustment. Hand
operation of governor differential lever bypasses the governor function.
Overspeeding could cause engine damage.
k.
Start and operate engine between 1100 and 1300 RPM by manually operating the differential
lever (29).
1.
Check gap between low speed spring cap (30) and high speed spring plunger (31) with feeler
gage (32). Gap must be 0.0015 to 0.0020 inches.
m To adjust governor gap, loosen nut (33) and turn screw (34) in governor operating shaft lever (35).
Governor gap must be 0.0015 to 0.002 inch with engine operating between 1100 to 1300 RPM.
n. Stop engine. Move the differential lever (29) to NO FUEL position.
o. Hold adjusting screw (34) in position and tighten locknut (33).
8-13
TM9-2815-202-34
8-6. GOVERNOR GAP ADJUSTMENT (Cont)
Aline shaft (36) in governor cover (27) with
differential lever (29) inside governor
housing (17).
Position gasket (28) and governor cover
(27) on governor assembly (17). For all
models except 7083-7391, secure with six
screws (25). For model 7083-7391, secure
with eight screws (25).
For all models except 7083-7391, place
bracket (23) on governor cover (28) and
secure with two remaining screws (25) and
four flat washers (26).
NOTE
Models 7083-7398 and 7083-7399
have a fuel line clamp under rear
bolt (21).
For all models except 7083-7391, secure
bracket (23) to support (24) with two bolts
(21 ) and two Iockwashers (22).
CAUTION
Before starting engine, insure
injector racks move to NO FUEL
position using governor stop lever.
Engine overspeed could result in
engine damage.
8-14 C h a n g e
1
TM9-2815-202-34
Hold speed control lever (37) in full fuel position and operate stop lever (20). If correctly installed,
operating stop lever will return speed control lever to idle position and related movement will be
felt in governor and injector control rack linkage.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-11 Install rocker arm covers.
Adjust throttle delay (7083-7395 and 7083-7396).
■ 8-8 Adjust starting aid screw (7083-7391, 7083-7395, and 7083-7396).
8-10 Adjust idle speed.
8-11 Install governor spring housing (Dual range limiting speed governor) (7083-7395 and
7083-7398).
■ 8-12 Install governor spring housing (Limiting speed governor) (7083-7391, 7083-7396, and
7083-7399).
8-13 Adjust buffer screw.
C h a n g e
1 8-15
TM9-2815=202-34
8-7. FUEL INJECTOR CONTROL LEVER ADJUSTMENT
●
This taskcovers: Adjustment
INITIAL SETUP
EQUIPMENT CONDITION
MODELS
, All
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
MANDATORY REPLACEMENT PARTS
1
Para Description
4-11 Rocker arm covers removed
8-6 Throttle delav disconnected
(7083-7395 and 7083-7396)
8-6 Starting aid screw backed out
(7083-7391, 7083-7395, and 7083-7396)
8-6 Governor spring housing removed
(Dual range limiting speed governor)
8-6 Governor spring housing removed
(Limiting speed governor)
8-6 Buffer screw backed out
2 Cotter pins (App F, Item 7)
Adjustment
HF”NT
NOTE
●
●
●
LEFT BANK
.
To ensure proper injector control
rack adjustment, adjust injector
control racks with yield link and
governor cover used with
governor.
\ub
I
RIGHT BANK
FIRING
ORDER
Letter “R” or “L” indicates
injector location, right or left bank,
as viewed from rear of engine.
Cylinder numbers start at front of
each bank.
RH.1L.3R.3L.4R.4 L.2R.2L.1R
n
Adjust No. 1 L injector control
lever first to establish a guide for
adjusting remaining injector
control levers.
●A
false fuel injector rack setting
may result if idle speed adjusting
screw is not backed out.
a. Loosen and hold locknut (1). Turn idle
speed adjusting screw (2) until 0.5 inch of
threads project from locknut.
CAUTION
Cover oil drain hole in cylinder head with clean rag to prevent cotter pin and clevis pin
from falling into engine.
8-16
Change 1
●
TM9-2815-202-34
●
●
b. Loosen eight rack control lever locknuts (3) and back out eight adjusting screws (4). Eight injector
control levers (5) should be loose on control tubes (6).
c.
Move linkage (7) connecting governor to control racks. Linkage must not bind.
d. Rotate clevis pins (8) in right and left bank control tube levers (9). Pins must rotate freely.
e. Check for slight movement between brackets (1 O), at each end of control tubes (6), on right and
left banks.
f.
Rotate control tube lever (9) to FULL FUEL position; then release lever (9). Control tube must
return to NO FUEL position.
9.
Remove cotter pin (11 ) and clevis pin (8) from right bank control tube Iever (9). Discard cotter pin.
h. Move governor speed control lever (12) to maximum speed position and hold with light finger
pressure.
CAUTION
Do not overtighten injector rack control lever adjusting screws during installation or
adjustment. Overtightening can result in damage to injector control tube.
Recommended torque of adjusting screws is 24-36 lb-in (3-4 N-m).
i.
●
Turn adjusting screw (4) on 1 L injector rack control lever until slight movement is felt on governor
speed lever (12), injector control rack (13) rolls up on control lever (5), or an increase in effort to
turn screw (4) is felt.
7%=2(’(IL
8-17
TM9-2815-202=34
8-7. FUEL INJECTOR CONTROL LEVER ADJUSTMENT (Cent)
j. Tightenadjustingscrew(4)l/8turn.
Hold adjusting screw and tighten locknut (3).
k. Check clevis pin (8). Pin must turn freely in control tube lever (9) when 1 L is in FULL FUEL
position.
1.
If clevis pin (8) fails to rotate freely in control tube lever (9), adjust injector control rack lever (5)
again.
m Check injector control rack lever adjustments. Hold speed control lever (12) in maximum engine
speed position. Using a screw driver, press downward on injector control rack (13); then slide
screw driver off from injector control rack. Control rack should spring back upward.
n. If injector control rack(13) does not spring back, loosen adjusting screw locknut (3) and tighten
adjusting screw (4) slightly. Tighten locknut. Check adjustment using steps h and i.
o. Move governor speed control lever (12) to maximum engine speed position. If injector control rack
(13) becomes tight before governor speed control lever reaches end of travel, setting is to tight.
Loosen locknut (3) and turn screw (4) slightly counterclockwise. Tighten locknut. Check setting
using steps i thru j.
Connect right bank throttle control rod (7) to control tube lever (9) using clevis pin (8) and cotter
pin (1 1).
Adjust 1 R injector rack control lever as outlined in steps e thru k.
8-18
●
TM 9-2815 -202-34
r.
Repeat check on 1 L and 1 R injector rack
control levers as outlined in step i. If 1 L is
loose, then 1R should be readjusted. If 1 R
is loose, than 1 R should be adjusted.
FULL FUEL
NOTE
Once 1 L and 1 R injector rack control
levers are adjusted, do not alter
their settings. Make further
adjustments only on remaining
control racks.
s. Hold governor speed control lever (12) in
FULL FUEL position. Check clevis pin (8)
for drag on right and left control tube lever.
Both pins should be free.
t
Move governor speed control lever (12) to
maximum speed position and hold in
position with light finger pressure.
u. Adjust 2L, 3L, and 4L, as outlined in steps e
thru k. Check adjustment on each injector
control rack (13). Do not readjust 1 L.
v. Move speed control lever (12) to maximum
speed position and hold in position with
light finger pressure.
w. Adjust 2R, 3R, and 4R as outlined in steps e
thru k. Do not readjust 1 R.
x. Turn idle speed adjusting screw (2) in until
it projects 0.20 inch from-locknut (1) to
permit starting of engine. Tighten locknut.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-11 Install rocker arm covers.
8-8 Adjust throttle delay (7083-7395 and
7083-7396).
8 - 9 Adjust starting aid screw (7083-7391,
7083-7395, and 7083-7396).
8-10 Adjust idle speed.
8-11 Install governor spring housing (Dual
range limiting speed governor)
(7083-7395 and 7083-7398).
8-12 Install governor spring housing (Limiting
speed governor) (7083-7391, 7083-7396,
and 7083-7399).
8-13 Adjust buffer screw.
Change 1
8-19
TM9-2815-202-34
8-8 THROTTLE DELAY ADJUSTMENT
This taskcovers: Adjustment
INITIAL SETUP
MODELS
EQUIPMENT CONDITION
7083-7395 7083-7396
Para Description
4-11 Rocker arm covers removed
Bufferscrew backed out
8-7
Throttle delay disconnected
8-6
Starting aid screw backed out
8-6
8-6
Governor spring housing cover
removed
TOOLSANDSPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Throttle delay gage (App B, Item 37)
Throttle delay gage pin (App B, Item 22)
Adjustment
NOTE
To provide adequate Lubrication of mechanical components, fill throttle delay reservoir
with clean engine oil. The oil reservoir does not haveto remain full during adjustment
procedure.
a. Insert throttle delay timing gage (1) on rack between injector body (2) and shoulder of injector rack
clevis (3) on 2R injector.
b. Secure throttle Iever (4) in maximum fuel position to put injector rack (5) against throttle delay
timing gage (1).
c.
Insert 0.069 inch end of throttle delay pin gage (6) into throttle delay cylinder fill hole (7).
d. Push throttle delay link (8) until piston (9) contacts pin gage (6).
CAUTION
Do not overtighten two U-bolt nuts. Damage to injector control tube or U-bolt clamp
could result.
NOTE
If either U-bolt nut is tightened without pin gage being inserted, recheck the setting.
e. Loosen two U-bolt nuts (1 O). Apply light pressure on delay link (8) towards pin gage (6). Tighten
two U-bolt nuts equally. Remove pin gage (6).
8-20
TM9-2815-202-34
f.
●
●
Check the throttle delay setting. If 0.072
inch end of pin gage enters fill hole (7),
tighten upper U-bolt nut (1 O). If 0.069 inch
end will not enter fill hole (7) without
resistance, tighten lower U-bolt nut (1 O).
MAXIMUM SPEED
9. Insert 0.072 inch end of pin gage (6) in
cylinder fill hole (7). Pin gage should not fit
back in hole.
h. Reverse pin gage (6) to 0.069 inch end and
insert pin gage in cylinder fill hole (7). H
should enter without resistance.
i.
Release throttle speed control lever (4) and
remove timing gage (1) and pin gage (6).
j.
Move throttle speed control lever (4) from
idle position to maximum speed position.
There should be no binding in movement of
control tube assembly (11 ).
6
(’=--\
4
END OF TASK
*
FOLLOW. -ON MAIN 1‘ENANCE
●
●
1
I
‘“x)%$
10
“ 11
Para Description
4-11 Install rocker arm covers.
8-9 Adjust starting aid screw (7083-7391,
7083-7395, and 7083-7396).
8-10 Adjust idle speed. ‘
8-11 Install governor spring housing (Dual
range limiting speed governor)
(7083-7395 and 7083-7398).
8-12 Install governor spring housing (Limiting
speed governor) (7083-7391, 7083-7396,
and 7083-7399).
8-13 Adjust buffer screw.
Change 1
8-21
TM9-2815-202-34
8-9. ADJUST STARTING AID SCREW ADJUSTMENT
●
This taskcovers: Adjustment
INITIAL SETUP
MODELS
EQUIPMENT CONDITION
I 7083-7391 7083-7395 7083-7396
●
Para Description
4-11 Rocker arm covers removed
TOOLS AND SPECIAL TOOLS
●
General mechanic tool kit (App B, Item 96)
Injector rack gage (App B, Item 33)
a
Adjustment
NOTE
Perform starting aid screw adjustment with engine shutdown.
a. Position shutdown lever (1) in RUN position and throttle lever (2) in IDLE position.
NOTE
Increase injector rack clevis to body clearance by turning starting aid screw against
governor gap adjusting screw or reduce by backing it out.
b. Hold starting aid screw (3) and loosen locknut (4). Position 0.385 inch gage (5) between 1 R
shoulder of injector rack clevis (6) and injector body (7) so that gage stays at about a 60 degree
slant without being held. Adjust starting aid screw until gage falls over from its own weight.
c. Hold starting aid screw (3) and tighten locknut (4).
NOTE
Movement of speed control lever is to take up clearance in governor linkage.
8-22
Change 1
TM9-2815-202-34
d. Check injector rack clevis (6) to injector body (7) clearance.
(1) Position stop lever (1) in RUN position.
(2) Move engine speed control lever (2) from IDLE speed to maximum speed position,
●
.
(3) Return speed control lever (2) to IDLE position.
(4) Check clearance of injector rack clevis (6) to injector body (7) and if necessary, adjust
using steps a thru d. Remove gage.
END OF TASK
FOLLOW-ON MAINTENANCE
*
(1,
Para Description
4-11 Install rocker arm covers
2
\
8-23
TM
9-2815-202-34
8-10. IDLE SPEED ADJUSTMENT
This task covers: Adjustment
INITIAL SETUP
EQUIPMENT CONDITION
MODELS
A l l
Para Description
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Turbocharger inlet sheild (App B, Item 81)
4-11 Rocker arm covers removed
8-6
Governor spring housing cover
removed (Dual range)
8-6
Governor spring housing
cover removed (Limited speed)
Buffer screw backed out
8-6
Adjustment
WARNING
Avoid contact with hot manifolds, pulleys, and other moving parts to
avoid personal injury.
Wear proper ear protection when running engine. Noise volume of
engine can cause hearing loss or injury.
Protective turbocharger air inlet sheild musr be installed prior to doing
maintenance when engine is running and air inlet has been removed.
Contact with rotating blades will cause injury to personel
Run engine in clean area when air intake ducting is removed. Dirt, dust, and particles
in unfiltered air can enter engine and damage parts or cause mechanical failure.
a. Start engine and operate coolant temperature of 160-185° (71.1-85.0°C) is attained.
b. PLace governor speed control lever (1) in IDLE position.
c
Hold screw (2) and loosen locknut (3). Adjust engine speed screw (2) to obtain 625+/-25
RPM. Hold adjusting screw (2) in position, and tighten locknut (3).
8-24
Change 1
TM 9-2815 -202-34
NOTE
●
If necessary use buffer screw to eliminate engine speed roll. Back out buffer screw after
engine idle speed is established.
e
d. Check engine idle speed RPM. if adjustment is needed, repeat steps a and b.
e. Stop engine.
●
●
.
.
END OF TASK
FOLLOW-ON MAINTENANCE
●
●
Para Description
4-11 Install rocker arm covers.
8-11 Install governor spring housing (Dual
range limiting speed governor)
(7083-7395 and 7083-7398).
8-12 Install governor spring housing (Limiting
I
speed governor) (7083-7391, 7083-7396,
and 7083-7399).
8-13 Adjust buffer screw.
I
Change 1
8-25
TM9-2815-202-34
8-11. MAXIMUM NO LOAD SPEED ADJUSTMENT (DUAL RANGE LIMITING SPEED
GOVERNOR)
This taskcovers: Adjustment
INITIAL SETUP
MODELS
MANDATORY REPLACEMENT PARTS
7083-7395 7083-7398
2 Lockwashers (App F, Item 92)
2 Gaskets (App F, Item 78)
●
TOOLSANDSPECIAL TOOLS
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Turbocharger inlet shield (App B,ltem 81)
Para Description
Governor spring housing
8-6
cover removed
Buffer screw backed out
8-6
&
Adjustment
NOTE
●
Buffer screw must project 0.625 inch from locknut to prevent interference while
adjusting the maximum No Load speed.
●
If the engine has not been adjusted since overhaul, insure four 0.100 inch shims (1)
and four 0.010 inch shims (2) should be in governor spring housing piston (3).
●
Maximum low speed screw (4) should extend from spring housing cover (5) 1.25
inch.
a. Install governor spring housing (6), cover (5), two gaskets (7), two Iockwashers (8), and two bolts
(9) on governor housing (10).
b. Connect oil or air supply line to governor spring housing (6).
WARNING
8-26
●
Avoid contact with hot manifolds, pulleys, and other moving parts to
avoid personal injury.
●
Wear proper ear protection when running engine. Noise volume of
engine can cause hearing loss or Injury.
●
Protective turbocharger air Inlet shield must be Installed prior to doing
maintenance when engine Is running and air inlet has been removed.
Contact with rotating blades will cause injury to personnel.
.
TM 9-2815 -202-34
CAUTION
Run engine in clean area when air intake ducting is removed. Dirt, dust, and particles
in unfiltered air can enter engine and damage parts or cause mechanical failure.
c. Start engine and run engine to attain coolant operating temperature of 160-185°F
(71.1 -85,0”C).
d. Move speed control lever (11) in maximum speed position. Apply oil or air pressure to governor
and note engine speed. Return engine to idle position.
e. Discontinue oil or air pressure to governor and stop engine. If additional adjustment is needed,
proceed with steps f thru k.
f, Remove two bolts (9) and two Iockwashers (8) securing governor spring housing (6) and cover (5)
to governor housing (1 O). Remove governor spring housing and cover. Discard two Iockwashers
and two gaskets (7).
CAUTION
Do not permit seal ring on piston to slide past inlet port, or seal ring will be damaged.
●
g. Remove piston (3) and sleeve (12) from governor spring housing (6).
8-27
TM9=2815-202-34
8-11. MAXIMUM NO LOAD SPEED ADJUSTMENT (DUAL RANGE LIMITING
SPEED GOVERNOR) (Cent)
NOTE
Removing shims will decrease engine speed and adding shims will increase the
engine speed. Each 0.010 inch shim will change engine speed approximately 10 RPM.
h. Remove or add shims (1 and 2) as required in piston (3) to adjust engine speed.
i. Place sleeve (12) into piston (3) and insert into governor spring housing (6).
j. Position governor spring housing (6) with two gaskets (7) and cover (5) on governor housing (1 O)
and secure with two bolts (9) and two Iockwashers (8).
WARNING
●
Avoid contact with hot manifolds, pulleys, and other moving parts to
avoid personal Injury.
●
Wear proper ear protection when running engine. Noise volume of
engine can cause hearing loss or injury.
●
Protective turbocharger air Inlet shield must be Installed prior to doing
maintenance when engine Is running and ah’ inlet has been removed.
Contact with rotating blades will cause injury to personnel.
CAUTION
Run engine in clean area when air intake ducting is removed. Dirt, dust, and particles
in unfiltered air can enter engine and damage parts or cause mechanical failure.
k. Checking HIGH MAXIMUM NO-LOAD ENGINE SPEED
(1) Start engine.
(2) Move speed control lever (11 ) to maximum speed position.
(3) Apply oil or air pressure to governor and note engine speed.
(4) Discontinue oil or air pressure to governor.
(5) Stop engine. If additional adjustment is needed, repeat steps f thru k.
8-28
TM9-2815-202-34
.
*
1. Adjusting LOW MAXIMUM NO-LOAD SPEED
(1) Loosen nut (13) and hold speed control lever (11 ) in maximum speed position.
NOTE
Turn adjusting screw (4) in to increase or out to decrease the engine speed.
(2) Adjust screw (4) to obtain low maximum speed 1350-1375 RPM.
(3) Hold screw and secure nut to cover (5).
m. Recheck both high maximum and low maximum engine speeds. Make adjustments if necessary
as outlined in steps b thru m.
●
●
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
8-13 Adjust buffer screw
8-29
TM9-2815-202-34
8-12. MAXIMUM NO-LOAD SPEED ADJUSTMENT (LIMITING SPEED GOVERNOR)
This task covers: Adjustment
INITIAL SETUP
MANDATORY REPLACEMENT PARTS
MODELS
fi 7083-7391 7083-7396 7083-7399
●
●
1 Gasket (App F, Item 78)
2 Copper washers (App F, Hem 164)
TOOLS AND SPECIAL TOOLS
●
EQUIPMENT CONDITION
General mechanics tool kit (App B, Item 96)
Turbocharger inlet shield (App B, Item 81)
Para Description
8-6
Governor spring housing
cover removed
8-6
Buffer screw backed out
Adjustment
WARNING
Avoid contact with hot manifolds, pulleys, and other moving parts to
avoid personal injury.
Wear proper ear protection when running engine. Noise volume of
engine can cause hearing loss or injury.
Protective turbocharger air inlet shield must be installed prior to doing
maintenance when e-ngine is running and air inlet has been removed.
Contact with rotating blades will cause injury to personnel.
CAUTION
.
Run engine in clean area when air intake ducting is removed. Dirt, dust, and particles
in unfiltered air can enter engine and damage parts or cause mechanical failure.
.
NOTE
Buffer screw must project 0.625 inch from locknut to prevent interference while
adjusting maximum NO-LOAD speed.
a. Start engine and run engine to attain coolant operating temperature of 160-185°F (71.1 -85. O”C).
b. Loosen spring retainer locknut (1). Back off high-speed spring retainer (2) approximately five
turns.
8-30
Change 1
TM9-2B15-2CJ2-34
●
e
.
*
.
Move speed mtfol lever :!,31 in maximum fmsdhn. !1- urn i-nigh speed spring ifefafms
24s2 RPM. w msdta H%3-7397 . K9tarn 2475 RPM,
4
i 2 :Q
&@,J”,
TM9-2815=202=34
8-13. GOVERNOR BUFFER SCREW ADJUSTMENT
Thistask covers: Adjustment
INITIAL SETUP
EQUIPMENT CONDITION
MODELS
Para Description
Bufferscrewbacked out
8-6
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Turbocharger Inlet shield (App B, Item 81)
Adjustment
WARNING
Avoid contact with hot manifolds, pulleys, and other moving parts to
avoid personal injury.
Wear proper ear protection when runnina engine. Noise volume of
engine can cause hearing loss or in jury.Protective turbocharger air inlet shield must be installed prior to doing
maintenance when engine is running and ah’ inlet has been removed.
Contact with rotating blades will cause injury to personnel.
CAUTION
Run engine in clean area when air intake ducting is removed. Dirt, dust, and particles
in unfiltered air can enter engine and damage parts or cause mechanical failure.
a. Start engine and operate until normal operating temperature is 165-185°F (71.1 -85. O”C).
b. Place governor speed control lever (1) in IDLE position.
c. Hold buffer screw (2) and loosen buffer screw locknut (3).
8-32
Change 1
●
TM 9-2815 -202-34
NOTE
e
●
Do not increase engine idle speed more than 15 RPM with buffer screw.
d. Hold nut (3) and turn screw (2) until it contacts differential lever as lightly as possible and
eliminates engine roll.
e. Move speed control lever (1) to FULL FUEL position. If maximum No Load speed has increased
more than 25 RPM, hold buffer screw nut (3) and back out buffer screw (2) until No-load speed
increase is less than 25 RPM.
f.
a
Hold buffer screw (2) and tighten locknut (3).
9. Move governor stop lever (4) to NO FUEL position.
END OF TASK
.
ml
,,
NO FUEL
POSITION ?
IIlm
@
.
8-33
TM9-2815-202-34
SECTtON W. E?4G1NE TESTthIG
8-14. CYLINDER COMPRESS1ON T E S T
Tl?istaskcovcws: Testing
IN!TIAL SETUP
EXPENDABL13’W RABLE SUPPLIES
MODELS
1 Spare fuel line (@p C, Rem 20)
EQUIPMENT CONDITION
TOOM AND SPECIAL TCKM
Pam Description
4-11 Rocker arm cove= removed
toot kit (~ B, kern 96)
CyMder adapter (App B, km 90]
Cylinder tester (App B, Item 90)
Fuel nut wench Moo B, kern 99
Twbochaqer inkt ‘khie~ (~ B, kern 81 )
Torque wench (Aw B, ttem 100)
Torque wrench (@p B, Item 101)
Gemr~ mechanics
Testing
WARMING
●
Avoid contact m-th hot manifcdds, pulley% and other moving ~ to
avoid personal Injuq.
●
Wear proper ear protection when running engine. Noise volume of
engine can cause hearing loss or injury.
●
Protective turbocharger air inlet shield must be instaJted prior to doing
maintenance when e-’hgine is running and air inlet has been removed.
Contact with rotating blades will cause injury to personnel.
CAUTION
RUFI engine in dean area when air intake dwthg is removed. DirL dust and parfkks
in WVtered air can enter engine and &rn*e parts or cawe mechanical failure.
NOTE
Start engine and operate unti~ coolant operating temperature is 165-185’F (71.1-
85.0°C). Stop engine and remove rocker arm covers.
a. Move governor control lever (1) to NO FUEL IxM&M?.
b. Loosen four fuel line nuts (2) and remove two fuel Wws (3).
8-34
Chame
1
.
TM9-2815-202-34
NOTE
Bar engine over to bring upper ends
of push rods of injector and valve
rocker arms in line horizontally.
c. Remove two rocker shaft bracket bolts (4)
and swing rocker arms (5) away from
injector and valves.
d, Loosen locknut (6) and back out adjusting
screw (7). Slide injector control lever (8) on
injector control tube (9) away from injector
control rack (10),
e. Remove bolt (1 1), convex washer (12), and
clamp (13) securing injector (14). Remove
injector.
CAUTION
Injector clamp must not interfere
with follower spring or exhaust valve
springs when installed. Damage
could occur to engine valve or
injector clamp.
f,
Install cylinder adapter (15) in injector tube.
Secure with clamp (13), convex washer
(12), and bolt (11 ). Torque bolt to 20-25 Ib-ft
(27-34 N-m). Attach cylinder tester (16) to
adapter.
CAUTION
Exhaust valve bridges must rest on
ends of exhaust valves when
tightening rocker arm shaft bolts or
damage to exhaust valves will
result.
n
v
8-35
TM9-2815-202-34
8-14. CYLINDER COMPRESSION TEST (Cent)
.
,
NO FUEL
1
9. Position rocker arms (5) over pressure
gage and adapter (15) and exhaust valves.
Install two rocker arm shaft bolts (4) and
torque to 90-100 Ib-ft (122-136 N-m).
NOTE
●
Do not crank engine using starter
motor to obtain compression
pressure. Engine must be running
to obtain accurate reading.
●
Variation in compression pressures
between cylinders must not exceed
25 PSI (172 kPa) at 600 RPM.
●
Use spare fuel line to fabricate a
jumper connection between fuel
inlet and return manifold
connectors. Fuel line cannot be
reinstalled on engine.
h. Install spare fuel line (17) between inlet
manifold (18) and return manifold (19).
WARNING
●
Avoid contact with hot
manifolds, pulleys, and
other moving parts to avoid
personal Injury.
Wear proper ear protection
when running engine. Noise
volume of engine can cause
hearing loss or injury.
●
Protective turbocharger air
inlet shield must be
Installed prior to doing
maintenance when engine Is
running and air Inlet has
been removed. Contact with
rotating blades will cause
injury to personnel.
CAUTION
Run engine in clean area when air
intake ducting is removed. Dirt, dust,
and particles in unfiltered air can
enter engine and damage parts or
cause mechanical failure.
i. Start engine and run at 600 RPM. Record
pressure shown on cylinder tester gage.
8-36
o/
Y
‘6
11
POSITION
TM 9-2815 -202-34
8-14. CYLINDER COMPRESSION TEST (Cent)
j.
Stop engine. Move governor control lever
(1) to NO-FUEL position.
k.
Remove spare fuel line (17), remove two
rocker arm shaft bolts (4) and swing rocker
arms (5) away from pressure gage adaptor
(15).
1.
Remove bolt (1 1), convex washer (12),
clamp (13), cylinder tester (16), and
cylinder adapter (15).
/
11
m. Aline dowel (20) on injector (14) with
locating hole in cylinder head. Install
injector in injector tube.
n.
Install clamp (13), convex washer (12), and
bolt (11) with convex side of washer facing
clamp (13). Torque bolt to 20-25 Ib-ft (27-34
N-m).
o.
Position rocker arms (5) over injector and
valves. Install two rocker arm shaft bolts (4).
Torque bolts to 90-100 Ib-ft (122-136 N-m).
P. Slide injector control tube lever (8) into
injector rack (1 O).
CAUTION
Do not bend fuel lines and do not
exceed specified torque on fuel
line nuts. Excessive tightening
will twist or fracture flared end of
fuel line and result in leaks.
“1
.
Never reuse fuel lines regardless
of their appearance. Always use
new fuel lines. Reused fuel lines
may not seal properly and result in
fuel leakage.
Install two fuel lines (3). Using fuel nut
wrench, torque four fuel line fiuts (2).
Torque fuel lines to 130-160 lb-in (14.7-18
N-m).
Repeat steps b thru q on remaining
cylinders.
Change 1
8-37
TM9-2815-202-34
8-14. CYLINDER COMPRESSION TEST (Cent)
s. Cylinder compression pressure of any one cylinder, measured in steps a thru r above, must not be
less than minimum pressures shown in Table 8-1.
●
END OF TASK
FOLLOW-ON MAINTENANCE
Para Paragraph
4-11 Install rocker arm covers
Adjust injector control racks
8-7
,
.
Table 8-1. Minimum Compression Pressure at 600 rpm
1
I
t Air
Altitude above
Density
‘Sea Level
Ibs. per
cu. ft.
psi
kPa
feet
meters
425
395
365
340
315
2928
2722
2515
2343
2170
500
2,500
5,000
7,500
10,000
152
762
1,524
2,286
3,048
t Air density at 500 ft. altitude based on 85° F(29.4”C) and
29.38 in. Hg (99.49 kPa) wet barometer.
8-38
.0715
.0663
.0613
.0567
.0525
TM9-2815-202-34
8-15. FUEL FLOW TEST
e
●
—
This taskcovers: Testing
INITIAL SETUP
MODELS
TOOLS AND SPECIAL TOOLS
■ All
General mechanics tool kit (App B, Item 96)
Turbocharger inlet shield (App”B, Item 81)
Testing
NOTE
if necessary, adapt a fuel line
extension to the fuel return line to
reach container.
a. Attach a fuel return line (1) beyond
restricted fitting on engine.
b. HoId open end of fuel return line (1) in a
container (2).
WARNING
● Avoid
contact with hot
manifolds, pulleys, and
other moving parts to avoid
personal injury.
/)
\
●
Wear proper ear protection when running engine. Noise volume of
engine can cause hearing loss or injury.
●
Protective turbocharger air inlet shield must be installed prior to doing
maintenance when engine is running and air inlet has been removed.
Contact with rotating blades will cause injury to personnel.
.
CAUTION
Run engine in clean area when air intake ducting is removed. Dirt, dust, and particles
in unfiltered air can enter engine and damage parts or cause mechanical failure.
o
c. Start engine and run at 1200 RPM NO-LOAD. Using a stop watch (3), measure fuel flow from fuel
return line (1) for one minute. Minimum fuel return rate is 0.8 GPM.
d. Stop engine. Remove fuel line extension if adapted. Connect fuel return line (1).
END OF TASK
Change 1
8-39
TM9-2815-202=34
8-16. FUEL PRESSURE TEST
●
Thistask covers: Testing
INITIAL SETUP
EQUIPMENT CONDITION
MODELS
Para Description
4-11 Rocker arm covers removed
●
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Fuel pressure gage (App B, Item 31)
Fuel nut wrench (App B, Item 99)
Turbocharger inlet shield (App B, Item 81)
Torque wrench (App B, Item 100)
Testing
a. Remove fuel inlet tube (l) from injector (2)andfuel inlet manifold(3).
b. Connect pressure gage (4)toinjector (2)and fuel manifold(3).
WARNING
Avoid contact with hot manifolds, pulleys, and other moving parts to
avoid personal injury.
Wear proper ear protection when running engine. Noise volume of
engine can cause hearing loss or injury.
Protective turbocharger air inlet shield must be installed prior to doing
maintenance when e-ngine is running and air inlet has been removed .Contact with rotating blades will cause injury to personnel.
CAUTION
b
Run engine in clean area when air intake ducting is removed. Dirt, dust, and particles
in unfiltered air can enter engine and damage parts or cause mechanical failure.
c. Start engine and operate at 1800 RPM. Note reading on fuel pressure gage (4). Fuel pressure
must be 50-70 PSI (345-482 kPa) at 1800 RPM.
d. Move governor stop lever (5) to NO-FUEL position to stop engine.
8-40
Change 1
TM9-2815-202-34
CAIJTIC?N
●
not bend fuel lines and do not exceed specified torque m tie! [he nuts.
Excessive tightening will twist or fracture Wed end of hei he and resu’r! h kaks.
Do
● Never reuse fuel
fuel
iines may
lines reaardiess of their amearance. AtwaYs use new tuei tines. Reused
not seal
and result k fuel leakage. -
p%perty
Inst#l fuel inlet tube (1) on injector (2] and fuel manifold (3). Using fuel nut wrench. torque he; WH
M)e nuts to 13&160 b-in (14.7-18.3 N-m).
.
END OF TASK
6XXLOWa MAINTENANCE
Pam
[email protected]
+11 hstaJl rocker am covers
change 1
841
TM9-2815-202-34
8-17. CRANKCASE
PRESSURE TEST
●
Thistaskcovers: Testing
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
I All
Food coloring (App C, Item 19)
TOOLS AND SPECIAL TOOLS
*
General mechanics tool kit (App B, Item 96)
Manometer (App B, Item 64)
Nonmetallic tubing (App B, Item 98)
Turbocharger Inlet shield (App B, Item 81)
Testing
a. Remove one tube connector (1) from manometer (2) by rotating in counterclockwise direction.
b. Turn other tube connector (3) clockwise until fully engaged and then back out one full turn.
c. Add five drops of food coloring to one pint of distilled water and mix.
d. Add colored solution (4) to manometer (2) until liquid level is opposite zero mark on manometer
scale with manomete~ in a vertical posifion.
●
NOTE
Eliminate air bubbles by tilting
manometer and gently tapping
manometer.
e. Install tube connector (1) until fully
engaged and then back out one full turn.
f.
Remove oil level gage and tube from oil
pan. Install hose adaptor (5) in oil pan.
9. Connect hose (6) to adaptor (5) and tube
connector (1). Mount manometer in vertical
position. Close manometer tube connector
attached to hose.
8-42
Change 1
.
TM 9-2815 -202-34
WARNING
Avoid contact with hot manifolds, pulleys, and other moving parts to
avoid personal injury.
Wear proper ear protection when running engine. Noise volume of
engine can cause hearing loss or injury.
Protective turbocharger air inlet shield must be installed prior to doing
maintenance when engine is running and air inlet has been removed.
Contact with rotating blades will cause injury to personnel.
CAUTION
Run engine in clean area when air intake ducting is removed. Dirt, dust, and
particles in unfiltered air can enter engine and damage parts or cause mechanical
failure.
If crankcase pressure is excessively high, this pressure may exceed the capacity of
manometer. To prevent blowing liquid out of manometer, discontinue test if liquid
level approaches limits of manometer scale by closing manometer tube connector.
h. Start engine and operate at 1800 RPM FULL LOAD. Slowly open manometer tube connector (1)
attached to hose (6), while carefully observing liquid level in manometer tube.
NOTE
●
■
●
A manometer measurement is the sum of the displacements from zero of the two
columns of liquid. The value expressed is in inches of water.
●
For models 7083-7391, 7083-7395, and 7083-7396, measurements must not exceed 4.5
inches of water at 2300 RPM, FULL LOAD.
●
For the 7083-7398 and 7083-7399, measurements must not exceed 1.5 inches of
water at 2300 RPM, FULL LOAD.
i.
When manometer tube connector (1) has been opened one full turn, measure crankcase pressure
on manometer scale.
J
Move governor stop lever to NO-FUEL position to stop engine.
k.
Disconnect hose (6) and remove adaptor (5).
1.
Install oil level gage rod and tube.
.
END OF TASK
Change 1
8-43
TM9-2815-202-34
8-18. AIR BOX PRESSUIRE TEST
This task Covers: Testing
lNITIAL SETUP
MODELS
EXPENDABLE/DURABLE SUPPLIES
AM
Mercury (App c, Item 28)
TOOLS AND SPECIAL TOOL
Manometer (App B, Item 64)
Nonmetallic tubing (App B, Item 98)
Turbocharger Inlet Shield (App B, Item 81)
Testing
WARNING
Mercury is a toxic material. Avoid contact with skin. Clean up any spilled
mercury. Small amounts of mercury may be disposed of by wiping with
aluminum foil.
a. Remove one tube connector (1) from manometer (2) by rotating connector in a counterclockwise
direction.
b. Turn remaining tube connector (3) until fully engaged and then back out one full turn.
c. Add mercury (4) to manometer (2) until mercury level is opposite zero mark on manometer scale
with manometer in a vertical position.
d. Install tube cnnector (1) until fully
engaged and then back out one full turn.
e. Connect hose (5) to air box drain tube (6)
and connect opposite end of hose to
manometer tube connector (1). Close
manometer tube connector (1) attached to
hose.
f.
8-44
Mount manometer (2) in a vertical position
and adjust scale until zero mark is opposite
of mercury level.
Change 1
TM9-2815-202-34
WARNING
●
Avoid contact with hot manifolds, pulleys, and other moving parts to
avoid personal injury.
●
Wear proper ear protection when running engine. Noise volume of
engine can cause hearing loss or injury.
●
Protective turbocharger air inlet shield must be installed prior to doinu
maintenance when e-naine is runnina and air inlet has been removed.Contact with rotating blades will cake injury to personnel.
CAUTION
*
Run engine in clean area when air intake ducting is removed. Dirt, dust, and particles
in unfiltered air can enter engine and damage parts or cause mechanical failure.
NOTE
A manometer measurement is the sum of the displacements from zero of the two
columns of mercury. This value is expressed as inches of mercury.
Start engine and operate at FULL LOAD at 2300 RPM, slowly open tube connector(1) and
measure air box pressure indicated on manometer.
For models 7083-7395 and 7083-7396, measurement is a maximum of 55.0 and a minimum of 45.0
inches of mercury. For models 7083-7398 and 7083-7399, measurement is a maximum of 44.0 and
a minimum of 36.0 inches of mercury. For model 7083-7391, measurement is a maximum of 62.0
and a minimum of 50.0 inches of mercury.
Move governor stop lever to NO-FUEL position to stop engine.
Disconnect hose (5) from air box drain tube (6) and manometer (2).
END OF TASK
●
●
●
Change 1
8-45
TM9-2815-202-34
SECTION V. ENGINE RUN-IN
8-19. ENGINE RUN-IN PREPARATION
This task covers: Engine Preparation
●
INITIAL SETUP
EXPENDABLE/DURABLE SUPPLIES
MODELS
Z All
Engine oil (App C, Item 16)
EQUIPMENT CONDITION
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
Para Description
4-11 Rocker arm covers rem wed
Fuel system primed
8-2
Engine prelubricated
8-2
.
a. Preparation
WARNING
Position exhaust piping to carry toxic carbon monoxide exhaust gases
away from test area.
(1) Position and secure engine to a dynamometer.
(2) Fill crankcase with correct grade of engine oil to FULL mark on oil gage rod. Do not over fill.
CAUTION
Prolonged use of starter motor and engine fuel pump to prime fuel systems can result
in damage to starter, fuel pump, injectors, and erratic running of engine due to the
amount of air in fuel lines and filters.
.
●
8-46
Change 1
TM 9-2815 -202-34
(3) Connect external source of fuel supply and fuel return to engine. Fill fuel filters with clean
fuel.
O
(4) Connect same type of air cleaners that are used with engine when installed in vehicle.
NOTE
Locate air intake so engine inducts cool fresh air.
(5) Connect engine cooling system to a heat exchanger or radiator, similar to vehicle type, to
cool engine. Fill cooling system with coolant.
.
(6) Provide an external source of 24 V dc electrical power for starting engine.
(7) Install oil pressure gage to main oil gallery.
(8) Install water temperature gage in thermostat housing or water outlet manifold.
(9) Connect tubing to exhaust outlet of turbocharger to conduct exhaust gases from engine.
(lo) Connect throttle control linkage to throttle control levers on governor.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
4-11 Install rocker arm covers
e
.
v
8-47
TM 9-2815-202-34
8-20. ENGINE RUN-IN
This task covers:
a. Run-In Procedure
b. Horsepower Correction and Acceptance Test
INITIAL SETUP
MODELS
EQUIPMENT CONDITION
All
Para Description
8-19 Engine prepared for run-in
TOOLS AND SPECIAL TOOLS
General mechanics tool kit (App B, Item 96)
CAUTION
Observe engine operation closely at all times. Operator must detect malfunctions which
may develop early. Correct minor problems immediately so that major problems will not
develop and cause engine damage.
a. Run-In Procedure
NOTE
●
When any original bearings, piston rings, pistons, or cylinder liners were replaced
during repair, use the long run-in schedule (Table 8-2).
●
When all original bearings, piston rings, pistons, or cylinder liners were reused during
repair, use the short run-in schedule (Table 8-3) or (Table 8-3.1) for model
7083-7391 only.
■
●
During Period 1, Table 8-2, 8-3, or 8-3.1; remove rocker arm covers, inspect for fuel
oil and coolant leaks in the rocker arm compartment, and install rocker arm covers
(Refer to Para 4-1 1).
9
●
After completion of Period 2, Table 8-2 or 8-3; adjust governor gap (Refer to Para
8-6).
9
●
After completion of Period 8, Table 8-2; Period 5, Table 8-3; or Period 4, Table 8-3.1;
adjust idle speed (Refer to Para 8-1 O), no-load speed (Refer to Para 8-11 for dual
range limiting speed governor or Para 8-12 for limiting speed governor), and
governor buffer screw (Refer to Para 8-13).
I
“
8-48
Change 1
TM W2msma
(1) LJshg run-in schedule (Tatn!e 8-2.$-3. CM 8-3.1 .]. s&M engine and m in enghe. Record
the
kAbw’hg data for eactl rim-h pmod.
CM sump temperame.
oil gamy preswre.
crankcase pressure.
Air intake manifold Vacuml.
[email protected]
air htake temperature.
Air box pressure.
9
Engine speed
8*
~r.
Period duration.
NOTE
Record the wowing data to Cmrec’t brake hcmqxwer C.Mrq W pv’er check (Period 9,
Table 8-2; Ptiocj 6. TaMe 8-3: or Pcmkd 5, Table 8-3.1).
Barometric presswe
Anbient air
Ambient
wet bulb temperature.
air dry Mb temperature.
TaMe &2 Long
Run-in Schedule
Engine Speed
Period
Number
(RPM)
1
15
600
o
2
3
15
15
15
20
20
20
2U
30
5
900
Ilcm
60
105
14-O(I
1800
160
240
210$1
2300
230Q
332
345
4
5
6
7
8
9
10
23CKI
600
( C-cxmcj Oti)
Full
I
I
I
I
I
Power Check
o
I
I
change
1
6’-49
TM 9-2815-202=34
8-20. ENGINE RUN-IN (Cent)
Table 8-3. Short Run-In Schedule
Period
Number
Time
(Minutes)
Engine Speed
(RPM)
Load
(Brake Horsepower)
1
2
3
4
5
5
!5
30
15
15
600
1200
2500
0
0
6
7
15
5
2300
600
(Cooling Off)
2300
2300
0
107
230
Full Power Check
0
Table 8-3.1. Run4n Schedule (Model 7083-7391 Only)
Period
Number
Time
(Minutes)
Engine Speed
(RPM)
Load
(Brake Horsepower)
1
2
10
5
10
1200
2475
2300
2475
2300
2475
(Cooling Off)
56
0
396
0
Full Power Check
3
4
5
6
5
20
5
0
(2) Tighten cylinder head bolts and adjust exhaust valve clearance after run-in (Refer to Para 4-27
and 8-4 respectively).
(3) For model 7083-7391 only, retorque right bank exhaust manifold stud nuts to 43-48 Ib-ft (59-67
N-m) after run-in (Refer to Para 5.1-3).
8-50
Change 1
TM 9-2815-202-34
b. Horsepower Correction and Acceptance Test.
(1) See Table 8-4 for listing of measurement term definitions.
Table 8-4. List of Measurement Term Definition
Symbol
BAROO
BAROcj
VP
Tdb
Twb
Ta
CFa
CFsg
CFti
BHPo
BHPc
Name
Observed Barometric Pressure
(Not corrected to Sea Level)
Dry Barometric Pressure
Water Vapor Pressure
Dry Bulb Temperature
Wet Bulb Temperature
Air Intake Temperature (At Air Cleaner)
Air Correction Factor
Fuel Specific Gravity Correction Factor
Fuel Temperature Correction Factor
(At Fuel Filter Outlet)
Brake Horsepower Observed
Brake Horsepower Corrected
(To 77°F and 29.31 inches Hg Dry)
Units
inches Hg
inches Hg
inches Hg
‘F
“F
“F
“ HP
HP
HP
HP
HP
(2) Dry Barometric Pressure (BAROd) using wet-bulb and dry-bulb temperatures.
(a) Measure wet-bulb and dry-bulb temperatures (T~b and Ta}.
(b) Record observed local barometric pressure (BARO.).
(c) Refer to Table 8-5 for water vapor pressure (VP) at observed wet-bulb and dry-bulb
temperatures.
Change 1
8-51
TM 9-2815-202-34
8-20. ENGINE RUN-IN (Cont)
Table 8-6. Water Vapor Pressure (inches HG)
Table 8-6.
8-52
TM 9-2815-202-34
(c) For model 7083-7391, refer to Table 8-7 for air correction factor (CFa).
Table 8-7. Air Correction Factor (CFa) in BHP (Model 7083-7391 Only)
table 8-8
Table 8-8.
C h a n g e
1 8-53
TM9-2815-202-34
8-20. ENGINE RUN-IN (Cont)
(5) Fuel temperature correction factor (CFft).
(a) Measure fuel temperature at fuel filter outlet.
(b) Refer to Table 8-9 and find fuel temperature correction factor (CFft).
Table 8-9. Fuel Temperature Correction Factor (CFft) in BHP
(6) Corrected brake horsepower (BHPc) is:
BHPC = BHPo + CFa + CFsg + CFft
(7) For all models except 7083-7391, a minimum of 380 corrected brake horsepower is acceptable.
(8) For model 7083-7391, a minimum of 418 corrected brake horsepower is acceptable.
END OF TASK
FOLLOW-ON MAINTENANCE
Para Description
3-3 Install engine in container (12268285)
3-4 Install engine in container (10909159/10923108).
8-54 C h a n g e 1
TM9-2815-202-34
APPENDIX A
REFERENCES
A-1. SCOPE
This appendix lists all forms, field manuals, technical manuals, and other publications referenced in
this manual. It also lists publications that should be consulted for additional information about engine
operation.
A-2. PUBLICATION INDEXES
The following indexes should be consulted for latest changes or revisions to references given in this
appendix and for new publications or instructions relating to material covered in this manual.
Consolidated Index of Army Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30
The Army Maintenance Management System (TAMMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 738-750
A-3. MAINTENANCE FORMS AND RECORDS
Recommended Changes to DA Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028
Recommended Changes to Equipment Technical Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028-2
Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF 368
A-4. REGULATIONS
Accident Reporting and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR-385-40
A-5. LUBRICATION
Lubrication Order for Recovery Vehicle, Full Tracked,
Light, Armored: M578 (NSN 2350-00-439-6242) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LO 9-2350-238-12
Lubrication Order for Carrier, Ammunition, Tracked:
M992 (NSN 2350-01-110-4660) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LO 9-2350-267-12
Lubrication Order for Howitzer, Heavy, Self-Propelled:
8-inch, M110A2 (NSN 2350.01.041.4590) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LO 9-2350-304-12
Lubrication Order for Howitzer, Medium, Self-Propelled:
155-mm M109A2 (NSN 2350-01-031-0586),
155-mm M109A3 (NSN 2350-01-031 -8851), and
155-mm M109A4 (NSN 2350-01-305-0028) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LO 9-2350-311-12
A-6. FIELD MANUALS
Principles of Automotive Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-8000
First Aid for Soldiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-11
A-1
TM9-2815-202-34
A-7. TECHNICAL MANUALS
Inspection, Care, and Maintenance of Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-214
Welding: Theory and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-237
Materials Used for Cleaning, Preserving, Abrading, and
Cementing Ordnance Materiel and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-247
Data Sheets for Ordnance Type Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-500
Preservation, Packaging, and Packing of Military Supplies and Equipment . . . . . . . . . . . . . . . . . . . . . . . TM 38-230-1
Preservation, Packaging, and Packing of Military Supplies and Equipment . . . . . . . . . . . . . . . . . . . . . . . TM 38-230-2
Procedures for Destruction of Tank–Automotive Equipment to Prevent
Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-750
Direct Support and General Support Maintenance
Repair Parts and Special Tools List for Engine, Diesel w/Container:
Model 7083-7391 (NSN 2815-01-335-4579), Engine, Diesel w/Container:
■
Model 7083-7395 (NSN 2815-01-043-7092) and (NSN 2815-01-260-0211),
Engine, Diesel w/Container: Model 7083-7396 (NSN 2815-01-040-3120) and
(NSN 2815-01-260-0212), Engine, Diesel w/Container:
Model 7083-7398 (NSN 2815-00-936-7659), Engine, Diesel w/Container:
Model 7083-7399 (NSN 2815-00-134-4845) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2815-202-24P
■
Operator’s Manual for Recovery Vehicle, Full Tracked,
Light Armored: M578 (NSN 2350-00-439-6242) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2350-238-10
Organizational Maintenance Manual for Recovery Vehicle, Full Tracked,
Light Armored: M578 (NSN 2350-00-439-6242) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM9-2350-238-20
Direct Support and General Support Maintenance Manual for Recovery Vehicle,
Full Tracked, Light Armored: M578 (NSN 2350-00-439-6242) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2350-238-34
Operator’s Manual for Carrier, Ammunition, Tracked:
M992 (NSN 2350-00-1 10-4660) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2350-267-10
organizational Maintenance Manual for Hull, Powerpack, Drive Controls,
Tracks, Suspension and Associated Components, Carrier, Ammunition,
Tracked: M992 (NSN 2350-00-1 10-4660) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM9-2350-267-20
Direct Support and General Support Maintenance Manual for Hull, Powerpack,
Drive Controls, Tracks, Suspension and Associated Components, Carrier,
Ammunition, Tracked: M992 (NSN 2350-00-1 10-4660) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2350-267-34
Operator’s Manual for Howitzer, Heavy, SeIf-Propelled:
8-inch, M110A2 (NSN 2350-01-041-4590) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . TM 9-2350-304-10
Organizational Maintenance Manual for Howitzer, Heavy, Self-Propelled:
8-inch, M110A2 (NSN 2350-01-041-4590) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2350-304-20
Direct Support and General Support Maintenance Manual for Hull and
Related Components: Howitzer, Heavy, Self-Propelled:
8-inch, M110A2 (NSN 2350-01-041-4590) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2350-304-34-1
Operator’s Manual for Howitzer, Medium, Self-Propelled:
155-mm M109A2 (NSN 2350-01-031-0586),
155-mm M109A3 (NSN 2350-01-031-8851), and
155-mm M109A3 (NSN 2350-01-031-8851) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2350-311-10
Organizational Maintenance Manual for Hull, Powerplant, Drive Controls, Tracks,
Suspension, and Associated Hardware for Howitzer, Medium, Self-Propelled:
155-mm M109A2 (NSN 2350-01-031-0586),
155-mm M109A3 (NSN 2350-01-031-8851), and
155-mm M109A4 (NSN 2350-01-305-0028) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2350 -311-20-1
A-2 C h a n g e 1
TM9-2815-202-34
Direct Support and General Support Maintenance
Manual for Hull, Powerplant, Drive Controls,
Tracks, Suspension, and Associated Hardware for
Howitzer, Medium, Self-Propelled:
155-mm M109A2 (NSN 2350-01-031-0586),
155-mm M109A3 (NSN 2350-01-031-8851), and
155-mm M109A4 (NSN 2350-01-305-0028) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2350-311-34-1
Direct Support, General Support, and Depot Maintenance
(including Repair Parts) for Starter, Engine, Electric, Assembly
(NSN 2920-00-226-6545) (Delco-Remy Model 1113943)
(Military PN 10911018-1); (NSN 2920-00-91 1-5637)
(Delco-Remy Model 1113904) (Military PN 10911018);
(NSN 2920-00-912-9510) (Delco-Remy Model 1113944) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2920-242-35
Direct Support and General Support Maintenance Manual
(including RPSTL) for Starter, Engine, Electric Assembly
(Leece-Neville M001 072 MB) (NSN 2920.00.267.9987) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2920-243-34
Direct Support, General Support, and Depot Maintenance
(including Repair Parts) for Starter, Engine, Electrical, Assembly
(NSN 2920-00-999-6216) (Prestolite Model-MFY61 01IUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2920-248-35
A-8. TECHNICAL BULLETINS
DA Technical Bulletin Warranty Program
Direct Support and General Support Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2815-202-34
Ordnance Engines: Run-In and Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2800-200-50
A-9. MILITARY SPECIFICATIONS
Clean Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . M IL-P-116
Military Standard Marking for Shipment and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-STD-129
A-10. SUPPLY CATALOGS
Shop Equipment Automotive Maintenance and Repair:
Field Maintenance, Supplemental No. 1, Less Power
(NSN 4910-00-754-0706) and
Shop Equipment Automotive Maintenance and Repair:
Field Maintenance, Supplemental No. 1,
Map only (NSN 4910.00.91 9. 0078) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SC 4910-95-A62
Shop Equipment, Automotive Maintenance and Repair:
Field Maintenance, Supplemental No. 2, Less Power
(NSN 4910-00-754-0707) and
Shop Equipment, Automotive Maintenance and Repair:
Field Maintenance, Supplemental No. 2,
Map only (NSN 4910.00.919.0093) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SC 4910-95-A63
Shop Equipment, General Purpose Repair,
Semitrailer Mounted: (NSN 4940-00-287-4894) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SC 4940-95-CL-B02
Tool Kit, General Mechanic's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SC 5180-90-CL-N05
A-3/A4 Blank
TM9-2815-202-34
APPENDIX B
TOOLS AND TEST EQUIPMENT
SPECIAL TOOLS AND COMMON TOOL SETS
Section I. INTRODUCTION
B-1 SCOPE
This appendix lists all common tool sets and supplemem sets and special tools needed t o
maintain the 8V71T Model 7083-7391. 7083-7395. 7083-7396, 7083-7398, and 7083-7399 engines.
B-2 EXPLANATION OF COLUMNS
a. Column 1 - Item number. This number is assigned to the entry in the listing and is referenced in the initial Setup to identify the item (e.g., Cradle (App B, Item 13)").
Initial Setup to identify the item (e.g., "Cradle (App B, Item 13)").
b.Column2-Description.This column lists the item by noun nomenclature and other descriptive
features (e.g, "puller, mechanical").
d. Column 4- National Stock Number. This is the National Stock Number (NSN) assigned to the item;
use it to requisition the item.
Change 1 B - 1
TM 9-2815-202-34
Section Il. COMMON TOOLS, SUPPLEMENTS, SPECIAL
TOOLS AND FIXTURES LIST
(2)
(1)
ITEM
NUMBER
001
002
003
004
005
006
007
008
009
010
011
012
013
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028
029
030
031
032
033
034
035
036
037
038
039
040
041
042
043
044
045
046
047
048
049
050
051
052
DESCRIPTION
(3)
PART
NUMBER
ADAPTER
J7932
ADAPTER 3/8-1 6
ADAPTER KIT-INSERT GRINDING
J6390-02
DIAL INDICATOR
J21224
ALIGNMENT TOOLS, TACHOMETER DRIVE
J23068
BALL ATTACHMENT, MICROMETER
J4757
BLOCKS, LAPPING
J22090-A
BRACKET
10903999
BRUSH, WIRE ROTARY
J7944
CALlPER, VERNIER (0-6.0 IN)
CLAMP, CYLINDER LINER HOLD-DOWN
J21793-B
COMPRESSOR, PISTON RING
J3272-03
COMPRESSOR, VALVE SPRING,
HEAD OFF ENGINE
J8062
COMPRESSOR, VALVE SPRING,
HEAD ON ENGINE
CRADLE
7950198
DRAIN UNIT
8706359
DRIVER, CAM
5344997
EXPANDER, SEAL
10881910
FIXTURE, CAM FOLLOWER HOLDING
FIXTURE, CYLINDER HEAD LIFTING
J22062-01
FIXTURE, HOLDING INJECTOR
J22396-1
FIXTURE, TURBOCHARGER HOLDING
J29086
GAGE PIN, THROTTLE DELAY
J25558
GAGE SET, DEPTH MICROMETER
GAGE SET, PISTON-LINER FEELER
J5438-01
GAGE SET, TELESCOPING
GAGE SET, THICKNESS
J1698-02
GAGE, CYLINDER BORE
GAGE, DEPTH
J22273-01
GAGE, DIAL INSERT RUNOUT
9320
GAGE, FLYWHEEL HOUSING
J9737-C
GAGE, FUEL PRESSURE
J8151
GAGE, INJECTOR PROTRUSION
J25521
GAGE, INJECTOR RACK
J24882
GAGE, INJECTOR TIP & CONCENTRICITY
J29584
J9462-02
GAGE, NEEDLE VALVE HEIGHT
J24599
GAGE, PISTON RING GROOVE
GAGE, THROTTLE DELAY
J25559
HT-80540
GRINDER, VALVE INSERT
HAMMER, SLIDE
J2619-01
J3154-1
HANDLE, DRIVER
HANDLE, THERMOSTAT SEAL INSTALLER
J7079-2
HONE, CYLINDER
10881880
HOOK, LIFTING, FLYWHEEL
INDICATOR, DIAL
INDICATOR, DIAL MAGNETIC BASE
J7872
INJECTOR TIMING GAGE
J1242
INJECTOR, TUBE, RECONDITIONING SET
INSTALLER, BALANCE WEIGHT COVER SEAL J9791
INSTALLER, BRIDGE GUIDE
J7482
INSTALLER, CRANKSHAFT OIL SEAL FRONT J9783
INSTALLER, CRANKSHAFT OIL SEAL REAR
J9727-A
INSTALLER, GEAR
CPR109365
B - 2
Change 1
(4)
NATIONAL
STOCK NUMBER
(5)
REFERENCE
5120-00-733-8890
5120-00-316-9170
5180-01-026-0307
4910-00-907-0713
5180-01-025-8062
5210-00-494-1738
3460-00-937-5521
4910-00-737-0432
5130-00-937-7281
5210-00-277-7549
5120-00-999-8618
5120-00-859-6259
TM9-2815-202-24P
SC4940-CL-B02
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
SC4940-CL-B02
TM9-2815-202-24P
TM9-2815-202-24P
5120-00-254-5049
TM9-2815-202-24P
5120-00-239-8686
4910-00-795-0198
4930-00-545-8639
4910-00-363-7556
5120-00-443-2508
2815-00-705-9278
4910-00-456-7620
5220-01-061-4248
4910-01-170-4914
5220-01-138-7558
5210-00-619-4045
5210-00-116-1631
5210-00-473-9350
5210-01-245-9564
5210-01-070-4543
5210-00-023-4798
4910-00-779-7103
5210-00-937-7284
6620-00-671-4509
5220-01-167-4281
5210-01-214-0246
5210-00-990-3327
5210-00-937-7285
5220-01-028-1109
5120-01-048-2200
4910-00-779-7078
5120-00-910-7868
5120-00-808-5082
5120-00-977-5578
5130-00-991-0699
4910-00-722-3877
5210-00-277-8840
5210-00-402-9619
5210-00-474-6400
2910-00-146-9619
5120-01-013-1678
5120-00-999-8616
5120-00-936-4377
5120-01-189-9623
5120-01-008-1600
SC4940-CL-B02
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
SC4940-95-CL-B02
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
SC4940-CL-B02
TM9-2815-202-24P
SC4940-CL-B02
TM9-2815-202-24P
SC4940-95-A63
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
SC-4910-95-A63
TM9-2815-202-24P
SC4940-95-CL-B02
TM9-2815-202-24P
TM9-2815-202-24P
SC4940-95-CL-B02
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-3
(1)
ITEM
NUMBER
053
054
055
056
057
058
059
060
061
062
063
064
065
066
067
068
069
070
071
072
073
074
075
076
077
078
079
080
081
082
083
084
085
086
087
088
089
090
091
092
093
094
095
096
097
098
099
100
101
102
103
104
105
(2)
(3)
PART
NUMBER
(4)
NATIONAL
STOCK NUMBER
INSTALLER, GOVERNOR COVER BEARING
INSTALLER, INJECTOR TUBE NEW STYLE
INSTALLATION CAP, VALVE GUIDE OIL SEAL
INSTALLER, OIL PUMP DRIVEN GEAR
INSTALLER, PISTON PIN RETAINER
INSTALLER, PLUG CUP
INSTALLER, THERMOSTAT SEAL
INSTALLER, VALVE GUIDE
INSTALLER, VALVE INSERT
INSTALLER, WATER PUMP DRIVE GEAR
LEAK DETECTOR, PISTON PIN RETAINER
MANOMETER
MICROMETER SET
J21068
J5286-20
5199913
J22398
J23762-A
J33420
J8550
10881889
10881873
J25257
J23987-01
J21478-1
4910-00-779-6078
5120-01-248-7737
PLIERS, PISTON RING
PLUG ADAPTOR
PULLER, COMBINATION LEG
PULLER, MECHANICAL
PULLER, MECHANICAL 2-JAW
PULLER, UNIVERSAL
REAMER, CYLINDER RIDGE
REAMER, INJECTOR BODY
REMOVER SET, VALVE BRIDGE GUIDE
REMOVER, BRIDGE GUIDE BROKEN
REMOVER, CYLINDER LINER
REMOVER, GOVERNOR COVER BEARING
REMOVER, GOVERNOR COVER BUSHING
REMOVER, VALVE GUIDE
REMOVER, VALVE INSERT
SHIELD, TURBOCHARGER INLET
SLING, FOUR LEG
SLING, MULTIPLE
SLING, THREE-LEGGED
STAND, MAINTENANCE
STUD, GUIDE
STUD, GUIDE SET
STUDS, CYLINDER HEAD GUIDE
TEST FIXTURE, DIESEL
TESTER, CYLINDER COMPRESSION
TESTER, DIESEL FUEL
TESTER, INJECTOR TIP CONCENTRICTY
FREENESS
79500177
J23019
J24420-A
J4871
DESCRIPTION
TESTER, SPRING
TOOL KIT, BLOWER
TOOL KIT, DIESEL INJECTOR
TOOL KIT, GENERAL MECHANICS
TOOL SET, FUEL PUMP
TUBING, NONMETALLIC
WRENCH, FUEL NUT
WRENCH, TORQUE 300 LB-IN
WRENCH, TORQUE 0-175 LB-FT
WRENCH, TORQUE 100-500 LB-FT
COMPRESSOR, PISTON RING
WRENCH, BOX
GAGE, INJECTOR TIMING
8708724
J21089
J7091-01
J7453
6248510
J21967-01
J8985
10919987
J23479-E
J26554-A
11643468
10930560
11643469
7950189
5345162
J25002
J9665
J29584
J6270-F
J23435-02
J1508-D
564-0077-011
10881875
F3001
9033917
NT5
J21223-02
J1853
(5)
REFERENCE
5120-01-232-0001
5120-00-127-7757
5120-01-297-2457
5120-00-977-5579
5120-00-733-8881
5120-00-733-8876
5120-01-033-8902
5210-01-061-4253
6685-00-857-4895
5210-00-554-7134
5120-00-494-1846
5120-01-130-8864
5180-00-999-4053
5120-00-740-3345
5120-00-595-9305
5180-00-338-6721
5110-00-237-8598
5110-00-937-7628
5120-00-999-8614
5120-00-999-8615
5120-00-387-9615
5120-01-145-4490
4910-00-779-7315
5120-00-733-8880
5120-01-165-1935
4910-01-127-7959
4910-00-140-6876
3940-00-977-7398
4910-00-001-3993
4910-00-795-0189
5315-00-779-7364
5120-01-048-2155
4910-00-591-6634
4910-00-255-8641
4910-00-808-4300
4910-00-355-6248
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
SC4910-95-A63
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
SC4940-95-A62
TM9-2815-202-24P
SC4940-95-CL-B02
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
SC4940-95-CL-B02
SC4940-95-CL-B02
SC4940-95-CL-B02
5210-00-990-3327
6635-00-641-7346
4940-00-611-7945
5180-01-038-0251
5180-00-699-5273
5180-00-219-8407
4720-00-271-9839
5120-01-147-7923
5120-00-247-2536
5120-00-640-6364
5120-00-542-5577
5120-00-250-6050
5120-00-907-8989
5220-00-387-9581
TM9-2815-202-24P
SC4940-95-A63
TM9-2815-202-24P
TM9-2815-202-24P
SC5180-90-CL-N05
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
TM9-2815-202-24P
SC4940-95-CL-B02
TM9-2815-202-24P
SC4940-95-CL-B02
TM9-2815-202-24P
TM9-2815-202-24P
Change 1
B-3/B-4 Blank
TM9-2815-202-34
APPENDIX C
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Section I.
INTRODUCTION
C-1. SCOPE. This appendix lists expendable supplies and materials needed to operate and maintain
the 8V71T series engines. These items are authorized by CTA 50-970. This appendix includes
expendable items (except Medical, Class V, Repair Parts, and Heraldic Items) and consumable materials.
C-2. EXPLANATION OF COLUMNS
a. Column 1 -- Item Number. This number is assigned to the entry in the listing and is referenced in
the narrative SETUP to identify the material (e.g., “Antiseize compound (App C, Item 1 )“).
b. Column 2 -- Description. Indicates the federal item name and, a description to identify the item.
c. Column 3 -- National Stock Number. This is the national stock number (NSN) assigned to the
item; use it to request or requisition the item.
d. Column 4 -- Unit of Measure (U/M). Indicates the measure used in performing the actual
maintenance function. This measure is expressed by an alphabetical abbreviation (e.g. EA, IN, PR). If the
unit of measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy the
requirements.
Section Il.
(1)
ITEM
NUMBER
001
002
003
004
005
006
007
008
009
010
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
(2)
DESCRIPTION
ANTISEIZE COMPOUND (MIL-A-907)
BOLT 5/16-18 X 1 7/8 IN.
BOLT 5/1 6-24 X 1 1/2 IN.
BOLT 5/16-24 X 3 IN.
BOLT 3/8-24 X 4 1/2 IN.
BOLT 5/8-1 1 X 2 IN.
CARBON REMOVING COMPOUND
MIL-S-12382 (ORD) TYPE 1
CINDOL 1705 LUBRICATING OIL
CLEANING SOLUTION, KIT
CLEANING SOLVENT, P-D-680
1 -QT CAN
1 -GAL CAN
(4)
(3)
NATIONAL
STOCK NUMBER
U/M
8030-00-597-5367
LB
5306-00-225-9093
5306-00-225-9099
5305-00-269-2820
5305-00-051-0827
6850-00-281-3044
EA
EA
EA
GA L
6850-00-598-7328
6850-00-664-5685
6850-00-281-1985
QT
GAL
C-1
TM9-2815-202-34
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (Cont)
(1)
ITEM
NUMBER
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028
029
030
031
032
033
034
035
036
037
038
(2)
DESCRIPTION
COVER PLATE, WATER HOLE
CROCUS CLOTH, P-C-458
CUTTING OIL
DESICCANT
EMERY CLOTH
ENGINE OIL-SAE 15/40 (MIL-L-21 04)
1-QT CAN
5-GAL DRUM
55-GAL DRUM
FLAT WASHER, 1/4 IN.
FLAT WASHER, 5/16 IN.
FOOD COLORING
FUEL LINE
FUEL OIL, DIESEL DF-2 REGULAR
BULK
5-GAL CAN
55-GAL DRUM, 16 GAGE
55-GAL DRUM, 18 GAGE
GREASE, GENERAL PURPOSE,
LITHIUM BASE
HEAT INDICATING CRAYON
INTERNATIONAL COMPOUND NO. 2
(72582) P/N 5198563
LAPPING COMPOUND, J3179-5
LINTLESS CORD
MASKING TAPE
MERCURY
NUT 3/8-24
PLASTIC GAGE
PRESERVATION OIL, MlL-C-16173
1-GAL
5-GAL
55-GAL
PRUSSIAN BLUE
SCREW #10-32 X 1.0 IN.
SCREW, SHEET METAL #1 O X 1 1/4 IN.
SEAL, CONTAINER
SEAL, CONTAINER
SEAL, CONTAINER
SEALANT, LOCTITE RC-620
50-CC
250-CC
c - 2Change
1
(3)
NATIONAL
STOCK NUMBER
(4)
U/M
2815-01-046-1965
5350-00-221-0872
9150-00-076-1567
6850-00-264-6572
EA
EA
GAL
PK
9150-01-152-4117
9150-01-152-4118
9150-01-152-4119
5310-00-823-8804
5310-00-081-4219
QT
GAL
GAL
EA
EA
4710-00-020-2734
EA
9140-00-286-5294
9140-00-286-5295
9140-00-286-5296
9140-00-286-5297
9150-01-091-9336
GAL
GAL
GAL
GAL
LB
QT
5350-01-157-6916
EA
7510-00-290-2027
6810-00-281-7453
5310-00-732-0559
RL
BTL
EA
8030-00-062-5866
8030-00-244-1293
8030-00-244-1294
GAL
GAL
GAL
5305-01-098-7194
EA
5330-01-288-4550
5330-01-142-4882
5330-01-288-9435
EA
EA
EA
8030-00-181-7603
8030-00-181-7529
CC
CC
TM 9-2815-202-34
(1)
(2)
ITEM
NUMBER
DESCRIPTION
039
040
041
042
043
044
045
046
047
048
049
050
SEALANT, RTV106
SEALANT, 567-47
SILICONE CARBIDE CLOTH, P-P-121
SILICONE LUBRICANT
STONE, SHARPENING
STONE, SHARPENING X-FINE
SULPHURIZED OIL, E.P. TYPE
WOOD BLOCK, 2 X 4 IN.
NUT 3/8-1 6
FLAT WASHER, 3/8 IN.
SEALANT, PIPE, TEFLON
GASKET CEMENT
(3)
NATIONAL
STOCK NUMBER
(4)
U/M
8040-00-941-9984
8030-01-166-0675
5350-00-224-7203
Oz
Oz
EA
5345-00-198-8050
5345-00-584-4607
EA
EA
5310-00-732-0558
5310-00-080-6004
1015-01-255-4144
8040-01-170-6503
EA
EA
TU
TU
Change 1 C-3/C-4 Blank
TM9-2815-202-34
APPENDIX D
ILLUSTRATED LIST OF MANUFACTURED ITEMS
Section I. INTRODUCTION
This appendix includes complete instructions for making items authorized to be manufactured or
fabricated at direct and general support maintenance.
Apart number index in alphanumeric order is provided for cross–referencing the part number of the item to
be manufactured to the figure which covers fabrication criteria.
All bulk materials needed for manufacture of an item are listed by part number or specification number in a
tabular list on the illustration.
Section Il. MANUFACTURED ITEMS PART NUMBER INDEX
ITEM
NO.
PART
NO.
1
2
3
4
5
6
7
8
9
10
12384626
12384627
12384628
12384629
12384630
12384631
12384632
12384633
12384634
12384635
11
12
13
14
12384636
12384637
12384638
12384639
NATIONAL
STOCK NUMBER
FIGURE
NO.
DESCRIPTION
TEST LEAD
BEARING TEST FIXTURE
GUIDE STUD
BAR TOOL
ADAPTOR
PLATE KIT
AIR NOZZLE PLATE KIT
TURBOCHARGER HOLDING FIXTURE
BACKPLATE TORQUING TOOL
CYLINDER HEAD PRESSURE
TESTING KIT
WATER OUTLET PLATE
SLEEVE
THREADED ROD
EXHAUST SEAL INSTALLER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Change 1 D - 1
TM9-2815-202-34
NOTES: To reduce 24 V dc to 18 V dc.
1. Cut a piece of 12-gage wire 6 inches long.
2. Cut a piece of 12-gage wire 12 inches long.
3. Cut a piece of 1-inch diameter rubber hose 7 inches long.
4. Attach a test clip to one end of 6 and 12 inch long 12 gage wire.
5. Drill a hole through end of two No. 2 K plugs in order to insert 12-gage wire through.
6. Insert one lead through hole in plug and connect to 50-watt resistor. Insert in rubber hose and
attach other lead to resistor.
FIGURE D-1 . TEST LEAD (P/N 12384626)
D-2
TM9-2815-202-34
1. Fabricate from 3/4-inch thick steel plate, items (A) and (B).
2. Fabricate from 3/8-inch thick steel plate, item (C).
3. Quantity required: one each, items A, B and C.
4. Additional items: One bolt 1/2-13 x 3 NSN 5305-00-071-1772. Three bolts 3/8-16 x 1 NSN
5305-00-269-3211. Two flat washers 1/2 NSN 5310-00-809-5997. Three flat washers 3/8 NSN
5310-00-080-6004. One nut 1/2-13 NSN 5310-00-768-0318.
5. All dimensions are in inches.
FIGURE D-2. BEARING TEST FIXTURE (P/N 12384627)
D-3
TM9-2815-202-34
1. Fabricated from NSN 5305-00-269-3228 (3/8-16 x 5) bolt by cutting off head of bolt. Saw or file
a 1/16-inch screwdriver slot in unthreaded end.
2. Quantity required, four.
3. All dimensions are in inches.
FIGURE D-3. GUIDE STUD (P/N 12384628)
D-4
TM9-2815-202-34
NOTES:
1. Fabricate from 1/4-inch thick steel plate.
2. Quantity required, one.
3. All dimensions are in inches.
FIGURE D-4. BAR TOOL (P/N 12384629)
D-5
TM9-2815-202-34
NOTES:
1. Fabricate from 1/2-inch thick steel square stock.
2. Weld a 1/2-inch drive socket NSN 5120-00237-0984 (ratchet side up) to plate.
3. Quantity required, one.
4. Additional items: Two 5/16-18 x 1 bolts NSN 5306-00-225-8499.
5. All dimensions are in inches.
FIGURE D-5. ADAPTOR (P/N 12384630)
D-6
TM9-2815-202-34
NOTES:
1. Fabricate from 1/4-inch thick steel plate. Two required, one with tapped hole and one without.
2. Fabricate from gasket material. Two required, one with hole in center and one without.
3. Additional items:
Eight bolts 7/16-14 x 3/4 NSN 5305-00-069-5571.
Eight Iockwashers 7/16 NSN 5310-00-209-0965.
Eight flat washers 7/16 NSN 5310-00-809-4061.
Eight nuts 7/16-14 NSN 5310-00-880-8189.
Eight bolts 7/16-14 x 3-1/4 NSN 5305-00-069-5580.
4. All dimensions are in inches.
FIGURE D-6. PLATE KIT (P/N 12384631)
D-7
TM9-2815-202-34
NOTES:
1. Fabricate from 1/4-inch thick steel plate. Two required, one with 1/4 NPTF threaded hole in
center and one without.
2. Fabricate from gasket material. Two required, one with hole in center and one without.
3. Additional items:
Two bolts 3/8-16 X 2-1/2 NSN 5305-00-269-3218.
Two Iockwashers 3/8 NSN 5310-00-637-9541.
Two flat washers 3/8 NSN 5310-00-080-6004.
Two nuts 3/8-16 NSN 5310-00-732-0558.
4. All dimensions are in inches.
FIGURE D-7. AIR NOZZLE PLATE KIT (P/N 12384632)
D-8
TM9-2815-202-34
NOTES:
1. Fabricate from 1/2-inch thick steel plate, item (A).
2. Weld 7/8-inch hex steel stock 13/16 inch long to center of steel plate.
3. Quantity required, one.
4. Fabricate from 1/2-inch thick plywood, item (B).
5. Quantity required, one.
6. Plywood block is placed over steel plate.
7. All dimensions are in inches.
FIGURE D-8. TURBOCHARGER HOLDING FIXTURE (P/N 12334633)
D-9
TM9-2815-202-34
NOTES:
1. Fabricate from 1/4-inch thick steel plate.
2. Weld a 5/8-inch socket 3/8-inch drive (ratchet side up) to center of 6 inch diameter plate.
3. Weld Suretite #96 band to outside rim of 6-inch round plate.
4. All dimensions are in inches.
FIGURE D-9. BACKPLATE TORQUING TOOL (P/N 12384634)
D-10
TM9-2815-202-34
NOTES:
1. Fabricate end plate from 3/8-inch thick steel plate, item (A).
2. Fabricate gasket for end plate from 1/8-inch thick rubber material except with 2-inch diameter
hole in center.
3. Quantity required, one each.
4. Additional items: Three bolts 3/8-16 x 1 NSN 5305-00-269-3211.
5. Fabricate blocking plates from 3/8-inch thick steel plate, item (B).
6. Fabricate gaskets for blocking plates from 1/8-inch thick rubber material.
7. Quantity required, ten each.
8. Additional items: Ten bolts 5/8-11 x 5 NSN 5305-00-724-6758. Twenty washers 5/8 NSN 531000-003-9174. Ten nuts 5/8-11 NSN 5310-00-763-8920.
9. All dimensions are in inches.
FIGURE D-10. CYLINDER HEAD PRESSURE TESTING KIT (P/N 12384635)
D-11
TM9-2815-202-34
NOTES:
1. Fabricate from 1/4-inch thick steel plate.
2. Fabricate from 1/8-inch thick rubber gasket material.
3. Quantity required: one each.
4. All dimensions are in inches.
FIGURE D-11. WATER OUTLET PLATE (P/N 12384636)
D=12
TM 9-2815 -202-34
NOTES:
1. Fabricate from 3/4-inch diameter steel tubing.
2. Grind off all burrs.
3. Quantity required: one.
4. All dimensions are in inches.
FIGURE D-12. SLEEVE (P/N 12384637)
Change 1
D-13
TM9-2815-202-34
NOTES:
1.
Fabricated from NSN 5306-01-072-5799 (5/16-18 x 36) rod, continous thread by cutting to length
of 6 inches. Saw or file a 0.06-inch screwdriver slot in one end.
2. Quantity required, one.
3. All dimensions are in inches.
FIGURE D-13. THREADED ROD (P/N 12384638)
D-14
Change 1
TM 9-2815-202-34
NOTES:
1. Fabricated from steel round stock
2. Quantity required, one.
3. All dimensions are in inches.
FIGURE D-14. EXHAUST SEAL INSTALLER (P/N 12384639)
Change 1 D-15/D-16 Blank
TM9-2815-202-34
APPENDIX E
GENERAL TORQUE LIMITS REQUIRED
FOR FASTENERS IN ENGINE
E-1. GENERAL
This section provides the general torque limits for fasteners used on the 8V71T series engines.
Special torque limits are indicated in the maintenance procedures for applicable components. These
general torque limits cannot be applied to fasteners that retain rubber components. The rubber
components will be damaged before the torque limit is reached.
E-2. TORQUE LIMITS
Table E-1 lists dry torque limits. Dry torque limits are used on fasteners that do not have lubricants
applied to the threads. No wet torques are given because all wet torques are listed in the
maintenance procedure. The torques given are suitable for grade 5, 5.1, 7, and 8 fasteners. No grade
1 or 2 fasteners are used on an 8V71T series engine.
E-3. HOW TO USE THE TORQUE TABLE
a. Measure the shaft diameter of the fastener and count the number of threads per inch.
b. Under the heading THREAD SIZE, look down the column until you find the diameter and threads
per inch of the fastener. Next, look across that row and read the torque limit in Ib-ft or N-m.
Table E-1. Torque Limits for Dry Fasteners
THREAD SIZE
inches
1/4-20
1 /4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/1 6-20
1/2-13
1/2-20
9/1 6-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14
1-8
1-14
TORQUE LIMIT
Ib-ft
8-10
13-17
15-19
30-35
35-39
46-50
57-61
71-75
83-93
90-100
107-117
137-147
168-178
240-250
290-300
410-420
475-485
580-590
685-695
N-m
10-12
11-14
18-23
20-26
41-47
47-53
62-68
77-83
96-102
113-126
122-136
146-159
186-200
228-242
325-339
393-407
556-569
644-657
786-800
928-942
E-1/E-2 Blank
TM9-2815-202-34
APPENDIX F
MANDATORY REPLACEMENT PARTS LIST
Section i. I N T R O D U C T I O N
F-1. SCOPE
This appendix is a cross-reference of item numbers to part numbers and is included for that purpose
only.
F-2. EXPLANATION OF COLUMNS
a. Column 1-- Item Number. This number is assigned to the entry in the listing and is referenced in
the Initial Setup to identify the item (e.g., “Cotter pin (App F, Item 7)”).
b. Column 2-- Description. This column identifies parts which appear in the Initial Setup of the
procedure under the heading “Mandatory Replacement Parts.”
c. Column 3 -- Part Number. This column indicates the primary part number used by the
manufacturer (individual, company, firm, corporation, or government activity), which controls the
design and characteristics of the item by means of engineering drawings, specifications,
standards, and inspection requirements to identify an item or range of items. The part number will
be followed by the Contractor and Government Entity Code (CAGE) in parentheses only when the
CAGE is required to requisition the part.
NOTE
When using the National Stock Number (NSN) to requisition a part, the part you get may have a
different part number from the number ordered, but go ahead and use or furnish it as the supply
part.
d. Column 4-- National Stock Number. This column indicates the NSN assigned to the item; use it
to request or requisition the item.
F-1
TM9-2815-202-34
Section Il.
(1)
(2)
ITEM DESCRIPTION
NO.
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028
029
030
031
032
033
034
035
036
037
038
039
040
041
F-2
BEARING
BEARING KIT
BOLT
BOLT
BOLT
BUSHING
COTTER PIN
CUP PLUG
CUP PLUG
CUP PLUG
CUP PLUG
CUP PLUG
EXPANDER
FILTER
FILTER ELEMENT
FILTER ELEMENT KIT
FLAT WASHER
FUEL LINE
FUEL LINE
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
REPLACEMENT PARTS LIST
(3)
(4)
PART
NO.
NSN
403877
5149460
5103248
5103534
5148373
5100929
103361
5117186
5132410
5139988
5150132
9428477
5148261 (72582)
5228587
CW226MP
5575032
1503536
5111526
5111527
105451
3291975
5102551
5103602
5104081
5104506
5104507
5108329
5108715
5113954
5117231
5117243
5117254
5117269
5117332
5117535
5117636
5117734
5117975
5117993
5118793
5120224
3120-00-851-4483
3120-01-086-8270
5306-01-078-4175
5306-01-078-4981
5306-00-514-6973
3120-00-831-8646
5315-00-234-1650
5340-00-728-3491
5340-00-231-0941
5340-01-144-1937
5340-00-939-1192
5340-00-450-5712
2910-00-374-4929
2910-00-287-1912
2940-00-745-7730
5310-00-551-0433
4710-00-020-2733
4710-00-020-2734
5330-00-197-8116
5330-00-735-6163
5330-01-058-3197
4730-00-745-7786
5330-01-078-7186
5330-01-079-9963
5330-01-088-5984
5330-00-973-1416
5330-00-081-3419
5330-00-735-4284
5330-00-972-8108
5330-00-735-4289
5330-00-745-7831
5330-00-735-4291
5330-00-725-2301
5330-00-844-2907
5330-00-735-4293
5330-00-745-7776
5330-00-847-6223
5330-00-973-1415
5330-00-844-2906
5330-00-862-6929
TM9-2815-202-34
(1)
(2)
(3)
(4)
ITEM
NO.
DESCRIPTION
PART
NO.
NSN
042
043
044
045
046
047
048
049
050
051
052
053
054
055
056
057
058
059
060
061
062
063
064
065
066
067
068
069
070
071
072
073
074
075
076
077
078
079
080
081
082
083
084
GASKET
5121714
5121835
GASKET
GASKET
5121894
GASKET
5122839
GASKET
5123123
GASKET
5123240
GASKET
5123638
GASKET
5123812
GASKET
5124225
5124798
GASKET
5124806
GASKET
GASKET
5124822
5126160
GASKET
5126161
GASKET
5126499
GASKET
5126618
GASKET
5128944
GASKET
5128945
GASKET
5128964
GASKET
5129743
GASKET
5130800
GASKET
5130995
GASKET
5136701
GASKET
5141588
GASKET
5144875
GASKET
5144901
GASKET
5145581
GASKET
5148810
GASKET
5150193
GASKET
5150361
GASKET
5161003
GASKET
5162747
GASKET
GASKET
5170468
GASKET
5190566
5197654
GASKET
5226186
GASKET
GASKET
8922593
8923492
GASKET
8923791
GASKET
8923792
GASKET
8924869
GASKET
GASKET, COMPRESSION 5103659
HOSE
5146040
5330-00-745-7669
5330-00-847-4967
5330-00-276-1842
5365-00-846-5985
5330-00-982-1053
5330-00-054-8290
5330-00-862-6934
5330-00-892-1764
5330-00-844-2905
5330-00-844-2904
5330-00-961-9807
5330-00-844-2903
5330-00-458-2325
5330-00-458-2324
5330-00-736-0228
5330-00-751-9011
5330-00-899-8325
5330-00-894-0200
5330-00-735-6167
5330-00-844-2908
5330-00-972-8100
5330-00-980-1546
5330-00-745-7827
5330-00-915-4511
5330-01-058-0584
5330-01-054-2399
5330-00-222-0801
5330-01-058-0585
5330-00-212-6290
5330-00-364-3550
5330-00-599-5577
5330-00-810-9308
5330-00-725-2388
5330-00-246-8237
5330-01-102-0193
5365-00-255-0296
5330-01-186-7543
5330-01-037-4129
5330-01-088-5982
5330-01-206-3265
5330-00-735-4296
5330-01-064-3386
2815-01-089-6878
F-3
TM9-2815-202-34
REPLACEMENT PARTS LIST (Cont)
(1)
(2)
(3)
(4)
ITEM
NO.
DESCRIPTION
PART
NO.
NSN
085
086
087
088
089
090
091
092
093
094
095
096
097
098
099
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
F-4
HOSE
JAM NUT
LOCK TAB
LOCKNUT
LOCKWASHER
LOCKWASHER
LOCKWASHER
LOCKWASHER
LOCKWASHER
LOCKWASHER
LOCKWASHER
LOCKWASHER
LOCKWASHER
LOCKWASHER
LOCKWASHER
LOCKWASHER
NUT
NUT, LOCKING
NUT,LOCKING
NUT, LOCKING
NUT, LOCKING
OIL SEAL
PACKING, PREFORMED
PIN
PIN
PLATE,LOCKING
PLATE, LOCKING
PLATE, LOCKING
PLUG
PLUG
PLUG
PLUG
PLUG
RETAINER
RETAINER
RING
RING
RING
RING
RING
RING
RING SET
RING SET
8924267
9413533
407648-2
5117972
MS35338-41
MS35338-43
MS35338-44
MS35338-45
MS35338-46
MS35338-47
MS35338-48
MS35338-49
MS35338-50
MS45904-76
178591
5177769
192481
MS21045-7
MS51968-11
9174753
9411981
SF534 (35311)
5193598
141346
5151576
5197378
5197385
585726
116337
5103045
5126389
5151277
5154319
5180250
5188405
5100764 (72582)
5102648
5179824
5185325
8924083
8926351 (72582)
5194961
5197180
4720-01-226-8070
5310-01-018-5266
5310-01-147-3135
5310-00-043-0427
5310-00-045-4007
5310-00-045-3296
5310-00-582-5965
5310-00-407-9566
5310-00-637-9541
5310-00-209-0965
5310-00-584-5272
5310-00-167-0680
5310-00-820-6653
5310-00-061-1258
5310-00-017-8591
5310-00-209-1543
5310-01-058-3353
5310-00-274-9364
5310-00-880-7745
5310-00-811-3627
5310-01-044-0769
5330-00-590-1717
5315-00-014-1346
5315-00-524-7660
2950-01-102-0127
5340-01-138-5407
2815-00-150-5064
5340-00-089-8037
5315-01-137-3373
2815-00-646-6940
5315-00-276-4818
5315-00-241-7484
2815-00-792-9020
2815-00-551-6146
2815-01-078-8886
2815-00-271-8983
2815-00-278-1536
2815-01-126-9533
2815-00-770-8406
2815-00-745-7829
TM9-2815-202-34
(1)
ITEM
NO.
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
(2)
(3)
(4)
DESCRIPTION
PART
NO.
NSN
RING, PISTON
RING, PISTON
RING, PISTON
RING, SEAL
RING, SEAL
RING, SEAL
RING, SEAL
RING, SEAL
RING, SEAL
RING, SEAL
RING, SEAL
RING, SEAL
RING, SEAL
RING, SEAL
RING, SEAL
RING, SNAP
RING, SNAP
SEAL
SEAL
SEAL
SEAL
SEAL
SEAL
SEAL
SEAL
SEAL
SEAL
SEAL
SEAL SET
SPACER
TUBE KIT
VANE SET
WASHER
WASHER
WASHER
WASHER, COPPER
WASHER, COPPER
WASHER, KEY
WASHER,KEY
WASHER,KEY
WASHER,SPRING
403671
403818-31
5197583
MS28775-112
5101691
5103544
5119973
5133752
5183305
5186577
5186579
5197377
5198257
5229167
8922221
400105
400408
5100617 (72582)
5106223
5107223
5107673
5108071
5115454
5117983
5132155
5177786
5574161
8924297
23500533(72582)
5144846
8925981
8921167
5138659
5165221
5199852
5152148
5155596
5150897
7520854(19207)
8926285
5104439
2990-00-852-9031
5310-00-153-2717
2990-00-930-3254
5330-00-599-2934
5330-01-105-6889
5330-01-088-6596
5330-00-171-8763
5330-00-936-6379
5330-00-591-7657
5310-00-291-2958
5330-00-814-9196
2815-00-169-0041
5330-00-930-3259
5330-00-364-3434
2815-00-080-5738
5365-01-137-8829
5365-00-930-3257
5330-01-083-3980
5330-01-083-3063
5330-01-207-7590
5330-01-126-4618
5330-00-154-8358
5330-00-973-8213
5330-00-961-9806
5330-00-961-9801
5330-00-846-9841
2930-00-866-9403
3120-00-091-4679
5330-01-207-7789
2540-01-105-3037
5330-00-769-4882
5310-00-599-1616
3120-01-038-1499
5310-00-264-1939
5310-00-271-7426
5310-00-274-9232
5310-01-233-1338
5310-00-595-8121
C h a n g e
1
F-5
TM9-2815-202-34
Section II. REPLACEMENT PARTS LIST (Cont)
(1)
(2)
ITEM DESCRIPTION
NO.
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
RING
PLUG, EXPANSION
NUT SPECIAL
GASKET
NUT, LOCKING
CUP PLUG
PLUG
GASKET
GASKET
RING, RETAINING
RING, SEAL
SEAL RING, METAL
THRUST WASHER
BEARING, SLEEVE
WASHER, FLAT
RING, RETAINING
SCREW, SELF-LOCKING
NUT, SELF-LOCKING
NUT, LOCKING
F-6 C h a n g e
1
(3)
(4)
PART
NO.
NSN
23509270 (72582)
5144559
5149038
12368978 (19207)
23505398
5150132
5126389
23506395 (72582)
12368975 (19207)
5149154
5198936
5197583
442030-1
441843-1
5198988
MS16627-100
23503754 (72582)
400768-13
5197402
5340-00-228-7441
5310-01-084-5253
5310-01-317-8619
5340-00-939-1192
2815-00-646-6940
2835-01-015-5414
5330-01-016-0443
5330-00-930-3254
3120-01-239-5139
3120-01-239-1369
5310-00-153-2717
5365-00-285-7124
5310-00-070-6870
5310-01-165-2272
TM9-2815-202-34
APPENDIX G
ENGINE REPAIR SPECIFICATIONS
Section I.
INTRODUCTION
G-1. SCOPE
This appendix lists the repair specifications for the 8V71T series engines.
G-2. EXPLANATION OF COLUMNS
a. Column 1 -- Point of Measurement. This column lists the area of the engine (e.g., “Cylinder
Block), then lists the specific component (e.g., “Main Bearing Bore”), and finally describes the critical
dimension (e.g., “Inside diameter”).
b. Column 2 -- New Minimum. This column lists the minimum acceptable dimension of the new
part. All dimensions are in inches unless stated differently.
c. Column 3 -- New Maximum. This column lists the maximum acceptable dimension of the new
part. All dimensions are in inches unless stated differently.
d. Column 4 -- Wear Limit. This column lists the maximum acceptable deviation for the used
part. All dimensions are in inches unless stated differently. An asterisk (*) in this column indicates the
part must keep the same minimum and maximum limit as the new part.
Section Il.
POINT OF MEASUREMENT
CYLINDER BLOCK
Cylinder Sleeve Bore
Inside diameter of bore
Oversize (0.010)
Oversize (0.020)
Oversize (0.030)
Sleeve bore out-of-round
Taper of sleeve bore
Cylinder Sleeve Counterbore
Inside diameter of counterbore
Depth of counterbore
Main Bearing Bore
Inside diameter of bearing bore
Camshaft Bearing Bore
Inside diameter of bearing bore
ENGINE REPAIR SPECIFICATIONS
NEW
MINIMUM
(inches)
NEW
MAXIMUM
(inches)
WEAR
LIMIT
(inches)
4.6256
4.6360
4.6460
4.6560
4.6275
4.6370
4.6470
4.6570
0.0010
0.0010
4.6275
4.6375
4.6475
4.6575
0.0020
0.0020
5.0460
0.4770
5.0510
0.4795
*
*
4.8120
4.8130
*
2.1875
2.1889
*
G-1
TM9-2815-202-34
Section Il.
ENGINE REPAIR SPECIFICATIONS (Cont)
(1)
POINT OF MEASUREMENT
CRANKSHAFT WITH MAIN BEARING
Crankshaft Journals
Diameter of main bearing journal
Diameter of connecting rod journal
Main bearing journal out-of-round
Connecting rod journal out-of-round
Taper of main bearing journal
Taper of connecting rod journal
Main Bearings
Inside diameter of bearing, vertical axis
Bearing to journal clearance
Thickness of bearing
Thrust Washer Bearings
Thickness of thrust washer bearings
Crankshaft end thrust clearance
(2)
NEW
MINIMUM
(inches)
4.4985
2.9985
4.5002
3.0002
0.00025
0.0005
0.0006
0.0008
4.5016
0.0014
0.1545
4.5040
0.0055
0.1552
0.1190
0.004
0.1220
0.011
PISTON, CONNECTING ROD, AND CYLINDER LINER ASSEMBLY
Cylinder sleeve
4.2489
Inside diameter of cylinder sleeve
4.6250
Outside diameter Standard size
4.6350
Oversize (0.010)
4.6450
Oversize (0.020)
4.6550
Oversize (0.030)
0.0000
Sleeve to cylinder block bore clearance
Sleeve out-of-round
0.0000
Taper of sleeve
Depth of cylinder sleeve below block
0.0450
Variation in depth between adjacent sleeves
Piston (trunk)
4.2393
Outside diameter of piston (at skirt)
Piston to cylinder sleeve clearance
0.0080
Piston out-of-round
Taper of piston
Inside diameter of piston pin bushing
1.5025
Piston (cross-head)
Outside diameter of dome (top)
4.2389
Piston skirt outside diameter
4.2428
Skirt to cylinder sleeve clearance
0.0045
1.5000
Piston pin bore diameter
Piston Pin (trunk)
Diameter of piston pin
1.4996
Length of piston pin
3.605
Pin-to-piston bushing clearance
0.0025
Pin to connecting rod bushing clearance
0.0025
Pin end to retainer clearance
0.016
G-2
MAXIMUM
(inches)
4.2511
4.6265
4.6365
4.6465
4.6565
0.0020
0.0020
0.0010
0.0500
0.0020
4.2415
0.0118
0.0005
0.0005
1.5030
4.2423
4.2450
0,0083
1.5030
1.5000
3.620
0.0034
0.0034
0.064
4)
WEAR
LIMIT
(inches)
0.0010
0.0005
0.0006
0.0055
0.018
●
0.025
0.0025
0.0020
0.0500
0.002
●
0.0140
●
●
1.505
0.0120
1.5040
1.498
0.010
0.010
0.064
TM9-2815-202-34
(1)
(2)
(3)
POINT OF MEASUREMENT
MINIMUM
(inches)
MAXIMUM
(inches)
PISTON, CONNECTING ROD, AND CYLINDER LINER ASSEMBLY (Cont)
Piston Pin (cross-head)
Piston pin diameter
1.5000
1.4996
Piston pin length
3.6150
3.6250
Slipper bushing clearance
0.0005
0.0105
Slipper bushing thickness
0.0870
0.0880
Piston Rings (trunk)
Gap of compression rings
Top compression (fire) ring
0.0230
0.0380
Second,third,and lower compression rings
0.0180
0.0430
Ring to groove side clearance
First ring
0.0040
0.0070
Second ring
0.0095
0.0130
Third ring
0.0075
0.0110
Fourth ring
0.0055
0.0090
Gap of oil control rings
0.0008
0.023
Ring-to-groove side clearance
Fifth ring
0.0015
0.0055
Sixth ring
0.0015
0.0055
Piston Rings (cross-head)
Fire Ring Gap
0.023
0.038
Fire Ring Clearance
0.0010
0.0050
Second and Third Compression Ring Gap
0.018
0.043
Second Compression Ring Clearance
0.0100
0.0130
Third Compression Ring Clearance
0.0040
0.0070
Oil Rings - Gap - Lower Groove
0.0080
0.0230
Oil Rings - Gap - Upper Groove
0.0050
0.0140
Oil Ring Clearance - Top Groove
0.0010
0.0040
Oil Ring Clearance - Bottom Groove
0.0010
0.0040
Connecting Rod (trunk)
Length of connecting rod
10.1240
(center bore to center bore - trunk)
10.1260
(center bore to center of pin - crosshead)
3.2495
3.2515
Diameter of lower bore
3.2495
3.2515
Inside diameter of upper bushing
1.5025
1.5030
Inside diameter of lower connecting
rod bearing
3.0005
3.0035
Thickness of bearing
0.1240
0.1245
Bearing-to-crankshaft journal clearance
0.0008
0.0045
Side clearance between rods
0.0080
0.0160
CAMSHAFT WITH BEARINGS
Diameter of end bearing surface
Diameter of intermediate bearing surface
Diameter of drive gear surface
Runout at center bearing surface
(camshaft supported on end bearings)
1.4960
1.4980
1.1875
4)
WEAR
LIMIT
(inches)
1.4980
0.012
0.0860
0.0600
0.0600
0.0100
0.0220
0.0150
0.0130
0.043
0.0080
0.0080
0.060
0.0070
0.060
0.0220
0.0130
0.0430
0.0340
0.0060
0.0060
1,5080
0.0045
1.4965
1.4985
1.1885
0.0020
G-3
TM9-2815-202-34
Section Il.
ENGINE REPAIR SPECIFICATIONS (Cont)
(1)
(2)
(3)
(4)
POINT OF MEASUREMENT
NEW
MINIMUM
(inches)
NEW
MAXIMUM
(inches)
WEAR
LIMIT
(inches)
2.1875
2.1880
0.0005
1.5000
0.0035
2.1840
0.0014
1.5010
0.0050
2.1860
0.0015
1.5010
0.0045
1.5030
0.0025
0.1190
0.0003
0.0050
0.1220
0.0150
5.2490
5.2490
0.001
(pressure)
5.2510
5.2510
0.001
(loose)
0.5 lb
4.0 lb
2.7 lb
1.6260
0.0010
1.6240
0.2350
0.0050
0.0590
1.6265
0.0025
1.6250
0.2450
0.0100
0.0610
1.1865
0.0015
(pressure)
1.1875
0.0000
0.002
0.008
CAMSHAFT WITH BEARINGS (Cont)
Camshaft Bearings
Outside diameter of end bearings
Bearing-to-block bore clearance
(end bearings)
Inside diameter of end bearings
Bearing-to-camshaft clearance (end bearings)
Outside diameter of intermediate bearings
Bearings-to-block bore clearance
(intermediate bearings)
Inside diameter of intermediate bearings
Bearing-to-camshaft clearance
(intermediate bearings)
Thickness of thrust washer bearing
Camshaft end thrust washer bearing end thrust
GEAR TRAIN
Crankshaft gear
Inside diameter of crankshaft timing gear surface
Inside diameter of timing gear
Timing gear-to-crankshaft clearance
Idler gear
Bearing preload
Variation in pull
Blower Drive Gear
Inside diameter gear bushing
Support-to-gear bushing clearance
Diameter of gear support
Thrust washer thickness
Gear and thrust
Thickness of thrust bearing
Camshaft Gear
Inside diameter of gear
Gear-to-camshaft clearance
Gear Train Backlash
Backlash between various mating gears
G-4
0.0060
0.0090
0.0180
0.0050
0.0120
0.0100
TM9-2815-202-34
(1)
POINT OF MEASUREMENT
OIL PUMP AND REGULATOR VALVES
Oil Pump Gears
Backlash adjustment with shims
(pump drive gear)
Pressure Relief Valve
Free length of large spring, inches
Compressed length of large spring
(64.5 +3 lb)
Free length of small spring, inches
Compressed length of small spring
(32 + 1 lb force)
Pressure Regulating Valve
Free length of spring, inches
Compressed length of spring
(64.5 + 3 lb)
Oil Cooler Bypass Valve
Force to compress spring to 0.75 inch
CYLINDER HEAD ASSEMBLY
Exhaust Valves, Guides and Inserts
Diameter of valve stem
Inside diameter of valve guide
Valve stem-to-guide clearance
Valve face seat angle (degrees)
Valve head-to-cylinder head position -(-) is recessed and (+) is protruding
Height of valve guide above cylinder head
Height of bridge guide above cylinder head
Diameter of valve head
Outside diameter of valve seat insert
Width of valve seat insert
Runout of valve seat
Cylinder Head Casting
Transverse warpage of cylinder head
Longitudinal warage of cylinder head
Diameter of cam follower bore
Diameter of valve seat insert counterbore
Depth of counterbore
Thickness of cylinder head
(top deck-to-fire-deck)
Diameter of cam follower
Follower-to-cylinder head clearance
Width of roller slot
Diameter of roller pin hole
Diameter of roller pin
Outside diameter of roller
Inside diameter of roller bushing
Pin-to-bushing clearance
Roller-to-follower side clearance
(2)
NEW
MINIMUM
(inches)
0.006
(3)
NEW
MAXIMUM
(inches)
0.012
(4)
WEAR
LIMIT
(inches)
0.012
2.96
2.11
2.57
58 lb
2.01
28 lb
2.96
2.11
58 lb
6.5 Ibs.
0.3100
0.3125
0.0020
30
0.3105
0.3135
0.0035
0.3090
0.3140
0.005
-0.0230
+0.0060
0.880
2.0400
1.185
1.2625
0.0937
0.0020
+0.038
1.175
1.2615
0.0468
1.0620
1.2600
0.3380
0.0630
1.2610
0.3520
3.5560
1.0600
0.0010
0.590
0.4362
0.4374
0.9077
0.4390
0.0013
0.0110
3.5680
1.0610
0.0030
0.598
0.4372
0.4377
0.9082
0.4395
0.0021
0.0230
0.0937
0.0020
0.0040
0.0080
1.0650
3.5360
0.0060
0.010
0.0230
G-5
TM9-2815-202-34
Section Il. ENGINE REPAIR SPECIFICATIONS (Cont)
POINT OF MEASUREMENT
CYLINDER HEAD ASSEMBLY (Cont)
Rocker Arms and Shafts
Diameter of rock arm shaft
Shaft-to-bushing clearance
Inside diameter of rocker arm shaft bushing
Valve and Push Rod Springs
Free length of push rod spring
Compressed length of push-rod spring
(184 lb force)
BLOWER ASSEMBLY
Blower Timing Gears
Blower timing gear backlash
Rotors
Rotor-to-gear side of housing clearance
Rotor-to-float side of housing clearance
Clearance between rotors
Trailing edge of of right hand rotor to
leading edge of left hand rotor
Leading edge of right hand rotor to
trailing edge of left hand rotor
BLOWER BY-PASS ASSEMBLY
By-pass valve spring load
(at 2.65 inches)
G-6
Change 1
MINIMUM
(inches)
MAXIMUM
(inches)
0.8735
0.8740
0.0025
0.8760
0.0010
0.8750
2.625
2.125
0.0005
0.0025
0.010
0.012
0.013
0.020
100 lb
ll0 lb
LIMIT
(inches)
●
0.0040
●
●
172 lb
0.0040
TM9-2815-202-34
GLOSSARY
Section I. ABBREVIATIONS
AOAP
ATTN
BHP
CCLW
CLW
Cont
cm
cu
DA
V dc
DF
DS
EIR
FOV
ft
gpm
GS
Hg
kg
kPa
lb
Ib-ft
lb-in
min
mm
N-m
NSN
PAM
Para
psi
qt
REV
rpm
SAE
Army Oil Analysis Program
attention
brake horsepower
counterclockwise
clockwise
continued
centimeter
cubic
Department of the Army
volts direct current
diesel fuel
Direct Support
Equipment Improvement Recommendation
Family of Vehicles
foot, feet
gallons per minute
General Support
mercury
kilogram
kilopascal
pound
pound-foot
pound-inch
minute
millimeter
newton-meter
National Stock Number
Pamphlet
Paragraph
pounds per square inch
quart
revolution
revolutions per minute
Society of Automotive Engineers
Glossary-1
TM9-2815-202-34
Section H. UNUSUAL TERMS
air box
brinelling
concentricity
chamfer
counterbore
cross-head piston
detent
dynamometer
endplay
ferrous
fillister head
hone
lap
matchmark
multimeter
NO-GO gage
no-load speed
nonferrous
peen
preload
run-in
runout
scored
spline
trunk type piston
turbocharger
woodruff key
a chamber in the cylinder block
containing cylinder inlet ports
hardening of metal causing brittleness from fatigue
roundness of inner surface
a beveled or grooved edge
a recessed surface around a bore
a two-piece piston with a crown and skirt
a spring loaded device for positioning a part
a mechanical device to measure engine power
axial movement
contains iron
slotted cylindrical screw head with a convex top
sharpen, enlarge, and smooth out
smooth and polish
to mark two mating surfaces to reassemble
in the position
multiple purpose electrical meter
a thickness gage designed for piston ring grooves
the maximum speed the governor allows
the engine without any load
has no iron content
to misshapen from pounding
the internal bearing load
engine break-in period
length of variation of an axially turning surface
grooved, scratched, or notched
a set of teeth on a shaft or bore for coupling
a one-piece piston
an air compressor driven by an exhaust gas turbine
a standard key used in mating grooves of a gear
and shaft
Section III. NOMENCLATURE CROSS-REFERENCE
air box cover
bearing shell
bolt
brass wire buffing wheel
cylinder liner
dipstick
engine rocker arm cover
engine coolant
fiber coupling
feeler gage
gasket
seal sleeve
Glossary-2
access cover
bearing sleeve
hexagon head cap screw
wire rotory brush
cylinder sleeve
liquid level gage (oil)
engine poppet cover
antifreeze, ethylene glycol mixture
flexible insert
thickness gage
ring spacer (injector)
seal spacer (blower rotor shaft)
TM9-2815-202-34
ALPHABETICAL INDEX
SUBJECT
PARA
A
Accessory Drive Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-14
Accessory Drive Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Accessory Drive Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Air Box Drains Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9
Air Box Heater Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Air Box Heater Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8
Air Box Heater Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Air Box Heater Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9
Air Box Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Air inlet Housing Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-11
Air inlet Housing Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Air inlet Housing Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Air inlet Housing Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Air inlet Housing Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Air Inlet Manifold to Turbocharger Removal/Installation (Models 7083-7391 and 7083-7396) . . 3-14
Air lnlet Manifold toTurbocharger Removal/lnstallation (Models 7083-7399) . . . . . . . . . . . . . . . . 3-15
B
Block Mounted Crankcase Breather Replacement (Mode l 7083-7391 ) . . . . . . . . . . . . . . . . . . . .
Block Mounted Crankcase Breather Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . .
Block Mounted Crankcase Breather Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . .
Blower Drive Gear and Support Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Gearand Support Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Gear and Support Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Gear and Support Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Gear and Support Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Shaft and Hub Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Shaft and Hub Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Shaft and Hub Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Shaft and Hub Replacement (Model7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Shaft and Hub Replacement (Model7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Repair (Model 7083-7391). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Repair (Model 7083-7395). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Repair (Model 7083-7396). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Repair (Model 7083-7398 ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Repair (Model 7083-7399). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change
5.1-13
4-15
5-13
5.1-18
4-19
5-18
6-20
7-19
5.1-15
4-16
5-15
6-17
7-16
5.1-40
4-41
5-40
6-42
7-41
1 INDEX-1
TM9-2815-202-34
ALPHABETICAL INDEX (Cont)
PARA
SUBJECT
C
Camshaft and Gear Assemblies Replacement (Model 7083-7391 ) . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Gear Assemblies Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Gear Assemblies Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Gear Assemblies Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Gear Assemblies Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Front Gear Cover and Damper Replacement (Mode1 7083-7391) . . . . . . . . . . . . . . .
Camshaft Front Gear Cover and Damper Replacement (Model 7083-7396) . . . . . . . . . . . . . . .
Camshaft Front Gear Cover and Damper Replacement (Model 7083-7399) . . . . . . . . . . . . . . .
Camshaft Front Gear Cover Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Front Gear Cover Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and General Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Breather Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Breather Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Maintenance (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Maintenance (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Maintenance (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Maintenance (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Maintenance (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block End Plates Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block End Plates Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block End Plates Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block End Plates Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block End Plates Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block Maintenance (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block Maintenance (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block Maintenance (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block Maintenance (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block Maintenance (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Assembly Removal/installation (Model 7083-7391 ) . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Assembly Removal/lnstallation (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Assembly Removal/installation (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Assembly Removal/lnstallation (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Assembly Removal/lnstallation (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Repair (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Repair (Model 7083-7395). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Repair (Model 7083-7396). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Repair (Model 7083-7398). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Repair (Model 7083-7399). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner Maintenance (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX-2
Change 1
5.1-28
4-29
5-28
6-30
7-29
5.1-20
5-20
7-21
4-21
6-22
3-2
6-16
7-14
8-17
5.1-34
4-35
5-34
6-36
7-35
5.1-29
4-30
5-29
6-31
7-30
5.1-35
4-36
5-35
6-37
7-36
8-14
5.1-26
4-27
5-26
6-28
7-27
5.1-37
4-38
5-37
6-39
7-38
5.1-33
TM9-2815-202-34
SUBJECT
PARA
C (Cont)
Cylinder Liner Maintenance (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner Maintenance (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner Maintenance (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Liner Maintenance (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-34
5-33
6-35
7-34
Destruction of Army Material to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differences between Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-9
E
Engine From/To Container(10909159/10923108) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine From/To Container (12268285). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lifting Brackets Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lifting Brackets Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lifting Brackets Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lifting Brackets Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lifting Brackets Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lower Front Cover Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . .
Engine Lower Front Cover Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lower Front Cover Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lower Front Cover Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lower Front Cover Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine On Maintenance Stand lnstallation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Preparation for Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rocker Arm Cover and Crankcase Breather Replacement (Mode17083-7391) . .
Engine Rocker Arm Cover and Crankcase Breather Replacement (Mode17083-7395) . . . . . . .
Engine Rocker Arm Cover and Crankcase Breather Replacement (Model 7083-7396) . . . . . . .
Engine Rocker Arm Cover Replacement (Model7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rocker Arm Cover Replacement (Model7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Water Manifolds Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Water Manifolds Replacement (Model 7083-7396. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Water Manifolds Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold and Tube Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust ManifoId and Tube Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold and Tube Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold and Tube Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Valve Clearance Adjustment (Hot or Cold Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change 1
3-4
3-3
5.1-5
4-7
5-5
6-8
7-6
5.1-7
4-28
5-27
6-29
7-28
3-16
8-2
5.1-9
4-11
5-9
6-12
7-10
5.1-6
5-6
7-7
1-10
1-7
5.1-3
5-3
6-4
7-4
4-3
8-4
INDEX-3
TM9-2815-202-34
ALPHABETICAL INDEX (Cont)
PARA
SUBJECT
F
Flywheel Assembly Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Assembly Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Assembly Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Assembly Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Assembly Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Housing Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Housing Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIywheel Housing Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Housing Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Housing Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel FiIter Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Assembly Repair (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Assembly Repair (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Assembly Repair (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Assembly Repair (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Assembly Repair (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel injector Control Lever Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FueI lnjector Timing Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Lines Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Lines Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Lines Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Lines Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Lines Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Strainer Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Strainer Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1-21
4-22
5-21
6-23
7-22
5.1-23
4-24
5-23
6-25
7-24
4-4
6-5
8-15
5.1-39
4-40
5-39
6-41
7-40
8-7
8-5
5.1-4
4-6
5-4
6-7
7-5
8-16
5.1-10
4-12
5-10
6-13
7-11
4-5
6-6
G
Glow Plug Controller and Harnesses Removal/installation (Model 7083-7391 ) . . . . . . . . . . . . . 5.1-8
Governor
and
Blower
Assembly
Removal/lnstallation
(Model
7083-7391)
5.1-17
4-18
Governor and Blower Assembly Removal/lnstallation (Model 7083-7395) . . . . . . . . . . . . . . . . .
5-17
Governor and Blower Assembly Removal/lnstallation (Model 7083-7396) . . . . . . . . . . . . . . . . .
INDEX-4 C h a n g e
1
-
TM9-2815-202-34
P A R A
S U B J E C T
G
(Cont)
Governor and Blower Assembly Removal/lnstaIlation (Model 7083-7398) . . . . . . . . . . . . . . . . .
6-19
Governor and Blower Assembly Removal/lnstallation (Model 7083-7399) . . . . . . . . . . . . . . . . .
7-18
Governor Buffer Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-13
Governor Cover and Throttle Control Rod Removal/Installation(Model 7083-7391) . . . . . . . . . 5.1-16
4-17
Governor Cover and Throttle Control Rod Removal/installation (Model 7083-7395) . . . . . . . . .
Governor Cover and Throttle Control Rod Removal/Installation (Model 7083-7396) . . . . . . . . .
5-16
Governor Cover and Throttle Control Rod Removal/lnstallation (Model 7083-7398) . . . . . . . . .
6-18
Governor Cover and Throttle Control Rod Removal/lnstallation (Model 7083-7399) . . . . . . . . .
7-17
Governor Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6
Governor Repair (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-41
4-42
Governor Repair (Dual-range Limiting Speed) (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . .
Governor Repair (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-41
Governor Repair (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-43
7-42
Governor Repair (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I
Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10
Idler Gear Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-24
Idler Gear Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-25
Idler Gear Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-24
Idler Gear Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-26
7-25
Idler Gear Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector Control Tube and Throttle Delay Replacement (Model 7083-7391 ) . . . . . . . . . . . . . . . . 5.1-25
4-26
Injector Control Tube and Throttle Delay Replacement (Model 7083-7395) . . . . . . . . . . . . . . . .
Injector Control Tube and Throttle Delay Replacement (Model 7083-7396) . . . . . . . . . . . . . . . .
5-25
6-27
Injector Control Tube Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-26
Injector Control Tube Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3
Interval and Adjustment Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L
Location and Description of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8
M
Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Malfunction, Test or inspection, and Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Malfunction, Test or inspection, and Corrective Action Procedures . . . . . . . . . . . . . . . . . . . . . . .
Maximum No-Load Speed Adjustment (Dual Range Limiting speed Governor) . . . . . . . . . . . . .
Maximum No-Load Speed Adjustment (Limiting Speed Governor) . . . . . . . . . . . . . . . . . . . . . . .
1-2
2-3
2-5
8-11
8-12
Change 1 INDEX-5
TM9-2815-202-34
ALPHABETICAL INDEX (Cont)
PARA
SUBJECT
O
Oil Cooler Assembly Repair (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-38
4-39
Oil Cooler Assembly Repair (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-38
Oil Cooler Assembly Repair (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-40
Oil Cooler Assembly Repair (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-39
Oil Cooler Assembly Repair (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
OilCoolerRemoval/installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7
Oil Level Gage Removal/lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-19
4-20
Oil Pan Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-19
Oil Pan Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-21
Oil Pan Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-20
Oil Pan Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Regulator and Relief Valve Replacement (Model 7083-7391) . . . . . . . . . . . . . . 5.1-30
4-31
Oil Pressure Regulator and Relief Valve Replacement (Model 7083-7395) . . . . . . . . . . . . . . . .
5-30
Oil Pressure Regulator and Relief Valve Replacement (Model 7083-7396) . . . . . . . . . . . . . . . .
6-32
Oil Pressure Regulator and Relief Valve Replacement (Model 7083-7398) . . . . . . . . . . . . . . . .
7-31
Oil Pressure Regulator and Relief Valve Replacement (Model 7083-7399) . . . . . . . . . . . . . . . .
Oil Pump Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-31
4-32
Oil Pump Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-31
Oil Pump Replacement (Model 7083-7396). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-33
Oil Pump Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-32
Oil Pump Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P
Piston and Connecting Rod Maintenance (Cross-head) (Model 7083-7391 ) . . . . . . . . . . . . . . . 5.1-32
4-33
Piston and Connecting Rod Maintenance (Cross-head) (Model 7083-7395) . . . . . . . . . . . . . . .
5-32
Piston and Connecting Rod Maintenance (Cross-head) (Model 7083-7396) . . . . . . . . . . . . . . .
6-34
Piston and Connecting Rod Maintenance (Trunk Type) (Model 7083-7398) . . . . . . . . . . . . . . . .
7-33
Piston and Connecting Rod Maintenance (Trunk Type) (Model 7083-7399) . . . . . . . . . . . . . . . .
2-2
Preliminary Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparation of Engine Prior to Removal of Engine Accessories and lnstallation
3-5
Maintenance Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-19
Preparation for Run-ln . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-11
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX-6
Change 1
TM9-2815-202-34
PARA
SUBJECT
R
Rear Oil Seal Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-22
4-23
Rear Oil Seal Replacement (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-22
Rear Oil Seal Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-24
Rear Oil Seal Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-23
Rear Oil Seal Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . .
8-20
Run-In Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S
StarterRemoval/Installation.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Aid Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8
8-9
2-4
T
Tachometer Drive Replacement (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-12
4-14
Tachometer Drive Replacement(Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12
Tachometer Drive Replacement (Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-15
Tachometer Drive Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-13
Tachometer Drive Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8
Thermostat, Thermostat Housing and Crossover Tubes Replacement (Model 7083-7395) . . . .
6-9
Thermostat, Thermostat Housing, and Crossover Tubes Replacement (Model 7083-7398) . . . .
8-8
Throttle Delay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger Oil Return Line Removal/lnstallation (Models 7083-7391 ,7083-7396, and
3-10
7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11
Turbocharger Oil Supply Line Removal/lnstallation (Models 7083-7395 and 7083-7398) . . . . . .
3-12
TurbochargerOilSupplyLineRemoval/installation (Model 7083-7391 and 7083-7396) . . . . . .
3-13
Turbocharger Oil Supply Line Removal/installation (Model 7083-7399) . . . . . . . . . . . . . . . . . . .
6-2
Turbocharger Regulator Replacement (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
Turbocharger Regulator Replacement (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger Removal/Installation (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-2
4-2
Turbocharger Removal/Installation (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . .
5-2
Turbocharger Removal/lnstallation(Model 7083-7396) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3
Turbocharger Removal/Installation (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3
Turbocharger Removal/Installation (Model 7083-7399) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger Repair (Model 7083-7391) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-36
4-37
Turbocharger Repair (Model 7083-7395). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-36
Turbocharger Repair (Model 7083-7396). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-38
Turbocharger Repair (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-37
Turbocharger Repair (Model 7083-7399). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change 1
INDEX-7
TM9-2815-202-34
ALPHABETICAL INDEX (Cont)
PARA
SUBJECT
W
1-6
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Removal/lnstallation (Model 7083-7391). . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-7
4-9
Water Pump Removal/lnstallation (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7
Water Pump Removal/lnstallation (Model 7083-7396). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10
Water Pump Removal/lnstallation (Model 7083-7398) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8
Water Pump Removal/lnstallation (Model 7083-7399). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Repair (Model 7083-7391 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1-42
4-43
Water Pump Repair (Model 7083-7395) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-42
Water Pump Repair (Model 7083-7396 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-44
Water Pump Repair (Model 7083-7398 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-43
Water Pump Repair (Model 7083-7399 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX-8
Change 1
By Order of the Secretary of the Army:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
THOMAS F. SIKORA
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA form 12-37-E, Blocks 1240,1107,0931,1216
Direct Support and General Support maintenance requirements for TM 9-2815-202-34.
PIN: 018418-001
This fine document...
Was brought to you by me:
Liberated Manuals -- free army and government manuals
Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly
available information, slap “watermarks” and other junk on it, and sell it.
Those masters of search engine manipulation make sure that their sites that
sell free information, come up first in search engines. They did not create it...
They did not even scan it... Why should they get your money? Why are not
letting you give those free manuals to your friends?
I am setting this document FREE. This document was made by the US
Government and is NOT protected by Copyright. Feel free to share,
republish, sell and so on.
I am not asking you for donations, fees or handouts. If you can, please
provide a link to liberatedmanuals.com, so that free manuals come up first in
search engines:
<A HREF=http://www.liberatedmanuals.com/>Free Military and Government Manuals</A>
– Sincerely
Igor Chudov
http://igor.chudov.com/
– Chicago Machinery Movers
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement