TM-5-2815-241-34-and-P
TM 5-2815-241-34&P
TECHNICAL MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)
EQUIPMENT DESCRIPTION
AND DATA
PAGE 1-3
MAINTENANCE
INSTRUCTIONS
PAGE 2-1
REPAIR PARTS AND
SPECIAL TOOLS LIST
PAGE C-1
ENGINE, DIESEL NTC-290
PART NO. 515501C94
(NSN 2815-00-375-5958)
Approved for Public Release; Distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
MARCH 1987
TM 5-2815-241-34&P
C1
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington D.C., 30 March 1992
NO. 1
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
MANUAL (INCLUDING REPAIR PARTS AND
SPECIAL TOOLS LIST)
FOR
ENGINE, DIESEL NTC-290
PART NO. 515501C94
(NSN 2815-00-375-5958)
Current as of 25 September 1991
TM 5-2815-241-34&P, dated 30 March 1987, is changed as follows:
1.
Remove old pages and insert new pages.
2.
New or changed material is indicated by an asterisk or by a vertical bar adjacent to the TA number.
3.
Remove Pages
Insert Pages
i thru iv
1-1 and 1-2
2-93 and 2-94
2-173 thru 2-116
2-739 and 2-140
2-145 and 2-146
2-155 and 2-156
2-159 and 2-160
2-175 and 2-176
2-181 and 2-182
2-213 and 2-214
2-219 and 2-220
2-233 and 2-234
2-237 and 2-238
2-241 and 2-242
2-253 and 2-254
2-271 thru 2-274
2-279 and 2-280
2-325 and 2-326
2-337 and 2-338
2-383 and 2-384
2-413 and 2-414
A- 1l(A-2 blank)
Appendix B (in its entirety)
Appendix C (in its entirety)
None
i thru iv
1-1 and 1-2
2-93 and 2-94
2-173 thru 2-116
2-139 and 2-140
2-145 and 2-146
2-155 and 2-156
2-159 and 2-160
2-175 and 2-176
2-181 and 2-182
2-213 and 2-214
2-219 and 2-220
2-233 and 2-234
2-237 and 2-238
2-241 and 2-242
2-253 and 2-254
2-271 thru 2-274
2-279 and 2-280
2-325 and 2-326
2-337 and 2-338
2-383 and 2-384
2-413 and 2-414
A-1 and A-2
Appendix B (in its entirety)
Appendix C (in its entirety)
D-1/(D-2 blank)
File this change sheet in front of the publication for reference purposes.
Approved for Public Release; Distribution is unlimted.
1
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
00869
Distribution:
To be distributed in accordance with DA Form 12-25-E (Block 3699) Direct and General Support maintenance requirements for TM 5-2815-241-34&P.
2
TM 5-2815-241-34&P
WARNING
EXHAUST GAS CAN KILL YOU
Exhaust gas is without color or smell, but can kill you. Breathing exhaust gas produces
symptoms of headache, dizziness, loss of muscular control, a sleepy feeling, and
coma. Brain damage or death can result from heavy exposure to exhaust fumes of fuelburning internal combustion engines. Exhaust gases can become dangerously concentrated under conditions of no air movement. Precautions must be followed to ensure
crew safety when the engine of any vehicle is operated for any purpose.
1.
DO NOT operate vehicle engine inside building unless ample ventilation is available.
2.
DO NOT idle engine for long periods without ventilator blower operating.
3. DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment doors removed unless necessary for maintenance purposes.
4.
BE ALERT at all times during vehicle operation for exhaust odors and exposure symptoms If either is present, IMMEDIATELY VENTILATE personnel compartments. If
symptoms persist, remove affected crew to fresh air; keep warm; DO NOT PERMIT
PHYSICAL EXERCISE; and, if necessary, give artificial respiration.
5.
FOR ARTIFICIAL RESPIRATION, REFER TO FM 21-11.
6.
BE AWARE; the field protective mask for chemical-biological-radiological (CBR)
protection will not protect you from exhaust gas fumes.
THE BEST DEFENSE AGAINST ENGINE EXHAUST FUMES IS GOOD VENTILATION.
WARNING
Particles blown by compressed air are hazardous. Make certain the air stream is
directed away from user and other personnel in the area. Compressed air used for
cleaning purposes shall not exceed 30 psi (207 kPa). User must wear safety goggles or
face shield to prevent personnel injury.
WARNING
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
WARNING
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety 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. Flashpoint for
type #1 drycleaning solvent is 100°F (38°C) and for type #2 is 138°F (59°C). If you
become dizzy while using 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.
Failure to observe these precautions could cause serious injury or death to personnel.
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
a
TM 5-2815-241-34&P
WARNING
Improper cleaning methods and use of unauthorized cleaning liquids or solvents can
injure personnel and damage equipment. Refer to TM 9-247, Materials Used for
Cleaning, Preserving, Abrading, and Cementing Ordnance Materiel and Related
Materials Including Chemicals.
WARNING
Repair of engine must be performed on engine repair stand (page 2-11). Due to
excessive weight assistance will be needed to prevent injury when lifting heavy parts.
WARNING
When fuel is forced from injector spray holes, keep hands and body away from spray
stream. High-pressure fuel may pierce the skin.
WARNING
Fuel is flammable and can explode. To avoid serious injury or death, keep fuel away
from open fire and keep fire extinguisher within easy reach when working with fuel.
Smoking is prohibited while working with fuel.
WARNING
Heat protective cloth mittens must be worn to prevent serious injury to hands when
handling heated parts.
WARNING
Approximately halfway through the cut, the tool will begin to cut the counterbore ledge.
Be prepared for the added load on the drill when the counterbore is being cut, or
personal injury could result.
WARNING
Extreme care must be taken when releasing springs under pressure. Injury to personnel
could result.
WARNING
Slave piston spring is under tension. Care must be taken when removing retaining ring,
spring retainer, and slave piston spring to prevent injury.
WARNING
Slave piston spring will be under tension when installing. Extreme care must be taken to
prevent injury.
WARNING
Pressure regulator spring is under tension. Maintain pressure on retaining yoke to
prevent injury.
b
*TM 5-2815-241-34&P
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, DC 30 March 1987
TECHNICAL MANUAL
NO. 5-2815-241-34&P
Direct Support and General Support Maintenance
(Including Repair Parts and Special Tools List)
ENGINE, DIESEL NTC-290
PART NO. 515501C94
(NSN 2815-00-375-5958)
Current as of 25 September 1991
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes, or if you know of a way to
improve the procedures, please let us know. Mail your letter, DA Form 2028
(Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located
in the back of this manual directly to: Commander, US Army Tank-Automotive
Command, ATTN: AMSTA-MB, Warren, Ml 48397-5000. A reply will be sent to you.
TABLE OF CONTENTS
Page
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
Section I.
General Information .....................................................................................
1-1
Section II.
Equipment Description and Data .............................................................
1-3
.............................................................
2-1
CHAPTER 1
CHAPTER 2
Section
Section
Section
Section
Section
Section
Section
Section
Section
Section
Section
Section
Section
Section
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
Xl.
XII.
XIII.
XIV.
MAINTENANCE INSTRUCTIONS
Service Upon Receipt ..................................................................................
Troubleshooting.. ..........................................................................................
General Maintenance Instructions .............................................................
Engine Disassembly and Assembly ...........................................................
Crankcase and Cylinder Block Maintenance.. ..........................................
Cylinder Head Maintenance ........................................................................
Crankshaft Maintenance.. ...........................................................................
Piston and Connecting Rod Maintenance.. ..............................................
Camshaft and Timing System Maintenance.. ...........................................
Engine Lubrication System Maintenance .................................................
Manifold Maintenance .................................................................................
Accessory Drive Maintenance ....................................................................
Engine Compression Brake Maintenance .................................................
Fuel System Maintenance.. .........................................................................
2-1
2-2
2-3
2-10
2-140
2-176
2-214
2-220
2-238
2-264
2-272
2-276
2-282
2-289
*This manual supersedes the engine information contained in TM-5-3805-254-14&P-1,
22 August 1980, and TM 5-3805-254-14&P-2, 12 June 1980, including all changes.
Approved for Public Release; Distribution is unlimted.
Change 1
i
TM 5-2815-241-34&P
TABLE OF CONTENTS - CONTINUED
Page
Section XV
Section XVI.
2-414
2-434
APPENDIX A.
APPENDIX B.
Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Testing, Adjustments, and Troubleshooting
on Engine Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXPENDABLE SUPPLIES AND MATERIALS LIST. . . . . . . . . . . . . . . . . . . .
APPENDIX C.
REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) . . . . . . . . . . . . . . . . .
C-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-1
Section XVII.
Section I.
Section II.
Group 01
2-404
A-1
B-1
ENGINE
0100 -ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MOUNTING BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0101 -CRANKCASE, BLOCK, CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . .
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0102 - CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT GEARS, AND BEARINGS . . . . . . . . . . . . . . . . . . . . . .
0103 - FLYWHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLYWHEEL HOUSING AND FLEXPLATE . . . . . . . . . . . . . . . . . . . . . . .
0104 - PISTONS, CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0105 -VALVES, CAMSHAFTS, AND TIMING SYSTEM . . . . . . . . . . . . . . . . . .
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARCASE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVES, SPRINGS, AND GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUSHRODS AND CAM FOLLOWERS . . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER HOUSING COVER AND BREATHER . . . . . . . . . . . . . . . . . .
ROCKER ARMS AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0106 -ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN AND DIPSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE BREATHER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE BREATHER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL FILTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATING OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0108-MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0109 -ACCESSORY DRIVING MECHANISMS . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0112-ENGINE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COMPRESSION BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
lllus
Fig.
Change 1
1-1
1-1
2-1
2-1
3-1
4-1
4-1
5-1
5-1
6-1
6-1
7-1
7-1
8-1
9-1
10-1
11-1
12-1
13-1
13-1
14-1
15-1
16-1
17-1
18-1
18-1
19-1
20-1
20-1
21-1
21-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
TM 5-2815-241-34&P
TABLE OF CONTENTS - CONTINUED
Page
Group 03
FUEL SYSTEM
0301 -CARBURETOR, FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0302- FUEL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINSHAFT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPRING PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ANEROID CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0305 -SUPERCHARGER, BLOWER, TURBOCHARGER, OR
ALTITUDE COMPENSATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0306 -TANKS, LINES, FITTINGS, HEADERS . . . . . . . . . . . . . . . . . . . . . . . . .
SHUTDOWN VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0309 -FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0311 - ENGINE STARTING AIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GLOW PLUG AND PREHEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0312 -ACCELERATOR, THROTTLE, OR CHOKE CONTROLS . . . . . . . . . . .
THROTTLE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Group 05
23
24
25
26
27
28
29
30
31
32
33
34-1
34-1
35-1
36-1
36-1
37-1
37-1
34
35
36
37
38-1
38-1
38
KIT-1
KIT-1
KIT
REPAIR KITS
9401 - REPAIR KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Group 95
29-1
29-1
30-1
30-1
31-1
31-1
32-1
32-1
33-1
33-1
22
BODY, CHASSIS, AND HULL ACCESSORY ITEMS
2210 - DATA PLATES AND INSTRUCTION HOLDERS . . . . . . . . . . . . . . . . . .
ENGINE DATA PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Group 94
22-1
22-1
23-1
23-1
24-1
25-1
26-1
27-1
28-1
COOLING SYSTEM
0503 -WATER MANIFOLD, HEADERS, THERMOSTATS, AND
HOUSING GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATERMANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0504 - WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATERPUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0505 - FAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAN HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Group 22
lllus
Fig.
GENERAL USE STANDARDIZED PARTS
9501 - BULK MATERIEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BULK-1
BULK MATERIEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BULK-1
Change 1
BULK
iii
TM 5-2815-241-34&P
TABLE OF CONTENTS - CONTINUED
Page
Section Ill.
Section IV.
lllus
Fig.
Special Tools List (Not Applicable)
Cross-References Indexes:
NATIONAL STOCK NUMBER INDEX . . . . . . . . . . . . . . . . . . . .
PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE AND ITEM NUMBER INDEX ................................
1-1
1-7
1-23
APPENDIX D.
ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . . . . . . . . . .
D-1
APPENDIX E.
INDEX
TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-1
Index 1
HOW TO USE THIS MANUAL
This manual is designed to help you disassemble, repair, and assemble the diesel engine. The tabbed table of
contents on the front cover is provided for quick reference to information frequently used. A complete table of
contents is located at the first pages of this manual for help in finding specific chapters and sections. At the
beginning of each chapter, a section index appears which lists sections included in that chapter. At the beginning
of each section, a more specific subject index is located, to help you find the exact paragraph you’re looking for.
There is also an alphabetical index located in the back of the manual for use in locating specific information.
Warnings listed in the front of this manual should be read and understood before performing any tasks. These
warnings advise you of threats to your personal safety, and the safety of others, which may occur if certain
precautions are not taken.
Cautions let you know when equipment will be damaged if certain procedures are not followed.
Notes are used to highlight important information which pertains to a specific procedure. They will also help you
understand the text to which they apply, and make it easier for you to perform the task.
Measurements in this manual are given in both US standard and metric units. A metric to US standard conversion
chart can be found on the inside back cover.
Location and directional terms in this manual (ie, front, rear, top, bottom, right, and left) apply as if you were
viewing the engine from the flywheel end. If direction of rotation is questionable, clockwise and counterclockwise
will be shown as if you were facing them.
Art in this manual is used to illustrate the task you are performing, help identify parts, and explain the actual
procedures involved in a task.
iv
Change 1
TM 5-2815-241-34&P
TA 242334
1-0
TM 5-2815-241-34&P
CHAPTER 1
INTRODUCTION
OVERVIEW
This chapter contains information on various forms used to report discrepancies found or improvements needed. It also provides the user with general information relating to the location and description of major components and specific equipment data.
Page
Section I.
Section II.
General Information ......................................................................................
Equipment Description and Data ................................................................
1-1
1-3
Section I. GENERAL INFORMATION
Page
Page
Equipment Improvement Report and
Maintenance Digest (EIR MD) . . . . . . . . . . . . . . . . . . . .
Destruction of Army Materiel to
Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Forms and Records . . . . . . . . . . . . . . .
1-2
1-1
1-1
Preparation for Storage and
Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reporting Equipment Improvement
Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-2
1-1
SCOPE
Type of Manual: Direct Support and General Support Maintenance Manual (Including Repair Parts
and Special Tools List).
Equipment Name and Model Number: Engine, diesel, NTC-290.
Purpose of Equipment: To provide power to move vehicle and power accessories such as, PTO and air
compressor.
MAINTENANCE FORMS AND RECORDS
Department of the Army forms and procedures used for equipment maintenance will be those
prescribed by DA PAM 738-750, The Army Maintenance Management System (TAMMS).
DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE
Refer to TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy
Use (US Army Tank-Automotive Command).
PREPARATION FOR STORAGE AND SHIPMENT
Preparation for storage and method of shipment will be at the discretion of the using facility.
1-1
TM 5-2815-241-34&P
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
If your diesel engine needs improvement, let us know. Send us an EIR. You, the user, are the only
one who can tell us what you don’t like about your engine. Let us know why you don’t like the design.
Put it on an SF 368 (Quality Deficiency Report). Mail it to Commander, US Army Tank-Automotive
Command, ATTN: AMSTA-MP, Warren, Ml 48347-5000. We will send you a reply.
EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD)
The quarterly Equipment Improvement Report and Maintenance Digest, TB 43-0001-39 series, contains
valuable field information on the equipment covered in this manual. The information in the TB 43-0001-39
series is compiled from some of the Equipment Improvement Reports that you prepared on the vehicles
covered in this manual. Many of these articles result from comments, suggestions, and improvement
recommendations that you submitted to the EIR program. The TB 43-0001-39 series contains information
on equipment improvements, minor alterations, proposed Modification Work Orders (MWO’s),
warranties (if applicable), actions taken on some of your DA Form 2028’s (Recommended Changes to
Publications), and advance information on proposed changes that may affect this manual. The information will help you in doing your job better and will help in keeping you advised of the latest changes to
this manual. Also refer to DA PAM 25-30, Consolidated Index of Army Publications and Blank Forms, and
appendix A, of this manual.
1-2
Change 1
TM 5-2815-241-34&P
Section II. EQUIPMENT DESCRIPTION AND DATA
Page
Page
Equipment Characteristics, Capabilities, and Features .................................
Equipment Data ............................................
General ..........................................................
1-3
1-9
1-3
Location and Description of
Identification Plates .................................
Location and Description of
Major Components.. .................................
1-8
1-4
GENERAL
This section contains information needed to familiarize you the user with the NTC-290 diesel engine. It
includes engine characteristics, capabilities and features, and location and description of components being repaired. Engine specifications are presented in tabular format.
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
CAPABILITIES
Able to develop 290 hp at 2100 governed rpm.
CHARACTERISTICS/FEATURES
Single turbocharged diesel engine
Six cylinder in-line, four stroke per cycle
Liquid cooled
Fuel injection
Three separate cylinder heads; one head per two cylinders
Internal fuel passages in cylinder heads
Overhead valve, using separate housings for rocker arms
Four valves per cylinder
Engine compression brake
Replaceable cylinder sleeves
One-piece pistons
Piston cooling nozzles
Preheater system for cold weather starting
Low oil pressure engine shutdown safety system
High coolant temperature shutdown safety system
Integral lubricating oil filter cooler assembly
External engine oil pump
Gear-driven air compressor
Alcohol evaporator system for air supply
Direct-driven fuel injection pump
Secondary fuel filter integral with fuel injection pump
Aneroid control valve
Electric or manual fuel shutdown valve
1-3
TM 5-2815-241-34&P
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
WATER MANIFOLD
Three sections of cast-iron piping and two steel tubes, containing thermostat, temperature gage
sending unit, high-temperature engine shutdown switch, and shutter control valve. The water
manifold serves as a passage for hot coolant that has circulated through the cylinder block and
cylinder heads to be delivered to the radiator.
ENGINE COMPRESSION BRAKE
Three separate units, one mounted above each of three rocker arm housings. They contain electrically operated solenoids that open engine exhaust valves near the top of the compression stroke.
The engine brake system is energized from a dash-mounted switch. The electrical solenoids are
supplied with power through a switch mounted on the fuel pump and controlled by the throttle lever.
ROCKER HOUSING COVER
Three separate aluminum covers, used to cover each rocker arm housing. The front rocker housing
cover contains the crankcase breather, oil filler opening, and cap. The center and rear rocker
housing covers are plain.
TA 242335
1-4
TM 5-2815-241-34&P
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED
ROCKER ARM HOUSING
Three separate aluminum housings, mounted above each of three cylinder heads. Each housing
contains two intake valve rocker arms, two exhaust valve rocker arms, and two fuel injector rocker
arms, ail mounted on a common shaft. Each rocker arm has an adjusting screw and locknut for
injector setting and valve adjustment.
CYLINDER HEAD
Three separate cast-iron assemblies, each mounted to cylinder block above two adjacent cylinders.
Each contains one fuel injector and two intake and exhaust valve assemblies per cylinder. The cylinder
head also includes the intake and exhaust ports, and passages for coolant to carry away heat from
engine combustion. Each contain internal fuel passages for fuel injectors connected by fuel crossovers between cylinder head assemblies.
OIL COOLER AND FILTER
A tube and shell type heat exchanger, used to dissipate heat from the engine lubricating oil, into the
cooling system. The oil cooler helps maintain lubricating oil temperature within proper operating
range of 165° to 195°F (74° to 91°C).
TURBOCHARGER
Mounted directly to exhaust manifold and consists of an exhaust-driven turbine wheel and an impeller
that forces additional air into combustion chambers. This allows engine to burn more fuel and therefore develop more horsepower. The turbocharger is engine oil lubricated and cooled.
FLYWHEEL HOUSING
Mounted directly to rear of engine block and used to connect main transmission to engine assembly.
Attached to the flywheel housing, are the rear engine mounting brackets.
EXHAUST MANIFOLD
Three sections of cast-iron piping, mounted directly to each of three cylinder head assemblies. The
turbocharger is mounted to the center section of the exhaust manifold. The exhaust manifold serves as
a passage for exhaust gases that power the turbocharger, then directs gases into the exhaust system.
1-5
TM 5-2815-241-34&P
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED
AIR INTAKE MANIFOLD
A hollow aluminum casting, mounted to cylinder head assemblies on drivers side of engine. It
receives intake air from turbocharger through air crossover connection and delivers it to intake ports
of each of three cylinder head assemblies.
ANEROID CONTROL VALVE
An air intake manifold pressure-controlled valve, mounted at fuel pump outlet line, to create a delay in
fuel supply line equal to the delay or lag of intake air pressure caused by slow turbocharger speed
buildup. Aneroid control valve eliminates excessive exhaust smoke caused by high fuel-to-air ratio.
LUBRICATING OIL PUMP
A geardriven gear pump, mounted on left side of engine, below air compressor. It draws lubricating
oil from oil pan and circulates it, under pressure, through engine oil passages. An integral pressure
regulator controls the lubricating oil pressure.
1-6
TM 5-2815-241-34&P
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED
FUEL PUMP
Is mounted to rear of air compressor, and driven by accessory drive through air compressor. It draws
fuel from fuel tank through fuel filters, and delivers to fuel injectors at the correct pressure for the
power requirements of the engine. The fuel pump is lubricated and cooled by fuel passing through fuel
pump internal passages. Electrically operated shutdown switch is mounted at fuel pump outlet.
ACCESSORY DRIVE
Is camshaft gear-driven, through crankshaft gear. Located on front of engine, the accessory drive is
used to drive air compressor and fuel pump. Pulley mounted on front of accessory drive, drives water
pump and fan hub assembly by V-belts.
WATER PUMP
A centrifugal pump mounted to front of cylinder block. It contains an impeller which draws coolant from
radiator, through water transfer connection, and circulates it through cylinder block, cylinder head
cooling passages, and engine-coolant cooled components. Coolant accumulates heat from engine
operation as it is circulated by water pump which returns it to radiator for heat dissipation.
AIR COMPRESSOR
A two-cylinder reciprocating piston air pump, mounted to and driven by engine accessory drive. Air
compressor is engine-oil lubricated and water-cooled by engine coolant and receives air for compression through pipe and fittings from air intake manifold. Adjustable governor, mounted to air
compressor cylinder head, controls maximum air pressure output. Air compressor outlet is connected by tubes and fittings to air reservoir.
FRONT ENGINE MOUNTING BRACKET
A steel bracket, with rubber bushings, that supports front of engine when in vehicle frame. It is
attached to engine and bolts to frame crossmember.
1-7
TM 5-2815-241-34&P
LOCATION AND DESCRIPTION OF IDENTIFICATION PLATES
The following illustrations show the location of identification instruction and data plates on the NTC 290
diesel engine. These views are provided to show where each plate is located.
•
•
Ref. No. 522815-C91
Advertised HP290 at 2100 RPM
Model NTC-290
Family
Date of Delivery
Identification
092
Cont. No. D092083 BX01
So. No. 15719
Engine No. 10437196
Date of manufacture
Manufactured by Cummins Engine Company, Inc., U.S.A.
•
CPL
0187
3-75
3002256
Fuel rate at advertised HP 158mm
3
/stroke
Valve lash cold .011 Int .023
Exh.
lnitial injection timing code
A8
Injector travel .170 Inch
Injector torque
Inch - Lbs.
Engine Exhaust Emission Control Information:
This
engine conforms to California regulation applicable
to 1975 model-year heavy duty diesel engines.
Engine Exhaust Emission Control Information: This
engine conforms to U.S. Environmental Protection
Agency regulations applicable to 1975 model-year
heavy duty diesel engines.
WARNING: Injury may result and warranty is voided
if fuel rate, RPM or altitudes exceed published maximum
valves for this model and application.
•
TA 242337
1-8
TM 5-2815-241-34&P
LOCATION AND DESCRIPTION OF IDENTIFICATION PLATES - CONTINUED
EQUIPMENT DATA
Specific engine data for the NTC-290 diesel engine are listed here in tabular format.
ENGINE
Manufacturer
Model
Type
Cummins Engine Company, Inc
NTC-290
Four-stroke cycle, turbocharged diesel
TA 242338
1-9
TM 5-2815-241-34&P
EQUIPMENT DATA - CONTINUED
Dimensions
Length
Width
Height
Net weight, dry
58.88 in. (14.96 cm)
33.63 in. (8.54 cm)
50.91 in. (12.93 cm)
2600 lb (11.80 kg)
Cylinders
Number
Arrangement
Firing order
Bore
Stroke
Displacement
Compression ratio
Six
lnline
1-5-3-6-2-4
5.5 in. (14.0 cm)
6 in. (15.2 cm)
855 cu in. (14 L)
13.5:1
Governed Speed
Full load
No load
Idle speed
2100 rpm
2400 rpm
600 rpm
Lubrication System
Type
Operating pressure (normal)
Operating pressure (minimum)
System capacity, including bypass filter
Operating temperature (normal)
Oil pump
Force fed
50 - 70 psi (345 - 483 kPa)
15 psi (100 kPa) at idle
44 qt (41.6 L)
200° - 250°F(95°C - 121°C)
Gear type
Cooling System
Type
Operating temperature (normal)
Thermostat
Liquid
165° - 195°F (74° - 91°C)
One
1-10
TM 5-2815-241-34&P
CHAPTER 2
MAINTENANCE INSTRUCTIONS
OVERVIEW
This chapter contains information for the guidance of maintenance personnel responsible for removing, testing, inspecting, repairing, and installing components of the NTC-290 diesel engine. It also
gives you checks that will help you find defects and corrective actions in Final Testing, Adjustments,
and Troubleshooting on Engine Test Stand that can be performed by the direct or general support
mechanic.
Page
Section I.
Section II.
Section III.
Section IV.
Section V.
Section VI.
Section VII.
Section VIII.
Section IX.
Section X.
Section Xl.
Section XII.
Section XIII.
Section XIV.
Section XV.
Section XVI.
Section XVII.
Service Upon Receipt ...................................................................................
Troubleshooting ............................................................................................
General Maintenance Instructions.. ............................................................
Engine Disassembly and Assembly.. ..........................................................
Crankcase and Cylinder Block Maintenance .............................................
Cylinder Head Maintenance ........................................................................
Crankshaft and Maintenance ......................................................................
Piston and Connecting Rod Maintenance ..................................................
Camshaft and Timing System Maintenance ..............................................
Engine Lubrication System Maintenance ...................................................
Manifold Maintenance .................................................................................
Accessory Drive Maintenance .....................................................................
Engine Compression Brake Maintenance ..................................................
Fuel System Maintenance ...........................................................................
Cooling System Maintenance.. ....................................................................
Final Testing, Adjustments, and Troubleshooting on
Engine Test Stand ......................................................................................
Engine Specifications ..................................................................................
2-1
2-2
2-3
2-10
2-140
2-176
2-214
2-220
2-236
2-264
2-272
2-276
2-262
2-269
2-404
2-414
2-434
Section I. SERVICE UPON RECEIPT
Page
Page
Cleaning ........................................................
Equipment Inspection.. ................................
2-2
2-2
Testing.. ...........................................................
Unpacking .......................................................
2-2
2-2
2-1
TM 5-2815-241-34&P
EQUIPMENT INSPECTION
The following explains what must be done upon initial receipt of engine. All tags and DA Form 2404,
Equipment Inspection and Maintenance Worksheet, must be checked to ensure that serial numbers
appearing on tags and forms match those on engine received. DA Form 2406, Materiel Condition
Status Report, must be checked to include items listed below.
1. Turbocharger
2. Turbocharger Crossover Tube
(Not Attached)
3. Fuel Pump, P/T Type G
4. Air Compressor
5. Secondary Fuel Filter
6.
7.
8.
9.
10.
11.
Aneroid Valve
Water Manifold
Intake Manifold
Exhaust Manifold
Oil Cooler with Oil Filter
Front Engine Mount
UNPACKING
The procedure for unpacking will be determined by the method of packing used by the sending facility.
CLEANING
WARNING
Improper cleaning methods and use of unauthorized cleaning liquids or solvents can
injure personnel and damage equipment. Refer to TM 9-247, Materials Used for
Cleaning, Preserving, Abrading, and Cementing Ordnance Materiel and Related
Materials Including Chemicals.
The method of cleaning will be at the discretion of the using facility. Cleaning procedure must include
the total removal of grease, dirt, and foreign material, from all mating surfaces, to eliminate the
introduction of contaminants into vital engine components.
TESTING
Engine to be tested is placed on a suitable engine test stand, and all applicable hoses, lines, fittings,
and wires are connected to monitoring gages and meters while simulating actual engine performance.
At this time, if a malfunction is found, the symptom index, found on page 2-422, is consulted for
direction to the possible corrective action.
Section II. TROUBLESHOOTING
If troubleshooting performed in TM 5-3805-254-34 failed to isolate the specific malfunction or
problem and removal of engine from chassis was deemed necessary, place engine on appropriate
engine test stand and hook up test and diagnostic equipment to further aid in locating fault.
If engine has been removed from chassis and established malfunction or problem noted on DA Form
2404 and DA Form 2406, perform maintenance procedure or procedures required.
2-2
TM 5-2815-241-34&P
Section Ill. GENERAL MAINTENANCE INSTRUCTIONS
Page
Page
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . .
2-8
2-3
2-5
2-6
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tagging Parts . . . . . . . . . . . . . . . . . . . . . . . . .
Taping Threads . . . . . . . . . . . . . . . . . . . . . .
Preliminary Starting Procedures . . . . . . . .
2-3
2-8
2-8
2-9
SCOPE
The purpose of this section is to provide general procedures which are applicable to all tasks. To avoid
repetition throughout engine maintenance, general procedures are given below.
CLEANING
The procedures for cleaning will be similar for most components and parts of the engine. Any cleaning
procedure that is peculiar to a specific part or component is covered in the paragraph relating to the
item.
The importance of cleaning must be fully understood in order to perform a successful component
repair. The presence of dirt or foreign matter can affect the operation of the component and possibly
cause premature breakdown. The following should apply to all cleaning procedures,
WARNING
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety goggles and gloves
and use only in well-ventilated area. Avoid contact with skin, eyes, and clothes and do
not breathe vapors. Do not use near open flame or excessive heat. Flashpoint for type
#1 Drycleaning solvent is 100°F (38°C) and for type #2 is 138°F (59°C). If you become
dizzy while using 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. Failure to
observe these precautions could cause serious injury or death to personnel.
1. Clean all parts before inspection, after repair, and before assembly.
2. Hands should be kept free of any accumulation of grease which can collect dust and grit.
3. After cleaning, all parts should be covered or wrapped to protect them from dust, dirt, and
foreign matter.
4. Observe all Warnings and Cautions when using drycleaning solvent (item 16, appendix B).
Personnel injury and damage to rubber and plastic parts may occur.
2-3
TM 5-2815-241-34&P
CLEANING - CONTINUED
CASTINGS
1. Scrape all gasket material from mating surfaces.
2. Clean inner and outer surfaces of castings, and all areas subject to oil and grease, with
drycleaning solvent (item 16, appendix B).
3.
Remove sludge, rust, and gum deposits from castings using a stiff brush.
WARNING
Particles blown by compressed air are hazardous. Make certain the airstream is
directed away from user and other personnel in the area. Compressed air used for
cleaning purposes shall not exceed 30 psi (207 kPa). User must wear safety goggles or
face shield to prevent injury.
4. Use clean, dry, compressed air to blow out and dry all tapped holes in castings.
OIL PASSAGES
Particular attention must be given to all oil passages in castings and machined parts. All oil passages
must be clean and free of obstruction.
1. Clean passages with a suitable piece of wire or probe to break up any sludge or gum deposits.
CAUTION
Do not allow drycleaning solvents to come in contact with seals or flexible hoses. These
cleaners cause leather, rubber, and synthetic materials to dry out, rot, and lose
pliability.
2. Wash passages by flushing with drycleaning solvent (item 16, appendix B).
3. Dry passages by blowing them out with compressed air.
OIL SEALS AND FLEXIBLE HOSES
Clean seals and flexible hoses with lubricating soap (item 15, appendix B) and water.
BALL BEARINGS
1.
Refer to TM 9-214, Inspection, Care, and Maintenance of Antifriction Bearings, for information
on care and maintenance of bearings.
2.
Bearings require special cleaning. After removing surface oil and gum deposits, place bearings
in hot oil, 140°F (60°C), to loosen hardened oil or grease. Wipe bearings dry; do not use
compressed air. After cleaning, coat bearings with a light film of lubricating oil (item 12,
appendix B), and wrap to protect from dust, dirt, and foreign matter, until parts are inspected
and assembled.
2-4
TM 5-2815-241-34&P
INSPECTION
The procedures for inspection will be similar for most components and parts of the engine. Any
inspection procedure that is peculiar to a specific part or component is covered in the paragraph
relating to that item.
CASTINGS
1.
Inspect all castings for cracks using a magnifying glass and strong light. Particularly check the
areas near studs, pipe plugs, threaded inserts, and in sharp corners and fillets.
2.
Inspect machined surfaces of castings for nicks, burrs, and raised metal. Mark damaged areas
for repair.
3. Check all mating flanges on housings and supports for warpage using a straightedge or surface
plate. Inspect mating flanges for discoloration which may indicate constant oil leakage.
4.
Inspect all pipe plug and capscrew tapped openings for damaged or stripped threads.
5. Check actual casting specifications against those given in the paragraph relating to the item.
BALL BEARINGS
Refer to TM 9-214 for inspection of bearings. Check actual bearing specifications against those given
in the paragraph relating to the item.
STUDS
Inspect all studs for stripped or damaged threads, bent or loose condition, and signs of stretching.
GEARS
1.
Inspect all gears for cracks, using a magnifying glass and strong light.
2. Inspect all gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces.
3. Check actual gear specifications against those given in the paragraph relating to the item.
BUSHINGS AND BUSHING-TYPE BEARINGS
1. Check all bushings and bushing-type bearings for secure fit in the castings or mating part in
which they are used.
2.
Inspect for wear, burrs, nicks, and out-of-round condition.
3. Check for dirt in lubrication holes or grooves. Holes and grooves must be clean and free from
damage to ensure proper lubrication.
4. Check actual bushing or bushing-type bearing specifications against those given in the paragraph relating to the item.
2-5
TM 5-2815-241-34&P
INSPECTION - CONTINUED
OIL SEALS
Inspect feather edge of oil seal for hardness or cracks. Metal-encased oil seals should not be replaced unless inspection indicates damage.
CORE HOLE PLUGS
Inspect core hole plugs for evidence of leakage. Replace if damaged or if leakage is evident.
REPAIR
The procedures for repair will be similar for most components and parts that make up the engine. Any
repair procedure that is peculiar to a specific part or component is covered in the paragraph relating to
the item. After repair, clean all parts thoroughly to prevent metal chips or abrasives, that may accumulate during repair, from entering moving parts of engine.
CASTINGS
1. Replace all cracked castings.
2. Replace all castings that do not meet specifications given in paragraph relating to that item.
3. Repair minor damage to machined surfaces with a fine file, emery cloth (item 1, appendix B),
or crocus cloth (item 4, appendix B) dipped in drycleaning solvent (item 16, appendix B).
Replace all castings with machined surfaces burred or nicked so badly that, after milling or
grinding, they still will not allow proper assembly or operation.
4.
Repair minor warpage of mounting flanges and gasket surfaces by moving the surface across a
sheet of emery cloth (item 1, appendix B) held tightly on a surface plate or similar flat surface.
Finish with crocus cloth (item 4, appendix B). Replace castings with flanges warped so badly
that they will not allow proper assembly or operation.
NOTE
Pipe plug threads in castings must be in good condition to prevent oil or water leakage.
5. Repair damaged pipe plug or screw threads in tapped holes by using the appropriate tap.
BALL BEARINGS
1. Replace all galled, pitted, or damaged bail bearings.
2. Replace all ball bearings that do not meet specifications given in paragraph relating to the part in
which they are installed.
3.
2-6
Refer to TM 9-214 for maintenance of bearings.
TM 5-2815-241-34&P
STUDS
1. Replace all bent or loose studs and studs showing signs of stretching.
2. Repair minor thread damage using a thread chaser.
3.
Replace all studs having stripped or damaged threads. If a stud has to be replaced, note the
following:
Removal
a. Using a stud extractor, unscrew studs slowly to prevent heating and possible seizure.
b. When studs are broken too short to use stud extractor, drill the stud and remove It with an
easyout.
Replacement
Only standard studs are supplied for replacement. If threaded openings are damaged and retapping
will not clean up threads, drill and tap opening to larger size and install a threaded insert.
NOTE
Ail replacement studs have a special coating and must have a small amount of micabased antiseize compound (item 2, appendix B) applied on threads before stud is
installed.
GEARS
1. Replace cracked gears.
2.
Replace gears that do not meet specifications given in paragraph relating to the port in which
they are installed.
3. Replace gears having worn, galled, or pitted teeth. Remove sharp fins and burrs from gear
teeth with crocus cloth (item 4, appendix B) dipped in drycleaning solvent (item 16,
appendix B).
BUSHINGS AND BUSHING-TYPE BEARINGS
When bushings or bushing-type bearings are damaged or worn beyond specified limits, the
associated parts with which they are used must also be replaced.
OIL SEALS
Oil seals must be replaced when the thin feather edge is found to be damaged or when the seal
material becomes hard or brittle.
Removal
Press or pry a damaged oil seal from the casting or adapter, being careful not to damage bore in
casting or adapter.
2-7
TM 5-2815-241-34&P
REPAIR - CONTINUED
Repair
When a casting oil seal bore or adapter is burred to a point where an oil tight seal is impossible, replace the casting or adapter. Remove slight nicks, burrs, and scratches from casting bore or adapter
with crocus cloth (item 4, appendix B) dipped in drycleaning solvent (item 16, appendix B).
Installation
Install a new oil seal in bore of casting or adapter, using proper oil seal installing tool.
ASSEMBLY
Extreme care must be taken in all component assembly operations to ensure satisfactory engine performance. General cautions are outlined below. Step-by-step procedures for assembly of various
components are covered in paragraphs relating to the specific components.
1. Cleanliness Is the most important factor to consider during the assembly of all components. The
smallest amounts of dirt and dust can be abrasive and cause premature component failure.
2. Coat all bearings and contact surfaces with lubricating oil (item 12, appendix B) to ensure
lubrication of parts during initial engine startup.
3.
Replace all gaskets, preformed packings, and lockwashers.
TAPING THREADS
Antiseizing tape (item 18, appendix B) is wrapped around threads, pipe plugs, screws, studs, and
other type of threaded attaching hardware, to provide a better seal and also to permit easier removal.
1.
Make sure item to be wrapped is clean and dry before applying antiseizing tape.
2. Start the tape one or two threads from the leading edge, joining the tape together with an overlap
of approximately 1/8 inch.
3. Wrap tape tightly in the same direction you would screw in the item being taped. Press tape into
threads without ripping or cutting tape.
TAGGING PARTS
Before disconnecting or separating electrical, air, hydraulic, or mechanical components, always
identify the mating parts for correct installation later. This can be done by tagging each part (item 17,
appendix B) with duplicate numbers or letters, or, in the case of electrical connections, identify the
terminal or circuit number on the individual wire or the wire number on the terminal or circuit.
Parts to be repaired must be tagged as needing repair. Note necessary information on repair tags.
2-8
TM 5-2815-241-34&P
PRELIMINARY STARTING PROCEDURES
WARNING
EXHAUST GAS CAN KILL YOU
Exhaust gas is without color or smell, but can kill you. Breathing exhaust gas produces
symptoms of headache, dizziness, loss of muscular control, a sleepy feeling, and
coma. Brain damage or death can result from heavy exposure to exhaust fumes of fuelburning internal combustion engines. Exhaust gases can become dangerously
concentrated under conditions of no air movement. Precautions must be followed to
ensure crew safety when the engine of any vehicle is operated for any purpose.
1.
DO NOT operate vehicle engine inside building unless ample ventilation is available.
2.
DO NOT idle engine for long periods without ventilator blower operating.
3.
DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment doors removed unless necessary for maintenance purposes.
4.
BE ALERT at all times during vehicle operation for exhaust odors and exposure
symptoms. If either is present, IMMEDIATELY VENTILATE personnel compartments. If symptoms persist, remove affected crew to fresh air; keep warm; DO
NOT PERMIT PHYSICAL EXERCISE; if necessary, give artificial respiration.
5.
FOR ARTIFICIAL RESPIRATION, REFER TO FM21-11.
6.
BE AWARE; the field protective mask for chemical-biological-radiological (CBR)
protection will not protect you from carbon monoxide poisoning.
THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION.
NOTE
Perform the following steps as they are applicable before starting engine in the engine
test stand.
1.
Make sure engine exhaust outlet is connected to a suitable shop exhaust system to evacuate
the engine exhaust gases safely from the testing area.
2. Check air inlet piping to ensure it is attached correctly and tight.
3. Make sure all cooling system water hoses and clamps are attached correctly and are tight
with no leaks.
4. Check all fuel lines and fittings to make sure they are attached correctly and are tight with
no leaks.
5.
Make sure all engine test stand gauges and controls are attached to engine properly and
are tight.
6. Check engine oil level with oil level dipstick to make sure crankcase is full. Oil level should
be between the H (high) and L (low) marks on dipstick.
2-9
TM 5-2815-241-34&P
Section IV. ENGINE DISASSEMBLY AND ASSEMBLY
Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11
Disassembly
Accessory Drive Removal ............................
Air Compressor and Fuel Pump
Removal ......................................................
Aneroid Control Valve Removal.. .................
Cam Follower Housing Removal.. ...............
Camshaft Removal (See Gearcase
Cover Removal). ..........................................
Compression Release Shaft
Removal ......................................................
Crankcase Access Cover Removal .............
Crankshaft Removal.. ...................................
Crosshead Removal .....................................
Cylinder Head Fuel Line Removal.. .............
Cylinder Head Removal.. ..............................
Engine Compression Brake
Housing Removal .......................................
Engine Oil Cooler Removal.. ........................
Exhaust Manifold Removal.. ........................
Fan Hub Removal .........................................
Flywheel Housing Removal .........................
Fuel Injector Removal ..................................
Gearcase Cover Removal.. ...........................
Intake Manifold Removal .............................
Lubricating Oil Pump Removal.. ..................
Oil Disptick Tube Removal ..........................
Oil Pan Removal ...........................................
Piston Assembly Removal ...........................
Piston Cooling Nozzle Removal ..................
Push Rod Removal .......................................
Rocker Arm Cover Removal.. .......................
Rocker Arm Housing Removal ....................
Turbocharger and Oil Line
Removal ......................................................
Water Header Cover Removal.. ....................
Water Inlet Housing Removal.. ....................
Water Manifold Assembly
Removal ......................................................
Water Pump Removal.. .................................
2-43
2-41
2-25
2-47
2-48
2-39
2-17
2-49
2-31
2-29
2-36
2-28
2-20
2-14
2-35
2-46
2-34
2-48
2-26
2-40
2-16
2-44
2-52
2-24
2-33
2-27
2-30
2-12
2-23
2-22
2-18
2-37
Assembly
Accessory Drive Installation . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor and Fuel Pump
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10
2-84
2-86
Page
Aneroid Control Valve
Installation ................................................
Cam Follower Housing
Installation.. ..............................................
Camshaft Installation ................................
Compression Release Shaft
Installation.. ..............................................
Crankcase Access Cover
Installation.. ..............................................
Crankshaft Installation ..............................
Crosshead Installation.. .............................
Cylinder Head Fuel Lines
Installation ................................................
Cylinder Head Installation.. .......................
Engine Compression Brake Housing
Installation.. ..............................................
Engine Oil Cooler Installation ...................
Exhaust Manifold Installation.. .................
Fan Hub Installation ..................................
Flywheel Housing Installation ..................
Fuel Injector Installation ............................
Gearcase Cover Installation.. ....................
Injector Timing Adjustment .......................
Intake Manifold Installation ......................
Lubricating Oil Pump
Installation ................................................
Oil Dipstick Tube Installation.. ..................
Oil Pan Installation .....................................
Piston Assembly Installation ....................
Piston Cooling Nozzle
Installation ................................................
Push Rod Installation .................................
Rocker Arm Cover Installation ..................
Rocker Arm Housing
Installation.. ..............................................
Turbocharger and Oil Line
Installation ................................................
Turbocharger Crossover Tube
Installation ................................................
Valve and Injector Adjustment.. ................
Water Header Cover Installation.. .............
Water Inlet Housing
Installation ................................................
Water Manifold Assembly
Installation ................................................
Water Pump Installation ............................
2-132
2-70
2-66
2-72
2-126
2-54
2-80
2-104
2-68
2-116
2-127
2-134
2-123
2-98
2-78
2-99
2-74
2-119
2-88
2-133
2-96
2-60
2-120
2-73
2-118
2-82
2-136
2-138
2-106
2-125
2-124
2-130
2-121
TM 5-2815-241-34&P
GENERAL
These tasks contain information needed to disassemble engine and its components, and to assemble
engine from its subassemblies into a complete engine.
Before disassembly, a visual inspection of engine and its subassemblies is recommended to determine if repair is required. Inspection of each subassembly and tagging of components and positions
will help ensure correct assembly. Remove and replace components and parts from engine in order in
which they appear in this section. Individual components may be removed by noting equipment condition to be performed.
Before assembly, it is important to check each subassembly to make sure nothing has been overlooked during inspection and repair.
Read and understand all WARNINGS, CAUTIONS, and NOTES.
Torque limits and tolerances will be included in each applicable task. It is important to pay attention to
all torque limits and tolerances. Section XVI, chapter 2 contains a complete list of all torque limits and
tolerances.
Any cleaning procedure, except for unique situations, can be found in section III, chapter 2, General
Maintenance Instructions. Lubricants should be kept in clean, covered containers. Work area should
be kept as clean as possible.
When engine is removed from chassis, support it on engine transport stand. Perform all necessary
disassembly procedures to prepare engine for mounting on suitable engine repair stand. Engine
maintenance is performed on the engine repair stand. For final assembly of engine, remove it from
the engine repair stand and remount engine on engine transport stand. Mounting procedures on
engine repair and transport stands are left up to the discretion of the repair facility.
Disassembly and assembly of the NTC-290 diesel engine must be performed In the order that the paragraphs are presented In this sect/on, starting with Turbocharger and Oil Line Removal.
2-11
TM 5-2815-241-34&P
TURBOCHARGER AND OIL LINE REMOVAL
INITIAL SETUP
Tools - Continued
Tools
Wrench, open-end, 1 1/4-inch
Wrench, open-end, 1 5/16-inch
Wrench, open-end, 1 3/8-inch
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Joint, universal, 1/2-inch drive
Screwdriver, flat-tip, 1/4-inch
Socket, 9/16-inch, 1/2-inch drive
Wrench, box-end, 1/2-inch
Wrench, box-end, 9/16-inch (two
required)
Wrench, open-end, 5/8-inch
Wrench, open-end, 3/4-inch
LOCATION
Equipment Condition
Engine mounted on engine support stand.
(Engine support stand and mounting instructions) will be at the discretion of the repair
facility.
ITEM
ACTION
REMARKS
1. Oil cooler (1) and
turbocharger (2)
Oil supply line and
fittings (3)
a. Using 1/2-inch box-end wrench and
3/4-inch open-end wrench, unscrew
and take off oil supply line and fitting
from oil cooler.
b. Using 5/8-inch and 3/4-inch open-end
wrenches, unscrew and take off oil supply line and fitting from turbocharger.
2. Bracket (4) on oil
cooler (1)
Screw (5), flat
washer (6), clamp
(7), and nut (8)
Using two 9/16-inch box-end wrenches,
unscrew and take off nut.
Pull off screw, flat washer, and clamp
from bracket and screw on nut to
prevent loss.
3. Turbocharger (2)
Screw (9) and
clamp (10)
Using 1/2-inch box-end wrench, unscrew
and take off screw, oil supply line, and
fittings from turbocharger.
Remove screw from clamp and install
on turbocharger to prevent loss.
4. Turbocharger (2) and
oil return hose
fitting (11)
Oil return tube and
hose (12) and
clamp (13)
a. Using 1/4-inch flat-tip screwdriver,
loosen clamp and disconnect oil return
tube and hose from oil return hose
fitting.
b. Using 1 3/8-inch and 1 5/16-inch openend wrenches, unscrew and take off oil
return tube and hose from turbocharger,
2-12
TM 5-2815-241-34&P
TURBOCHARGER AND OIL LINE REMOVAL - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
5. Right side of
cylinder block (14)
Oil return hose
fitting (11)
Using 1 1/4-inch open-end wrench,
unscrew and take off.
6. Exhaust
manifold (15)
Four nuts (16),
turbocharger (2),
and gasket (17)
a. Using 1/2-inch drive 9/16-inch socket,
6-inch extension, universal joint, and
ratchet handle, unscrew and take off
four nuts.
b. Take off turbocharger and gasket.
Discard gasket and screw four nuts
onto exhaust manifold to prevent loss.
TA 242339
2-13
TM 5-2815-241-34&P
EXHAUST MANIFOLD REMOVAL
INITIAL SETUP
Tools
Personnel Required
Chisel, cold, 1/2-inch
Extension, 6-inch, 1/2-inch drive
Goggles, safety
Hammer, ball-peen, 16-ounce
Handle, ratchet, 1/2-inch drive
Socket, 5/8-inch, 1/2-inch drive
LOCATION
Two
Equipment Condition
Turbocharger and oil lines removed
(page 2-12).
ACTION
REMARKS
ITEM
WARNING
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
1. Exhaust manifold (1)
Four nut locking
plates (2) and four
key washers (3)
Using 16-ounce ball-peen hammer and
1/2-inch cold chisel, bend back tabs on nut
locking plates and key washers.
2.
Eight screws (4),
four nut locking
plates (2), and
eight sleeve
bearings (5)
Using 1/2-inch drive W-inch socket,
6-inch extension, and ratchet handle,
unscrew and take off.
Discard nut locking plates.
3.
Four screws (6),
four key washers
(3), and two retaining straps (7)
Using 1/2-inch drive 5/8-inch socket,
6-inch extension, and ratchet handle,
unscrew and take off.
Discard key washers.
2-14
TM 5-2815-241-34&P
EXHAUST MANIFOLD REMOVAL - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
CAUTION
Exhaust manifold is in three sections and could separate, causing damage to equipment. Assistance will be needed to perform step 4.
4. Cylinder head (8)
Exhaust manifold (1)
and six gaskets (9)
With assistance, take off.
Discard gaskets.
TA 242340
2-15
TM 5-2815-241-34&P
OIL DIPSTICK TUBE REMOVAL
INITIAL SETUP
Tools
Handle, ratchet, 1/2-inch drive
Socket, 5/8-inch, 1/2-inch drive
Wrench, box-end, 9/16-inch
LOCATION
ITEM
ACTION
REMARKS
1. Oil cooler (1)
Screw (2), lockwasher (3), and
bracket (4)
a. Using 9/16-inch box-end wrench, unscrew and take off.
Discard lockwasher.
b. Reinstall screw in oil cooler to prevent
loss.
2. Oil pan (5)
Two screws (6) and
two lockwashers (7)
Using 1/2-inch drive 5/8-inch socket and
ratchet handle, unscrew and take out.
Discard lockwashers.
3.
Oil dipstick tube
(8) and gasket (9)
Pull out of oil pan to remove.
Discard gasket.
4.
Two screws (6) and
oil dipstick
tube (8)
Install two screws in oil dipstick tube to prevent loss.
TA 242341
2-16
TM 5-2815-241-34&P
CRANKCASE ACCESS COVER REMOVAL
INITIAL SETUP
Tools
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
LOCATION
ITEM
ACTION
REMARKS
1. Right side of
cylinder block (1)
Four screws (2) and
four lockwashers (3)
Using 1/2-inch drive 9/16-inch socket and
ratchet handle, unscrew and take out.
Discard lockwashers.
2.
Crankcaseaccess
cover (4) and
gasket (5)
Take off.
Discard gasket.
TA 242342
2-17
TM 5-2815-241-34&P
WATER MANIFOLD ASSEMBLY REMOVAL
INITIAL SETUP
Tools
Wrench, open-end, 9/16-inch
LOCATION
ACTION
REMARKS
ITEM
1. Rear and center
cylinder heads (1)
Four screws (2) and
four lockwashers (3)
Using 9/16-inch open-end wrench, unscrew and take out.
Discard lockwashers.
2.
Four screws (4) and
four lockwashers (5)
Using 9/16-inch open-end wrench, unscrew and take out.
Discard lockwashers.
3.
Water manifold
center and rear
sections (6) and
four gaskets (7)
Carefully pull out and remove.
Discard gaskets.
4. Front cylinder
head (8)
Two screws (9) and
two lockwashers (10)
Using 9/16-inch open-end wrench, unscrew and take out.
Discard lockwasher.
5.
Two screws (11) and
two lockwashers (12)
Using 9/16-inch open-end wrench, unscrew and take out.
Discard lo&washers.
CAUTION
Care must be taken not to damage connector tube. Connector tube remains with water
manifold front section.
2-18
TM 5-2815-241-34&P
WATER MANIFOLD ASSEMBLY REMOVAL - CONTINUED
LOCATION
6.
ITEM
Water manifold front
section (13), connectar tube (14),
packing (15), and
two gaskets (16)
ACTION
REMARKS
Carefully pull up and take off.
Discard packing and gaskets.
TA 242343
2-19
TM 5-2815-241-34&P
ENGINE OIL COOLER REMOVAL
INITIAL SETUP
Tools
Personnel Required
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Socket, 3/4-inch, 1/2-inch drive
Wrench, box-end, 7/16-inch
LOCATION
Two
Equipment Condition
Water manifold removed (page 2-18).
ACTION
REMARKS
ITEM
1. Rear water header
cover (1)
Six screws (2) and
six lockwashers (3)
Using 7/16-inch box-end wrench, unscrew
and take out.
Discard lockwashers.
2. Right side of
cylinder block (4)
Rear water header
cover (1), gasket
(5), water transfer
tube (6), and two
packings (7)
Take off and pull out.
Discard gasket and packings.
3. Engine oil cooler
brace (8)
Screw (9), lockwasher (10), and
flat washer (11)
Using 1/2-inch drive 3/4-inch socket,
6-inch extension, and ratchet handle,
unscrew and take out.
Discard lockwasher.
NOTE
When performing step 4, support oil filter shell to prevent it from falling,
4. Oil filter
shell (12)
Retaining screw (13)
Using 1/2-inch drive 9/16-inch socket and
ratchet handle, loosen.
Retaining screw remains attached to
oil filter shell.
5. Engine oil
cooler (14)
Oil filter
shell (12)
Lower and remove.
6. Oil filter
shell (12)
Oil filter cartridge
(15) and packing (16)
Take out.
Discard oil filter cartridge and
packing.
2-20
TM 5-2815-241-34&P
ENGINE OIL COOLER REMOVAL - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
When performing steps 7 and 8, assistance will be needed to support oil cooler while
removing hardware, to prevent oil cooler from falling.
7. Engine oil
cooler (14)
Six screws (17) and
six lockwashers (18)
Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
unscrew and take out.
Discard lockwashers.
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
8. Right side of
cylinder block (4)
Engine oil cooler
(14) and gasket (19)
With assistance, take off.
Discard gasket.
TA 242344
2-21
TM 5-2815-241-34&P
WATER INLET HOUSING REMOVAL
INITIAL SETUP
Tools
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
LOCATION
ITEM
ACTION
REMARKS
REMOVAL
1. Right front of
cylinder block (1)
Four screws (2) and
four lockwashers (3)
Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
unscrew and remove.
Discard lockwashers.
2.
Screw (4) and
lockwasher (5)
Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
unscrew and remove.
Discard lockwasher.
3.
Water inlet housing
(6) and gasket (7)
Take off.
Discard gasket.
TA 242345
2-22
TM 5-2815-241-34&P
WATER HEADER COVER REMOVAL
INITIAL SETUP
Tools
Handle, ratchet, 1/2-inch drive
Socket, 7/16-inch, 1/2-inch drive
LOCATION
ITEM
ACTION
REMARKS
1. Right side of
cylinder block (1)
Six screws (2) and
six lockwashers (3)
Using 1/2-inch drive 7/16-inch socket and
ratchet handle, unscrew and take out.
Discard lockwashers.
2.
Water header cover
(4) and gasket (5)
Take off.
Discard gasket.
TA 242346
2-23
TM 5-2815-241-34&P
PISTON COOLING NOZZLE REMOVAL
INITIAL SETUP
Tools
Handle, ratchet, 1/2-inch drive
Socket, 1/2-inch, 1/2-inch drive
LOCATION
ACTION
REMARKS
ITEM
REMOVAL
NOTE
Steps given are typical for all six piston cooling nozzles.
1. Piston cooling
nozzle (1)
Screw (2) and
lockwasher (3)
Using 1/2-inch drive 1/2-inch socket and
ratchet handle, unscrew and take out.
Discard lockwasher.
2. Right side of
cylinder block (4)
Piston cooling
nozzle (1) and
packing (5)
Pull out of cylinder block.
Discard packing.
TA 242347
2-24
TM 5-2815-241-34&P
ANEROID CONTROL VALVE REMOVAL
INITIAL SETUP
Equipment Condition
Tools
Engine removed from engine transport stand
and mounted on engine repair stand. (Engine
repair stand and mounting instructions will be at
discretion of repair facility.)
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Wrench, open-end, 9/16-inch
Wrench, open-end, 5/8-inch
Wrench, open-end, 7/8-inch
LOCATION
ITEM
ACTION
REMARKS
1. Intake manifold (1)
Vacuum line nut (2)
Using 9/16-inch open-end wrench, loosen
and disconnect.
2. Aneroid control
valve (3)
Fuel line nuts (4)
Using 5/8-inch and 7/8-inch open-end
wrenches, loosen and disconnect.
3.
Fuel line nuts (5)
Using 5/8-inch and 9/16-inch open-end
wrenches, loosen and disconnect.
4. Intake manifold (1)
Two screws (6), two
lockwashers (7), two
spacers (8), aneroid
control valve (3)
and bracket (9)
a. Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
unscrew and take out.
b. Take off aneroid control valve with
bracket.
Discard lockwashers.
TA 242348
2-25
TM 5-2815-241-34&P
INTAKE MANIFOLD REMOVAL
INITIAL SETUP
Tools
Personnel Required
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Wrench, open-end, 1-inch
Two
Equipment Condition
Aneroid control valve removed (page 2-25).
LOCATION
ACTION
REMARKS
ITEM
1. Intake manifold (1)
Air compressor hose
nuts (2)
Using 1-inch open-end wrench, loosen
and disconnect.
2.
Seven screws (3),
seven lockwashers
(4) and seven flat
washers (5)
Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
unscrew and take out.
Discard lockwashers.
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
3. Cylinder head (6)
Intake manifold (1)
and three gaskets (7)
With assistance, take off.
Discard gaskets.
TA 242349
2-26
TM 5-2815-241-34&P
ROCKER ARM COVER REMOVAL
INITIAL SETUP
Tools
Handle, ratchet, 1/2-inch drive
Screwdriver, flat-tip, 1/4-inch
Socket, 9/16-inch, 1/2-inch drive
LOCATION
ACTION
REMARKS
ITEM
CAUTION
Do not damage injector adjustment procedure decal on rocker arm cover.
1. Front rocker arm
cover (1)
Crankcase breather
hose (2) and
clamp (3)
Using 1/4-inch flat-tip screwdriver, loosen
clamp and take off hose.
NOTE
Step 2 is typical for all three rocker arm covers.
2.
Five screws (4),
five lockwashers
(5), five flat
washers (6), rocker
arm cover(l), and
gasket (7)
a. Using 1/2-inch drive 9/16-inch socket
and ratchet handle, unscrew and take
off.
b. Take off rocker arm cover.
Discard gasket and lockwashers.
TASK ENDS HERE
TA 242350
2-27
TM 5-2815-241-34&P
ENGINE COMPRESSION BRAKE HOUSING REMOVAL
INITIAL SETUP
Tools
Equipment Condition
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Screwdriver, flat-tip, 3/8-inch
Socket, 3/4-inch, 1/2-inch drive
LOCATION
Rocker arm cover removed (page 2-27).
ITEM
ACTION
REMARKS
1. Three engine compression brake
housings (1)
Six lock tabs (2),
eighteen nuts (3)
and twelve lockwashers (4)
a. Using 3/8-inch flat-tip screwdriver, pry
ends of lock tabs away from nuts.
b. Using VP-inch drive 3/4-inch socket,
6-inch extension and ratchet handle,
unscrew and take off.
Discard lock tabs and lockwashers.
2.
Front lifting eye
(5), rear lifting eye
(6), two spacers (7)
three engine compression brake
housings (I), and
three gaskets (8)
Take off.
Discard gaskets.
TA 242351
2-28
TM 5-2815-241-34&P
CYLINDER HEAD FUEL LINE REMOVAL
INITIAL SETUP
Tools - Continued
Tools
Wrench, open-end, 9/16-inch
Wrench, open-end, 5/8-inch
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Wrench, open-end, 1/2-inch
LOCATION
ITEM
ACTION
REMARKS
a. Using 1/2-inch open-end wrench,
loosen and disconnect fuel line nuts.
b. Using 5/8-inch open-end wrench, unscrew and take out fittings.
Install fittings on fuel line nuts to
prevent loss.
1. Rear cylinder
head (1)
Two fuel line nuts
(2) and two
fittings (3)
2. Fuel shutoff
switch (4)
Fuel line nut (5)
and fitting (6)
Using 5/8-inch and 1/2-inch open-end
wrenches, loosen and disconnect.
3. Fuel pump (7)
Fuel line nut (8)
and fitting (9)
Using 9/16-inch open-end wrench, loosen
and disconnect fuel line nut.
4. Left side of
cylinder block
Three screws (10),
three lockwashers
(11), three clamps
(12), and two fuel
lines (13)
Using 1/2-inch drive 9/16-inch socket and
ratchet handle, unscrew and take off.
Discard lockwashers.
Install three screws in cylinder block to
prevent loss.
TASK ENDS HERE
TA 242352
2-29
TM 5-2815-241-34&P
ROCKER ARM HOUSING REMOVAL
INITIAL SETUP
Tools
Materials/Parts
Handle, ratchet, 3/8-inch drive
Mallet, rubber
Screwdriver, flat-tip, 3/8-inch
Socket, 7/16-inch, 3/8-inch drive
Wrench, box-end, 5/8-inch
Wrench, box-end, 3/4-inch
LOCATION
Tags, marker (item 17, appendix B)
Equipment Condition
Engine compression brake housings removed
(page 2-28).
ACTION
REMARKS
ITEM
NOTE
Before performing following steps, tag rocker arm housings with location on engine.
Steps given are typical for all three rocker arm housings.
1. Intake and exhaust
valve rocker
arms (1)
Locknut (2) and
adjusting screw (3)
Using 3/4-inch box-end wrench and 3/8inch flat-tip screwdriver, loosen locknut and
unscrew adjusting screw until rocker arm
moves freely.
2. Fuel injector rocker
arm (4)
Locknut (5) and
adjusting screw (6)
Using 3/8-inch drive 7/16-inch socket,
ratchet handle, and 3/4-inch box-end
wrench, loosen locknut and unscrew adjusting screw until rocker arm moves freely.
NOTE
Rocker arm studs are different lengths. Before performing step 3, tag rocker arm studs.
See illustration for location and lengths.
TA 242353
2-30
TM 5-2815-241-34&P
ROCKER ARM HOUSING REMOVAL - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
3. Rocker arm
housing (7)
Six rocker arm
studs (8)
Using 5/8inch box-end wrench, unscrew
and take out.
4. Cylinder head (9)
Rocker arm housing
(7) and gasket (10)
Using rubber mallet, tap lightly and take off.
Discard gasket.
CROSSHEAD REMOVAL
INITIAL SETUP
Tools
Screwdriver, flat-tip, l/Cinch
Wrench, open-end, 9/16-inch
Equipment Condition
Rocker arm housings removed (page 2-30).
Materials/Parts
Tags, marker (item 17, appendix B)
TA 242354
2-31
TM 5-2815-24134&P
CROSSHEAD REMOVAL - CONTINUED
LOCATION
1. Crosshead (1)
ACTION
REMARKS
ITEM
Locknut (2) and
adjusting screw (3)
Using 9/16-inch open-end wrench and
1/4-inch flat-tip screwdriver, loosen
locknut and unscrew adjusting screw two full
turns.
NOTE
Before performing step 2, tag crossheads, from front cylinder to rear cylinder, for
identification and location as shown in table below.
2. Cylinder heads (4)
Twelve crossheads (1)
Take off.
TASK ENDS HERE
TA 242355
2-32
TM 5-2815-241-34&P
PUSH ROD REMOVAL
INITIAL SETUP
Equipment Condition
Materials/Parts
Rocker arm housings removed (page 2-30).
Tags, marker (item 17, appendix B)
LOCATION
ACTION
REMARKS
ITEM
NOTE
Before removing, tag push rods, from front cylinder to rear cylinder, for location as
shown in table below.
Cylinder heads (1)
Push rods (2)
Pull out.
PUSH ROD LOCATION AND DESCRlPTlON
TAG No.
CYL No.
LOCATION
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
1
1
2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
EXHAUST
INJECTOR
INTAKE
INTAKE
INJECTOR
EXHAUST
EXHAUST
INJECTOR
INTAKE
INTAKE
INJECTOR
EXHAUST
EXHAUST
INJECTOR
INTAKE
INTAKE
INJECTOR
EXHAUST
W/COLLAR
THICK
THIN
THIN
THICK
W/COLLAR
W/COLLAR
THICK
THIN
THIN
THICK
W/COLLAR
W/COLLAR
THICK
THIN
THIN
THICK
W/COLLAR
TASK ENDS HERE
TA 242356
2-33
TM 5-2815-241-34&P
FUEL INJECTOR REMOVAL
INITIAL SETUP
Materials/Parts
Tools
Extension, 6-inch, VP-inch drive
Handle, ratchet, 1/2-inch drive
Puller, fuel injector
Socket, 1/2-inch, 1/2-inch drive
Tags, marker (item 17, appendix B)
Equipment Condition
Rocker arm housings removed (page 2-30).
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps given are typical for all six fuel injectors.
1. Cylinder head (1)
Fuel injector link
(2), two screws (3),
and fuel injector
clamp (4)
a. Take out fuel injector link.
b. Using 1/2-inch drive 1/2-inch socket,
6-inch extension, and ratchet handle,
unscrew and take out.
CAUTION
To avoid dropping plunger, do not turn fuel injector upside down. Place fuel injectors In
a rack for protection and tag by number from cylinder removed.
2.
Fuel injector (5)
Using fuel injector puller, pull out.
TASK ENDS HERE
TA 242357
2-34
TM 5-2815-241-34&P
FAN HUB REMOVAL
INITIAL SETUP
Tools
Extension, 10-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Socket, 3/4-inch, 1/2-inch drive
LOCATION
ITEM
ACTION
REMARKS
1. Fan hub assembly (1)
Three screws (2)
Using 1/2-inch drive 3/4-inch socket and
ratchet handle, loosen.
2.
Fan hub adjuster
screw (3) and two
fan belts (4)
a. Using 1/2-inch drive 9/16-inch socket
and ratchet handle, loosen.
b. Take off two fan belts and check for
cracks.
Discard fan belts if defective.
3. Water pump (5)
Two screws (6) and
two lockwashers (7)
Using 1/2-inch drive 3/4-inch socket, 10inch extension, and ratchet handle, unscrew and take out.
Discard lockwashers.
Fan hub assembly (1)
Lift off.
TASK ENDS HERE
TA 242358
2-35
TM 5-2815-241-34&P
CYLINDER HEAD REMOVAL
INITIAL SETUP
Tools
Personnel Required
Handle, hinged, 3/4-inch drive
Screwdriver, flat-tip, 1/4-inch
Socket, 11/16-inch, 3/4-inch drive
Two
Equipment Condition
Materials/Parts
Cylinder head fuel lines removed (page 2-29).
Rocker arm covers removed (page 2-27).
Tags, marker (item 17, appendix B)
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps given are typical for all three cylinder heads. Before removing, tag cylinder heads
for location. Fuel crossovers are between front and center cylinder head and center and
rear cylinder head only.
1. Cylinder head (1)
Four screws (2),
four lockwashers
(3), fuel crossover
(4), and four
packings (5)
Using 1/4-inch flat-tip screwdriver, loosen
and take off.
Discard packings and lockwashers.
NOTE
Use suitable material to plug fuel crossover passages to prevent any dust or dirt from
entering.
2.
Twelve screws (6)
and twelve hardened
washers (7)
Using 3/4-inch drive 11/16-inch socket
and hinged handle, unscrew and take out.
Discard hardened washers.
Warning
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
3. Cylinder block (8)
Cylinder head (1)
and cylinder head
gasket (9)
Take off.
Discard gasket.
NOTE
Install crossheads in respective positions according to table and illustration shown in
Crosshead Removal (page 2-31).
2-36
TM 5-2815-24134&P
CYLINDER HEAD REMOVAL - CONTINUED
TASK ENDS HERE
WATER PUMP REMOVAL
INITIAL SETUP
T o o l s
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Socket, 7/8-inch, 1/2-inch drive
Wrench, open-end, l-inch
Wrench, open-end, 11/16-inch
Equipment Condition
Fan hub removed (page 2-35).
TA 242359
2-37
TM 5-2815-24134&P
WATER PUMP REMOVAL - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
1. Water pump (1)
Air compressor
coolant hose (2)
Using l-inch open-end wrench, unscrew
and disconnect.
Move out of way.
2.
Idler pulley
locknut (3)
Using 11/16-inch open-end wrench,
loosen.
3.
Idler pulley adjusting screw (4) and
two water pump
belts (5)
a. Using 1/2-inch drive 7/8-inch socket
and ratchet handle, loosen.
b. Take off water pump belts and check for
cracks.
Discard water pump belts If defective.
4. Front of cylinder
block (6)
Seven screws (7),
seven lockwashers
(8), water pump (1),
and gasket (9)
a. Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
unscrew and take off screws and
lockwashers.
b. Take off water pump and gasket.
Discard gasket and lockwashers.
TA 242360
2-38
TM 5-2815-241-34&P
COMPRESSION RELEASE SHAFT REMOVAL
INITIAL SETUP
Equipment Condition
Tools
Water pump removed (page 2-37).
Wrench, box-end, 9/16-inch
LOCATION
1. Left rear of
cylinder block (1)
2.
Left front of cylinder block (4)
ITEM
ACTION
REMARKS
Screw (2) and
lockwasher (3)
Using 9/16-inch box-end wrench, unscrew
and take out.
Discard lockwasher.
Compression release
shaft (5) and
packing (6)
Pull out.
Discard packing.
TASK ENDS HERE
TA 242361
2-39
TM 5-2815-241-34&P
LUBRICATING OIL PUMP REMOVAL
INITIAL SETUP
Tools
Tools - Continued
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
LOCATION
Socket, 5/8-inch, 1/2-inch drive
Wrench, open-end, 1 7/8.inch
ITEM
ACTION
REMARKS
1. Bottom of lubricating oil pump (1)
Tubing nut (2)
Using 1 7/8-inch open-end wrench, loosen
and disconnect.
2. Oil pan (3)
Two screws (4), two
lockwashers (5)
suction tube with
flange (6), and
gasket (7)
Using 1/2-inch drive 9/16-inch socket and
ratchet handle, unscrew and take off.
Discard gasket and lockwashers.
3. Left side of
cylinder block (8)
Five screws (9),
five lockwashers
(10), lubricating
oil pump (1), and
gasket (11)
Using 1/2-inch drive 5/8-inch socket,
6-inch extension, and ratchet handle,
unscrew and take off.
Discard gasket and lockwashers.
TASK ENDS HERE
TA 242362
2-40
TM 5-2815-241-34&P
AIR COMPRESSOR AND FUEL PUMP REMOVAL
INITIAL SETUP
Tools
Personnel Required
Handle, ratchet, 1/2-inch drive
Oil filter removing tool
Socket, 9/16-inch, 1/2-inch drive
Wrench, box-end, 5/8-inch
Wrench, box-end, half-moon, 5/8-inch
Wrench, open-end, 11/16-inch
Wrench, open-end, 7/8-inch
Wrench, open-end, 1-inch
LOCATION
ITEM
Two
Equipment Condition
Aneroid control valve removed (page 2-25).
Cylinder head fuel lines removed
(page 2-29).
Lubricating oil pump removed (page 2-40).
ACTION
REMARKS
1. Fuel pump (1)
Secondary fuel
filter (2)
Using oil filter removing tool, loosen and
take off.
Discard.
2. Cylinder block (3)
Air compressor
coolant hose (4)
and hose nut (5)
Using l-inch and 7/8-inch open-end
wrench, loosen and disconnect.
3. Air compressor
bracket (6)
Screw (7), lockwasher (8), and
flat washer (9)
Using 1/2-inch drive 9/16-inch socket and
ratchet handle, unscrew and take off.
Discard lockwasher.
TA 242363
2-41
TM 5-2815-241-34&P
AIR COMPRESSOR AND FUEL PUMP REMOVAL - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
4. Accessory drive
flange (1)
Four screws (2) and
four lockwashers (3)
Using 5/8-inch half-moon box-end wrench,
unscrew and take out.
Discard lockwashers.
5.
Air compressor (4),
fuel pump (5)
coupler (6) and
gasket (7)
With assistance, take off.
Discard gasket.
6. Fuel pump mounting
flange (8)
Two nuts (9), two
lockwashers (10),
and two flat
washers (11)
Using 11/16-inch open-end wrench, unscrew and take off.
Discard lockwashers.
7.
Two screws (12),
two lockwashers
(13), and two
flat washers (14)
Using 5/8-inch box-end wrench, unscrew
and take out.
Discard lockwashers.
8.
Fuel pump (5)
coupler (15), and
gasket (16)
Take off.
Discard gasket.
TASK ENDS HERE
2-42
TA 242364
TM 5-2815-241-34&P
ACCESSORY DRIVE REMOVAL
INITIAL SETUP
Equipment Condition
Tools
Extension, 6-inch, 1/2-inch drive
Handle, hinged, 1/2-inch drive
Puller, accessory drive pulley
Screwdriver, flat-tip, 1/4-inch
Socket, 11/4-inch, 1/2-inch drive
Wrench, box-end, half-moon, 5/8-inch
ITEM
LOCATION
Air compressor and fuel pump removed
(page 2-41).
ACTION
REMARKS
1. Gearcase cover (1)
Self-locking nut (2)
and flat washer (3)
Using 1/2-inch drive 11/4-inch socket,
6-inch extension, and hinged handle,
unscrew and take off.
2.
Pulley (4) and oil
slinger (5)
Using accessory drive pulley puller, take
off.
3. Accessory drive
shaft (6)
Key (7)
Using 1/4-inch flat-tip screwdriver, pry
out.
4. Left front of
cylinder block (8)
Five screws (9),
five lockwashers
(10), accessory
drive (11), and
gasket (12)
Using 5/8-inch half-moon box-end wrench,
unscrew and take off.
Discard gasket and lockwashers.
TASK ENDS HERE
TA 242365
2-43
TM 5-2815-241-34&P
OIL PAN REMOVAL
INITIAL SETUP
Personnel Required
Tools
Two
Handle, ratchet, 1/2-inch drive
Socket, 1/2-inch, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Socket, 5/8-inch, 1/2-inch drive
Socket, 3/4-inch, 1/2-inch drive
Socket, 13/16-inch, 1/2-inch drive
Wrench, box-end, 3/4-inch
Wrench, open-end, 1 7/8-inch
ACTION
REMARKS
ITEM
LOCATION
NOTE
If oil pump has been removed, proceed to step 3.
1. Oil pump bottom (1)
Nut (2)
Using 1 7/8-inch open-end wrench, loosen
and disconnect.
2. Oil pan (3)
Two screws (4), two
lockwashers (5),
suction tube with
flange (6) and
gasket (7)
Using 1/2-inch drive 9/16-inch socket and
ratchet handle, unscrew and take off.
Discard gasket and lockwashers.
3
Two screws (8), two
lockwashers (9), and
two nuts (10)
Using 1/2-inch drive 13/16-inch socket,
ratchet handle, and 3/4-inch box-end
wrench, unscrew and take out.
Discard lockwashers.
4
Four screws (11)
and four
lockwashers (12)
Using 1/2-inch drive 3/4-inch socket and
ratchet handle, unscrew and take out.
Discard lockwashers.
5
Four screws (13),
four lockwashers
(14), and spacer (15)
Using 1/2-inch drive 5/8-inch socket and
ratchet handle, unscrew and take out.
Discard lockwashers.
2-44
TM 5-2815-241-34&P
OIL PAN REMOVAL - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
6.
Twenty-eight screws
(16) and twentyeight lockwashers (17)
Using 1/2-inch drive 5/8-inch socket and
ratchet handle, unscrew and take out.
Discard lockwashers.
7.
Four screws (18)
and four
lockwashers (19)
Using 1/2-inch drive 1/2-inch socket and
ratchet handle, unscrew and take out.
Discard lockwashers.
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
8. Bottom of cylinder
block (20)
Oil pan (3) and
gasket (21)
Take off.
Discard gasket.
TASK ENDS HERE
TA 242366
2-45
TM 5-2815-241-34&P
FLYWHEEL HOUSING REMOVAL
INITIAL SETUP
Tools
Personnel Required
Two
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Pliers, diagonal-cutting, 8-inch
Socket, 7/8-inch, 1/2-inch drive
Socket, 15/16-inch, 1/2-inch drive
Equipment Condition
Oil pan removed (page 2-44).
Materials/Parts
Gasket, flywheel housing
LOCATION
ACTION
REMARKS
ITEM
1. Flywheel housing (1)
Lockwire (2), six
screws (3) and
flex plate (4)
a. Using 8-inch diagonal-cutting pliers,
cut lockwire.
b. Using 1/2-inch drive 7/8-inch socket,
6-inch extension, and ratchet handle,
unscrew and take off.
2.
Nine screws (5) and
nine lockwashers (6)
Using 1/2-inch drive 15/16-inch socket,
6-inch extension, and ratchet handle,
unscrew and take out.
Discard lockwashers.
WARNING
Due to excessive weight, assistance will be needed to prevent personnel injury when
lifting heavy parts.
3. Cylinder block (7)
Flywheel housing (1)
and flywheel housing
gasket (8)
a. With assistance, take off flywheel
housing.
b. Take out flywheel housing gasket,
Discard gasket.
TASK ENDS HERE
TA 242367
2-46
TM 5-2815-241-34&P
CAM FOLLOWER HOUSING REMOVAL
INITIAL SETUP
Equipment Condition
Tools
Accessory drive removed (page 2-43).
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps given are typical for all three cam follower housings.
1. Cam follower
housing (1)
Six screws (2) and
six lockwashers (3)
Using 1/2-inch drive 9/16-inch socket and
ratchet handle, unscrew and take out.
Discard lockwashers.
2. Left side of
cylinder block (4)
Cam follower housing
(1) and gasket (5)
Take off.
TASK ENDS HERE
TA 242368
2-47
TM 5-2815-241-34&P
GEAR CASE COVER REMOVAL
INITIAL SETUP
Personnel Required
Tools
Two
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 7/16-inch, 12-point, 1/2inch drive
Socket, 5/8-inch, 1/2-inch drive
Socket, 7/8-inch, 1/2-inch drive
LOCATION
Equipment Condition
Accessory drive removed (page 2-43).
Oil pan removed (page 2-44).
ACTION
REMARKS
ITEM
1. Gearcase cover (1)
Six screws (2) and
six lockwashers (3)
Using 1/2-inch drive 7/8-inch socket,
6-inch extension, and ratchet handle,
unscrew and take out.
Discard lockwashers.
2.
Vibration damper and
pulley (4)
Take off.
3.
Two screws (5) and
two lockwashers (6)
Using 1/2-inch drive 12-point, 7/16-inch
socket and ratchet handle, unscrew and
take out.
Discard lockwashers.
4.
Six screws (7) six
lockwashers (8), and
engine mount (9)
Using 1/2-inch drive 5/8-inch socket and
ratchet handle, unscrew and take off.
Discard lockwashers.
5.
Thirteen screws (10)
and thirteen lockwashers (11)
Using 1/2-inch drive 5/8-inch socket and
ratchet handle, unscrew and take out.
Discard lockwashers.
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
6. Front of cylinder
block (12)
2-48
Gearcase cover (1)
and gasket (13)
With assistance, take off.
Discard gasket.
TM 5-2815-241-34&P
GEARCASE COVER REMOVAL - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
When performing step 7, rotate camshaft while removing. Failure to do so may cause
damage to camshaft and camshaft bearings.
Camshaft with gear
(14) and thrust
washer (15)
Pull out.
TASK ENDS HERE
CRANKSHAFT REMOVAL
INITIAL SETUP
Tools
Chisel, cold, 1/2-inch
Goggles, safety
Hammer, ball-peen, 16-ounce
Handle, hinged, 3/4-inch drive
Handle, ratchet, 1/2-inch drlve
Tools - Continued
Screwdriver, flat-tip, 3/8-inch
Socket, 9/16-inch, 1/2-inch drive
Socket, 15/16-inch, 3/4-inch drive
Socket, 1 1/2-inch, 3/4-inch drive
TA 242369
2-49
TM 5-2815-241-34&P
CRANKSHAFT REMOVAL - CONTINUED
INITIAL SETUP - CONTINUED
Materials/Parts
Equipment Condition
Covering, suitable, connecting rod
Tag, marker (item 17, appendix B)
LOCATION
Oil pan removed (page 2-44).
Gearcase cover removed (page 2-48).
ACTION
REMARKS
ITEM
1. Rear of cylinder
block (1)
Eight screws (2),
eight lockwashers
(3), rear cover (4),
and gasket (5)
Using 1/2-inch drive 9/16-inch socket and
ratchet handle, unscrew and take off.
Discard gasket and lockwashers.
2. Connecting rod
caps (6)
Twelve nuts (7) and
twelve hardened
washers (8)
Using 3/4-inch drive 15/16-inch socket and
hinged handle, unscrew and take off.
Discard hardened washers.
NOTE
Tag connecting rod caps, lower bearings, and upper bearings to aid in correct
reassembly.
3. Crankshaft (9)
Connecting rod caps
(6), lower bearing
(10), and upper
bearing (11)
Take off.
WARNING
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
CAUTION
Use suitable covering over connecting rod bolts to protect journals.
4. Main bearing
caps (12)
Fourteen lock
plates (13)
Using 16-ounce ball-peen hammer and
1/2-inch cold chisel, bend back tabs on
lock plates.
5.
Fourteen screws (14)
and fourteen lock
plates (13)
Using 3/4-inch drive 1 1/2-inch socket and
hinged handle, unscrew and take out.
Discard lock plates.
2-50
TM 5-2815-241-34&P
CRANKSHAFT REMOVAL - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
NOTE
Tag main bearing caps, lower bearings, and upper bearings to aid in inspection and
assembly.
6. Bottom of cylinder
block (1)
Seven main bearing
caps (12), seven lower
bearings (15), and
seven ring dowels (16)
Take off.
Discard ring dowels.
7.
Crankshaft (9)
upper bearings (17),
and thrust
washers (18)
a. Lift out crankshaft.
b. Take out upper bearings and thrust
washers.
8. Rear cover (4)
Seal (19)
Using 3/8-inch flat-tip screwdriver, pry
out.
Discard seal.
14
13
TASK ENDS HERE
TA 242370
2-51
TM 5-2815-241-34&P
PISTON ASSEMBLY REMOVAL
INITIAL SETUP
Personnel Required
Tools
Two
Reamer, ridge
Equipment Condition
Materials/Parts
Crankshaft removed (page 2-49).
Cloth, emery (item 1, appendix B)
LOCATION
ACTION
REMARKS
ITEM
CAUTION
If ridge in cylinder bore is present and must be removed, care should be taken not to
remove more material than necessary.
NOTE
Steps given are typical for all six piston assemblies.
1. Cylinder block (1)
Using ridge reamer, remove ridge.
Cylinder bore (2)
CAUTION
When performing step 2, care should be taken not to damage cylinder bore. Use emery
cloth to remove rough surface left by ridge reamer.
2.
Using emery cloth, remove rough surface.
Cylinder bore (2)
NOTE
Before performing steps 3 and 4, cleaning of cylinder bores may be required. See
general cleaning procedures, General Maintenance Instructions, page 2-3.
When installing connecting rod cap to connecting rod, make sure tang on connecting
rod and connecting rod cap are alined properly.
2-52
TM 5-2815-241-34&P
PISTON ASSEMBLY REMOVAL - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
3. Cylinder bore (2)
Piston assembly (3)
With assistance, push out.
4. Piston assembly (3)
Upper bearing shell
(4), lower bearing
shell (5), connecting
rod cap (6), and
nut (7)
a. Put on.
b. Tighten nuts.
Nuts are tightened to secure parts
only. DO NOT TORQUE.
TASK ENDS HERE
TA 242371
2-53
TM 5-2815-241-34&P
CRANKSHAFT
INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Cloth, crocus (item 4, appendix B)
Crankshaft and bearing kit
Dowel, ring (seven required)
Gasket, rear cover
Gear oil (item 9, appendix B)
Lock plates (14 required)
Lockwashers (eight required)
Oil, lubricating (item 12, appendix B)
Seal, rear cover
Washer, thrust (four required)
Bar, pry
Hammer, ball-peen, 16-ounce
Handle, hinged, 3/4-inch drive
Handle, ratchet, 3/4-inch drive
Indicator, dial
Mandrel, seal
Punch, driftpin, 1/8-inch
Socket, 9/16-inch, 1/2-inch drive
Socket, 1 1/2-inch, 3/4-inch drive
Wrench, torque, 0 to 250 ft lb (0 to
350 N-m), 1/2-inch drive
Wrench, torque, 100 to 600 ft lb
(140 to 840 N-m), 3/4-inch drive
Equipment Condition
Cylinder block mounted on engine repair stand
(page 2-11).
LOCATION
1. Cylinder block (1)
ACTION
REMARKS
ITEM
Fourteen screws (2)
and seven main
bearing caps (3)
Using 3/4-inch drive 1 1/2-inch socket and
hinged handle, unscrew and take off.
CAUTION
Do not touch wear surface of main bearings and thrust rings with hands. Acid from hands
can cause premature bearing failure.
NOTE
Before performing steps 2 thru 5, coat upper main bearings, ring dowels, upper thrust
rings, and crankshaft main journals with lubricating oil.
2.
New upper main bearing number seven (4)
Put in and aline with oilhole and ring dowel
hole in cylinder block.
3.
Six new upper main
bearings (5) and
seven new ring
dowels (6)
a. Aline oilholes in upper main bearings
with oilholes in cylinder block, and put
in.
b. Put ring dowels in holes in cylinder
block.
2-54
TM 5-2815-241-34&P
CRANKSHAFT INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
When performing step 4, care should be taken not to damage crankshaft journals and
upper main bearings. Engine damage could result.
4.
New crankshaft (7)
Lower into cylinder block.
5. Rear main crankshaft
journal (8)
Two new thrust
washers (9)
Put in.
Roll thrust washer around crankshaft
until thrust washer seats evenly with
new upper main bearing.
TA 242372
2-55
TM 5-2815-241-34&P
CRANKSHAFT INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Before performing steps 6 and 7, coat lower main bearings and lower thrust rings with
lubricating oil.
6. Crankshaft main
bearing journals (1)
Seven new lower main
bearings (2)
Put in and aline notch in lower main bearing
with ring dowels in cylinder block.
7. Rear main bearing
cap (3)
Two new thrust
washers (4)
Aline ring dowel grooves with ring dowels on
rear main bearing cap and put on.
NOTE
Before performing step 8, coat main bearing capscrew threads with lubricating oil and
coat under head of screws and lockplates with gear oil.
Position main bearing caps with number identification stamp facing camshaft side of
engine.
8. Cylinder block (5)
Six main bearing
caps (6), rear main
bearing cap (3)
fourteen new lock
plates (7) and fourteen capscrews (8)
a. Position six main bearing caps and rear
main bearing cap on cylinder block.
b. Using 3/4-inch drive 1 1/2-inch socket
and ratchet handle, screw in.
Do not tighten.
NOTE
When performing step 9, torque capscrews in the order shown in Main Bearing
Capscrew Tightening Sequence (page 2-57).
9.
2-56
Fourteen capscrews (8)
Using 3/4-inch drive 1 1/2-inch socket and
100 to 600 ft lb (140 to 840 N•m) torque
wrench, torque in step sequence shown in
Main Bearing Capscrew Torquing Sequence
(page 2-57).
TM 5-2815-241-34&P
CRANKSHAFT INSTALLATION - CONTINUED
MAIN BEARING CAPSCREW
TORQUING SEQUENCE
MIN FT/Lbs(kgml MAX FT/Lbs(kgm)
Step 1
Step 2
Step 3
Step 4
Step 5
Tighten to
Advance to
Loosen to
Tighten to
Advance to
140
300
0
140
300
(19,4)
(41,5)
(19,4)
(41,5)
150 (20,7)
310 (42,9)
0
150 (20,7)
310 (42,9)
TA 242373
2-57
TM 5-2815-241-34&P
CRANKSHAFT INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Method for mounting dial indicator is at discretion of using facility. Set contact point of
dial indicator on crankshaft end face.
10. Cylinder block (1)
Crankshaft (2)
a. Using pry bar, pry crankshaft toward
front of cylinder block.
Set dial lndicator to zero.
b. Using pry bar, pry crankshaft toward
rear of cylinder block.
Dial Indicator reading should be 0.007
to 0.017 Inch (0.18 to 0.43 mm). If
reading Is less than 0.007 Inch (0.18
mm), perform step 11. If reading Is
more than 0.017 Inch (0.43 mm),
Install oversized thrust rings.
11.
Fourteen screws (3)
and crankshaft (2)
a. Using 3/4-inch drive 1 1/2-inch socket
and hinged handle, loosen screws one
turn,
b. Using pry bar, pry crankshaft toward
front and rear of cylinder block.
Perform steps 9 and 10 agaln.
12. Seven main bearing
caps (4)
Fourteen new lock
plates (5)
Using 1/8-inch driftpin punch and 16-ounce
ball-peen hammer, bend tabs of lock plates
against heads of screws (3).
NOTE
Before performing step 13, clean crankshaft seal area with crocus cloth. Crankshaft
seal area must be clean and dry.
13. Cylinder block (1)
Eight screws (6),
eight new lockwashers (7), rear
cover (8), and new
gasket (9)
a. Position rear cover and gasket on front of
cylinder block.
b. Screw in eight screws and lockwashers.
Hand tighten only.
NOTE
Method for mounting dial indicator is at discretion of using facility. Position dial indicator
on crankshaft end face and set contact point on edge of cover opening. Set dial indicator
to zero.
2-58
TM 5-2815-241-34&P
CRANKSHAFT INSTALLATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
14.
Crankshaft (2)
Check dial indicator reading, while rotating
crankshaft. Total reading should not exceed
0.005 inch (0.13 mm).
If total dial Indicator reading Is less
than 0.005 Inch (0.13 mm), perform
next step. If reading exceeds 0.005
Inch (0.13 mm), remove rear cover
and clean mating surfaces. Perform
steps 13 and 14 again.
15.
Eight screws (6)
Using 1/2-inch drive 9/16-inch socket and
0 to 250 ft lb (0 to 350 N•m torque wrench,
tighten to 24 to 29 ft lb (33.6 to 40.6 N•m).
New seal (10)
Using seal mandrel and 16ounce ball-peen
hammer, put in.
16.
Rear cover (8)
TASK ENDS HERE
TA 242374
2-59
TM 5-2815-241-34&P
PISTON ASSEMBLY INSTALLATION
INITIAL SETUP
Materials/Parts - Continued
Tools
Compressor, piston ring, ST-1176
Expander, piston ring, ST-763
Gage, thickness
Handle, ratchet, 1/2-inch drive
Socket, 15/16-inch, 1/2-inch drive
Wrench, torque, 0 to 250 ft lb (0 to
350 NY•m), 1/2-inch drive
Oil, lubricating (item 12, appendix B)
Piston ring set
Covering, suitable connecting rod
Personnel Required
Two
Materials/Parts
Equipment Condition
Gear oil (item 9, appendix B)
LOCATION
Crankshaft installed (page 2-54).
ACTION
REMARKS
ITEM
CAUTION
Care should be taken not to scratch cylinder sleeves. Piston ring failure may occur.
NOTE
New rings and bearings are included with piston assembly.
Before performing step 1, lightly coat cylinder sleeves and piston rings with lubricating
oil.
Number stamped on side of connecting rod and cap indicate cylinder number from which
the piston was removed. Check ring end gap in cylinder number stamped on connecting
rod and connecting rod cap.
Steps given are typical for all six piston assemblies and all four piston rings.
2-60
TM 5-2815-241-34&P
PISTON ASSEMBLY INSTALLATION - CONTINUED
LOCATION
1. Cylinder sleeve (1)
ITEM
New chrome-plated
compression ring
(2), two new compression rings (3),
new oil ring (4), and
piston (5)
ACTION
REMARKS
a.
Put new piston rings in cylinder sleeve
and, using head of piston, push into
cylinder 2 inches.
b. Using thickness gage, measure new
piston rings end gap. (See table
below).
c. Take out new piston rings from cylinder
sleeve.
TA 242375
2-61
TM 5-2815-241-34&P
PISTON ASSEMBLY INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
Over expanding piston rings during installation on piston can cause piston ring distortion. This will cause scoring of cylinder sleeves and premature piston ring failure.
Never file or grind chrome plated piston rings.
Never use chrome plated piston rings in chrome plated cylinder sleeves.
NOTE
Expand piston rings only enough to pass over piston.
Piston rings must be installed in same number piston and cylinder sleeve that ring end
gap was checked.
2. Piston assembly (1)
New chrome-plated
compression ring (2),
new compression ring
(3), new compression
ring (4), and new
oil ring (5)
a. Using ST-763 piston ring expander,
expand each ring and install in proper
ring groove on piston as shown.
b. Rotate piston rings to separate ring endgap openings as shown.
3. Connecting rod (6)
Two nuts (7), two
new hardened connecting rod washers
(8), and connecting
rod cap (9)
Unscrew and take off.
4.
Two connecting
rod bolts (10)
Using suitable covering, cover threads.
NOTE
Before performing next step, coat piston sides, piston rings, and upper connecting rod
bearings with lubricating oil and position piston ring end gap 90 degrees apart.
5. Piston (1)
2-62
Chrome-plated compression ring (2),
compression ring (3),
compression ring (4),
and oil ring (5)
Using ST-1176 piston ring compressor,
compress piston rings to piston.
TM 5-2815-241-34&P
PISTON ASSEMBLY INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
Piston assemblies must always be installed in same number cylinder as number stamped
on side of connecting rod. Numbered side of connecting rod must always face camshaft
side of engine to ensure proper operation.
NOTE
When performing step 6, assistance will be needed to guide connecting rod through
cylinder sleeve and onto crankshaft connecting rod journal.
6. Cylinder block (11)
Piston (1)
Push into cylinder sleeve until connecting
rod seats on crankshaft connecting rod
journal.
TA 242376
2-63
TM 5-2815-241-34&P
PISTON ASSEMBLY INSTALLATION - CONTINUED
LOCATION
7. Connecting rod
bolts (1)
ACTION
REMARKS
ITEM
Thread cover (2)
Take off.
Discard.
NOTE
Before performing step 8, coat lower connecting rod bearings and connecting rod bolts
with lubricating oil and coat hardened washers with gear oil.
When performing step 8, match and aline numbers stamped on connecting rods and
connecting rod caps.
8. Crankshaft (3)
Connecting rod cap
(4), two new
hardened connecting
rod washers (5), and
two nuts (6)
a. Put connecting rod cap on crankshaft.
b. Install hardened connecting rod washers
and nuts using 1/2-inch drive 15/16inch socket and ratchet handle, and
screw in until snug.
Do not tighten.
9.
Two nuts (6)
Using 1/2-inch drive 15/16-inch socket and
0 to 250 ft lb (0 to 350 N-m) torque wrench,
torque in step sequence shown in Connecting Rod Nut Torquing Sequence.
CONNECTING ROD NUT TORQUING SEQUENCE
TIGHTENING SEQUENCE
Step 1 Tighten to
Step 2 Tighten to
Step 3 Loosen to
Step 4 Tighten to
Step 5 Advance to
Step 6 Advance to
2-64
TIGHTENING VALUES
FT LB (NY•M)
70 - 75 (98 - 105)
140 - 150(196 - 210)
0 (zero)
25 - 30 (35 - 42)
70 - 75 (98 - 105)
140 - 150(196 - 210)
TM 5-2815-241-34&P
PISTON ASSEMBLY INSTALLATION - CONTINUED
LOCATION
10. Crankshaft (3)
ITEM
Connecting rod
with connecting
rod cap (4)
ACTION
REMARKS
Using thickness gage, measure side
clearance.
Side clearance should be 0.006 to
0.011 inch (0.15 to 0.28 mm).
TASK ENDS HERE
TA 242377
2-65
TM 5-2815-241-34&P
CAMSHAFT INSTALLATION
INITIAL SETUP
Tools
Equipment Condition
Indicator, dial
Piston assemblies Installed (page 2-60).
Materials/Parts
Grease, extreme-pressure (item 10,
appendix B)
Washer, thrust bearing
LOCATION
ACTION
REMARKS
ITEM
NOTE
Before performing the following steps, coat both sides of thrust bearing washer and
camshaft lobes and journals with extreme-pressure grease.
1. Camshaft and
gear (1)
New thrust
washer (2)
Put on.
Grooves must face camshaft gear.
CAUTION
When performing step 2, care must be taken to prevent damaging camshaft bushings
and camshafts.
NOTE
When performing step 2, aline timing marks, two O’s (zeros) on camshaft gear and
crankshaft gear as shown in view.
2. Cylinder block (3)
Camshaft and gear
(1) and crankshaft
gear (4)
Put in.
Rotate while Installing to aline
timing marks.
NOTE
Method used for mounting dial indicator is at discretion of using facility. Set contact
point of dial indicator on camshaft gear tooth.
2-66
TM 5-2815-241-34&P
CAMSHAFT INSTALLATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
3. Cylinder block (3)
Camshaft and
gear (1)
a.
Rotate gear in one direction as far as it
will move.
b. Set dial indicator to zero.
4.
Camshaft and
gear (1)
Rotate gear and read dial indicator for gear
backlash.
Normal backlash Is 0.0045 to 0.0105
inch (0.114 to 0.267 mm) on a new
gear, with a minimum of 0.002 inch
(0.05 mm).
TASK ENDS HERE
TA 242378
2-67
TM 2815-241-34&P
CYLINDER HEAD INSTALLATION
INITIAL SETUP
Tools
Materials/Parts - Continued
Bit, screwdriver, flat-tip, 1/4inch drive
Handle, ratchet, 3/4-inch drive
Socket, 1 1/16-inch, 3/4-inch drive
Wrench, torque, 0 to 200 in. lb
(0 to 23 N•m), 1/4-inch drive
Wrench, torque, 0 to 600 ft lb
(0 to 840 N•m), 3/4-inch drive
Lockwashers (four required)
Oil, lubricating (item 12, appendix B)
Packings, fuel crossover (four required)
Washers, hardened (12 required)
Equipment Condition
Piston assemblies installed (page 2-60).
Materials/Parts
Gasket, cylinder head
Grommet, water (as required)
LOCATION
ACTION
REMARKS
ITEM
CAUTION
When performing step 1, care should be taken to position cylinder head gasket over
dowel pins with word TOP visible or gasket damage may result.
NOTE
Steps given are typical for all three cylinder heads.
Before performing step 1, if waterholes in cylinder block are free of erosion, use gasket
with standard white grommets, 0.097 to 0.103 inch (3.8 to 4.1 mm) thick. If erosion is
evident, use black grommets, 0.107 to 0.113 inch (4.2 to 4.4 mm) thick. No grommet
retainers are required.
1. Cylinder block (1)
New cylinder head
gasket (2) and new
water grommets (3)
Put on.
CAUTION
Use care when installing cylinder head not to damage machined surface.
2.
Cylinder head (4)
Put on.
CAUTION
Correct cylinder head screws have letters NT forged on top of screwheads. Do not use
any other type screw. Screws will break, preventing engine assembly.
2-68
TM 5-2815-241-34&P
CYLINDER HEAD INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Before performing step 3, coat cylinder head screws with lubricating oil.
3. Cylinder head (4)
Twelve capscrews
(5) and twelve new
hardened washers (6)
Using 3/4-inch drive 1 1/16-inch socket
and ratchet handle, screw in until snug.
Do not tighten.
NOTE
When performing step 4, tighten capscrews in order shown in Cylinder Head Capscrew
Tightening Sequence.
4.
Using 3/4-inch drive 1 1/16-inch socket
and 0 to 600 ft lb (0 to 840 N•m) torque
wrench, torque in steps sequence shown in
Cylinder Head Torquing Sequence.
Twelve cap
screws (5)
CYLINDER HEAD CAPSCREW
TIGHTENING SEQUENCE
NOTE
Before performing step 5, coat packings with lubricating oil.
TA 242379
2-69
TM 5-2815-241-34&P
CYLINDER HEAD INSTALLATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
5. Cylinder head (1)
Four new
packings (2)
Put in.
6.
Fuel crossover (3),
four screws (4),
and four new
lockwashers (5)
Using 1/4-inch drive flat-tip screwdriver bit
and 0 to 200 in. lb (0 to 23 N•m) torque
wrench, tighten to 34 to 38 in. lb (3.9 to
4.4 N•m).
TASK ENDS HERE
CAM FOLLOWER HOUSING INSTALLATION
INITIAL SETUP
Tools
Socket, 9/16-inch, 1/2-inch drive
Wrench, torque, 0 to 250 ft lb
(0 to 350 N.m), 1/2-inch drive
Equipment Condition
Camshaft installed (page 2-66).
Materials/Parts
Gasket, cam follower housing
Lockwasher (six required)
TA 242380
2-70
TM 5-2815-241-34&P
CAM FOLLOWER HOUSING INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps given are typical for all three cam follower housings.
Position gasket with sealing material side away from cylinder block.
1. Cylinder block (1)
New gasket (2) and
cam follower
housing (3)
Aline with dowel pins and put on.
2.
Six screws (4) and
six new lockwashers (5)
a. Screw in until snug.
b. Using 1/2-inch drive 9/16-inch socket
and 0 to 250 ft lb (0 to 350 Nom) torque
wrench, tighten to 30 to 35 ft lb (42 to 49
Nom) as shown in Cam Follower Housing
Screw Tightening Sequence.
TASK ENDS HERE
TA 242381
2-71
TM 5-2815-241-34&P
COMPRESSION RELEASE SHAFT INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Lockwasher
Oil, lubricating (item 12, appendix B)
Packing, preformed
Wrench, box-end, 9/16-inch
LOCATION
ACTION
REMARKS
ITEM
NOTE
Before performing step 1, coat packing with lubricating oil.
1. Compression release
shaft (1)
New preformed
packing (2)
Slide on and position in groove (3).
2.
Front of cylinder
block (4)
Compression release
shaft (1)
Put in.
3.
Left rear of cylinder block (5)
Screw (6) and new
lockwasher (7)
Using 9/16-inch box-end wrench, screw in
and tighten.
TASK ENDS HERE
TA 242382
2-72
TM 5-2815-241-34&P
PUSH ROD INSTALLATION
INITIAL SETUP
Equipment Condition
Cylinder heads installed (page 2-68).
LOCATION
ACTION
REMARKS
ITEM
NOTE
Before installing push rods, check tags for location as shown in chart below.
Cylinder heads (1)
Push rod (2)
Put in.
Position with ball-end down.
PUSH ROD LOCATION AND DESCRIPTION
TAG No.
CYL No.
LOCATION
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
1
1
2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
EXHAUST
INJECTOR
INTAKE
INTAKE
INJECTOR
EXHAUST
EXHAUST
INJECTOR
INTAKE
INTAKE
INJECTOR
EXHAUST
EXHAUST
INJECTOR
INTAKE
INTAKE
INJECTOR
EXHAUST
W/COLLAR
THICK
THIN
THIN
THICK
W/COLLAR
W/COLLAR
THICK
THIN
THIN
THICK
W/COLLAR
W/COLLAR
THICK
THIN
THIN
THICK
W/COLLAR
TASK ENDS HERE
TA 242383
2-73
TM 5-2815-241-34&P
INJECTOR TIMING ADJUSTMENT
INITIAL SETUP
Equipment Condition
Tools
Push rods installed (page 2-73).
Barring tool, crankshaft
Injector timing tool, ST-593
Materials/Parts
Cam follower housings gaskets
(as required)
LOCATION
ACTION
REMARKS
ITEM
NOTE
Timing procedure is performed on cylinders one, three, and five.
Camshaft must be pushed back against rear of cylinder block for zero end play.
1. Injector sleeve (1)
ST-593 injector timing tool (2)
Position into injector sleeve.
2. ST-593 injector
timing tool (2)
Push rod (3) and
timing tool rod (4)
Aline and put timing tool rod into push rod
socket.
3.
Knurled
holddowns (5)
Tighten evenly until timing tool is secured to
cylinder head.
NOTE
Make sure ST-593 injector timing tool is flat on cylinder head, otherwise incorrect timing
will occur.
4.
Dial indicator
supports (6 and 7)
Loosen.
5. Cylinder block (8)
Crankshaft (9)
Using crankshaft barring tool, rotate crankshaft clockwise to TDC (top dead center).
Piston travel plunger (10) will be near
full upward position.
6. ST-593 injector
timing tool (2)
Dial indicators
(11 and 12)
a.
2-74
Push down to fully compressed
position.
b. Note readings on both dial Indicators.
c. Raise both dial indicators 0.020 inch
from noted readings.
d. Using thumbscrew (15), lock in place.
TM 5-2815-241-34&P
INJECTOR TIMING ADJUSTMENT - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
To ensure that piston is on compression stroke, both dial indicators must move in same
direction.
7. Cylinder block (8)
Crankshaft (9)
Using crankshaft barring tool, rotate
crankshaft back and forth to make sure
piston is precisely at TDC (top dead center)
on compression stroke.
TDC is Indicated by maximum clockwise position of dial indicator pointer.
8. Dial indicator (11)
Dial face (13), dial
indicator pointer
(14), and
thumbscrew (15)
a. Set dial face to aline zero with dial
indicator pointer.
b. Turn thumbscrew to lock dial face.
TA 242384
2-75
TM 5-2815-241-34&P
INJECTOR TIMING ADJUSTMENT - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
Crankshaft (2)
Using crankshaft barring tool, rotate crankshaft clockwise 90 degrees ATDC (after top
dead center).
Piston travel plunger (3) will be near
its lowest position.
10. Dial indicator (4)
Dial face (5), dial
indicator pointer (6),
and thumbscrew (7)
a. Set dial face to aline zero with dial
indicator pointer.
b. Turn thumbscrew to lock dial face.
11. Cylinder block (1)
Crankshaft (2)
Using crankshaft barring tool, rotate crankshaft counterclockwise through TDC to 45
degrees BTDC (before top dead center).
12. ST-593 injector
timing tool (8)
Piston travel
plunger (3) and dial
indicator stem (9)
Using crankshaft barring tool, rotate crankshaft clockwise until piston travel plunger on
fixture is in contact with dial indicator stem.
13.
Dial indicator (10)
Using crankshaft barring tool, slowly rotate
crankshaft in clockwise direction until dial
indicator reads 0.0032 inch (0.0812 mm)
before zero.
This position is actually 0.2032 Inch
before zero on dial Indicator since the
pointer has rotated twice.
14.
Dial indicator (4)
Note reading.
Reading should be within limits given
In table.
9. Cylinder block (1)
NOTE
If Injector timing is not within specification given, perform step 15 before making
changes in cam follower housing gaskets to correct injector timing.
15. ST-593 injector
timing tool (8)
2-76
Dial indicators
(4 and 10)
a. Check dial indicator positioning. Be sure
dial indicators are not bottoming or
binding.
Carefully recheck TDC.
TM 5-2815-241-34&P
INJECTOR TIMING ADJUSTMENT - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
b. If required, advance or retard by adding
or removing cam follower housing
gaskets.
Remove gaskets to retard injector
timing and add gaskets to advance
timing. Push rods and cam follower
housings must be removed. See Push
Rod Removal (page 2-33) and Cam
Follower Housing Removal
(page 2-47).
NOTE
Support ST-593 injector timing tool while performing next step.
16. ST-593 injector
timing tool (8)
Knurled
holddowns (11)
Loosen enough to remove injector timing
tool from engine.
11
INJECTION TIMING CODES
AND PUSH ROD TRAVEL
TIMING (1)
CODE
PUSH ROD TRAVEL (2)
(INCHES)
FAST
SLOW
AS
- 0.035
-0.037
(1) Check the engine dataplate to find the Timing Code.
(2) Measure the push rod travel when the piston is at
0.2032 inch Before Top Dead Center.
TASK ENDS HERE
TA 242385
2-77
TM 5-2815-241-34&P
FUEL INJECTOR INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Puller, fuel injector
Socket, 1/2-inch, 1/2-inch drive
Wrench, torque, 0 to 250 ft lb
(0 to 350 N•m), 1/2-inch drive
Oil, lubricating (item 12, appendix B)
Packing, preformed (fuel injector)
Gasket (two required)
Equipment Condition
Injector timing adjusted (page 2-74).
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps given are typical for all six fuel injectors.
Coat packings and injector with lubricating oil.
1. Fuel injector (1)
Two new gaskets (2)
and preformed
packing (3)
Roll on.
NOTE
Install fuel injectors in same cylinder from which they were removed.
Position fuel injectors with filter screen facing exhaust manifold side of engine.
2. Cylinder head (4)
Fuel injector (1)
Aline and put in.
NOTE
Method for mounting valve spring compressor is at discretion of using facility.
2-78
TM 5-2815-241-34&P
FUEL INJECTOR INSTALLATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
3.
Fuel injector (1)
Using fuel injector puller, seat fuel injector.
4.
Fuel injector clamp
(5) and two
screws (6)
a. Using 1/2-inch drive 1/2-inch socket,
6-inch extension, and ratchet handle,
screw in until screw just seats on fuel
injector clamp.
Do not tighten.
b. Using 1/2-inch drive 1/2-inch socket,
6-inch extension, and 0 to 250 ft lb (0 to
350 N•m) torque wrench, torque two
screws to 11 to 12 ft Ib (15.4 to
16.8 N•m).
5.
Fuel injector
link (7)
Put in.
TASK ENDS HERE
TA 242386
2-79
TM 5-2815-241-34&P
CROSSHEAD INSTALLATION
INITIAL SETUP
Equipment Condition
Tools
Cylinder heads installed (page 2-68).
Adapter set, torque, ST-669, 3/8inch drive
Gage, thickness
Handle, ratchet, 3/8-inch drive
Socket, 9/16-inch, 3/8-inch drive
Wrench, torque, 0 to 150 ft lb
(0 to 210 N•m), 3/8-inch drive
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps given are typical for all 12 crossheads.
Crossheads are tagged by location from front cylinder to rear cylinder. Check tags for
location. See illustration.
Wide crossheads are for exhaust valves and narrow crossheads are for intake valves.
1. Cylinder head (1)
Crosshead (2)
Put on.
Adjusting screw must face exhaust
side of engine.
2. Crosshead (2)
Locknut (3) and adjusting screw (4)
Using 3/8-inch drive ST-669 torque adapter
set, 9/16-inch socket and ratchet handle,
loosen.
NOTE
When performing step 3, apply light finger pressure to rocker arm contact surface on
crosshead.
When using new crossheads and guides, advance adjusting screw one-third turn to
straighten stem on its guide and to compensate for slack in threads.
When using old crossheads and guides, it may be necessary to advance the screw onehalf turn in order to straighten the stem in its guide.
3. Crosshead (2)
2-80
Adjusting screw (4)
Using 3/8-inch drive ST-669 torque adapter
set, screw in until adjusting screw seats on
valve stem.
Do not tighten.
TM 5-2815-241-34&P
CROSSHEAD INSTALLATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
4. Crosshead (2)
Valve spring
retainer (5)
Using thickness gage, check for minimum
clearance of 0.020 inch (0.51 mm).
5.
Locknut (3) and
adjusting screw (4)
Using 3/8-inch drive ST-669 torque adapter
set, 9/16-inch socket and 0 to 150 ft lb (0
to 210 N•m) torque wrench, tighten to 22
to 26 ft lb (30.8 to 36.4 N•m).
CROSSHEAD LOCATION
TAG NO.
CYL. NO.
VALVE
1
1
EXHAUST
2
1
INTAKE
3
2
INTAKE
4
5
2
3
EXHAUST
EXHAUST
6
3
7
8
4
4
INTAKE
INTAKE
EXHAUST
9
5
EXHAUST
10
11
5
6
INTAKE
INTAKE
1 2
6
EXHAUST
TASK ENDS HERE
TA 242387
2-81
TM 5-2815-241-34&P
ROCKER ARM HOUSING INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Gasket
Washers, steel, engine compression brake
(six required)
Adapter set, torque, ST-669, 3/8
inch drive
Handle, ratchet, 3/8-inch drive
Socket, 7/16-inch, 3/8-inch drive
Socket, M-inch, 3/8-inch drive
Wrench, torque, 0 to 150 ft lb
(0 to 210 N•m), 3/8-inch drive
Equipment Condition
Injector timing adjusted (page 2-74).
ACTION
REMARKS
ITEM
LOCATION
NOTE
Steps given are typical for all three rocker arm housings.
1. Cylinder head (1)
New gasket (2)
Put on.
2. intake and exhaust
valve rocker
arms (3)
Locknut (4) and
adjusting screw (5)
Using 3/8-inch drive ST-669 torque adapter
set and ratchet handle, loosen locknut and
unscrew adjusting screw three turns.
3. Fuel injector
rocker arm (6)
Locknut (7) and
adjusting screw (8)
Using 3/8-inch drive ST-669 torque adapter
set, 7/16-inch socket, and ratchet handle,
loosen locknut and unscrew adjusting screw
three turns.
4. Cylinder head (1)
Rocker arm
housing (9)
Put on.
Aline ball socket on rocker arm with
socket in push tube.
5. Rocker arm
housing (9)
Six new engine compression brake steel
washers (10)
Put on.
NOTE
Rocker arm studs are different lengths, See illustration for locations and lengths.
2-82
TM 5-2815-241-34&P
ROCKER ARM HOUSING INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
Using 3/8-inch drive 5/8-inch socket and
ratchet handle, screw in until snug.
Do not tighten.
Six rocker arm
studs (11)
6.
NOTE
When performing step 7, tighten rocker arm studs in sequence shown in Rocker Arm
Stud Tightening Sequence below.
7.
Six rocker arm
studs (11)
a.
Using 3/8-inch drive 5/8-inch socket
and 0 to 150 ft lb (0 to 210 N•m) torque
wrench, tighten to 40 to 45 ft lb (56 to
63 N•m).
b. Tighten to 60 to 65 ft lb (84 to 91 N•m).
TASK ENDS HERE
TA 242388
2-83
TM 5-2815-241-34&P
ACCESSORY DRIVE INSTALLATION
INITIAL SETUP
Tools
Materials/Parts
Barring tool, crankshaft
Indicator, dial
Wrench, box-end, half-moon, 5/8-inch
Gasket, accessory drive
Lockwashers (five required)
Equipment Condition
Camshaft installed (page 2-66).
LOCATION
ACTION
REMARKS
ITEM
1. Cylinder block (1)
Crankshaft (2)
a. Using crankshaft barring tool, rotate
crankshaft until piston number one is at
TDC (top dead center) on compression
stroke.
Rocker arms for cylinder number one
will be loose.
b. Using crankshaft barring tool, rotate
engine 90 degrees ATDC (after top dead
center).
2. Accessory drive (3)
Key (4) and new
gasket (5)
a. Put key in keyway.
b. Put on gasket and aline.
NOTE
When performing step 3, aline timing marks on camshaft gear and accessory drive gear
(see illustration).
3. Cylinder block (1)
Accessory drive (3)
Put in.
4. Accessory drive (3)
Five screws (6)
and five new
lockwashers (7)
Using 5/8-inch half-moon box-end
wrench, screw in and tighten.
NOTE
Method used for mounting dial indicator is at discretion of using facility. Set contact
point of dial indicator on accessory drive gear tooth.
2-84
TM 5-2815-241-34&P
ACCESSORY DRIVE INSTALLATION - CONTINUED
-
LOCATION
-
5. Cylinder block (1)
ITEM
Gear (8) and camshaft gear (9)
ACTION
REMARKS
a. Rotate gear in one direction as far as it
will move.
b. Set dial indicator to zero.
c. Rotate gear in opposite direction and
check dial indicator for backlash reading
of 0.0045 to 0.0105 inch (0.114 to
0.267 mm).
TASK ENDS HERE
TA 242389
2-85
TM 5-2815-241-34&P
AIR COMPRESSOR AND FUEL PUMP INSTALLATION
INITIAL SETUP
Materials/Parts - Continued
Tools
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Wrench, box-end, half-moon, 5/8-inch
Wrench, open-end, 11/16-inch
Wrench, open-end, l-inch
Lockwasher, air compressor bracket
Lockwasher, fuel pump to air compressor (four
required)
Personnel Required
Two
Materials/Parts
Equipment Condition
Gasket, air compressor to accessory
drive
Gasket, air compressor to fuel pump
Lockwasher, air compressor to
accessory drive (four required)
LOCATION
ITEM
Accessory drive installed (page 2-84).
ACTION
REMARKS
1. Air compressor (1)
Crankshaft (2)
Rotate to position part numbers stamped on
gear towards engine (see illustration).
2. Fuel pump (3)
New gasket (4) and
coupler (5)
Put on gasket and aline couplers.
3. Air compressor (1)
Fuel pump (3)
Aline and put together.
4. Fuel pump (3)
Two nuts (6) two
new lockwashers (7)
and two flat
washers (8)
Using 11/16-inch open-end wrench, screw
in until snug.
Do not tighten.
5.
Two screws (9), two
new lockwashers
(10), and two
flat washers (11)
Using 5/8-inch half-moon box-end wrench,
screw in and tighten.
6.
Two nuts (6)
Using 11/16-inch open-end wrench,
tighten.
7. Air compressor (1)
New gasket (12) and
coupling (13)
Put on.
2-86
TM 5-2815-241-34&P
AIR COMPRESSOR AND FUEL PUMP INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
8. Accessory drive (14)
Air compressor (1)
and fuel pump (3)
Put on and aline couplings.
9.
Four screws (15)
and four new
lockwashers (18)
Using 5/8-inch half-moon box-end wrench,
screw in and tighten.
10. Air compressor
bracket (17)
Screw (18), new
lockwasher (19), and
flat washer (20)
Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
screw in and tighten.
11. Cylinder block (21)
Air compressor coolant hose (22)
Using 1-inch open-end wrench, screw in
and tighten.
TASK ENDS HERE
TA 242390
2-87
TM 5-2815-241-34&P
LUBRICATING OIL PUMP INSTALLATION
INITIAL SETUP
Tools
Materials/Parts
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Indicator, dial
Socket, 5/8-inch, 1/2-inch drive
Wrench, torque, 0 to 250 ft lb
(0 to 350 N•m), 1/2-inch drive
LOCATION
1. Oil pump (1)
Gasket
Lockwasher (five required)
Equipment Condition
Air compressor and fuel pump installed
(page 2-86).
ACTION
REMARKS
ITEM
New gasket (2)
Put on.
NOTE
When performing step 2, aline gear teeth on oil pump to mesh with gear teeth on
camshaft.
2. Cylinder block (3)
Oil pump (1)
Put in.
3. Oil pump (1)
Five screws (4)
and five new
lockwashers (5)
Using 1/2-inch drive 5/8-inch socket,
6-inch extension, and ratchet handle,
screw in until snug.
4.
Five screws (4)
Using 1/2-inch drive 5/8-inch socket,
6-inch extension, and 0 to 250 ft lb (0 to 350
N•m) torque wrench, tighten to 40 to 46 ft lb
(56 to 63 N•m).
NOTE
Method used for mounting dial indicator is at discretion of using facility. Set contact
point of dial indicator on oil pump gear teeth.
2-88
TM 5-2815-241-34&P
LUBRICATING OIL PUMP INSTALLATION - CONTINUED
LOCATION
5. Cylinder block (3)
ITEM
Oil pump gear (6)
ACTION
REMARKS
a. Rotate gear in one direction as far as it
will move.
b. Set dial indicator to zero.
c. Rotate gear in opposite direction and
check dial indicator reading for backlash
of 0.002 to 0.016 inch (0.051 to
0.40 mm).
TASK ENDS HERE
TA 242391
2-89
TM 5-2815-241-34&P
GEARCASE COVER INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Cutting fluid, lapping (item 5, appendix B)
Gasket, gearcase cover
Lockwasher, camshaft support (three required)
Lockwasher, engine mount (eight required)
Lockwasher, gearcase cover to engine
(13 required)
Lockwasher, vibration damper (six required)
Oil, lubricating (item 12, appendix 6)
Packing, camshaft support
Prussian blue (item 13, appendix B)
Seal, accessory drive
Seal, crankshaft
Shims, camshaft support (as required)
Assembly tool, pulley, ST-386
Barring tool, crankshaft
Extension, 6-inch, 1/2-inch drive
Gage, depth
Gage, thickness
Hammer, ball-peen, 16-ounce
Handle, ratchet, 1/2-inch drive
Indicator, dial
Mandrel, seal, ST-1173
Mandrel, seal, ST-1259
Pilot, seal, ST-1260
Socket, 7/16-inch, 12-point, 1/2inch drive
Socket, 9/16-inch, 1/2-inch drive
Socket, 5/8-inch, 1/2-inch drive
Socket, 7/8-inch, 1/2-inch drive
Socket, 1 1/16-inch, 1/2-inch drive
Straightedge, 24-inch
Wrench, torque, 0 to 250 ft lb
(0 to 350 N•m), 1/2-inch drive
Personnel Required
Two
Equipment Condition
Lubricating oil pump installed (page 2-88).
LOCATION
1. Cylinder block (1)
ACTION
REMARKS
ITEM
New gasket (2)
Aline with dowel pins (3) and put on.
CAUTION
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
2.
Gearcase cover (4)
Aline with dowel pins and put on.
3. Gearcase cover (4)
Thirteen screws (5)
and thirteen new
lockwashers (6)
Using 1/2-inch drive 5/8-inch socket,
6-inch extension, and ratchet handle,
screw in until snug.
Do not tighten.
2-90
TM 5-2815-241-34&P
GEARCASE COVER INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Method used for mounting dial indicator is at discretion of using facility. Position dial
indicator on crankshaft end face and set contact point of dial indicator on crankshaft
oil seal bore.
4. Cylinder block (1)
Crankshaft (7)
a. Set dial indicator to zero.
b. Using crankshaft barring tool, rotate
crankshaft and check dial indicator
reading for runout not to exceed 0.010
inch (0.25 mm).
5.
Gearcase cover (4)
Aline.
6. Gearcase cover (4)
Thirteen screws (5)
Using 1/2-inch drive 5/8-inch socket and
0 to 250 ft lb (0 to 350 N•m) torque wrench,
tighten to 45 to 50 ft lb (63 to 70 N•m).
TA 242392
2-91
TM 5-2815-241-34&P
GEARCASE COVER INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
7. Bottom of cylinder
block (1)
Gearcase cover (2)
Using 24-inch straightedge and thickness
gage, make sure bottom of gearcase cover
and oil pan mounting surface are flush within
0.004 inch (0.10 mm).
NOTE
Before performing step 8, coat seals with lubricating oil.
8. Gearcase cover (2)
New crankshaft
seal (3)
a. Using 16-ounce ball-peen hammer, ST1259 seal mandrel, and ST-1260 seal
pilot, put in.
b. Using depth gage, check clearance of
crankshaft seal with boss on gearcase
cover.
Minimum clearance Is 0.030 Inch
(0.78 mm). Seal should not touch
bottom of bore.
9.
New accessory drive
seal (4) and oil
slinger (5)
Using 16-ounce ball-peen hammer, ST1173 seal mandrel, and ST-386 pulley
assembly tool, put in.
ST-1173 seal mandrel will put In seal
to required depth.
10.
Camshaft support (6)
a. Put in and hold against stop.
b. Using thickness gage, measure distance
between camshaft support and gearcase
cover.
Clearance should be 0.008 to 0.013
Inch (0.20 to 0.33 mm). Shim as
needed.
c. Take out.
NOTE
Before performing step 11, coat packing with lubricating oil.
11.
2-92
Camshaft support
(6), new shims (7)
and new packing (8)
Put in.
TM 5-2815-241-34&P
GEARCASE COVER INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
12. Camshaft support (6)
Three screws (9) and
three new lockwashers (10)
Using 1/2-inch drive 9/16-inch socket and
ratchet handle, screw in and tighten.
13. Accessory drive
shaft (11)
Key (12) and
pulley (13)
Put on.
14.
Self-locking nut
(14) and flat
washer (15)
Using 1/2-inch drive 1 1/16-inch socket,
6-inch extension, and ratchet handle,
screw in until snug,
15.
Self-locking
nut (14)
Using 1/2-inch drive 1 1/16-inch socket,
6-inch extension, and 0 to 250 ft lb (0 to 350
N•m) torque wrench, tighten to 95 to 100 ft
lb (133 to 140 N•m).
NOTE
Each time the crankshaft vibration damper is removed or replaced, it should be lapped
to the crankshaft to provide maximum contact area between mating parts.
Ensure that all mating surfaces are free of burrs, nicks, and gouges. Do not attempt
lapping until all imperfections have been removed.
TA 242393
2-93
TM 5-2815-241-34&P
GEARCASE COVER INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
Crankshaft face (2)
Apply a light coat of lapping cutting fluid.
17. Crankshaft face (2)
Vibration damper (3)
Put on and lap by turning vibration damper
one-fourth to one-half turn back and forth,
until both crankshaft and vibration damper
are mated.
18.
Vibration damper (3)
a. Take off.
b. Clean all cutting fluid from crankshaft
and vibration damper.
19. Gearcase cover (1)
Crankshaft face (2)
Apply a light even coat of prussian blue.
20. Crankshaft face (2)
Vibration damper (3)
Put on and turn one-quarter turn and take
off.
Contact area should be 100 percent
for distance of 1/2 Inch (12.70 mm)
at large diameter of crankshaft face.
Remainder of taper must have 70 to 80
percent of contact.
21.
Six screws (4), six
new lockwashers (5),
and engine mount (6)
Using 1/2-inch drive 5/8-inch socket,
6-inch extension, and ratchet handle,
screw in and tighten.
22. Engine mount (6)
Two screws (7) and
two new lockwashers (8)
Using 1/2-inch drive 12-point 7/16-inch
socket and ratchet handle, screw in and
tighten.
16.
Gearcase cover (1)
CAUTION
Do not lubricate when using gearcase cover casting numbers 115562, 115563, 175183,
and 175185.
23. Gearcase cover (1)
Crankshaft face (2)
Lubricate with lubricating oil.
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
24. Crankshaft face (2)
Vibration damper (3)
Put on.
Have assistant hold In place.
25. Vibration damper (3)
Six screws (9) and
six new lockwashers (10)
Using 1/2-inch drive 7/8-inch socket and
ratchet handle, screw in until snug.
2-94
Change 1
TM 5-2815-241-34&P
GEARCASE COVER INSTALLATION - CONTINUED
LOCATION
26. Vibration damper (3)
ACTION
REMARKS
ITEM
Using 1/2-inch drive 7/8-inch socket and
0 to 250 ft lb (0 to 350 N•m) torque wrench,
tighten to 115 to 125 ft lb (161 to 175 N•m).
Six screws (9)
NOTE
Method used for mounting dial indicator is at discretion of using facility. Position dial
indicator on gearcase cover and set contact point of dial indicator on vibration damper
face.
27. Gearcase cover (1)
Vibration damper (3)
a. Set dial indicator to zero.
b. Using crankshaft barring tool, rotate
engine and check dial indicator reading
for runout not to exceed 0.004 inch
(0.10 mm).
TASK ENDS HERE
TA 242394
2-95
TM 5-2815-241-34&P
OIL PAN INSTALLATION
INITIAL SETUP
Tools
Materials/Parts - Continued
Lockwasher, oil pan front (four required)
Lockwasher, oil pan rear (four required)
Lockwasher, oil pan sides (28 required)
Lockwasher, suction tube flange (two required)
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, l/Pinch, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Socket, 5/8-inch, 1/2-inch drive
Wrench, open-end, 1 7/8-inch
Wrench, torque, 0 to 150 ft lb
(0 to 210 N•), 1/2-inch drive
Personnel Required
Two
Materials/Parts
Equipment Condition
Gasket, oil pan
Gasket, suction tube flange
LOCATION
1. Cylinder block (1)
Lubricating oil pump installed (page 2-88).
ACTION
REMARKS
ITEM
New gasket (2)
Put on.
Aline holes In gasket with screw holes
in cylinder block.
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
2.
Oil pan (3)
Put on.
Aline screw holes In oil pan with screw
holes In gasket and cylinder block.
3. Oil pan (3)
Four screws (4)
and four new
lockwashers (5)
Using l/P-inch drive 1/2-inch socket,
6-inch extension, and ratchet handle,
screw in.
Do not tighten.
4.
Four screws (6),
four new lockwashers
(7), and spacer (8)
a. Position spacer on front of oil pan.
b. Using 1/2-inch drive 5/8-inch socket,
(i-inch extension, and ratchet handle,
screw in.
Do not tighten.
5. Oil pump (9)
Suction tube with
flange (10) and
nut (11)
a. Position suction tube with flange on oil
pump.
b. Screw on by hand.
Do not tighten.
2-96
TM 5-2815-241-34&P
OIL PAN INSTALLATION - CONTINUED
ITEM
LOCATION
ACTION
REMARKS
8. Oil pan (3)
Suction tube with
flange (10), two
screws (12), two
new lockwashers (13),
and new gasket (14),
a. Position suction tube with flange and
gasket on oil pan.
b. Using 1/2-inch drive 9/16-inch socket
and ratchet handle, screw in and
tighten.
7. Oil pump (9)
Nut (11)
Using 1 7/8-inch open-end wrench,
tighten.
8. Oil pan (3)
Four screws (4)
Using 1/2-inch drive 1/2-inch socket, 6inch extension, and 0 to 150 ft lb (0 to 210
N•m) torque wrench, screw in and torque
evenly 15 to 20 ft lb (20 to 27 N•m).
9.
Four screws (6),
twenty-eight screws
(15) and twentyeight new
lockwashers (16)
Using 1/2-inch drive 5/8-inch socket,
6-inch extension, and 0 to 150 ft lb (0 to
210 N•m) torque wrench, screw in and
torque evenly 35 to 40 ft lb (47 to 54 N•m).
TASK ENDS HERE
TA 242395
2-97
TM 5-2815-241-34&P
FLYWHEEL HOUSING INSTALLATION
INITIAL SETUP
Tools
Materials/Parts
Barring tool, crankshaft
Extension, 6-inch, 1/2-inch drive
Hammer, plastic-faced
Handle, ratchet, 1/2-inch drive
Indicator, dial
Pliers, slip-joint, &inch
Scribe, machinist
Socket, 3/4-inch, 1/2-inch drive
Socket, 13/16-inch, 1/2-inch drive
Socket, 7/8-inch, 1/2-inch drive
Socket, 15/16-inch, 1/2-inch drive
Wrench, box-end, 3/4-inch
Wrench, torque, 0 to 250 ft lb
(0 to 350 N•m), 1/2-inch drive
LOCATION
1. Cylinder block (1)
Gasket, flywheel housing
Lockwasher, flywheel housing to engine (nine
required)
Lockwasher, flywheel housing to oil pan (six
required)
Wire, locking (item 21, appendix B)
Personnel Required
Two
Equipment Condition
Oil pan installed (page 2-96).
ACTION
REMARKS
ITEM
New flywheel housing
gasket (2)
Put in.
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
2.
Flywheel housing (3)
Using assistance, aline with dowel pins and
put on.
3. Flywheel housing (3)
Nine screws (4)
and nine new
lockwashers (5)
Using 1/2-inch drive 15/16-inch socket,
b-inch extension, and ratchet handle,
screw in until snug.
Do not tighten.
4. Cylinder block (1)
Flywheel housing (3)
Using machinist scribe, mark flywheel
housing at 12, 3, 6, and 9 o’clock
positions.
2-98
TM 5-2815-241-34&P
FLYWHEEL HOUSING INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Method used for mounting dial indicator is at discretion of using facility. Position dial
indicator on crankshaft face and set contact point of dial indicator on inner bore of
flywheel housing.
5. Flywheel housing (3)
Inner bore (6)
a. Using crankshaft barring tool, rotate
crankshaft until dial indicator is at
9 o’clock position on flywheel housing.
b. Set dial indicator to zero.
c. Using crankshaft barring tool, rotate
crankshaft until dial indicator is at
3 o’clock position on flywheel housing.
d. Note that reading on dial indicator does
not exceed 0.008 inch (0.20 mm).
If dial indicator reading meets or Is
below specification, proceed to step
7. If dial Indicator reading exceeds
specification, perform step 6.
8. Cylinder block (1)
Flywheel housing (1)
Using plastic-faced hammer, move flywheel
housing one-half of dial indicator reading
towards 9 o’clock position.
TA 242396
2-99
TM 5-2815-241-34&P
FLYWHEEL HOUSING INSTALLATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
7. Flywheel housing (1)
Inner bore (2)
a. Set dial indicator to zero.
b. Using crankshaft barring tool, rotate
crankshaft until dial indicator is at
9 o’clock position on flywheel housing.
c. Note that reading on dial indicator does
not exceed 0.008 inch (0.20 mm).
If dial Indicator readings vary when
positioned across from Initial starting
point, check flywheel housing for
out-of-round condition.
If out-of-round, discard flywheel
housing.
8.
Inner bore (2)
a. Using crankshaft barring tool, rotate
crankshaft until dial indicator is at
12 o’clock position on flywheel housing.
b. Set dial indicator to zero.
c. Using crankshaft barring tool, rotate
crankshaft until dial indicator is at
6 o’clock position on flywheel housing.
d. Note that reading on dial indicator does
not exceed 0.008 inch (0.20 mm).
If dial Indicator reading exceeds
specification, perform step 9. If dial
indicator reading meets or Is below
specification, proceed to step 10.
9. Cylinder block (3)
Flywheel housing (1)
Using plastic-faced hammer, move flywheel
housing one-half of dial indicator reading
towards 12 o’clock position.
Inner bore (2)
a. Set dial indicator to zero.
b. Using crankshaft barring tool, rotate
crankshaft until dial indicator is at
12 o’clock position on flywheel housing.
c. Note that reading on dial indicator does
not exceed 0.008 inch (0.20 mm).
If dial Indicator reading meets or Is
below specification, perform step 11.
If dial indicator readings vary when
positioned across from Initial starting
point, check flywheel housing for
out-of-round condition.
If out-of-round, discard flywheel
housing.
10. Flywheel housing (1)
2-100
TM 5-2815-241-34&P
FLYWHEEL HOUSING INSTALLATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
11.
Crankshaft (4)
Push forward to remove end clearance.
12.
Outer face (5)
a. Set contact point of dial indicator on
outer face of flywheel housing and set
dial indicator to zero.
b. Using crankshaft barring tool, rotate
crankshaft until dial indicator is at
6 o’clock position on flywheel housing.
c. Note that reading on dial indicator does
not exceed 0.008 inch (0.20 mm).
If dial Indicator reading meets or is
below specification, perform step 13.
If dial indicator reading exceeds
specifications, tap flywheel housing
with inserted plastic-face hammer and
repeat steps 11 and 12.
13.
Nine screws (6)
Using 1/2-inch drive 15/16-inch socket,
6-inch extension, and 0 to 250 ft lb (0 to 350
N•m) torque wrench, tighten evenly to 150
ft lb (210 N•m).
TA 242397
2-101
TM 5-2815-241-34&P
FLYWHEEL HOUSING INSTALLATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
14. Crankshaft (1)
Flex plate (2)
Aline screw holes and put on.
15. Flex plate (2)
Six screws (3)
Using 1/2-inch drive 7/8-inch socket,
6-inch extension, and ratchet handle,
screw in until snug.
Do not tighten.
16.
six screws (3)
Using 1/2-inch drive 7/8-inch socket,
6-inch extension, and 0 to 250 ft lb (0 to 360
N•m) torque wrench, tighten alternately to
190 to 200 ft lb (266 to 280 N•m).
17. Six screws (3)
Three new
locking wires (4)
Thread one locking wire through two screws
and, using 6-inch slip-joint pliers, twist
ends to secure (see illustration).
18. Oil pan (5)
Four screws (6)
and four new
lockwashers (7)
Using 1/2-inch drive 3/4-inch socket,
6-inch extension, and ratchet handle,
screw in and tighten.
19.
Two screws (8),
two new lockwashers
(9), and two
nuts (10)
Using 1/2-inch drive 13/16-inch socket,
ratchet handle, and 3/4-inch box-end
wrench, screw in and tighten.
2-102
TM 5-2815-241-34&P
FLYWHEEL HOUSING INSTALLATION - CONTINUED
TASK ENDS HERE
TA 242398
2-103
TM 5-2815-241-34&P
CYLINDER HEAD FUEL LINE INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Lockwasher (three required)
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Wrench, open-end, 1/2-inch
Wrench, open-end, 9/16-inch
Wrench, open-end, 5/8-inch
LOCATION
Equipment Condition
Cylinder heads installed (page 2-68).
Air compressor and fuel pump installed
(page 2-86).
ACTION
REMARKS
ITEM
CAUTION
Do not overtighten fuel line fittings and fuel line nuts. Damage or leaks may result.
1. Rear cylinder
head (1)
Two fuel line
fittings (2)
Using 5/8-inch open-end wrench, screw
in.
Position fitting toward intake side of
engine and slightly downward.
NOTE
Position steel feed line on lower fitting.
2. Two fuel line
fittings (2)
Two fuel line
nuts (3)
Using 1/2-inch open-end wrench, screw
in.
Do not tighten.
3. Left side of
engine block (4)
Three screws (5),
three new lockwashers (6), and
three clamps (7)
with fuel lines
Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
screw in.
Do not tighten.
4. Fuel shutoff
switch (8)
Fuel line nut (9)
Using 5/8-inch open-end wrench and
1/2-inch open-end wrench, screw in and
tighten.
2-104
TM 5-2815-241-34&P
CYLINDER HEAD FUEL LINE INSTALLATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
5. Fuel pump (10)
Fuel line nut (11)
and elbow (12)
Using 9/16-inch and 1/2-inch open-end
wrenches, screw in and tighten.
6. Left side of
engine block (4)
Three screws (5)
Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
tighten.
7. Rear cylinder
head (1)
Two fuel line nuts
(3) and two fuel
line fittings (2)
Using 5/8-inch and 1/2-inch open-end
wrenches, tighten.
TASK ENDS HERE
TA 242399
2-105
TM 5-2815-241-34&P
VALVE AND INJECTOR ADJUSTMENTS
This task covers:
a. Dial Indicator Method
(page 2-108)
b. Torque Method (page 2-112)
INITIAL SETUP
Tools - Continued
Tools
Wrench, torque, 0 to 150 in. lb (0 to 17.5
N•m), ST-753-1, 3/8-inch drive
Actuator, rocker arm, ST-1193
Adapter set, ST-669, 3/8-inch drive
Barring tool, crankshaft
Gage, thickness
Indicator, dial, ST-1170
Socket, 7/16-inch, 1/4-inch drive
Wrench, torque, 0 to 150 ft lb
(0 to 210 N•m), 3/8-inch drive
LOCATION
Equipment Condition
Rocker arm housings installed (page 2-82).
ACTION
REMARKS
ITEM
DIAL INDICATOR METHOD
Checking Plunger-Free Travel
CAUTION
In order to prevent excessive loading of the injector actuating system and possible
failure, all injectors must be checked as follows.
NOTE
Steps given are typical for all six injectors.
1. Injector rocker
arm (1)
Adjusting screw (2)
and locknut (3)
Using 3/8-inch drive ST-669 adapter set
and 1/4-inch drive 7/16-inch socket,
loosen.
2. Rocker arm
housing (4)
ST-1170 dial
indicator (5)
a. Put on.
b. Position ST-1170 dial indicator on top of
injector plunger.
Set dial Indicator to zero.
2-106
TM 5-2815-241-34&P
VALVE AND INJECTOR ADJUSTMENTS - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
Injector plunger (6)
3.
Using crankshaft barring tool, rotate engine and check dial indicator (5) reading
for plunger-free travel not exceeding
0.206 inch (5.3 mm).
NOTE
If plunger-free travel exceeds 0.206 inch (5.23 mm), torque method of adjustment
(steps 17 thru 23) must be used.
ST-1170 dial
indicator (5)
If injector free travel is within limits, proceed to adjustment procedures.
Adjustment
NOTE
During repairs, injectors and valves are cold set with temperature of oil and component
parts within 10oF (-11°C) of ambient air room temperature. Final hot-set adjustments
will be made on engine test stand. See Final Testing, Adjustments, and Troubleshooting on Engine Test Stand (page 2-414).
The following injector and valve adjusting procedures and Engine Specifications (page
2-434) require injectors be adjusted before valves.
TA 242400
2-107
TM 5-2815-241-34&P
VALVE AND INJECTOR ADJUSTMENTS - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DIAL INDICATOR METHOD - CONTINUED
5. Gearcase cover (1)
Accessory drive
pulley (2) timing
mark (3), and
pointer (4)
Using crankshaft barring tool, rotate
crankshaft in direction of engine rotation
until timing mark A or 1-6 VS is alined with
pointer.
NOTE
Both intake and exhaust rocker arm for cylinder number five must be loose (valves
closed). Injector plunger for cylinder number three must be at top of travel before
beginning adjustment.
6. Rocker arm
housing (5)
Number five cylinder
(6), intake rocker arm
(7) and exhaust
rocker arm (8)
Both rocker arms must be loose.
If rocker arms are not loose, repeat
step 5.
7. Rocker arm
housing (9)
Number three cylinder (10) and injector
plunger (11)
Injector plunger must be at top of travel.
If not at top of travel, repeat step 5.
TA 242401
2-108
TM 5-2815-241-34&P
VALVE AND INJECTOR ADJUSTMENTS - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
8.
Injector rocker arm
(12) adjusting
screw (13), locknut
(14) plunger (15)
a. Using 3/8-inch drive ST-669 adapter
set and 1/4-inch drive 7/16-inch socket, loosen locknut and screw in adjusting
screw until plunger contacts rocker arm
cup.
b. Advance adjusting screw 15 degrees to
squeeze oil from rocker arm cup.
c. Loosen adjusting screw one-half turn.
9. Rocker arm
housing (16)
Injector plunger
(17) and ST-1170
dial indicator (18)
Position ST-1170 dial indicator, position on
top of injector plunger.
TA 242402
2-109
TM 5-2815-241-34&P
VALVE AND INJECTOR ADJUSTMENTS - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
DIAL INDICATOR METHOD - CONTINUED
10. Rocker arm
housing (1)
Injector rocker arm
(2), injector plunger
(3) and ST-1193
rocker arm
actuator (4)
a. Using ST-1193 rocker arm actuator,
press injector rocker arm down toward
fuel injector until fuel injector reaches
bottom.
b. Release rocker arm and press down
again.
11.
ST-1170 dial
indicator (5)
Set ST-1170 dial indicator to zero.
12.
Adjusting screw (6)
and locknut (7)
Using 3/8-inch drive ST-669 adapter set
and 1/4-inch drive 7/16-inch socket, screw
in until ST-1170 dial indicator reads 0.170
inch (4.3 mm).
13.
Rocker arm (2) and
injector plunger (3)
Bottom plunger and release rocker arm to
allow injector plunger to rise.
ST-1170 dial indicator must show
travel of 0.170 inch (4.32 mm).
14.
Adjusting screw (6)
and locknut (7)
Using 3/8-inch drive ST-669 adapter set
and 1/4-inch drive 7/16-inch socket,
and 0 to 150 ft lb (0 to 210 N•m) torque
wrench, torque locknut to 25 to 35 ft lb
(35 to 49 N°m).
Check adjustment by performing steps
10 thru 14 again.
TA 242403
2-110
TM 5-2815-241-34&P
VALVE AND INJECTOR ADJUSTMENTS - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
With accessory drive pulley timing mark at A or 1-6 VS, number three injector has been
adjusted. Valves in number five cylinder now must be adjusted.
15. Rocker arm
housing (8)
Intake rocker arm
(9), locknut (10), and
adjusting screw (11)
a. Using 3/8-inch drive ST-669 adapter
set, and 1/4-inch drive 7/16-inch
socket, loosen locknut and unscrew
adjusting screw.
b. Using thickness gage, put in between
rocker arm and crosshead.
Clearance should be 0.011 inch
(0.28 mm).
c. Using 3/8-inch drive ST-669 adapter set
and 0 to 150 ft lb (0 to 210 N•m) torque
wrench, torque to 25 to 35 ft lb (35 to
49 N•m).
16.
Exhaust rocker arm
(12), locknut (13),
and adjusting
screw (14)
Perform same adjustment procedures described in step 15.
Clearance should be 0.023 Inch
(0.58 mm).
NOTE
Repeat steps 5 thru 16 as per Injector and Valve Set Position table below.
INJECTOR AND VALVE SET POSITION
ADJUST
CYLINDER
ROTATION
DIRECTION
Start
Advance
Advance
Advance
Advance
Advance
to
to
to
to
to
PULLEY
POSITION
1-6
2-5
3-4
1-6
2-5
3-4
“VS”
“VS”
“VS”
“VS”
“VS”
“VS”
INJECTOR
3
6
2
4
1
5
VALVE
5
3
6
2
4
1
NOTE: Two complete revolutions of the pulley are required
to adjust all injectors and valves.
TA
242404
2-111
TM 5-2815-241-34&P
VALVE AND INJECTOR ADJUSTMENTS - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
TORQUE METHOD
Preadjustment Setup
NOTE
Injector plungers are adjusted before valves are adjusted.
Loosening all injector rocker arm adjusting screws and locknuts will indicate difference
between cylinders that have been adjusted and cylinders needing adjustment.
Steps given are typical for all three rocker arm housings.
17. Rocker arm
housing (1)
Injector rocker arm
(2), locknut (3),
and adjusting
screw (4)
Using 3/8-inch drive ST-669 adapter set,
and 1/4-inch drive 7/16-inch socket,
loosen locknut and unscrew adjusting screw
one turn.
TA 242405
2-112
TM 5-2815-241-34&P
VALVE AND INJECTOR ADJUSTMENTS - CONTINUED
LOCATION
18. Gearcase cover (5)
ACTION
REMARKS
ITEM
Rotate crankshaft until timing mark A or 1-6
VS is alined with pointer.
Accessory drive
pulley (6), timing
mark (7) and
pointer (8)
Adjustment
NOTE
During repairs, injectors and valves are cold set with temperature of oil and component
parts within 10oF (-11 °C) of ambient air room temperature. Final hot-set adjustments
will be made on engine test stand. See Final Testing, Adjustments, and Troubleshooting on Engine Test Stand (page 2-414).
The following injector and valve adjusting procedures and Engine Specifications (page
2-434) require that injectors be adjusted before valves.
TA
242406
2-113
TM 5-2815-241--34&P
VALVE AND INJECTOR ADJUSTMENTS - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
TORQUE METHOD - CONTINUED
NOTE
Steps given are typical for all three rocker arm housings.
19. Rocker arm
housings (1)
Two injector rocker
arms (2), two locknuts
(3), two adjusting
screws (4), and two
cups (5)
a. Using 3/8-inch drive ST-669 adapter
set, and 1/4-inch drive 7/16-inch
socket, loosen locknut and screw in
adjusting screw until top of injector
link touches cup.
b. Advance adjusting screw 15 degrees to
squeeze oil from cup.
c. Unscrew adjusting screw one turn.
NOTE
Use ST-753-1 torque wrench to adjust injectors. Set torque wrench on value required to
pull to zero. Loosen adjusting screw each time and pull to torque value given in each
tightening sequence.
20. Two injector
rocker arms (2)
Two adjusting
screws (4)
a. Using 3/8-inch drive ST-669 adapter
set, 1/4-inch drive 7/16-inch socket,
and ST-753-10 to 150 in. lb (0 to 17.5
N•m) torque wrench, tighten to 30 in. lb
(3.5 N•m).
b. Tighten to 50 in. lb (5.8 N•m).
c. Tighten to 72 in. lb (8.4 N•m).
d. Hold adjusting screws and tighten
locknuts to 40 to 45 ft lb (54 to 61 N•m).
TA 242407
2-114
Change 1
TM 5-2815-241-34&P
VALVE AND INJECTOR ADJUSTMENTS - CONTINUED
ACTION
LOCATION
REMARKS
ITEM
21. Rocker arm
housing (6)
Intake rocker arm
(7), locknut (8), and
adjusting screw (9)
a.
Using 3/8-inch drive ST-669 adapter
set, and 1/4-inch drive 7/16-inch
socket, loosen locknut and unscrew
adjusting screw.
b. Using thickness gage, put in between
rocker arm and crosshead.
When using Torque Method, valves
and injector are adjusted In same
cylinder before rotating crankshaft for
next cylinder. See Table below for
clearance.
22.
Locknut (8)
Using 3/8-inch drive ST-669 adapter set,
1/4-inch drive 7/16-inch socket, and 0 to
150 ft lb (0 to 210 N•m) torque wrench,
torque to 40 to 45 ft lb (54 to 61 N•m).
23.
Exhaust rocker arm
(10), locknut (11),
and adjusting
screw (12)
Perform same adjustment procedures described in steps 21 and 22.
NOTE
Repeat steps 17 thru 23 as per illustration shown below.
VALVE CLEARANCE
INTAKE VALVES
EXHAUST VALVES
COLD
SET
HOT
SET
COLD
SET
HOT
SET
0.014 in.
(0.36 mm)
0.014 in.
(0.36 mm)
0.027 in.
(0.69 mm)
0.027 in.
(0.69 mm)
TASK ENDS HERE
TA510652
Change 1
2-115
TM 5-2815-241-34&P
ENGINE COMPRESSION BRAKE HOUSING INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Extension, 6-inch, 1/2-inch drive
Gage, thickness
Hammer, 8-ounce, ball-peen
Key, hex, 3/16-inch
Socket, 3/4-inch, 1/2-inch drive
Wrench, box-end, 9/16-inch
Wrench, torque, 0 to 250 ft lb
(0 to 350 N•m), 1/2-inch drive
LOCATION
Gasket (three required)
Lock tab (six required)
Lockwasher (12 required)
Equipment Condition
Valve and injector adjustment performed
(page 2-106).
ACTION
REMARKS
ITEM
NOTE
Steps given are typical for all three engine compression brake housings,
I. Three rocker arm
housings (1)
Three new gaskets
(2) and three engine
compression brake
housings (3)
Put on.
2. Three engine compression brake
housings (3)
Two spacers (4),
front lifting eye
(5) and rear lifting eye (6)
a.
Put two spacers on two front engine
compression brake housing studs.
b. Put lifting eyes on either side of center
engine compression brake housing as
shown.
NOTE
Two lifting eyes are positioned on both sides of center engine compression
brake housing.
Lock tabs are installed on two studs located in center of each engine
compression brake housing.
Two spacers are installed on two front studs of front engine compression
brake housing.
3.
Six new lock
tabs (7)
Put on two center studs of each engine
compression brake housing.
4.
Twelve new lockwashers (8) and
eighteen nuts (9)
Using 1/2-inch drive 3/4-inch socket, 6inch extension, and 0 to 250 ft lb (0 to 350
N•m) torque wrench, screw on and tighten
to 55 to 60 ft lb (77 to 84 N•m) as shown
in Tightening Sequence.
2-116
TM 5-2815-241-24&P
ENGINE COMPRESSION BRAKE HOUSING INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
5.
Six new lock
tabs (7)
Using 8-ounce ball-peen hammer, bend
long tab over housing and one short tab
against flat of nut.
6.
Six locknuts (10)
Using 9/16-inch box-end wrench, loosen.
7.
Six adjusting
screws (11)
Using 3/16-inch hex key, unscrew until
slave piston seats in bore.
NOTE
Adjustment must be made with exhaust valves closed. Rotate engine until markings on
accessory drive pulley line up with pointer on gearcase cover and adjust the corresponding cylinder’s adjusting screw.
6.
Six adjusting screws
(11) and six locknuts (10)
a. Using 3/16-inch hex key and thickness
gage, screw in adjusting screws until
clearance is 0.018-inch (0.46 mm).
b. Using 3/16-inch hex key and 9/16-inch
box-end wrench, hold adjusting screws
and tighten locknuts.
TASK ENDS HERE
TA 242409
2-117
TM 5-2815-241-34&P
ROCKER ARM COVER INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Screwdriver, flat-tip, 1/4-inch
Socket, 9/16-inch, 3/8-inch drive
Wrench, torque, 0 to 50 ft lb
(0 to 70 N•m), 3/8-inch drive
Gasket
Lockwasher (five required)
Equipment Condition
Engine compression brake housing installed
(page 2-116).
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps given are typical for all three rocker arm covers.
Only front rocker arm cover contains oil filler cap and crankcase breather.
1. Engine compression
brake housing (1)
New gasket (2) and
rocker arm cover (3)
Put on.
2. Rocker arm cover (3)
Five flat washers
(4) five new lockwashers (5) and
five screws (6)
Using 3/8-inch drive 9/16-inch socket and
0 to 50 ft lb (0 to 70 N•m) torque wrench,
screw in and tighten to 12 to 17 ft lb (16.8 to
23.8 N•m).
3.
Crankcase breather
hose (7) and
clamp (8)
a. Put on.
b. Using 1/4-inch flat-tip screwdriver,
tighten clamp.
TASK ENDS HERE
TA 242410
2-118
TM 5-2815-241-34&P
INTAKE MANIFOLD INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Gasket (three required)
Lockwasher (seven required)
Extension, 6-inch, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Wrench, open-end, l-inch (two
required)
Wrench, torque, 0 to 50 ft lb
(0 to 70 N•m), 1/2-inch drive
LOCATION
Equipment Condition
Cylinder heads installed (page 2-68).
ITEM
ACTION
REMARKS
1. Cylinder head (1)
Three new gaskets
(2) three screws
(3), three new
lockwashers (4),
and three flat
washers (5)
Put one screw, lockwasher, and flat washer
through gasket and into hole at bottom of
each intake port.
2.
Intake manifold (6)
Put onto screws (3).
3.
Four screws (7),
four new lockwashers
(8), and four flat
washers (9)
Screw in.
Do not put screws in holes marked A.
Seven screws
(3 and 7)
Using 1/2-inch drive 9/16-inch socket, 6inch extension and 0 to 50 ft lb (0 to 70 N•m)
torque wrench, tighten to 20 to 25 ft lb
(28 to 35 N•m).
Air compressor hose
nuts (10)
Using two l-inch open-end wrenches, put
on and tighten.
5. Intake manifold (6)
TASK ENDS HERE
TA
242411
2-119
TM 5-2815-241-34&P
PISTON COOLING NOZZLE INSTALLATION
INITIAL SETUP
Tools
Materials/Parts
Handle, ratchet, 1/2-inch drive
Socket, 1/2-inch, 1/2-inch drive
Wrench, torque, 0 to 150 ft lb
(0 to 210 N•m)
LOCATION
Lockwasher
Packing, preformed
ACTION
REMARKS
ITEM
NOTE
Step given is typical for all six piston cooling nozzles.
Right side of
cylinder block (1)
Piston cooling
nozzle (2), new
preformed packing
(3), screw (4), and
new lockwasher (5)
a. Put packing on piston cooling nozzle and
put in.
b. Put lockwasher on screw and, using
1/2-inch drive 1/2-inch socket and
ratchet handle, screw in until snug.
C. Using 1/2-inch drive 1/2-inch socket
and 0 to 150 ft lb (0 to 210 N•m) torque
wrench, tighten to 16 to 22 ft lb (22.4 to
30.8 N•m).
TASK ENDS HERE
TA 242412
2-120
TM 5-2815-241-34&P
WATER PUMP INSTALLATION
INITIAL SETUP
Tools - Continued
Tools
Extension, 6-inch, 1/2-inch drive
Gage, belt tension, ST-1274
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Socket, 7/8-inch, 1/2-inch drive
Wrench, open-end, l-inch
Wrench, open-end, 1 1/16-inch
LOCATION
1. Front of cylinder
block (1)
Wrench, torque, 0 to 250 ft lb (0 to 350 N•m),
1/2-inch drive
Materials/Parts
Belt, water pump (two required)
Gasket, water pump
Lockwasher (seven required)
ITEM
New gasket (2),
water pump (3)
seven new lockwashers (4), and
seven screws (5)
ACTION
REMARKS
a. Position on front of cylinder block.
b. Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and 0 to 250 ft lb (0 to
350 N•m) torque wrench, torque screws
to 10 ft lb (13 N•m).
c. Repeat torquing to 20 ft lb (27 N•m).
d. Repeat torquing for final torque of 30 ft lb
(41 N•m).
TA 242413
2-121
TM 5-2815-241-34&P
WATER PUMP INSTALLATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
2. Water pump (1)
Idler pulley adjusting screw (2) and
two new water pump
belts (3)
a. Using 1/2-inch drive 7/8-inch socket
and ratchet handle, loosen Idler pulley
adjusting screw and lower Idler pulley.
b. Position water pump belts on pulleys
and, using 1/2-inch drive 7/8-inch
socket, ratchet handle, and ST-1274
belt tension gage, tighten idler pulley
adjusting screw to adjust idler pulley to
obtain 120 to 140 lb belt tension.
3.
Idler pulley locknut (4)
Using 1 1/16-inch open-end wrench,
tighten idler pulley locknut.
4.
Air compressor
coolant hose (5)
a. Position on water pump and hand
tighten.
b. Using 1-inch open-end wrench,
tighten.
TASK ENDS HERE
TA 242414
2-122
TM 5-2815-241-34&P
FAN HUB INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Fan belt (as required)
Lockwasher (two required)
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Socket, 3/4-inch, 1/2-inch drive
Equipment Condition
Water pump installed (page 2-121).
LOCATION
ITEM
ACTION
REMARKS
1. Water pump (1)
Fan hub assembly (2)
Put on.
2.
Two new lockwashers
(3) and two
screws (4)
Using 1/2-inch drive 3/4-inch socket and
ratchet handle, screw in and tighten.
3. Fan hub pulley (5)
Fan belts (6)
a. Put on.
b. Using 1/2-inch drive 9/16-inch socket
and ratchet handle, tighten adjusting
screw (7).
Fan belts should have 7/16-inch
(11.11 mm) deflection per foot
(0.3 m) when adjusted.
4.
Three screws (8)
Using 1/2-inch drive 3/4-inch socket and
ratchet handle, tighten.
TASK ENDS HERE
TA 242415
2-123
TM 5-2815-241-34&P
WATER INLET HOUSING INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Gasket, water inlet housing
Lockwasher (five required)
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Wrench, torque, 0 to 150 ft lb (0 to
210 N•m), 1/2-inch drive
Equipment Condition
Water pump installed (page 2-121).
LOCATION
Right front of
cylinder block (1)
ITEM
New water inlet
housing gasket (2),
water inlet housing
(3), five new lockwashers (4), and
five screws (5)
ACTION
REMARKS
a. Position water inlet housing and gasket
on cylinder block.
b. Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
screw in five screws and lockwashers
until snug.
c. Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and 0 to 150 ft lb (0 to
210 N•m) torque wrench, torque to 30 to
35 ft lb (40.6 to 47.4 N•m).
TASK ENDS HERE
TA 242416
2-124
TM 5-2815-241-34&P
WATER HEADER COVER INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Gasket, water header cover
Lockwasher (six required)
Handle, ratchet, 1/2-inch drive
Socket, 7/16-inch, 1/2-inch drive
Wrench, torque, 0 to 150 ft lb (0 to
210 N•m), 1/2-inch drive
LOCATION
Right side of
engine block (1)
ITEM
New water header
cover gasket (2),
water header cover
(3), six new lockwashers (4) and
six screws (5)
ACTION
REMARKS
a. Position water header cover gasket and
water header cover to right side of
engine block.
b. Using 1/2-inch drive 7/16-inch socket
and ratchet handle, screw in six screws
and lockwashers until snug.
c. Using 1/2-inch drive 7/16-inch socket
and 0 to 150 ft lb (0 to 210 N•m) torque
wrench, torque to 25 to 28 ft lb (33.9 to
37.9 N•m).
TASK ENDS HERE
TA
242417
2-125
TM 5-2815-241-34&P
CRANKCASE ACCESS COVER INSTALLATION
INITIAL SETUP
Tools
Equipment Condition
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Wrench, torque, 0 to 150 ft lb (0 to
210 N•m), 1/2-inch drive
Engine removed from engine repair stand and
mounted on engine transport stand. (Engine
transport stand and mounting instructions will
be at discretion of repair facility.)
Materials/Parts
Gasket, crankcase access cover
Lockwasher (four required)
LOCATION
Right side of
engine block (1)
ITEM
New crankcase access
cover gasket (2),
crankcase access cover
(3), four new lockwashers (4), and four
screws (5)
ACTION
REMARKS
a.
Position crankcase access cover gasket
and crankcase access cover on right
side of engine block.
b. Using 1/2-inch drive 9/16-inch socket
and ratchet handle, screw in four screws
with lockwashers until snug.
c. Using 1/2-inch drive 9/16-inch socket
and 0 to 150 ft lb (0 to 210 N•m) torque
wrench, torque to 31 to 35 ft lb (42 to
49 N•m).
TASK ENDS HERE
TA 242418
2-126
TM 5-2815-241-34&P
ENGINE OIL COOLER INSTALLATION
INITIAL SETUP
Tools
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Socket, 9/16-inch, 1/2-inch drive
Socket, 3/4-inch, 1/2-inch drive
Socket, 7/16-inch, 1/2-inch drive
Wrench, box-end, 7/16-inch
Wrench, torque, 0 to 150 ft lb (0
to 210 N•m), 1/2-inch drive
Materials/Parts - Continued
Gasket, water header cover
Lockwasher, oil cooler, front (six required)
Lockwasher, oil cooler, rear
Lockwasher, water header cover (six
required)
Oil, lubricating (item 12, appendix B)
Packing, preformed, water transfer tube
(two required)
Packing, preformed, oil filter
Materials/Parts
Personnel Required
Cartridge, oil filter
Gasket, oil cooler
Two
2-127
TM 5-2815-241-34&P
ENGINE OIL COOLER INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
CAUTION
When performing step 1, assistant must support oil cooler and gasket in position as
hardware is being installed to prevent damaging oil cooler gasket.
1. Right side of
engine block (1)
New oil cooler
gasket (2), engine
oil cooler (3), six
new lockwashers (4),
and six screws (5)
a. With assistance, position new oil cooler
gasket and engine oil cooler on engine
block.
b. Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and ratchet handle,
screw in until snug.
c. Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and 0 to 150 ft lb (0 to
210 N•m) torque wrench, torque to 30 to
35 ft lb (40.6 to 47.4 N•m).
2. Engine oil
cooler (3)
Flat washer (6),
new lockwasher (7)
and screw (8)
a. Using 1/2-inch drive 3/4-inch socket,
&inch extension, and ratchet handle,
screw in until snug.
b. Using 1/2-inch drive 3/4-inch socket,
6-inch extension, and 0 to 150 ft lb (0
to 210 N•m) torque wrench, torque to 95
to 105 ft lb (128.8 to 142.4 N•m).
3. Right side of
engine block (1)
Two new packings
(9), water transfer
tube (10), new gasket
(11), rear water
header cover (12),
six new lockwashers
(13), and six
screws (14)
a. Lubricate two new packings with lubricating oil and position one on each end of
connector tube.
b. Position water transfer tube in engine oil
cooler and rear water header cover.
c. Install new gasket between engine block
and rear water header cover, and screw
in six screws and new lockwashers.
d. Using 7/16-inch box-end wrench,
tighten.
e. Using 1/2-inch drive 7/16-inch socket
and 0 to 150 ft lb (0 to 210 N•m) torque
wrench, torque to 7 to 10 ft lb (9.8 to
14 N•m).
2-128
TM 5-2815-241-34&P
ENGINE OIL COOLER INSTALLATION - CONTINUED
LOCATION
4. Engine oil
cooler (3)
ITEM
New packing (15),
new oil filter cartridge (16), oil
filter shell (17),
and oil filter
screw (18)
ACTION
REMARKS
a. Lubricate new packing with lubricating oil
and position on engine oil cooler.
b. Place oil filter cartridge in oil filter shell
and position on engine oil cooler.
c. Using 1/2-inch drive 9/16-inch socket
and 0 to 150 ft lb (0 to 210 N•m) torque
wrench, torque to 25 to 35 ft lb (33.9 to
47.4 N•m).
TASK ENDS HERE
TA 242419
2-129
TM 5-2815-241-34&P
WATER MANIFOLD ASSEMBLY INSTALLATION
INITIAL SETUP
Tools
Materials/Parts - Continued
Wrench, open-end, 9/16-inch
Oil, lubricating (Item 12, appendix B)
Packing, preformed, connector tube
Packing, preformed, water manifold (as
required)
Materials/Parts
Gasket, water manifold (six required)
Lockwasher (12 required)
LOCATION
ACTION
REMARKS
ITEM
NOTE
If all water manifold sections have been separated, all four preformed packings must be
replaced.
1. Front cylinder
head (1)
Two new gaskets (2),
new preformed packing (3), water manifold front section
(4) with connector
tube (5), four new
lockwashers (6),
and four screws (7)
a. Lubricate two new gaskets with lubricating oil and place in position on front
cylinder head.
b. Lubricate new preformed packing with
lubricating oil and position on end of
connector tube.
C. Lower water manifold front section with
connector tube onto front cylinder head
positioning connector tube into water
inlet housing.
d. Put in four new lockwashers and four
screws.
Hand tighten only.
2. Rear and center
cylinder heads (8)
Four new gaskets
(9), new preformed
packing (10), rear
and center water
manifold sections
(11), eight new lockwashers (12), and
eight screws (13)
a.
2-130
Lubricate four new gaskets with lubricating oil and place in position on
rear and center cylinder heads.
b. Lubricate new preformed packing with
lubricating oil and place in position
on end of center water manifold section.
C. Position rear and center water manifold
sections on rear and center cylinder
heads making sure to fully engage center
water manifold section with front water
manifold section.
d. Put in eight new lockwashers and eight
screws.
Hand tighten only.
TM 5-2815-241-34&P
WATER MANIFOLD ASSEMBLY INSTALLATION - CONTINUED
LOCATION
3. Water manifold front
section (4) and rear
and center manifold
section (11)
ITEM
Twelve screws (7)
ACTION
REMARKS
Using 9/16-inch open-end wrench,
tighten.
TASK ENDS HERE
TA 242420
2-131
TM 5-2815-241-34&P
ANEROID CONTROL VALVE INSTALLATION
INITIAL SETUP
Tools
Materials/Parts
Extension, 6-inch, 1/2-inch drive
Socket, 9/16-inch,1/2-inch drive
Wrench, open-end, 9/16-inch
Wrench, open-end, 5/8-inch
Wrench, open-end, 7/8-inch
Wrench, torque, 0 to 50 ft lb (0
to 70 N•m), 1/2-inch drive
LOCATION
Lockwasher (two required)
Equipment Condition
Intake manifold installed (page 2-119).
ITEM
ACTION
REMARKS
1. Intake manifold (1)
Aneroid control
valve (2), bracket
(3), two screws (4)
two new lockwashers
(5) and two
spacers (6)
a. Position aneroid control valve on
intake manifold.
b. Using 1/2-inch drive 9/16-inch socket,
6-inch extension, and 0 to 50 ft lb torque
wrench (0 to 70 N•m), screw in and
tighten to 20 to 25 ft lb (28 to 35 N•m)
torque.
2.
Fuel line nuts (7)
Using 5/8-inch and 7/8-inch open-end
wrenches, put on and tighten.
3.
Fuel line nuts (8)
Using 5/8-inch and 9/16-inch open-end
wrenches, put on and tighten.
4.
Vacuum line nut (9)
Using 9/6-inch open-end wrench, put on
and tighten.
TASK ENDS HERE
TA 242421
2-132
TM 5-2815-241-34&P
OIL DIPSTICK TUBE INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Socket, 9/16-inch, 12-inch drive
Socket, 5/8-inch, 1/2-inch drive
Wrench, torque, 0 to 150 ft lb
(0 to 210 N•m), 1/2-inch drive
LOCATION
Gasket
Lockwasher, bracket
Lockwasher, oil dipstick tube (two required)
ACTION
REMARKS
ITEM
NOTE
Remove screw from oil cooler before installation of oil dipstick tube.
1. Oil pan (1)
New gasket (2) oil
dipstick tube (3), two
new lockwashers (4),
and two screws (5)
a. Position gasket and oil dipstick tube on
oil pan and put in two screws with new
lockwashers and tighten until snug.
b. Using 1/2-inch drive 5/8-inch socket
and 0 to 150 ft lb (0 to 210 N•m) torque
wrench, torque to 30 to 35 ft lb (40 to
47 N•m).
2. Oil cooler (6)
Screw (7), new
lockwasher (8)
and bracket (9)
a. Screw in.
b. Using 1/2-inch drive 9/16-inch socket
and 0 to 150 ft lb (0 to 210 N•m) torque
wrench, torque to 30 to 35 ft lb (40 to
47 N•m).
TASK ENDS HERE
TA 242422
2-133
TM 5-2815-241-34&P
EXHAUST MANIFOLD INSTALLATION
INITIAL SETUP
Tools
Materials/Parts
Chisel, cold, 1/2-inch
Extension, 6-inch, 1/2-inch drive
Goggles, safety
Hammer, ball-peen, 16-ounce
Socket, 5/8-inch, 1/2-inch drive
Wrench, torque, 0 to 150 ft lb (0
to 210 N•m), 1/2-inch drive
Gasket (six required)
Key washer (four required)
Locking plate, nut, exhaust manifold (four
required)
Personnel Required
Two
LOCATION
ACTION
REMARKS
ITEM
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
CAUTION
Exhaust manifold is in three sections and care must be taken when installing not to allow
sections to separate. Assistance will be needed to support exhaust manifold while
performing steps 1 and 2.
1. Cylinder heads (1)
Six new gaskets (2)
and exhaust
manifold (3)
a. Position six new gaskets on cylinder
head dowels.
b. With assistance, position exhaust manifold on cylinder heads.
2. Exhaust manifold (3)
Four new nut locking
plates (4), eight
sleeve bearings (5)
and eight screws (6)
Position four new nut locking plates with
screws and spacers on exhaust manifold and
screw in until finger tight.
3.
Two retaining straps
(7), new key washers
(8), and four
screws (9)
Position two retaining straps with screws
and new key washers on exhaust manifold
and screw in until finger tight.
2-134
TM 5-2815-241-34&P
EXHAUST MANIFOLD INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
Twelve screws (6
and 9)
4.
Using 1/2-inch drive 5/8-inch socket, 6inch extension, and 0 to 150 ft lb (0 to 210
N•m) torque wrench, torque to 25 ft lb
(34 N•m).
WARNING
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
5.
Four new nut locking
plates (4) and four
new key washers (8)
Using 16-ounce ball-peen hammer and
1/2-inch cold chisel, bend up tabs of new
nut locking plates and new key washers.
TASK ENDS HERE
TA 242423
2-135
TM 5-2815-241-34&P
TURBOCHARGER AND OIL LINE INSTALLATION
INITIAL SETUP
Tools - Continued
Tools
Wrench, open-end, 1 5/16-inch
Wrench, open-end, 1 3/8-inch
Wrench, torque, 0 to 150 ft lb (0 to 210 N•m),
1/2-inch drive
Extension, 6-inch, 1/2-inch drive
Joint, universal, 1/2-inch drive
Screwdriver, flat-tip, 1/4-inch
Socket, 9/16-inch, 1/2-inch drive
Wrench, box-end, 9/16-inch (two
required)
Wrench, open-end, 1/2-inch
Wrench, open-end, 5/8-inch
Wrench, open-end, 3/4-inch
Wrench, open-end, 1 1/4-inch
LOCATION
Materials/Parts
Compound, antiseize (item 2, appendix B)
Gasket
ACTION
REMARKS
ITEM
NOTE
Remove nuts from studs on exhaust manifold and tape from all openings on
turbocharger. Make sure oil return line fitting is facing down.
1. Exhaust manifold (1)
New gasket (2)
turbocharger (3),
and four nuts (4)
a. Coat mounting studs on exhaust manifold
with antiseize compound.
b. Position new gasket on exhaust manifold
with convex side toward turbocharger.
c. Position turbocharger on exhaust
manifold.
d. Screw on four nuts until finger tight.
e. Using 1/2-inch drive 9/16-inch socket,
6-inch extension, universal joint, and 0
to 150 ft lb (0 to 210 N•m) torque
wrench, torque nuts to 22 to 28 ft lb (30
to 38 N•m).
2. Right side of
cylinder block (5)
Oil return hose
fitting (6)
Using 1 1/4-inch open-end wrench, screw
in and tighten.
3.
Oil return tube (7),
hose (8), and
clamp (9)
a. Position clamp on hose end of oil return
tube and hose.
b. Position hose end of oil return tube and
hose on oil return hose fitting.
c.
Using 1/4-inch flat-tip screwdriver,
tighten clamp.
d. Position oil tube and hose fitting on
turbocharger oil return hose fitting (6).
e. Using 1 3/8-inch and 1 5/16-inch openend wrenches, tighten.
2-136
TM 5-2815-241-34&P
TURBOCHARGER AND OIL LINE INSTALLATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
4. Oil cooler (10) and
turbocharger (3)
Oil supply line
and fittings (11)
a. Using 1/2-inch and 3/4-inch open-end
wrenches, screw on to oil cooler and
tighten oil supply line and fittings.
b. Using 5/8-inch and 3/4-inch open-end
wrenches, screw on to turbocharger,
and tighten oil supply line and fittings.
5. Turbocharger (3)
Screw (12) and
clamp (13)
Remove screw from turbocharger and position clamp on turbocharger and screw in
and tighten using 1/2-inch open-end
wrench.
6. Bracket (14)
Screw (15), flat
washer (16), clamp
(17), and nut (18)
a.
Remove nut from screw and install screw
with flat washer and clamp through
bracket. Screw on nut finger tight.
b. Using two 9/16-inch box-end wrenches,
tighten.
NOTE
FOLLOW-ON MAINTENANCE: Perform final testing, adjustments, and troubleshooting
on engine test stand (page 2-414).
TASK ENDS HERE
TA 242424
2-137
TM 5-2815-241-34&P
TURBOCHARGER CROSSOVER TUBE INSTALLATION
INITIAL SETUP
Materials/Parts
Tools
Extension, 6-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Pry bar, lb-inch
Socket, 9/16-inch, 1/2-inch drive
Wrench, open-end, 7/16-inch
LOCATION
Gasket
Lockwasher (four required)
ACTION
REMARKS
ITEM
NOTE
Turbocharger crossover tube is removed from engine before removing engine from
vehicle to allow installation of front lifting eye. It is shipped with engine to allow testing
and adjustments to be accomplished on engine test stand.
1. Top of engine (1)
Lifting eye (2)
Using 18-inch pry bar, unscrew and take
out.
2. Turbocharger air
outlet (3)
Hose (4), hose
clamp (5), and hose
clamp (6)
a. Push on hose (4).
b. Put hose clamps (5) and (6) over
hose.
3. Top of intake
manifold (7)
New gasket (8)
Aline holes in gasket and intake manifold
and put on.
4.
Turbocharger crossover tube (9)
Position on intake manifold (7) and Into
hose (4).
5.
Four screws (10),
four new lockwashers
(11), and four flat
washers (12)
Using 1/2-inch drive, 9/16-inch socket, 6inch extension, and ratchet handle, screw
In and tighten.
6. Hose (4)
Hose clamp (5)
Position on lower portion of hose and using
7/16-inch open-end wrench, tighten.
7.
Hose clamp (6)
Position on upper portion of hose and using
7/16-inch open-end wrench, tighten.
2-138
TM 5-2815-241-34&P
TURBOCHARGER CROSSOVER TUBE INSTALLATION - CONTINUED
NOTE
FOLLOW-ON MAINTENANCE: Perform final testing, adjustments, and troubleshooting
on engine test stand (page 2-412).
TASK ENDS HERE
TA 242425
2-139
TM 5-2815-241-34&P
Section V. CRANKCASE AND CYLINDER BLOCK MAINTENANCE
Page
Cylinder Block.. ...............................................
Gearcase Cover.. .............................................
2-140
2-172
Page
Oil Pan .........................................................
2-175
CYLINDER BLOCK
This task covers:
a. Disassembly (page 2-141)
b. Cleaning/Inspection (page 2-142)
c. Repair (page 2-153)
d. Assembly (page 2-168)
INITIAL SETUP
Tools
Tools - Continued
Adapter, drive, flex, 1/2-inch drive
Adapter, ST-1064
Bit, drill, 23/64-inch
Bit, drill, 23/32-inch
Bit, drill, 1 1/32-inch
Drill, electric, portable, 1/2-inch
Driver, bushing, camshaft, ST-1228
Driver, bushing, ST-1010-9
Driver, sleeve, repair
Driver, sleeve, salvage
Driver, sleeve, ST-1229
Driver, ST-1059
File, mill, flat, wide
Gage, bore, dial
Gage, concentricity, ST-1252
Gage, depth, dial indicator
Gage, thickness
Goggles, safety
Hammer, ball-peen, 16-ounce
Hammer, plastic-faced
Handle, driver, repair sleeve
Handle, ratchet, 3/8-inch drive
Handle, ratchet, 1/2-inch drive
Holder, ST-1065
Insert kit, screw thread, ST-476
Insert kit, screw thread, ST-1230
Key, hex, 1/2-inch
Key, square, 5/16-inch
Machine, milling
Micrometer, 0- to 1-inch
Micrometer, 6-inch to 7-inch
Micrometer, gate, tool bit
Micrometer, inside, 2- to 3-inch
Puller assembly, sleeve, ST-1202
Puller, bridge, sleeve, ST-1201
2-140
Change 1
Puller, pin
Ruler, 24-inch (60.9 mm)
Socket, 1 1/16-inch, 1/2-inch drive
Socket, 1 1/2-inch, 3/4-inch drive
Tool, boring, ST-1081
Tool, boring, ST-1177
Tool, counterbore, ST-1059
Tool, salvage, cylinder sleeve, ST-1168
Tool, salvage, cylinder sleeve, ST-1068
Tool, salvage, cylinder sleeve, ST-1184
Wrench, box-end, 7/16-inch
Wrench, box-end, 9/16-inch
Wrench, open-end, 1/2-inch
Wrench, open-end, 11/16-inch
Wrench, torque, 0 to 150 ft lb (0 to 210 N•m)
Wrench, torque, 0 to 600 ft lb (0 to 813.6
N•m)
Materials/Parts
Cloth, emery (item 1, appendix B)
Dye, leak-detection (item 7, appendix B)
Gasket, cylinder sleeve
Oil, lubricating (item 12, appendix B)
Packing, cylinder sleeve
Packing, preformed, cylinder sleeve
Pin, straight, cylinder block (as required)
Prussian blue (item 13, appendix B)
Rag, wiping (item 14, appendix B)
Tags, marker (item 17, appendix B)
Tape, antiseizing (item 18, appendix B)
Personnel Required
Two
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY
NOTE
Steps 1 and 2 are typical for the removal of all six cylinder sleeves.
1. Cylinder block (1)
Cylinder sleeve (2),
preformed packing
(3), packing (4),
and gasket (5)
Using ST-1201 sleeve puller bridge (6) and
ST-1202 sleeve puller assembly (7),
remove.
Discard preformed packing, packing,
and gasket.
2. Cylinder sleeve (2)
Shim or spacer (8)
a. Remove from sleeve and, using 0- to 1inch micrometer, measure thickness.
Record readings so same shim or
spacer thickness can be installed.
b. Tag shim or spacer, keep together with
respective sleeve, and hold for
inspection.
TA 242426
2-141
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY - CONTINUED
NOTE
Tag location of plug removal for installation.
3. Cylinder block (1)
Pipe Plug (2)
Using 7/16-inch box-end wrench, loosen
and remove.
4.
Pipe plug (3)
Using 3/8-inch drive ratchet handle, loosen
and remove.
5.
Pipe plug (4)
Using 1/2-inch hex key, loosen and
remove.
6.
Pipe plug (5)
Using 9/16-inch box-end wrench, loosen
and remove.
7.
Pipe plug (6)
Using 5/16-inch square key, loosen and
remove.
8.
Fitting (7)
Using 1/2-inch open-end wrench, loosen
and remove.
9.
Fitting (8)
Using 11/16-inch open-end wrench,
loosen and remove.
TA 242427
2-142
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CLEANING/INSPECTION
Particles blown by compressed air are hazardous. Make certain the airstream is directed away from user and other personnel in the area. Compressed air used for
cleaning purposes shall not exceed 30 psi (207 kPa). User must wear safety goggles or
face shield to prevent injury.
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety 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. Flash point for Type
#1 Drycleaning Solvent is 100oF (38°C) and for Type #2 is 138° F (59° C). If you become
dizzy while using 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. Failure to
observe these precautions could cause serious injury or death to personnel.
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
10.
Cylinder block (1)
a. Using compressed air, clean water
pump air bleed hole (2) in number one
cylinder bore (3).
b. Using compressed air, blow all dirt and
cleaning solvent from all capscrew
holes (4).
c. Remove scale from sleeve counterbore
ledge (5).
d. Using emery cloth, clean lower sleeve
bore (6).
TA 242428
2-143
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CLEANING/INSPECTION - CONTINUED
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
CAUTION
Inspection of cylinder block must be performed on a flat surface to prevent distortion. Do
not leave on engine repair stand (page 2-11).
NOTE
Decision to salvage or discard cylinder block due to crack size or location will be left up
to the repair facility.
11.
2-144
Cylinder block (1)
a. Using leak-detection dye, inspect for
cracks, porosity, or leaks.
If cracks, porosity, or leaks exist,
and cylinder block is deemed unrepairable, discard cylinder block.
b. Inspect cylinder block mating surface
(2), near water passage holes (3), for
pits and scratches.
If pits and scratches are more than
0.003 inch (0.08 mm) deep in the
area 1/18 to 3/32 inch (1.59 to 2.38
mm) near water passage holes, tag
water passage hole for sleeving,
step 24.
If pits and scratches are within 1/32
to 3/32 inch (0.79 to 2.38 mm) from
cylinder sleeve counterbore (4), tag
cylinder block for resurfacing, steps
25 and 26.
c. Using 24-inch (60.9 mm) ruler, check
distance A from cylinder head mating
surface (2) to main bearing bore
centerline (5).
If measurement varies more than
0.002 inch (0.05 mm) throughout
length of cylinder block, tag cylinder
block for resurfacing, steps 25
and 26.
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
Using 6- to 7-inch inside micrometer,
check cylinder sleeve lower bore
diameter B.
If diameter is greater than 6.126
inches (155.80 mm), tag cylinder
block for repair sleeve, steps 29
thru 35.
e. Inspect cylinder sleeve counterbore (4)
for damaged or cracked counterbore
ledge (6).
If damage or crack can be repaired by
enlarging and installing salvage
sleeve, tag cylinder sleeve counterbore for installing salvage sleeve,
steps 57 thru 63.
If damage or crack cannot be repaired
by enlarging and installing salvage
sleeve, discard cylinder block.
Check
cylinder head capscrew threads
f.
for damage.
If damage exists, tag for thread repair, step 27.
d.
TA 242429
Change 1
2-145
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CLEANING/INSPECTION - CONTINUED
Cylinder block (1)
12.
a. Check main bearing capscrew threads
(2) for damage.
If damage exists, tag for thread
repair, step 28.
b. Check main bearing caps (3) for looseness in cylinder block.
If any perceptible clearance or
shake exists, tag main bearing cap
for replacement, steps 36 thru 39.
CAUTION
Main bearing cap bolts must be tightened alternately and slowly to ensure proper seating
of bearing caps.
13. Cylinder block (1)
Main bearing
caps (3)
Position in cylinder block in their respective locations as tagged.
14. Main bearing
caps (3)
Main bearing
capscrews (4)
a. Lubricate with clean lubricating oil.
b. Install through main bearing caps.
c. Using 3/4-inch drive 1 1/2-inch socket
and 0 to 600 ft lb torque wrench, tighten
each capscrew to 140 to 150 ft lb
(197 to 210 N•m) to seat main bearing
caps, then continue to tighten each capscrew to 300 to 310 ft lb (407 to 420
N•m).
15.
Main bearing
bore (5)
Using dial bore gage (6), measure main
bearing bores horizontally, vertically, and
diagonally.
If main bearing cap has been determined to be distorted, or If main
bearing bore diameter is greater than
4.7505 inch (120.883 mm), tag
cylinder block for reaming, steps 41
thru 50.
16. Cylinder block (1)
Camshaft
bushings (8)
a.
2-146
Inspect for chips, scores, or scratches.
If camshaft bushings are chipped,
scored, or scratched, tag camshaft
bushings for replacement, steps 51
and 52.
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
b. Inspect to ensure oil passages (9) between camshaft bushings and cylinder
block are properly alined.
If oil passages are not alined, tag
camshaft bushings for replacement,
steps 51 and 52.
c. Using 2- to 3-inch inside micrometer
(10), measure camshaft bushing inside
diameter, A, horizontally and vertically.
If camshaft bushing inside diameter is
greater than 2.0015 inches (50.838
mm), tag camshaft bushings for
replacement, steps 51 and 52.
17. Cylinder block (1)
Straight pins (7)
Inspect straight pins for nicks, or out of
round.
If nicked or out of round, repair, step
40.
TA 242430
2-147
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
CLEANING/INSPECTION - CONTINUED
18. Cylinder block (1)
Counterbore (2)
a. Using 6-inch to 7-inch micrometer,
measure counterbore diameter, A.
If diameter is greater than 6.5635
inches (188.713 mm), tag counterbore for salvage sleeve, steps 57
thru 63.
b. Using dial indicator depth gage, measure counterbore depth, B.
If depth is greater than 0.412 inch
(10.486 mm), tag counterbore for
salvage sleeve, steps 57 thru 63.
c. Using dial indicator depth gage, measure counterbore depth at four equally
spaced points at the edge of the bore.
If there is a total of 0.001 inch (0.03
mm) difference in these measurements, tag counterbore for cutting,
steps 53 thru 56.
If counterbore ledge (3) is not flat with
the top of the cylinder block within
0.0014 inch (0.038 mm) overall, tag
counterbore for cutting, steps 53
thru 56.
d. Check that counterbore ledge (3) is at a
90-degree angle to cylinder sleeve
bore.
If counterbore ledge is not at a
go-degree angle to cylinder sleeve
bore, to within 0.005 inch (0.13
mm), tag counterbore for cutting,
steps 53 thru 56.
19.
Cylinder sleeve (4)
a. Using leak-detection dye, inspect for
cracks just under top flange (5) at
bottom of sleeve (6) or above gasket
groove (7).
If cracks exist, discard cylinder
sleeve.
b. Inspect for corrosion, pits, or erosion.
If corrosion, pits, or erosion exists
1/16 inch (1.59 mm) deep or more,
discard cylinder sleeve.
c. Inspect underside of cylinder sleeve top
flange (5) for dents, or pitting.
If dents or pitting cannot be removed
by lapping, discard cylinder sleeve.
2-148
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
d. Using dial bore gage, measure cylinder
sleeve inside diameter, C.
If diameter is greater than 5.505 inch
(139.83 mm), discard cylinder
sleeve.
e. Inspect for scoring or vertical grooving
on inside bore.
If scores or grooves cannot be removed during deglazing, discard
cylinder sleeve.
f. Deglaze cylinder sleeves that have
passed checks and inspections.
WARNING
Particles blown by compressed air are hazardous. Make certain the air stream is
directed away from user and other personnel in the area. Compressed air used for
cleaning purposes shall not exceed 30 psi (207 kPa). User must wear safety goggles or
face shield to prevent personnel injury.
NOTE
After cylinder sleeves are deglazed, clean thoroughly with compressed air to remove all
particles from cylinder sleeve. Coat bores with lubricating oil after cleaning.
TA 242431
2-149
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATlON
ACTION
REMARKS
ITEM
CLEANING/INSPECTION - CONTINUED
NOTE
If cylinder sleeves are to be reused, they must be installed in their original location for
checking cylinder sleeve protrusion. If one or more cylinder sleeves were discarded, a
new cylinder sleeve must be substituted. After cylinder sleeve protrusion is adjusted,
the shims and spacers used for adjustment must be kept with that cylinder sleeve and
shims, spacers, and cylinder sleeves must be tagged for their respective location in
cylinder block for assembly.
20.
Cylinder sleeve (1)
a. Using 0- to 1-inch micrometer (2),
measure and record cylinder sleeve
flange (3) width.
Do not Include bead (4) when taking
measurements.
b. Using dial indicator depth gage (5),
measure and record counterbore (6)
ledge depth.
c. Subtract counterbore ledge depth (step
b) from cylinder sleeve flange width
(step a).
If the difference is less than 0.003
inch (0.06 mm), add shims or
spacers so protrusion, A, is between
0.003 to 0.006 inch (0.06 to
0.15 mm).
If the difference is greater than 0.006
inch (0.15 mm), tag counterbore (6)
for cutting, steps 53 thru 56, and
record the amount of material to be
removed.
NOTE
The thinnest shim available is 0.007 inch (0.18 mm), therefore it may be necessary to
use a combination of counterbore cutting and adding shims or spacers to achieve the
correct protrusion of 0.003 to 0.006 inch (0.08 to 0.15 mm).
If material to be removed during counterbore cutting will result in counterbore depth
exceeding 0.412 inch (10.46 mm), cylinder block cannot be reused, unless a salvage
sleeve can be installed, steps 57 thru 63.
2-150
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
21. Cylinder block (7)
ITEM
Cylinder sleeve (1)
ACTION
REMARKS
a.
Install, without preformed packing,
packing, or gasket.
b. Using thickness gage (8), check clearance between cylinder sleeve (1) and
cylinder block (7). Clearance should be
0.002 inch (0.05 mm) to 0.006 inch
(0.15 mm).
Clearance less than 0.002 inch (0.05
mm) is permissible as long as any
cylinder sleeve to cylinder block
contact does not cause cylinder
sleeve to be out of round, step 22.
If clearance is greater than 0.008 inch
(0.15 mm), tag cylinder block for
cylinder sleeve lower bore repair
sleeve, steps 29 thru 35.
TA 242432
2-151
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
CLEANING/INSPECTION - CONTINUED
22. Cylinder block (1)
Cylinder sleeve (2)
a. Using dial bore gage (3), check cylinder sleeve for out-of-round condition.
If cylinder sleeve is more than 0.002
Inch (0.05 mm) out of round in gasket
area due to cylinder sleeve to cylinder block contact, tag cylinder block
for cylinder sleeve lower bore
repair sleeve, steps 29 thru 35.
b. Remove, and using dial bore gage (3),
check cylinder sleeve for out-of-round
condition.
If cylinder sleeve is more than 0.002
inch (0.05 mm) out of round in gasket
area, cylinder sleeve is distorted.
Discard cylinder sleeve.
23.
Cylinder sleeve
lower bore (4)
Using ST-1252 concentricity gage, check
counterbore to lower cylinder sleeve bore
concentricity.
If cylinder sleeve lower bore is not
concentric within 0.005 inch (0.13
mm) total indicator reading, tag
cylinder block for cylinder sleeve
lower bore repair sleeve, steps 29
thru 35.
TA 242433
2-152
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR
WARNING
Repair of engine must be performed on engine repair stand (page 2-11). Due to
excessive weight assistance will be needed to prevent injury when lifting heavy parts.
24. Cylinder block (1)
Eroded water passage
holes (2)
a. Using ST-1010 water hole counterboring
tool, enlarge water passage hole for
sleeve.
b. Slide sleeve onto stop end of ST-1010-9
bushing driver.
c. Aline sleeve in top of water passage
hole.
d. Using 16-ounce ball-peen hammer,
strike ST-1010-9 bushing driver to drive
sleeve into water passage hole until it
bottoms.
Sleeve will protrude above surface
of cylinder block.
NOTE
If cylinder block is to be resurfaced, it is not necessary to file sleeve flush with top of
cylinder block. If cylinder block is not resurfaced, perform step e.
e.
Using a wide flat mill file, file
sleeve flush with top of cylinder
block.
TA 242434
2-153
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
NOTE
Steps 24 and 26 are provided for cylinder block if tagged for resurfacing.
Cylinder block (1)
25.
a. Position main bearing pads (2) of
cylinder block on milling machine.
b. Remove grooved headless pins (3) from
cylinder head mounting surface (4).
WARNING
Due to excessive weight, assistance will be needed to prevent personal injury when
lifting heavy parts.
CAUTION
When resurfacing cylinder block, do not remove so much material that the height, A,
from the centerline of the main bearing bore to the top surface of the cylinder block is
less than 18.994 inches (482.448 mm), or cylinder block will become unusable.
NOTE
Cylinder block may be salvaged by removing a maximum of 0.010 inch (0.25 mm) of
material from the top surface.
c. Using a milling machine, remove only
enough material from top of cylinder
block to repair damage.
26.
Cylinder block (1)
Remove from milling machine.
NOTE
The following step is provided for cylinder head capscrew threads tagged for repair.
27. Cylinder block (1)
2-154
Cylinder head
capscrew hole (5)
a. Using a dial indicator depth gage with a
1/4-inch wide blade seated in center
taper of hole (5), determine depth of
hole.
If depth is 2 11/32 inches (59.53 mm)
deep, proceed to steps b,c,d, and e.
If depth is 2 9/18 inches (85.09 mm)
deep, proceed to steps f, g, and h.
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
WARNING
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
Particles blown by compressed air are hazardous. Make certain the air stream is
directed away from user and other personnel in the area. Compressed air used for
cleaning purposes shall not exceed 30 psi (207 kPa). User must wear safety goggles or
face shield to prevent personnel injury.
b. Using 1/2-inch portable electric drill
and 23/32-inch drill bit, drill hole to
a depth of 1 7/8 inches (47.63 mm).
C. Using ST-476 screw thread insert kit,
tap hole to 1 3/4-inch (44.45 mm)
depth.
d. Clean all chips and shavings from hole
with compressed air.
e. Using ST-476 screw thread insert kit,
install screw thread insert to a depth
of 1/2 inch (12.70 mm) below top
surface of cylinder block (1).
f. Using 1/2-inch portable electric drill
and 23/64-inch drill bit, drill hole to
a depth of 2 1/16 inches (52.39 mm).
g. Using ST-476 screw thread insert kit,
tap hole to 1 15/16-inch (49.21 mm)
depth.
h. Clean all chips and shavings with compressed air from hole.
i. Using ST-476 screw thread insert kit,
install screw thread insert to a depth
of 11/16 inch (17.46 mm) below top
surface of cylinder block.
5
(TYPlCAL)
TA 242435
2-155
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
WARNING
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
NOTE
Step 28 is for main bearing capscrew threads tagged for repairs and steps 29 thru 35 are
for cylinder block tagged for sleeve lower bore repairs.
28. Cylinder block (1)
Main bearing
capscrew hole (2)
a. Using 1/2-inch portable electric drill
and 1 1/32-inch bit, drill hole 2.675 to
2.705 inches (68.16 to 68.74 mm)
deep from main bearing cap pad (3).
b. Using ST-1230 screw thread insert kit,
tap hole of 2.425 to 2.455 inches (61.60
to 62.36 mm) deep.
c. Using inserting tool from kit, install
screw thread insert 0.860 to 0.890 inch
(21.84 to 22.61 mm) deep below main
bearing cap pad (3).
29. Cylinder block (1)
ST-1081 boring
tool (4)
Install assembled ST-1081 boring tool,
allowing bore adapter (5) to engage counterbore, and holes in adapter plate (6) to
match holes in cylinder block.
30.
Adapter plate (6)
a. Fasten in place with capscrews (7).
b. Using 1/2-inch drive, 1 1/16-inch socket,
I
and 0 to 150 ft lb (0 to 210 N•m)
torque wrench, screw in and torque capscrew 50 to 75 ft lb (6.9 to 10.4 kgm).
TA 242436
2-156
Change 1
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
31. Adapter plate (6)
Torque reaction
bar (8)
Install into place.
32. ST-1081 boring
tool (4)
Drive gear (9), 1/2inch drive flex
drive adapter (10)
and 1/2-inch portable electric drill (11)
Engage 1/2-inch drive flex drive adapter
into 1/2-inch portable electric drill,
fasten in place, and engage onto drive
gear.
WARNING
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
NOTE
Be sure ST-1081 boring tool drive shaft is in maximum up position before turning on
drill.
33.
1/2-inch portable
electric drill (11)
a. Using 1/2-inch portable electric drill,
apply a slight downward pressure until
maximum depth of bore is complete.
b. Pull drive shaft of ST-1081 boring tool up
until shaft is in up position.
34. Cylinder block (1)
ST-1081 boring
tool (4)
Remove from cylinder block.
TA 242437
2-157
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
NOTE
Inside diameter chamfer of repair sleeve is installed towards top surface of cylinder
block.
35. Cylinder block (1)
a. Push through upper bore and position in
lower bore (3).
b. Insert repair sleeve driver handle into
repair sleeve driver, and position on
repair sleeve.
c. Install locator over repair sleeve driver
handle and into counterbore (4).
d. Using 16-ounce ball-peen hammer, tap
gently on repair sleeve driver handle until repair sleeve is located on starting
radius, then drive repair sleeve into
place.
When repair sleeve is in correct
position, the repair sleeve driver
handle will become free for removal.
Repair sleeve (2)
NOTE
Steps 36 thru 39 are provided for cylinder blocks tagged for main bearing cap
replacement.
Replacement main bearing caps have 0.015 inch (0.36 mm) material in bore. Other
dimensions are the same as finished main bearing caps. Number 7 replacement main
bearing cap does not have cap to block dowel holes and must be machined to block
width.
TA 242430
2-158
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
36. Cylinder block (1)
ACTION
REMARKS
ITEM
Main bearing cap (5)
Place in correct position in cylinder block.
Main bearing caps provide a 0.0015 to
0.0045 inch (0.04 to 0.11 mm) interference fit in cylinder block.
NOTE
Steps 34 thru 36 apply to replacing the number 7 main bearing cap.
37.
Locating dowels (6)
Remove from block.
38.
Main bearing cap (5)
a. Using prussian blue on block surface,
place main bearing cap in position, and
locate dowel holes in main bearing cap.
b. Remove main bearing cap.
c. Install dowels in cylinder block and reinstall main bearing cap.
Install all caps and tag cylinder block for
main bearing bore reaming, steps 41
thru 50.
39.
40.
Straight pins (7)
a. If nicked, using emery cloth remove all
nicks.
b. If out of round, using pin puller,
remove.
c. Using plastic-faced hammer, install
new straight pins.
TA 242439
2-159
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
NOTE
Steps 39 thru 48 are provided for cylinder block tagged for main bearing reaming.
41. Cylinder block (1)
Main bearing
caps (2)
a. Using wide flat mill file, remove 0.002 to
0.003 inch (.051 to .076 mm) of stock
from milled seating surface of main
bearing caps which are determined to be
distorted.
If replacement cap is being used,
removing this material is not
necessary.
b. Remove two undamaged main bearing
caps, preferably one from each end of
block or as far apart as possible.
42.
ST-1177 boring
tool (3)
Insert proper centering rings, with oiler up,
in two undamaged bores, and tap with
plastic-faced hammer to seat.
43.
Main bearing
caps (2)
Using 0 to 600 ft lb (0 to 813.6 N•m) torque
wrench, reinstall and torque to
specifications.
See procedure, step 14.
NOTE
If centering ring must be installed where replacement main bearing caps have been substituted, limit torque to 10 ft lb (14 N•m).
ST-1177 boring
tool (3)
44.
a. Install with proper cutting tools.
b. Using lubricating oil, lubricate cutting
tools and main bearing bores.
CAUTION
Be sure tool bit cutting edge is turned in the same direction as 1/2-inch portable electric
drill rotation.
Keep ST-1177 boring tool and main bearing bores well lubricated during all boring
operations.
2-160
Change 1
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
WARNING
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
45.
ST-1177 boring
tool (3)
a. Attach 1/2-inch portable electric drill to
ST-1177 boring tool swivel joint.
b. Turn on 1/2-inch portable electric drill
and ream main bearing bore.
c. Turn off 1/2-inch portable electric drill
and remove from ST-1177 boring tool
swivel joint.
46. Cylinder block (1)
ST-1177 boring
tool (3)
Adjust to next main bearing bore to be cut.
47.
Cylinder block (1)
Repeat steps 45 and 46 until all main bearing
bores to be cut are reamed.
48.
ST-1177 boring
tool (3)
Remove from cylinder block.
49.
Cylinder block (1)
Thoroughly clean cylinder block.
See page 2-3, for general cleaning
instructions.
50.
Main bearing
bore (4)
Using a dial bore gage, check size of all
main bearing bores, see steps 14 and 15.
TA 242440
2-161
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTlNUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
NOTE
Steps 51 and 52 are provided for cylinder blocks tagged for camshaft bushing
replacement.
51. Cylinder block (1)
Using ST-1228 camshaft bushing driver
(3), remove.
Camshaft
bushings (2)
CAUTION
Positioning of new camshaft bushing in number seven bushing bore (rear of cylinder
block) is critical. The new bushing must be pressed in, leaving clearance between
bushing and rear face of cylinder block to allow oil to drain from hole at rear of camshaft.
Hydraulic lock will occur if oil drain passage is blocked.
Be sure oil hole in camshaft bushings is alined with oil feed hole in cylinder block.
Damage to engine will occur if camshaft bushings are installed improperly.
NOTE
Number one camshaft bushing (front of cylinder block) is different from the other six
camshaft bushings.
52.
2-162
Camshaft
bushings (2)
a. Position on ST-1228 camshaft bushing
driver (3), alining oil hole (4) with oil
hole in camshaft bushing bore.
b. Press in to position in camshaft bushing
bore.
C. Check oil hole alinement.
If oil hole (4) is not alined, reposition
camshaft bushings.
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps 53 thru 56 are provided for cylinder blocks tagged for counterbore cutting.
53.
ST-1059 driver (5),
ST-1084 adapter (6),
and ST-1065
holder (7)
Attach together and place unit on cylinder
block with holddown holes matching in
cylinder block.
54. ST-1064 adapter (8)
Holddown capscrews
and washers (8)
Install through ST-1064 adapter into cylinder
block, finger tight. Using 1/2-inch drive
1 1/18-inch socket and 0 - 800 ft lb (0 813.8 N•m) torque wrench, torque to 50 to
75 ft lb (70 to 105 N•m).
TA 242441
2-183
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
NOTE
Tool bit must rotate freely and clear counterbore ledge.
55. Cylinder block (1)
Counterbore (2)
Using dial indicator depth gage, measure
depth of counterbore through four counterbore measuring holes on ST-1064 adapter.
The average of the four readings will
be the present depth of counterbore.
58.
ST-1059 counterbore
tool (3)
a. Rotate adjusting nut until tool bit is
resting on lowest part of counterbore
ledge and there is clearance between
housing (4) and adjusting nut (5).
NOTE
The distance between housing and adjusting nut equals amount of material that will be
removed from counterbore ledge.
b. Using a thickness gage of the same
thickness as amount of material needed
to be removed from counterbore ledge
(step 20) rotate adjusting nut
until thickness gage is just held between
adjusting nut and top of housing. Tighten
locking nut (8).
c. Hold down on handle (7), applying more
pressure on tool bit side, and rotate
handle in a clockwise direction until
unit turns freely and is bottomed out
between adjusting nut and top of
housing.
d. Measure depth of counterbore as described in step 55.
Compare with specifications in
step 18.
2-164
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps 57 thru 63 are provided for cylinder blocks tagged for cylinder sleeve counterbore
salvage sleeve.
57. ST-1168 cylinder
sleeve salvage tool (8)
Cutting tool (9)
Remove from holding plate (10).
58. Cylinder block (1)
ST-1168 cylinder
sleeve salvage tool (8)
a. Place on cylinder block above bore to be
cut.
b. Install mounting capscrews into cylinder
block.
Using 0 - 150 ft lb (0 - 210 N•m)
torque wrench, tighten to 25 to 35 ft lb
(33.9 to 47.5 N•m).
TA 242442
2-165
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
59. Cylinder block (1)
ST-1168 cylinder
sleeve salvage tool (2)
a. Retract tool holder by pulling up on
orifice retractor knob (3).
b. Loosen setscrew in back end of tool bit
(4) and push setpin all the way in.
C. Lock setscrew.
60.
Tool bit gate
micrometer (5)
a. Adjust to 6.750 inch (171.45 mm).
b. Insert tool bit and hold firmly against stop
and hardened pad.
C. Loosen setscrew and allow setpin to
come out against tool bit gate micrometer spindle.
d. Lock setscrew.
NOTE
As a further check, back off thimble on tool bit gate micrometer and recheck tool bit
length.
61.
2-166
ST-1168 cylinder
sleeve salvage tool (2)
a. Insert tool bit (4) into tool holder and
tighten lock screw.
Tool bit must be held all the way in
against tool holder.
b. Turn tool holder until tool bit recess
is at large opening in adapter plate (6).
C. While pulling up on retractor knob (3)
and pushing down on set collar (7),
place a 0.004-inch (0.10 mm) thickness gage between cylinder block and
tool bit.
d. Lower tool bit onto thickness gage.
e. Loosen set collar (7) setscrew and back
off set collar (7) counterclockwise until
salvage sleeve can be placed between
set collar (7) and boring tool ST-1177
main body (8) to be used as a depth
indicator.
f. Tighten setscrew in set collar.
Remove thickness gage.
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
The thickness gage is used to make sure that the salvage sleeve will not be below the top
of the cylinder block.
g. Place 1/2-inch portable electric drill
and 1/2-inch drive flex adapter on drive
shaft (9).
Approximately halfway through the cut, the tool will begin to cut the counterbore ledge.
Be prepared for the added load on the drill when the counterbore is being cut, or
personal injury could result.
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
h. Operating 1/2-inch portable electric
drill, bore hole until drill freewheels.
Stop immediately when drill
freewheels.
i. Pull up on retractor knob (3) and remove
tool bit (4) from tool holder.
j. Remove ST-1168 cylinder sleeve salvage
tool from cylinder block.
62.
Cylinder block (1)
Using emery cloth, deburr counterbore.
TA 242443
2-167
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
63. Cylinder block (1)
Cylinder sleeve
counterbore (2)
a. Using wiping rag, clean thoroughly.
b. Place salvage sleeve on cylinder sleeve
counterbore.
c. Using salvage sleeve driver, drive
salvage sleeve into bore until it bottoms.
A solid sound can be heard when salvage sleeve bottoms.
NOTE
Salvage sleeve will protrude above top of cylinder block by 0.004 inch (0.10 mm) and
must be filed even with top of cylinder block. Remove all burrs with emery cloth.
The salvage sleeve is designed to be 0.005 to 0.010 inch (0.13 to 0.25 mm) above
required counterbore depth. Check depth and cut to specifications as described in step
18 and in steps 53 thru 56.
ASSEMBLY
NOTE
Steps 64 thru 68 are typical for installing all six cylinder sleeves in cylinder block.
TA 242444
2-168
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Before installing cylinder sleeves, check cylinder sleeve protrusion as described in
step 20.
Be sure to install cylinder sleeves in their respective counterbores as tagged.
64. Cylinder sleeve (3)
Shims or spacer (4)
Install onto cylinder sleeve.
65.
New gasket (5)
Install in gasket groove (6).
Be sure gasket is not twisted.
66.
New packing (7)
Install in packing groove (8).
Be sure packing is not twisted.
67.
New preformed
packing (9)
Install in preformed packing groove (10).
Be sure preformed packing is not
twisted.
NOTE
Lubricate gasket, packing, and preformed packing just prior to installation. The packing
and preformed packing will increase in size when they are in contact with lubricating oil
for an extended period of time.
6
8
1 0
TA 242445
2-169
TM 5-2815-241-3&P
CYLINDER BLOCK - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY - CONTINUED
NOTE
Lubricate machined portions of cylinder block, on which gasket, packing, and preformed packing seat, with a light coat of clean lubricating oil.
68. Cylinder block (1)
Cylinder sleeve (2)
a. Place in cylinder block.
Be careful not to dislodge gasket,
packing, and preformed packing.
b. Press into position by hand.
c. Using ST-1229 sleeve driver (3) and
16-ounce ball-peen hammer, drive
cylinder sleeve securely into cylinder
block so it fits squarely into cylinder
block bore.
d. Install ST-1184 cylinder sleeve salvage
tool so foot of tool rests upon cylinder
sleeve fire ring.
e. Using 0 - 150 ft lb (0 - 210 N•m)
torque wrench, tighten securing cap
screws to 50 ft lb (70 N•m) torque.
f. Check cylinder sleeve protrusion. See
step 20.
g. Check cylinder sleeve for out-of-round
condition. See step 22.
If cylinder sleeve is out of round,
remove and check for cause of
distortion.
TA 242446
2-170
TM 5-2815-241-34&P
CYLINDER BLOCK - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
NOTE
Be sure to wrap pipe plug threads with antiseizing tape before installation, and install as
tagged in steps 3 thru 7
69. Cylinder block (1)
Pipe plug (4)
Screw in and tighten using 7/16-inch box
wrench.
70.
Pipe plug (5)
Screw in and tighten using 3/8-inch drive
ratchet handle.
71.
Pipe plug (8)
Screw in and tighten using 1/2-inch hex
key.
72.
Pipe plug (7)
Screw in and tighten using 9/16-inch boxend wrench.
73.
Pipe plug (8)
Screw in and tighten using 5/16-inch square
key.
74.
Fitting (9)
Screw in and tighten using 1/2-inch openend wrench.
75.
Fitting (10)
Screw in and tighten using 11/16-inch
open-end wrench.
NOTE
FOLLOW-ON MAINTENANCE:
Install crankshaft (page 2-54).
TASK ENDS HERE
TA 242447
2-171
TM 5-2815-241-34&P
GEARCASE COVER
This task covers:
c. Repair (page 2-174)
d. Assembly (page 2-174)
a. Disassembly (page 2-172)
b. Cleaning/Inspection (page 2-172)
INITIAL SETUP
Equipment Condition
Tools
Gearcase cover removed (page 2-48).
Gage, bore, dial
Handle, ratchet, 1/2-inch drive
Mandrel, ST-598
Press, arbor
Socket, 9/18-inch, 1/2-inch drive
ACTION
REMARKS
ITEM
LOCATION
DISASSEMBLY
1. Gearcase cover (1)
Crankshaft seal (2)
2.
Accessory
Remove.
Discard.
Remove.
Discard.
drive
seal (3)
3.
Camshaft support
(4), three screws
(5), lockwashers
(6), and flat
washers (7)
Using 1/2-inch drive 9/16-inch socket and
ratchet handle, unscrew and take off.
Discard lockwashers.
4. Camshaft
support (4)
Shim pack (8)
Remove from camshaft support.
Hold for assembly.
CLEANING/INSPECTION
NOTE
For general cleaning procedures, see General Maintenance Instructions page 2-3.
5.
2-172
Gearcase cover (1)
Inspect for cracks or other damage.
If cracks or other damage exists,
discard gearcase cover.
TM 5-2815-241-34&P
GEARCASE COVER - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
6. Gearcase cover (1)
Trunnion (9)
Inspect inside diameter for wear.
If wear is excessive, tag gearcase
cover for trunnion bushing
installation.
7.
Accessory drive
bushing (10)
a. Inspect inside diameter for scoring or
pitting.
If scoring or pitting exists, tag
accessory drive bushing for
replacement.
b. Using dial bore gage, check inside
diameter.
If inside diameter is larger than
1.571 inch (39.90 mm), tag for
replacement.
8.
Camshaft support (4)
a. Inspect for cracks or other damage.
If cracks or other damage exists,
discard camshaft support.
b. Using dial bore gage, check inside
diameter.
If inside diameter is greater than
1.757 inch (44.83 mm), discard
camshaft support.
TA 242448
2-173
TM 5-2815-241-34&P
GEARCASE COVER - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR
NOTE
Perform step 9 or 10 if gearcase trunnion or accessory drive bushings need replacement.
9. Gearcase cover (1)
10.
Trunnion (2)
Using arbor press, press bushing into
trunnion.
Be sure chamfered side of bushing is
toward gearcase.
Accessory drive
bushing (3)
a. Using ST-598 mandrel, drive out and
install new bushing.
ASSEMBLY
NOTE
Install new crankshaft seal, accessory drive seal, and camshaft support after gearcase
cover is installed on cylinder block.
FOLLOW-ON MAINTENANCE:
Install on cylinder block (page 2-90).
TASK ENDS HERE
OIL PAN
This task covers:
Cleaning/Inspection
TA 242449
2-174
TM 5-2815-241-34&P
OIL PAN - Continued
INITIAL SETUP
Tools
Key, square, 1/2-inch
Key, square, 3/8-inch
Equipment Condition
Materials/Parts
Oil pan removed from engine (page 2-44).
Gasket, drain plug
Dye, leak-detection (item 7,
appendix B)
ACTION
REMARKS
ITEM
LOCATION
CLEANING/INSPECTION
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
1.
Oil pan (1)
a. Using leak detection dye, inspect oil pan
for cracks.
If cracks exists, discard.
b. Inspect holes for damaged threads.
If damage exists, discard.
2. Oil pan (1)
Drain plugs (2)
and gasket (3)
a. Using 3/8-inch and 1/2-inch square
keys, unscrew and take out. Inspect
holes and drain plugs gasket for
damage.
If damaged, discard.
b. Using 3/8-inch and 1/2-inch square
keys, screw in and tighten.
NOTE
FOLLOW-ON MAINTENANCE:
Install oil pan (page 2-96).
TASK ENDS HERE
TA 242450
Change 1
2-175
TM 5-2815-241-34&P
Section VI. CYLINDER HEAD MAINTENANCE
CYLINDER HEAD
This task covers:
a. Disassembly (page 2-177)
b. Cleaning (page 2-180)
c. Inspection (page 2-180)
d. Repair/Assembly (page 2-191)
INITIAL SETUP
Tools - Continued
Tools
Arbor set, valve guide, ST-663
Brush, wire
Checking tool, injector tip protrusion, ST-981
Compressor, spring, valve
Cutter, injector sleeve, ST-884
Cutter, valve seat insert, ST-662
Cutting tool, bead, ST-788
Driftpin, 1/4-inch
Driver, tool, ST-1122
Driver tool, valve seat insert, ST-257
Eccentricimeter
Extension, 3-inch, 1/2-inch drive
Extractor, valve seat, ST-1133
Gage, bore, dial
Grinder, surface
Grinder, valve seat, ST-685
Hammer, ball-peen, 16-ounce
Hammer, plastic-faced
Handle, ratchet, 1/2-inch drive
Holder, injector sleeve cutter,
ST-884-1
Holding tool, injector sleeve,
ST-1179
Indicator, dial, ST-547
Key, hex, 5/32-inch
Key, hex, 3/16-inch
Machine, refacer, valve
Mandrel, crosshead guide, ST-633
Mandrel, installation, injector
sleeve, ST-1227
Mandrel, valve guide, ST-1217
Micrometer, 0- to 1-inch
Micrometer, 2- to 3-inch
Micrometer, depth
Micrometer, inside
Pencil
Pilot, injector sleeve cutter,
ST-884-6
Press, arbor
Press, drill, suitable
2-176
Change 1
Puller, dowel, ST-667
Puller, dowel, ST-1134
Puller, injector sleeve, ST-1244
Roller tool, expanding, ST-880
Rule, machinist’s, steel
Socket, 1/2-inch, 1/2-inch drive
Socket, impact wrench, injector sleeve puller,
ST-1247
Staking tool, insert, ST-1124
Tester, vacuum, 6-volt, ST-417
Tester, vacuum, 12-volt, ST-417-A
Tester, vacuum, 110-volt, ST-1257
Tester, valve spring
Wrench, torque, 0 to 150 in. lb (0 to
16.9 N•m), 1/2-inch drive
Wrench, torque, 0 to 175 ft lb (0 to 245
N•m), 1/2 inch drive
Materials/Parts
Collet, half (16 required)
Crocus cloth (item 4, appendix B)
Cutting fluid, lapping (item 5, appendix B)
Grease, extreme-pressure (item 10,
appendix B)
Oil, lubricating (item 12, appendix B)
Packing, preformed, injector sleeve (two
required)
Prussion blue (item 13, appendix B)
Tags, marker (item 17, appendix B)
Tape, antiseizing (item 18, appendix B)
References
TM 55-1500-335-23, Inspection Methods,
Non-Destructive
Equipment Condition
Cylinder head removed (page 2-36).
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY
WARNING
Extreme care must be taken when releasing springs under pressure. Injury to personnel
could result.
NOTE
Steps given are typical for all three cylinder heads.
1. Cylinder head (1)
Valve spring
compressor (2)
a. Screw stud (3) into rocker lever capscrew hole (4).
b. Install valve spring compressor pivot
head (5) on stud (3).
TA 242451
2-177
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY - CONTINUED
NOTE
Each of the eight valve springs can be reached without relocating stud. Compress one
valve spring at a time to remove half collets.
2. Valve spring (1)
Compression head (2)
Place on valve spring retainer (3) and
press down valve spring compressor (4).
Remove and discard half collets (5).
3. Valve guide (6)
Valve spring retainer (3), valve
spring (1), and
spring seat (7)
Lift off.
NOTE
Tag valves (8) as to their location in cylinder head (9) so they can be reassembled in
the same valve guide (6).
4. Cylinder head (9)
Valve (8)
Using 16-ounce ball-peen hammer, tap
valve (8) down lightly to remove from
cylinder head (9).
Tag valves (8) and hold for
inspection.
TA 242452
2-178
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
All fuel passage pipe plugs in cylinder heads must be removed before cleaning. Do not
discard pipe plugs. Hold plugs for reinstallation.
The number and location of pipe plugs may vary because of cylinder head location on
cylinder block.
5. Cylinder head (9)
Four pipe plugs (10)
Using 5/32-inch hex key, loosen and
remove.
6.
Four pipe plugs (11)
Using 3/16-inch hex key, loosen and
remove.
TA 242453
2-179
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
INSPECTION
NOTE
Steps given are typical for all three cylinder heads.
For more complete inspection of cylinder head, polish mating surfaces with crocus
cloth.
For tagging parts, see General Maintenance Instructions, page 2-3.
a. Using magnetic inspection method, inspect for cracks.
If cracks are found, discard cylinder
head (1).
b . Visually inspect surface near water passage holes (2) for pits and scratches.
c . Using steel machinist’s rule, measure
length of pits and scratches.
If pits and scratches are more than
2/32 to 5/32-inch (1.59 to 3.97 mm)
from edge of water hole, discard cylinder head (1).
d . Check for warped mating surfaces.
If cylinder head Is warped, tag
cylinder head for resurfacing. See
steps 24 and 25.
7. Cylinder head (1)
8.
2-180
Valve seat
insert (3)
Visually inspect for cracks or burns.
If cracks or bums exist, tag valve
seat for replacement. See steps
26 thru 34.
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
9. Cylinder head (1)
10. Valve seat
insert (3)
ITEM
ACTION
REMARKS
Valve seat
insert (3)
Using plastic-faced hammer, carefully tap
cylinder head around valve seat insert.
If valve seat insert bounces, tag
for replacement. See steps 26
thru 34.
Valve seat width (4)
Using steel machinist’s rule, measure
width.
If width (4) exceeds 0.125 inch
(3.18 mm) at any one point, and
cannot be narrowed to between 2/32
and 4/32-inch (1.66 to 3.18 mm)
during regrind, tag valve seat for
replacement. See steps 28 thru 34.
TA 242454
2-181
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
11. Cylinder head (1)
Injector sleeve (2)
Visually inspect cup seating area (3)
for scratches.
If cup seating area is scratched, tag
for replacement. See steps 35
thru 48.
12. Cup seating area (3)
Injector cup (4)
Lightly coat injector cup with prussian
blue.
13. Injector sleeve (2)
Injector
assembly (5)
a. Using 1/2-inch drive 1/2-inch socket,
3-inch extension, and ratchet handle,
install injector assembly. Secure
with clamp (6) and capscrews (7).
Using 1/2-inch drive, 1/2-inch
socket, and 0 to 175 ft lb (0 to
245 N•m) torque wrench, tighten
capscrews (7) alternately In 4 ft lb
(5.4 N•m) Increments to 10 to 12 ft lb
(13.5 to 16.2 N•m).
b. Using 1/2-inch drive 1/2-inch socket,
3-inch extension, and ratchet handle,
remove capscrews (7) clamp (6), and
injector assembly.
TA 242455
2-182
Change 1
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
14. Injector sleeve (2)
and cup seating
area (3)
ITEM
ACTION
REMARKS
Check seat pattern in bottom of injector
sleeve (2).
Blued band (8) on Injector sleeve
In cup seating area must be 0.060
inch (1.52 mm) minimum width, and
be located approximately 0.469 inch
(11.91 mm) from bottom of cylinder
head surface (1). If seating pattern
does not meet these specifications,
tag injector sleeve for replacement.
See steps 35 thru 48.
TA 242456
2-183
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
15. Cylinder head (1)
Injector
assembly (2)
a. Using 1/2-inch drive 1/2-inch socket,
3-inch extension, and ratchet handle,
install injector assembly. Secure with
clamp (3) and capscrews (4).
b. Using 1/2-inch drive 0 to 175 ft lb (0 to
245 N•m) torque wrench, tighten capscrews alternately in 4 ft lb (5.4 N•m)
increments to 10 to 12 ft lb (14 to 16.8
N•m).
16.
Injector tip (5)
Using ST-547 dial indicator and ST-981
injector tip protrusion checking tool (6),
measure injector tip protrusion.
Injector tip protrusion must be
0.060 to 0.070 Inch (1.52 to 1.78
mm). If Injector tip protrusion Is not
within these specifications, tag injector sleeve (7) for replacement.
See pages 35 thru 48.
TA 242457
2-184
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
17.
ITEM
Valve guide (8)
ACTION
REMARKS
a. Inspect for chips, cracks, burrs, or
broken sections.
If chipped, cracked, or broken, or
burrs are found, tag valve guide
for replacement. See step 23.
b. Set dial bore gage (9) at 0.4552 inch
(11.562 mm). Attempt to insert gage
into valve guide bore (10).
If gage goes into bore, tag valve
guide for replacement. See step 23.
c. Check for out-of-round bores.
If bore is out of round, tag valve
guide for replacement. See step 23.
d. Check valve guide protrusion (11) from
cylinder head surface (12).
If protrusion is less than 1.315
inches (33.43 mm), tag valve guide
for replacement. See step 23.
TA 242458
2-185
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
18. Cylinder head (1)
19.
Crosshead guide (2)
Crosshead (4)
a. Using 0- to l-inch micrometer (3),
check outside diameter.
If outside diameter Is less than
0.432 In. (10.97 mm), tag cross.
head guide for replacement. See
step 22.
b. Using steel machinist rule, check for
straightness.
If crosshead guide Is not at right angle
to milled surface of cylinder head, tag
crosshead guide for replacement.
See step 22.
a. Using magnetic inspection method, inspect for cracks.
If cracks are found, discard crosshead.
TA 242459
2-188
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
b. Inspect adjusting screw threads (5)
and crosshead threads for wear or
distortion.
If adjusting screw threads (5) or
crosshead threads are damaged, discard valve crosshead.
c. Set dial bore gage at 0.4402 inch
(11.181 mm). Attempt to Insert gage
into bore (6).
If bore gage goes Into bore (6), discard valve crosshead (4).
d. Check for out of round bore by gaging
at several points 90 degrees apart.
If bore Is out of round, discard
valve crosshead (4).
e. inspect for excessive wear on rocker
arm contact area (7) and on valve stem
contact area (8).
If excessive wear Is found on either
rocker arm contact area (7) or valve
stem contact area (8), discard valve
crosshead (4).
TA 242460
2-187
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
WARNING
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
20.
Valve (1)
a. Using a wire brush, clean valves and
polish with crocus cloth.
b. Inspect valve head (2) for cups,
cracks, pits.
If cups, cracks, or pits are found,
discard valve.
c. Using 0- to 1-inch micrometer, check
valve head rim thickness (3).
If thickness Is less than 0.105 Inch
(2.87 mm), discard valve.
d. Using 0- to 1-inch micrometer (4),
check valve stem diameter (5).
If valve stem diameter (5) is less
than 0.449 Inch (11.41 mm), discard valve.
e. Check collet recesses (6) for wear.
If new collet will not fit in recesses
securely, discard valve.
TA 242461
2-188
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Welded valves which have two types of metal, may be magnetic tested. However, due to
change of metal at weld, there will be magnetic leakage at this point. This will be indicated by a broad fuzzy pattern of magnetic particles.
f . Using magnetic inspection method, inspect for magnetic indications.
If indications appear over 1/2 inch
(12.70 mm) in length or more than
five indications are spaced closer
than 1/8 inch (3.18 mm) In area (7),
discard valve.
g. If magnetic indications appear in areas
(8), (9), (10), or (11), discard valve.
TA
242462
2-189
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
INSPECTION - CONTINUED
21.
Valve spring (1)
a. Inspect for distortion, cracks, breaks
and missing or collapsed coils.
If valve spring Is collapsed, broken,
cracked, or distorted, discard valve
spring.
b. Check valve spring free length.
Approximate free length is 2.685
inches (68.199 mm). If valve spring
does not meet this specification,
discard valve spring.
WARNING
Extreme care must be taken when releasing springs under pressure. Injury to personnel
could result.
c. Using valve spring tester (2), test
valve spring tension.
Apply load to valve spring tester.
If valve spring compresses to length
of 1.724 inches (43.789 mm) before
load reaches 143 pounds (94.895
kg), discard valve spring.
TA 242463
2-190
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR/ASSEMBLY
NOTE
Step 22 is typical for all cylinder head crosshead guide pins tagged for replacement.
22. Cylinder head (3)
Crosshead guide
pin (4)
a. Using ST-667 or ST-1134 dowel puller
(5), remove crosshead guide pin.
b. Using arbor press and ST-633 crosshead guide mandrel, press new crosshead guide pin into cylinder head to
obtain protrusion (6) of 1.860 to
1.860 inches (47.24 to 47.75 mm).
If new crosshead guide pin will not
fit securely in cylinder head, discard cylinder head.
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CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR/ASSEMBLY - CONTINUED
NOTE
Step 23 is typical for all cylinder head valve guides tagged for replacement.
23. Cylinder head (1)
Valve guide (2)
a. Using a 16-ounce ball-peen hammer
and 1/4-inch driftpin (3) drive valve
guide out from underside of cylinder
head.
b. Inspect valve guide bore in cylinder
head (1).
If valve guide bore In cylinder head
is damaged, discard cylinder
head.
c. Using arbor press and ST-1217 valve
guide mandrel (4), install new valve
guide into cylinder head.
If new valve guide Is not secure In cylinder head, discard cylinder head.
TA 242465
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CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps 24 and 25 are typical for all cylinder heads tagged for resurfacing.
24. Cylinder head (1)
25. Cylinder head
mating surface (7)
Valve seat
insert (5)
Using ST-1133 valve seat extractor (6),
remove all valve seat inserts.
Using surface grinder, resurface cylinder
head mating surface.
Only remove as much material as
necessary to repair damage to
cylinder head mating surface. If cylinder head must be resurfaced so
cylinder head height (8) is less than
4.340 inches (110.24 mm), discard
cylinder head.
TA 242466
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CYLINDER HEAD - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
REPAIR/ASSEMBLY - CONTINUED
NOTE
Steps 26 through 31 are typical for all cylinder head valve seat Inserts tagged for
replacement or previously removed during cylinder head resurfacing.
26. Cylinder head (1)
Valve seat
Insert (2)
If cylinder head has not been resurfaced,
use ST-1133 valve seat extractor (3) to
remove valve seat inserts tagged for
replacement.
CAUTION
Each replacement valve seat insert’s outside diameter and thickness must be measured
and compared to relating valve seat counterbore in cylinder head before counterboring.
These measurements will prevent overboring and damage to the cylinder head.
27.
Valve seat
insert (2)
a. Using 2-to3-inch micrometer,
measure outside diameter.
Record reading and compare to specifications in the following table.
b . Using 0- to 1-inch micrometer, measure thickness.
Record reading and compare to specifications in the following table.
28.
Valve seat
counterbore (4)
a. Using depth micrometer (5), measure
depth (6).
Record reading and compare to specifications in the following table.
b . Using inside micrometer (7), measure
inside diameter.
Record reading and compare to specifications in the following table.
NOTE
After comparing measurements of removed valve seat insert and valve seat counterbore
in cylinder head to the following table, choose the next oversize for replacement valve
seat insert, and counterbore the cylinder head to dimensions specified for that oversize
valve seat insert.
2-194
TM
5-2815-241-34&P
CYLINDER HEAD - CONTINUED
VALVE SEAT INSERT SPECIFICATIONS
VALVE SEAT
INSERT
CYLINDER HEAD VALVE
SEAT COUNTERBORE
DEPTH
IN. (MM)
1st oversize
standard
2nd oversize
standard
3rd oversize
0.005
(0.137)
0.010
(0.25)
0.015
(0.38)
4th oversize
5th oversize
VALVE INSERT
OUTSIDE
DIAMETER
IN. (MM)
2.0075/2.0085
(50.991151.016)
2.0125/2.0135
(51.118151.143)
2.0225/2.0235
(51.372/51.397)
2.0325/2.0335
(51.626151.651)
2.0425/2.0435
(51.880151.905)
CYLINDER HEAD
COUNTERBORE
INSIDE DIAMETER
IN. (MM)
2.0045/2.0055
(50.914150.940)
2.0095/2.0105
(51.041/51.067)
2.0195/2.0205
(51.295151.321)
2.0295/2.0305
(51.549151.575)
2.0395/2.0405
(51.803/51.829)
INSERT
THICKNESS
IN. (MM)
0.278/0.282
(7.0617.16)
0.278/0.282
(7.0617.16)
0.283/0.287
(7.1917.29)
0.288/0.292
(7.32/7.42)
0.293/0.297
(7.44/7.54)
TA 242467
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CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR/ASSEMBLY - CONTINUED
29. Cylinder head
mating surface (1)
a. Clamp base of ST-663 valve guide
arbor set (2) to cylinder head mating
surface near valve seat insert
bore (3).
b. Center ST-662 valve seat insert cutter
(4) in valve seat insert bore (3) and
on ST-1217 valve guide mandrel (5).
After tool assembly is centered, be
sure tool assembly Is securely
clamped to cylinder head.
NOTE
To ensure a perfectly flat bottom of bore for valve seat inserts to seat correctly, allow
cutter to turn several revolutions at exact moment the proper depth in cylinder head is
reached.
30. Cylinder head (6)
Valve seat insert
bore (3)
Using ST-257 valve seat insert driver tool
(7), cut counterbore (8) 0.006 to 0.010
inch (0.1524 to 0.2540 mm) deeper than
insert thickness to allow staking of cylinder head to secure valve seat insert.
TA 242468
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CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
Overstaking around valve seat insert may crack cylinder head.
31.
Valve seat
insert (9)
a . Using ST-257 valve seat insert driver
tool (10), drive valve seat insert into
valve seat bore (11), until fully
seated.
b. Using ST-1122 tool driver (12) over
shaft of ST-1124 insert staking tool
(13), stake valve seat insert into cylinder head.
c. Check valve seat width.
See step 10.
d. Remove tools secured to cylinder head.
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CYLINDER HEAD - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
REPAIR/ASSEMBLY - CONTINUED
CAUTION
Do not apply side pressure to ST-685 valve seat grinder motor. This action will cause the
valve seat to be ground off-center.
NOTE
Steps 32, 33, and 34 are typical for all cylinder head valve seat inserts marked for
regrinding.
3 2 . Cylinder head (1)
Valve seat
insert (2)
a. Using ST-685 valve seat grinder and the
correct arbor from ST-663 valve guide
arbor set, grind valve seat inserts to
specifications below.
b. Check seat width. It should be no
smaller than dimension A and no larger
than dimension B.
If seat width is wider than dimension
B, material can be removed from
points (3) and (4) with specially
dressed grind stones. Narrowing
should not extend beyond chamfer on
valve seat insert. Chamfer provides
metal for staking insert Into cylinder
head.
33.
Using eccentricimeter (5), check valve
seat insert runout. Total runout should not
exceed 0.002 inch (0.05 mm).
if runout exceeds this measurement,
repeat step 32.
34.
a. Remove all tools from valve seat insert.
b. Clean cylinder head. See General
Maintenance Instructions, page 2-3.
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CYLINDER HEAD - CONTINUED
TA 242470
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CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR/ASSEMBLY - CONTINUED
NOTE
Steps 35 thru 48 are typical for all cylinder head fuel injector sleeves tagged for
replacement.
35. Cylinder head (1)
Fuel injector
sleeve (2)
Install ST-1244 injector sleeve puller (3) to
fuel injector sleeve.
CAUTION
Make sure extractor tip (4) of ST-1244 injector sleeve puller is firmly seated against
bottom of injector sleeve to prevent cylinder head damage.
36.
Fuel injector
sleeve (2)
Using ST-1247 injector sleeve puller
impact wrench socket and ST-1244 injector
sleeve puller (3), remove fuel injector
sleeve and discard.
37.
Preformed
packing (5)
Remove.
Discard.
TA 242471
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TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
38. Cylinder head (1)
Injector bore (6)
Inspect the bead in the bottom of the cylinder head injector bore for smoothness.
If the bead Is not smooth, use ST788 bead cutting tool with ST-884-1
Injector sleeve cutter holder and
ST-884-6 injector sleeve cutter pilot
to cut the bead in the Injector bore.
39.
New preformed
packing (5)
Coat new packing with clean lubricating oil,
and install packing into cylinder head packing groove.
CAUTION
Do not strike mandrel with hammer before installing ST-1179 injector sleeve holding
tool. Damage to injector sleeve could result.
40. Cylinder head
injector bore (6)
Injector
sleeve (7)
Using ST-1227 injector sleeve Installation
mandrel (8), push injector sleeve into
cylinder head injector bore, until it bottoms.
TA 242472
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CYLINDER HEAD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
REPAIR/ASSEMBLY - CONTINUED
41. Cylinder head (1)
Injector sleeve (2)
and ST-1179 injector
sleeve holding tool (3)
a. Install ST-1179 injector sleeve holding
tool and tighten nut (5) to 35 to 40 lb ft
(49 to 56 N•m) torque.
b. Insert ST-1227 injector sleeve installation mandrel (4) into injector sleeve.
42. Injector sleeve (2)
ST-1227 injector
sleeve installation
mandrel (4)
Using 16-ounce ball-peen hammer, strike
mandrel with two moderate blows to ensure
that injector sleeve is properly seated.
43.
ST-1179 injector
sleeve holding
tool nut (5)
Using 1/2-inch drive 0 to 175 ft lb (0 to 245
N•m) torque wrench, tighten to 35 to 40 ft lb
(49 to 56 N•m).
TA 242473
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TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
44. Cylinder head (1)
Injector sleeve (2)
Position ST-880 expanding roller tool (6)
into injector sleeve.
45. Injector sleeve (2)
ST-880 expanding
roller tool (6)
Adjust depth of expanding roller tool so
that roller (7) extends 0.5 inch (12.7 mm)
into injector sleeve.
CAUTION
Overrolling of injector sleeve will cause deformation of sleeve into preformed packing
groove.
46.
ST-880 expanding
roller tool (6)
a. Using 1/2-inch drive 0 to 150 in. lb (0 to
16.9 N•m) torque wrench, tighten roller
(7) until a 75 in. lb maximum torque
reading is reached.
b. Remove tools from injector sleeve.
TA
242474
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TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
REPAIR/ASSEMBLY - CONTINUED
47.
ST-884 injector
sleeve cutter (1)
Size, grind, and inspect cutter. Make
sure it is ground to the exact specifications as listed in the following table.
CUTTER SPECIFICATIONS
ITEM
2
3
4
5
6
7
8
9
10
2-204
SPECIFICATION
IN. (MM)
0.080 - 0.090 (2.0320 - 2.2860)
0.0015 - 0.0025 (0.0381 - 0.0635)
0.0077 - 0.0097 (0.1955 - 0.2463)
1.0815 - 1.0635(41.0210 - 41.5290)
15-degree angle relief
15-degree angle relief
30-degree, 9-minute angle relief
0.375 (9.5250)
0.312 (7.9375)
ITEM
11
12
13
14
15
16
17
18
19
SPECIFICATION
IN. (MM)
0.125 (3.1750)
0.375 (9.5250)
0.010 (0.2540)
0.0937 (2.3812)
0.384 - 0.386 (9.7536 - 9.8044)
0.226 - 0.236 (5.7404 - 5.9944)
0.3425 (8.6995)
1.250 (31.7500)
0.375 (9.5250)
TA 242475
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
To determine amount of cut to injector sleeve seat, measure tip protrusion. See steps 18
and 19.
When cutting injector sleeve seat, use a solid stream of good cutting fluid to allow cutter
to cut freely without grabbing.
48. Cylinder head (20)
Injector sleeve (21)
Using ST-884 injector sleeve cutter (22)
and suitable drill press, cut injector
sleeve just enough to provide for proper
seating of injector and to maintain correct
injector tip protrusion. See steps 12
thru 16.
If Injector seating area or Injector
tip protrusion are not within specifications, recut Injector sleeve seat.
TA 242476
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TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR/ASSEMBLY - CONTINUED
NOTE
Steps 49, 50, and 51 are typical for all cylinder head valves requiring refacing.
Valve refacer operating instructions are provided with the valve refacer machine.
49.
Valve (1)
Insert valve stem in valve refacer chuck on
guide area of stem (2).
50. Valve refacer
Valve (1)
a. Check valve for out-of-round condition.
If runout exceeds 0.001 inch (0.03
mm), valve is warped. Discard valve.
b. Using ST-685 valve seat grinder, wet
grind valve to an exact 30-degree angle
from horizontal, just enough to reface
completely around the valve head.
If after grinding, valve head thickness
(3) Is less than 0.105 Inch (2.67
mm), discard valve.
c. Compare refaced valve to the following
table.
VALVE SPECIFICATIONS
ITEM
INTAKE AND
EXHAUST VALVES
NEW MINIMUM
2
stem
0.4500 inch (11.4300 mm)
3
valve head
thickness
seat angle
refacing valve
seating area
0.105 inch (2.67 mm)
4
5
2-206
30 degrees
0.0625 inch (1.59 mm)
NEW MAXIMUM WORN LIMITS
0.4510 inch
(11.4554 mm)
0.4490 inch
(11.4046 mm)
0.105 inch
(2.67 mm)
30 degrees
0.0625 inch
(1.59 mm)
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
51. Valve (1)
ITEM
Valve seating
area (5)
ACTION
REMARKS
a. Using pencil, mark valve seating area
as shown below.
b. Insert valve into cylinder head valve
guide to fully closed position. Rotate
10 degrees.
A good valve seat area will be indicated if all pencil marks are broken. If
pencil marks are not broken, readjust
valve refacer machine, redress
ST-685 valve seat grinder, and reface
valve.
TA 242477
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TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR/ASSEMBLY - CONTINUED
NOTE
Wrap threaded ends of pipe plugs with antiseizing tape to prevent leakage.
Applicable pipe plug locations for each cylinder head are shown in the following table.
52. Cylinder head (1)
Four pipe plugs
(2 and 3)
Using 5/32-inch hex key, install where
applicable and tighten.
53.
Four pipe plugs
(4 and 5)
Using 3/16-inch hex key, install where
applicable and tighten.
CYLINDER HEAD PIPE PLUG LOCATION
PIPE
PLUG
2
3
4
5
FORWARD CYLINDER
HEAD
MIDDLE CYLINDER
HEAD
REAR CYLINDER
HEAD
open
3/8-inch (9.54 mm)
1/8-inch (3.18 mm)
3/8-inch (9.54 mm)
open
3/8-inch (9.54 mm)
open
3/8-inch (9.54 mm)
1/8inch (3.18 mm)
3/8-inch (9.54 mm)
open
3/8-inch (9.54 mm)
TA 242478
2-208
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
NOTE
Be sure to install valves in original locations as tagged in step 4.
Steps 54 thru 64 are typical for all cylinder head valve assemblies.
54.
Cylinder head (1)
Be sure cylinder head is clean.
If cylinder head needs cleaning, see
General Maintenance Instructions,
page 2-3.
55. Cylinder head (1)
Valve (6)
Dip valve stem in clean lubricating oil and
insert into valve guides (7).
56.
Cylinder head (1)
Place cylinder head, mating surface down,
on wooden bench or other protective
surface.
57. Valve guide (7)
Valve spring
spacer (8)
If valve seat insert and valve have been
refaced more than a total of 0.030 inch
(0.76 mm), place a maximum of two valve
spring spacers over valve guide (7).
TA 242479
2-209
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR/ASSEMBLY - CONTINUED
58. Valve guide (1)
Valve spring seat
(2), valve spring
(3), and valve spring
retainer (4)
Assemble onto valve guide.
WARNING
Extreme care must be taken when installing springs under pressure. Injury to personnel
could result.
59. Cylinder head (5)
Valve spring
compressor (6)
a. Install stud (7) into rocker lever cap
screw hole (8).
b. Install valve spring compressor pivot
head (9) on stud (7).
c. Place compression head (10) on valve
spring retainer (4), press down valve
spring compressor, and install new half
collets (11).
d. Remove valve spring compressor and
stud (7) from cylinder head.
TA 242480
2-210
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
Never vacuum test cylinder head with injectors installed. Installation of injectors while
head is removed from block could cause misalinement of valves in valve seat area and
result in leakage during testing which would not necessarily occur during actual engine
operation.
NOTE
Steps 60 thru 64 are typical for all valves. (Vacuum tester operating instructions are
provided with tester.)
60. Cylinder head (5)
Valve (12)
Using ST-417, ST-417-A, or ST-1257
vacuum testers, hold vacuum cup (13) over
head of valve and seat flat on cylinder
head surface surrounding valve.
61.
Vacuum pump (14)
a. Operate vacuum pump until hand (15)
on vacuum gage (16) reaches 18 to
25 inches vacuum, then close shutoff
valve (17) and stop pump.
b. Start timing when hand on gage reaches
l&inches vacuum.
c. Stop timing when hand on gage reaches
8-inches vacuum.
If elapsed time is less than 10 seconds, valve seat is unsatisfactory.
TA
242481
2-211
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
REPAIR/ASSEMBLY - CONTINUED
62. Cylinder head (1)
Valve (2)
a. Using plastic-faced hammer, tap stem
end of valve and retest by repeating
steps 60 and 61.
If valve seating Is satisfactory,
proceed to next step.
b. Check for leaking connections in tester
by placing vacuum cup against a clean
window glass or any smooth flat surface.
Repair any leaks In test equipment.
c. Check valve and seat area to be sure
they are free of dirt particles, Retest
valve seating.
If valve seating Is unsatisfactory,
regrind seat and reface valve. See
steps 32, 33, and 34 and steps 49,
50, and 51.
NOTE
It is possible to mistake leakage around valve seat insert for valve seat leakage. If this
type of leak is suspected, proceed with the following step.
63. Cylinder head (1)
2-212
Valve seat
insert (3)
a. Apply extreme-pressure grease around
outside edge of valve seat insert to make
a grease seal.
b. Perform vacuum test and inspect grease
seal for a break indicating air leakage
between wall of counterbore and valve
seat insert.
Restake valve seat Insert. See
step 31.
c. Vacuum test and recheck for air leakage
around valve seat insert.
If air leakage Is present, see steps
26 thru 31. Replace valve seat Insert.
TM 5-2815-241-34&P
CYLINDER HEAD - CONTINUED
LOCATION
64. Cylinder head (1)
ACTION
REMARKS
ITEM
Vacuum test and check valve seating.
If test is unsatisfactory, repeat
steps 60 thru 64.
If test is satisfactory, perform
follow-on maintenance.
Valve (2)
NOTE
Be sure cylinder head is clean. If cylinder head needs cleaning, see General
Maintenance Instructions, page 2-3.
Be sure to keep valve crossheads and fuel injector assemblies together with cylinder
head for engine reassembly.
FOLLOW-ON MAINTENANCE: Install cylinder head (page 2-68).
TASK ENDS HERE
TA
242482
2-213
TM 5-2815-241-34&P
Section VII. CRANKSHAFT MAINTENANCE
Page
Crankshaft Assembly . . . . . . . . . . . . . . . . .
Page
2-214
Vibration Damper. . . . . . . . . . . .
2-219
CRANKSHAFT ASSEMBLY
This task covers:
a. Cleaning (page 2-214)
b. Disassembly (page 2-214)
c. Inspection (page 2-215)
d. Repair (page 2-217)
e. Assembly (page 2-218)
INITIAL SETUP
Tools
Materials/Parts - Continued
Grinder, crankshaft
Indicator, dial
Mandrel, hollow-core
Micrometer, 3- to 4-inch
Micrometer, 4- to 5-inch
Micrometer, depth
Mittens, cloth, heat-protective
Press, arbor
Puller, gear, circular-type
Torch, heating, oxy/acetylene
Key, machine
Grease, extreme-pressure (item 10,
appendix B)
Tags, marker (item 17, appendix B)
Equipment Condition
Crankshaft assembly removed (page 2-49).
References
Materials/Parts
TM 55-1500-335-23, Inspection Methods,
Non-Destructive
Bearing set
Cloth, emery (item 1, appendix B)
LOCATION
ACTION
REMARKS
ITEM
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
DISASSEMBLY
WARNING
Heat-protective cloth mittens must be worn to prevent serious injury to hands when
handling heated parts.
1. Crankshaft (1) with
assembled parts
2-214
Change 1
Crankshaft gear (2)
and machine key (3)
a. Using a oxy/acetylene heating torch,
heat crankshaft gear to 300° to 400°F
(150° to 205°C).
TM 5-2815-241-34&P
CRANKSHAFT ASSEMBLY - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
b. Using circular-type gear puller, pull
crankshaft gear from crankshaft.
c. Remove machine key.
Discard.
INSPECTION
2.
Crankshaft (1)
a. Inspect for cracks.
Discard if cracked.
b. Inspect for and using depth micrometer,
measure depth of scratches and nicks on
bearing journals.
If scratches and nicks exceed depth of
0.020 inch (0.508 mm), discard
crankshaft. If depth of scratches and
nicks is 0.020 inch (0.508 mm) or
less, tag for grinding.
3. Crankshaft (1)
Connecting rod
journals (4)
a. Using 3- to 4-inch micrometer, measure diameter of six connecting rod
journals in several places. Check for
out-of-round condition. Connecting rod
journals should be 3.122 to 3.125
inches (79.293 to 79.375 mm).
Tag crankshaft connecting rod journals for grinding if worn smaller than
3.122 inches (79.298 mm) or more
than 0.002 Inch (0.05 mm) out of
round.
b. Using 3- to 4- inch micrometer, measure six connecting rod journals for
taper across length of journals.
Tag for grinding if taper exceeds
0.0005 inch (0.0127 mm).
TA 242483
2-215
TM 5-2815-241-34&P
CRANKSHAFT ASSEMBLY - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
4. Crankshaft (1)
Main bearing
journals (2)
a. Using 4- to 5-inch micrometer, measure diameter of seven main bearing
journals in several places. Check for
out-of-round condition. Main bearing
journals should be 4.4975 to 4.500
inches (114.24 to 114.30 mm).
Tag crankshaft main bearing journals
for grinding if worn smaller than
4.4975 Inches (114.23 mm) or more
than 0.002 inch (0.05 mm) out-ofround.
b. Using 4-to 5-inch micrometer, measure seven main bearing journals for
taper across length of journals.
Tag for grinding If taper exceeds
0.0005 Inch (0.0127 mm).
5.
Thrust bearing
flanges (3)
a. Inspect for and, using depth micrometer, measure depth of scratches,
nicks, and score marks.
If scratches, nicks, or score marks
exceed 0.020 inch (0.568 mm), discard crankshaft. If scratches, nicks
or score marks are 0.020 Inch (0.508
mm) or less, tag for grinding.
b. Using 3 to 4-inch micrometer, measure distance between thrust bearing
flanges. Distance must be 3.001 to
3.006 inches (76.225 to 76.352 mm).
If distance exceeds 3.006 inches
(76.352 mm), tag for grinding.
c. Using dial indicator, check thrust bearing flanges for flatness. Flatness should
vary no more than 0.003 inch
(0.076 mm).
If flatness exceeds 0.003 inch
(0.0076 mm), tag for grinding
2-216
TM 5-2815-241-34&P
CRANKSHAFT ASSEMBLY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
6.
Crankshaft (1)
Using magnetic inspection procedure,
inspect for cracks.
Discard If cracked.
7.
Crankshaft gear (4)
Inspect for cracks, breaks, nicks, and
scratches by visual and magnetic
inspection.
Discard If cracked or broken. Polish
out small nicks and scratches with
emery cloth.
REPAIR
NOTE
Main bearing and connecting rod bearing sets are available in 0.010-, 0.020-,
0.030-, and -040-inch (0.254, 0.508, 0.762, and 1.016 mm) undersizes. Thrust
bearings are in 0.010- and 0.020-inch (0.254 and 0.508 mm) oversizes. When
grinding crankshaft, do not remove more material than necessary to clean up bearing
surfaces and fit the next size bearing or washer.
Perform step 8 only if crankshaft grinding is required.
8.
Crankshaft (1)
Using crankshaft grinder, grind as
necessary.
TA
242484
2-217
TM 5-2815-241-34&P
CRANKSHAFT ASSEMBLY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
9.
Crankshaft (1)
a. Mark size of rod and main bearings to be
used on front counterweight as shown in
view A.
b. Mark size of front and rear thrust washers to be used on rear counterweight as
shown in view B.
ASSEMBLY
WARNING
Heat-protective cloth mittens must be worn to prevent serious injury to hands when
handling heated parts.
10. Crankshaft (1)
Crankshaft gear (2)
and new machine
key (3)
a. Heat crankshaft gear for one hour at
450°F (214°C).
b. Position new machine key on crankshaft.
c. Lubricate crankshaft gear flange with
extreme-pressure grease, aline crankshaft gear with crankshaft, and using
arbor press and hollow-core mandrel,
press crankshaft gear into position.
NOTE
Pack proper size bearings, as marked on crankshaft, with crankshaft for assembly.
NOTE
FOLLOW-ON MAINTENANCE: install crankshaft assembly and bearings
(page 2-54).
TASK ENDS HERE
TA 242485
2-218
TM 5-2815-241-34&P
VIBRATION DAMPER
This task covers:
Cleaning/Inspection
INITIAL SETUP
Materials/Parts - Continued
Tools
Rags, wiping (item 14, appendix B)
Mittens, cloth, heat-protective
Equipment Condition
Materials/Parts
Vibration damper removed (page 2-48).
Dye, leak-detection (item 7,
appendix B)
LOCATION
ACTION
REMARKS
ITEM
CLEANING/INSPECTION
Vibration damper (1)
1.
Wipe clean with rag.
WARNING
Heat-protective cloth mittens must be worn to prevent serious injury to hands when
handling heated parts.
a. Coat with leak-detection dye.
b. Heat in oven to 200°F (93°C).
c. Inspect for any indications of leakage.
Discard if leaking.
2.
NOTE
FOLLOW-ON MAINTENANCE: Install vibration damper (page 2-90).
TASK ENDS HERE
TA 242486
2-219
TM 5-2815-241-34&P
Section VIII. PISTON AND CONNECTING ROD MAINTENANCE
PISTON AND CONNECTING ROD
This task covers:
a. Disassembly (page 2-220)
b. Cleaning/inspection (page 2-222)
c. Repair (page 2-231)
d. Assembly (page 2-235)
INITIAL SETUP
Tools
Tools - Continued
Socket, 15/16-inch, 1/2-inch drive
Vise, machinist’s
Wrench, torque, 0 to 150 ft lb (0 to
210 N•m), 1/2-inch drive
Arbor, expanding
Container, 2-gallon
Expander, piston ring
File, half-round
Fixture, checking, connecting rod,
ST-561
Gage, bore, dial
Gage, plug, ST-205
Gage, ring groove, ST-560
Gage, thickness
Handle, hinged, 1/2-inch drive
Machine, boring, ST-526
Mandrel and block, ST-870
Mandrel, piston pin
Mandrel set, ST-1242
Micrometer, 0-to 1-inch
Micrometer, 1-to 2-inch
Micrometer, 5- to 6-inch
Mittens, cloth, heat-protective
Plate, surface
Pliers, snap-ring, 6-inch
Press, arbor
Scraper
Materials/Parts
Cutting fluid, lapping (item 5, appendix B)
Prussian blue (item 13, appendix B)
Ring set, piston (six required)
Soap, lubricating (item 15, appendix B)
Tags, marking (item 17, appendix B)
Washers, connecting rod (12 required)
Equipment Condition
Piston and connecting rod removed
(page 2-52).
References
TM 55-1500-335-23, Inspection Methods,
Non-Destructive
ACTION
LOCATION
REMARKS
ITEM
DISASSEMBLY
NOTE
Steps given are typical for all six pistons and connecting rods. Be sure to tag all pistons,
bearings, and bearing caps to their respective connecting rod and location in cylinder
block. If a new or reground crankshaft is used, discard used bearings.
1. Connecting rod (1)
2-220
Change 1
Bearing cap (2), two
nuts (3) and two
washers (4)
Take off.
Discard washers.
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
Upper bearing (5)
2.
Take out.
Tag and hold for inspection.
3. Bearing cap (2)
Lower bearing (6)
Take out.
Tag and hold for inspection.
4. Piston (7)
Four piston
rings (8)
Using piston ring expander, take off.
5. Piston pin bore (9)
Two retaining
rings (10)
Using 6-inch snap-ring pliers, take out.
WARNING
Heat-protective cloth mittens must be worn to prevent serious injury to hands when
handling heated parts.
CAUTION
Pistons must be heated in hot water to prevent piston damage during piston pin removal.
Do not drive piston pin with hammer. Driving may cause distortion of piston, causing
piston seizure in cylinder sleeve.
8.
Piston (7) and
connecting rod (1)
a. Submerge in 2-gallon container of boiling water for 15 minutes to allow pistons
to expand.
b. Remove from boiling water, clamp connecting rod gently in machinist’s vise.
c. Push piston pin (11) out of piston pin
bore (9).
d. Tag piston, piston pin (11), and connecting rod, and hold for inspection.
TA 242487
2-221
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CLEANING/INSPECTION
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
Pistons should be inspected at ambient temperatures of 70° to 90°F (2° to 32°C).
7.
Piston (1)
a. Inspect wear surface for scoring, scuffing, and cracks.
If scoring, scuffing, or cracks exist,
discard piston.
b. Inspect piston pin bore (2) for fractures.
If fractures exist, discard piston.
c. Using ST-560 ring groove gage (3)
check top and second ring groove lands
(4) depth for wear.
If shoulders of gage (5) touch ring
groove lands (4), discard piston.
d. Using dial bore gage, measure piston
pin bore (2) Inside diameter.
If piston pin bore (2) exceeds 1.999
inch (50.775 mm) at 70°F (21°C)
discard piston. Add 0.0005 inch
(0.013 mm) per each 10°F (5.5°C)
over 70°F.
TA 242488
2-222
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
8.
Piston (1)
a. Using 5- to 6-inch micrometer,
measure piston skirt diameter at right
angle to piston pin bore.
For barrel ground pistons proceed
with step b.
For straight or tapered ground pistons
proceed with step c.
b. Measure at location A.
If diameter is less than 5.483 inch
(139.27 mm), discard piston.
c. Measure at location B and C.
If diameter is less than 5.483 inch
(139.27 mm), discard piston.
9.
Piston pin (6)
a. Using 1-to 2-inch micrometer,
measure outside diameter.
If outside diameter is less than 1.9978
inch (50.754 mm), discard piston
pin.
b. Using 1- to 2-inch micrometer, check
piston pin for out-of-round condition.
If piston pin is out-of-round more than
0.001 inch (0.03 mm), discard
piston pin.
TA
242489
2-223
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
CLEANING/INSPECTION - CONTINUED
10.
Connecting rod (1),
bearing cap (2),
and two bolts (3)
Using magnetic inspection procedure,
inspect for cracks.
Pay particular attention to cracks in
critical areas (4).
If cracks exist, discard connecting
rod.
11. Connecting rod (1)
Bearing cap (2),
two nuts (5), and
two new washers (6)
a. Put bearing cap on connecting rod and
install nuts and new washers.
b. Using 1/2-inch drive 15/16-inch
socket and 0 to 150 ft lb (0 to 210 N•m)
torque wrench, tighten nuts as shown in
table below.
CONNECTING ROD NUTTIGHTENING SEQUENCE
TORQUE VALVE
TIGHTENING SEQUENCE
Step
Step
Step
Step
Step
Step
12.
2-224
1.
2.
3.
4.
5.
6.
Tighten to
Advance to
Loosen to
Tighten to
Advance to
Advance to
Crankpin bore (7)
FT LB
70 - 75
140 - 150
0
25 - 30
70 - 75
140 - 150
(N•m)
(95 - 102)
(190 - 203)
(0)
(34 - 41)
(95 - 102)
(190 - 203)
a. Using dial bore gage (8), measure
inside diameter at points A - A and B B
up to 30° either side of parting line C,
and record readings.
If crankpin bore diameter Is not
between 3.2722 to 3.2736 inch
(83.114 to 83.149 mm), tag connecting rod for crankpin bore resizing.
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
b. Measure at points D - D and E - E, and
record readings.
If crankpin bore diameter is not
between 3.2722 to 3.2732 inch
(83.114 to 83.139 mm), tag connecting rod (1) for crankpin bore
resizing.
13.
Piston pin bushing
bore (9)
Using dial bore gage, check inside
diameter.
If inside diameter is greater than
2.0025 inch (50.884 mm).
TA 242490
2-225
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CLEANlNG/lNSPECTlON - CONTINUED
NOTE
All connecting rod assemblies must be checked for twist, length, and alinement. The
ST-561 connecting rod checking fixture must be calibrated before use.
14.
Connecting
rod (1)
Select connecting rod that has been
checked for correct crankpin bore (2)
to piston pin bore (3) center length of
12 inches (304.60 mm).
NOTE
For identification purposes, the connecting rod selected in step 14 will be referred to as
“master connecting rod” in the following steps.
15. Master connecting
rod (1)
Bearing cap (4)
Make sure bearing cap is torqued correctly.
See step 11.
16.
Piston pin
mandrel (5)
Insert into piston pin bore (3).
Mandrel Is furnished with checking
fixture kit.
NOTE
The expanding arbor must be installed with locking pin down and on center line of rod.
17.
Expanding arbor (6)
Insert into crankpin bore (2).
Tighten to snug only.
TA 242492
2-226
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
ACTION
LOCATION
REMARKS
ITEM
NOTE
Procedure for checking connecting rods is typical for use of the ST-561 connecting rod
checking fixture.
18. ST-561 connecting
rod checking
fixture (7)
Holder plate
knob (8)
a. Loosen.
Raise high enough so piston pin
mandrel (5) will clear Indicator pins
(9) when installed.
b. Raise holder plate (10) and retighten
holder plate knob.
19.
Master connecting
rod (1)
Position in checking fixture by seating
expanding arbor (6) in base (11) and piston
pin mandrel (5) against frame (12).
20.
Holder plate
knob (8)
a.
21.
Two dial
indicators (13)
Set dials to zero.
Loosen and slowly lower holder plate
(10) until indicator pins (9) just seat on
piston pin mandrel (5).
b. Tighten holder plate knob securely.
TA
242493
2-227
TM 5-2815-241-34&P
PISTON AND CONNECTlNG ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CLEANING/INSPECTION - CONTINUED
22. ST-561 connecting
rod checking
fixture (1)
Master connecting
rod (2)
Gently remove and rotate 160° horizontally
and place back into checking fixture allowing
dial indicators (3) to register a reading.
If both dial indicators (3) register
readings other than original zero “0”
settings, record these readings.
23.
Dial indicator (3)
Set zero “0” to one-half readings recorded in
step 20.
Checking fixture (1) is now
calibrated.
24.
Master connecting
rod (2)
a. Remove from checking fixture (1).
b. Remove piston pin mandrel and expanding arbor.
NOTE
Connecting rod alinement measurements read directly from dial indicators, indicate
comparative length and misalinement of bores. Measurements apply with or without
piston pin bushings installed.
25. Connecting rod (4)
Bearing cap (5)
Make sure bearing cap is torqued correctly.
See step 11.
26.
Piston pin
mandrel (6)
Insert into piston pin bore (7).
27.
Expanding arbor (8)
Insert into crankpin bore (9).
Tighten to snug only.
28.
Connecting rod (4)
a. Set into ST-561 connecting rod checking
fixture (1).
See steps 18 thru 21.
b. Check dial indicator (3) readings for
length and compare to length set up in
calibration of checking fixture (1).
Record reading.
c. Check dial indicator (3) readings for
alinement of bores and compare the
difference of reading from one dial
indicator to other.
Record reading.
2-228
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
d. Remove from checking fixture (1),
rotate 180° horizontally, and place back
into checking fixture (1).
e. Compare reading for length with recorded reading. Length must be within
0.001 inch (0.0254 mm).
If reading is greater than 0.001 inch
(0.0254 mm), discard connecting
rod.
f. Compare reading for alinement of bores
with recorded reading. Total reading
must not exceed 0.004 inch (0.10 mm)
with piston pin bushing installed and
bored to size, or 0.008 inch (0.20 mm)
without piston pin bushing.
If reading exceeds these specifications, discard connecting rod.
g. Using thickness gage (10) between
piston pin mandrel (6) and dial holding
plate, check connecting rod twist. Twist
must not exceed 0.010 inch (0.25 mm)
with piston pin bushing installed and
bored to size, or 0.020 inch (0.51 mm)
without piston pin bushing.
If reading exceeds these specifications, discard connecting rod.
2-229
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
CLEANING/INSPECTION - CONTINUED
29. Connecting rod (1)
Two bolts (2)
Check that boltheads rest squarely on milled
surface (3) of connecting rod.
If boltheads do not rest squarely on
milled surface, tag connecting rod for
milled surface repair.
30. Connecting rod (1)
and bearing cap (4)
Two bolts (2), two
nuts (5), and two
washers (6)
a. Using 1/2-inch drive 15/16-inch socket
and hinged handle, unscrew and take
off.
b. Using 0- to 1-inch micrometer, check
inside diameter of boltholes (7).
If diameter is greater than 0.6249 Inch
(15.872 mm), discard connecting
rod and bearing cap.
31. Connecting rod (1)
Two bolts (2)
a. Check for distorted or damaged threads.
If threads are distorted or damaged,
discard bolt.
b. Using 0- to 1-inch micrometer, check
smallest outside diameter.
If smallest outside diameter is less
than 0.540 inch (13.72 mm) discard
bolt.
32.
Connecting rod (1)
a. Using 0- to 1-inch micrometer, check
fillet radius (8) at all corners
where connecting rod is milled for
bolthead.
If fillet radius does not measure 0.045
to 0.055 inch (1.14 to 1.40 mm), tag
connecting rod for milled surface
repair.
b. Check fillet radius (8) for nicks and
dents.
If nicks and dents are deeper than
1/16 inch (1.59 mm), discard connecting rod. if nicks and dents
exist but are less than 1/16-inch
(1.59 mm) deep, tag connecting rod
for milled surface repair.
33.
Two nuts (5)
Check for distorted or damaged threads.
If threads are distorted or damaged,
discard nut.
2-230
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
34.
ACTION
REMARKS
ITEM
Bearing cap (4),
two bolts (2),
two nuts (5), and
two washers (6)
Put on and torque nuts as specified in
step 11.
REPAIR
NOTE
Perform steps 35, 36, and 37 for connecting rods tagged for milled surface repair.
35. Connecting rod (1)
Bearing cap (4),
two bolts (2), and
two nuts (5)
Using 1/2-inch drive 15/16-inch socket and
hinged handle, unscrew and take off.
36.
Connecting rod (1)
a. Using half-round file, file milled surface
of connecting rod a maximum of 1/16
inch (1.59 mm).
b. Form a fillet radius (8) at ail corners
where connecting rod (1) is milled for
bolthead to a dimension of 0.045 to
0.055 inch (1.14 to 1.40 mm).
Fillet radius must be 1/2 inch (12.7
mm) in length or more. Blend radii at
ends of cut.
37.
Bearing cap (4),
two bolts (2), two
nuts (5), and two
washers (6)
Put on and torque nuts as specified in
step 11.
2-231
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
NOTE
Perform steps 38 thru 41 for connecting rods tagged for crankpin bore resizing.
38.
Connecting rod (1)
a. Make sure bearing cap (2) is torqued
correctly.
See step 11.
b. Using ST-870 mandrel and block, push
out old piston pin bushing (3).
c. Using ST-561 connecting rod checking
fixture, recheck connecting rod length.
If connecting rod length is 11.991
inch (304.57 mm) or less, connect.
ing rod cannot be resized. Discard.
d. Using 1/2-inch drive 15/16-inch socket
and hinged handle, unscrew and take off
two nuts (4), two bolts (5), two washers
(6), and bearing cap (2).
NOTE
The maximum amount of material that can be ground and lapped off connecting rod and
bearing cap mating surfaces, can be determined by subtracting 11.991 inch (304.57
mm) from the actual length of the connecting rod to be repaired, as measured using the
ST-561 connecting rod checking fixture.
During grinding and lapping operation, parts must be clamped securely to ensure
proper contact of entire mating surfaces and proper alinement of bolt bores when
assembled. Boltholes must remain perpendicular to machined mating surfaces.
e. Using surface plate and cutting fluid,
lap connecting rod, bearing cap (2),
and mating surfaces (7).
f. Using prussian blue, check seating of
mating surfaces (7).
Seating pattern must show a minimum
of 75 percent contact.
Seating pattern in area outside bolt
center line (area farthest from crankpin bore center line) must indicate
100 percent seating.
2-232
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
g. Put on bearing cap (2), bolts (5), nuts
(4), and washers (6).
h. Torque nuts as specified in step 11.
i. Using ST-526 boring machine, grind
crankpin bore (8) to 3.2720 to 3.2725
inch (83.119 to 83.134 mm) inside
diameter.
Finished surface must be 75 microinch or better to ensure proper contact with bearings.
j. Using ST-561 connecting rod checking
fixture, check connecting rod
alinement.
See step 28.
k. Install new heavy wall piston pin
bushing (3).
See steps 38 thru 41.
I. Bore piston pin bushing (3) off center to
restore connecting rod (1) to original
11.998- to 12.000-inch (304.75 to
304.80 mm) length.
2-233
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
REPAIR - CONTINUED
39. Block (1)
Connecting rod (2)
a.
Place on block and support in horizontal
position.
b. Line up mark on guide sleeve (3) with
middle of boss on connecting rod.
c. Using ST-1242 mandrel set (4), assembly sleeve (5), guide sleeve (3),
and arbor press, push in new piston pin
bushing (6), making sure oil hole in piston pin bushing and piston pin bore (7)
are lined up.
Push in until assembly sleeve (5)
contacts side of connecting rod boss.
40. Connecting rod (2)
Piston pin
bushing (6)
Using ST-1242 mandrel set (4), removal
sleeve (8), and arbor press, push out.
WARNING
Safety goggles must be worn to prevent eye injury caused by flying steel chips.
Connecting rod (2)
41.
a.
b.
c.
d.
e.
2-234
Change 1
Fill lubricating holes with lubricating
soap to keep out shavings.
Mount in ST-526 boring machine or
equivalent.
Lower mandrel should have only the
two horizontal blades in place to
properly locate the side position of the
piston pin end of connecting rod (2).
Bore piston pin bushing (6) to 2.001-to
2.0015-inch (50.83 to 50.84 mm) inside diameter.
Remove from ST-526 boring machine, or
equivalent, and using ST-205 plug
gage, check inside diameter.
If inside diameter is less than 2.001
inch (56.83 mm), continue boring
operation, steps a, b, and c.
If inside diameter is greater than
2.0015 inch (50.84 mm), replace
piston pin bushing (6).
See steps 38 thru 41.
Using scraper, remove any sharp edges
from piston pin bushing (6).
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
f. Clean throughly.
Make sure all shavings and soap are
removed from oil passages.
g. Using ST-561 connecting rod checking
fixture, recheck all dimensions on rebushed and rebored connecting
rods (2).
See steps 14 thru 28.
2-235
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY
CAUTION
Pistons are machined to a very close weight tolerance. Make sure the same part number
piston is used throughout the engine. Weight difference will affect engine operation.
42. Piston (1)
Retaining ring (2)
Using 6-inch snapring pliers, put in
groove in piston bore.
Heat-protective cloth mittens must be worn to prevent serious injury to hands when
handling heated parts.
CAUTION
Pistons must be heated in hot water to prevent piston damage during piston pin
installation.
Do not drive piston pins with hammer. Driving may cause distortion of piston, causing
piston seizure in cylinder sleeve.
Be sure retaining ring is firmly seated in groove of piston pin bore to prevent serious
engine damage.
Do not attempt to push in piston pin after piston has cooled. At 70°F (21°C), the piston
pin fit is 0.0001 to - 0.0003 inch (0.003 to - 0.008 mm), which prevents piston pin
assembly unless piston is heated.
NOTE
Install new or inspection-approved pistons on connecting rod. Be sure to install pistons
on their companion connecting rod, as tagged during disassembly.
43.
2-236
Piston pin (3) and
retaining ring (4)
a. Submerge in container of boiling water
for 15 minutes to allow pistons to
expand.
b. Remove from boiling water and place
connecting rod in piston.
c. Push piston pin through piston pin bore
(5) and connecting rod bore before piston cools.
d. Using 6-inch snapring pliers, put
retaining ring in groove in piston pin
bore (5).
TM 5-2815-241-34&P
PISTON AND CONNECTING ROD - CONTINUED
LOCATION
44. Connecting rod (6)
ACTION
REMARKS
ITEM
Take off.
Bearing cap (7),
two nuts (8), and
two washers (9)
NOTE
Install new or inspection-approved connecting rod bearings. Be sure to install bearings
to their respective connecting rod and bearing cap, as tagged during disassembly. If
crankshaft is new or has been machined, install new bearings. If an upper or lower
bearing has been replaced with a new bearing, its other half must also be replaced with
a new bearing.
45. Connecting rod (6)
Upper bearing (10)
Put in.
46. Bearing cap (7)
Lower bearing (11)
Put in.
47. Connecting rod (6)
Bearing cap (7),
two washers (9), and
two nuts (8)
a. Put on.
b. Hand tighten, to keep bearings from
slipping out of connecting rod.
48.
Bearings (10 and 11)
and four piston
rings (12)
Keep together with piston (1) and connecting rod (6), tag location in cylinder block,
hold for engine assembly.
NOTE
FOLLOW-ON MAINTENANCE:
Install pistons and connecting rods (page 2-60).
TASK ENDS HERE
2-237
TM 5-2815-241-34&P
Section IX. CAMSHAFT AND TIMING SYSTEM MAINTENANCE
OVERVIEW
The following paragraphs provide maintenance instructions for the camshaft and timing system of the
NTC-290 diesel engine. For camshaft bearing repair, see section V, page 2-140.
Page
Cam Follower Assembly.. ............................
Camshaft and Gear Assembly.. ...................
2-254
2-238
Page
Rocker Arm Housing and
Push Rod ..............................................
2-242
CAMSHAFT AND GEAR ASSEMBLY
This task covers:
a. Cleaning (page 2-238)
b. Inspection (page 2-239)
c. Disassembly (page 2-239)
d. Assembly (page 2-240)
INITIAL SETUP
Materials/Parts
Tools
Key, machine, camshaft gear
Rags, wiping (item 14, appendix B)
Gage, thickness
Key, hex, 3/16-inch
Mandrel and block ST-691
Micrometer, 1- to 2-inch
Micrometer, 0- to 1-inch
Mittens, cloth, heat-protective
Press, arbor
V-blocks
Equipment Condition
Camshaft and gear removed (page 2-48).
References
TM 55-1500-335-23, Inspection Methods,
Non-Destructive
LOCATION
ACTION
REMARKS
ITEM
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
2-238
Change 1
TM 5-2815-241-34&P
CAMSHAFT AND GEAR ASSEMBLY - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION
1. Camshaft and gear
assembly (1)
Bearing journals (2)
Using a 1-to 2-inch micrometer, measure
diameter.
If diameter is less than 1.996 Inches
(59.70 mm), replace camshaft. New
camshaft bearing journals will be
1.997 to 1.998 inches (50.72 to
50.75 mm).
2.
Camshaft (3)
Inspect for breaks, pits, scoring, or
scuffing. Inspect for cracks or imperfections by visual and magnetic inspection
methods.
If broken, cracked, pitted, scored, or
scuffed, replace camshaft.
3. Camshaft and gear
assembly (1)
Camshaft gear (4)
Inspect for chips, cracks, visible wear,
sharp fins, nicks, and burrs.
If chipped, cracked, worn, nicked, or
sharp fins and burrs are observed,
replace camshaft gear.
4.
Thrust bearing (5)
Using a 0- to 1-inch micrometer, measure
thickness.
If less than 0.083 inch (2.11 mm),
replace thrust bearing.
Thrust bearing (5)
Remove.
DISASSEMBLY
5. Camshaft and gear
assembly (1)
2-239
TM 5-2815-241-34&P
CAMSHAFT AND GEAR ASSEMBLY - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
DISASSEMBLY - CONTINUED
WARNING
Heat-protective cloth mittens must be worn to prevent serious injury to hands when
handling heated parts.
CAUTION
Never support gear on outer gear surface. Always support hub area to prevent damage
to parts or equipment.
6. Camshaft and gear
assembly (1)
Camshaft gear (2)
a. Support camshaft and gear in V-blocks
and heat camshaft gear to 300° to 400°F
(148° to 204°C).
b. Using arbor press and ST-691 mandrel
and block, press camshaft from camshaft gear.
7. Camshaft (3)
Camshaft gear
machine key (4)
Remove.
Discard.
8.
Vent plug (5)
Using 3/16-inch hex key, unscrew and take
out.
ASSEMBLY
CAUTION
Parts must be free from dust and dirt to prevent damage.
9. Camshaft (3)
2-240
New camshaft gear
machine key (4)
Place in camshaft keyway.
TM 5-2815-241-34&P
CAMSHAFT AND GEAR ASSEMBLY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
WARNING
Heat-protective cloth mittens must be worn to prevent serious injury to hands when
handling heated parts.
CAUTION
Never support gear on outer gear surface. Always support hub area to prevent damage
to parts or equipment.
10.
Camshaft (3) and
camshaft gear (2)
a. Support camshaft and gear in V-blocks
and heat camshaft gear to 300° to 400°F
(148° to 204°C).
b. Using arbor press and ST-691 mandrel
and block, press camshaft gear onto
camshaft.
c. Using thickness gage, check clearance
between camshaft gear and camshaft
flange (6).
Clearance should not exceed 0.0015
Inch (0.38 mm).
11. Camshaft and
gear (1)
Vent plug (5)
Using 3/16-inch hex key, screw in and
tighten.
12.
Thrust bearing (7)
Install.
NOTE
FOLLOW-ON MAINTENANCE:
Install camshaft and gear (page 2-66).
TASK ENDS HERE
2-241
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD
This task covers:
a. Disassembly (page 2-242)
b. Cleaning (page 2-244)
c. Inspection (page 2-245)
d. Assembly (page 2-251)
INITIAL SETUP
Materials/Parts
Tools
Bit, drill, 9/32-inch
Driftpin, brass, 3/4-inch
Drill, electric, 3/8-inch
Gage, bore, dial
Gage, radius, 1/4-inch
Gage, radius, 5/16-inch
Goggles, safety
Hammer, ball-peen, 16-ounce
Key, hex, 5/32-inch
Mandrel and block, ST-691
Micrometer, 1- to 2-inch
Press, arbor
Punch, pin, 1/4-inch
Screwdriver, flat-tip, 3/8-inch
Wrench, box-end, 7/16-inch
Wrench, box-end, 3/4-inch
LOCATION
Bushing, rocker arm (as required)
Cloth, emery (item 1, appendix B)
Locknut (six required)
Oil, lubricating (Item 12, appendix B)
Packing, preformed (two required)
Prussian blue (item 13, appendix B)
Solvent, drycleaning (item 16, appendix B)
Tags, marker (item 17, appendix B)
Equipment Condition
Rocker arm housing removed (page 2-30).
References
TM 55-1500-335-23, Inspection Methods,
Non-Destructive
ACTION
REMARKS
ITEM
DISASSEMBLY
NOTE
Steps given are typical for all three rocker arm housings
1. Rocker arm
housing (1)
2-242
Change 1
Six rocker arms (2)
Tag and number rocker arms in sequence
1 thru 6 starting from front of rocker arm
housing.
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
2. Rocker arm
housing (1)
Six engine compression brake steel
washers (3)
Using 3/8-inch flat-tip screwdriver, pry
out.
Discard engine compression brake
steel washers.
3.
Rocker arm shaft
setscrew (4)
Using 5/32-inch hex key, unscrew and
remove.
CAUTION
When removing rocker arm shaft, center driftpin on rocker arm shaft and tap lightly.
Striking rocker arm housing or rocker arm will cause damage.
NOTE
When removing rocker arm shaft, remove and set aside rocker arms (2) as they become
free from rocker arm shaft.
4.
Rocker arm shaft (5)
Using 16-ounce ball-peen hammer and
3/4-inch brass driftpin, drive out.
5. Rocker arm shaft (5)
Preformed
packing (6)
Remove.
Discard packings.
2-243
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY - CONTINUED
6. Rocker arms (1,3,
4, and 6)
Four rocker arm
adjusting screws
(7) and four
locknuts (8)
Using 3/4-inch box-end wrench and
3/8-inch flat-tip screwdriver, loosen
and remove as an assembly.
7. Rocker arms
(2 and 5)
Two rocker arm
adjusting bolts
(9) and two
locknuts (8)
Using 3/4-inch and 7/16-inch box-end
wrenches, loosen and remove as an
assembly.
8. Rocker arm
adjusting screws (7)
and rocker arm
adjusting bolts (9)
Six locknuts (8)
Unscrew.
Discard six locknuts.
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
2-244
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
INSPECTION
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety 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. Flashpoint for type
#1 drycleaning solvent is 100°F (38°C) and for type #2 is 138°F (59°C). If you become
dizzy while using 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. Failure to
observe these precautions could cause serious injury or death to personnel.
NOTE
Steps given are typical for all rocker arm bushings.
9. Rocker arm (10)
10.
Rocker arm
bushing (11)
a. Using drycleaning solvent, clean and
wipe dry with rag and inspect for cracks
and pitting.
Discard, if cracked or pitted.
b. Using bore gage, measure inside diameter at several points for wear.
If inside diameter exceeds 1.128 Inch
(28.664 mm), discard rocker arm
bushing.
Rocker arm
bushing (11)
Using arbor press and ST-691 mandrel and
block, press out.
Install new rocker arm bushing, see
steps 22 and 23.
2-245
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
ITEM
LOCATION
ACTION
REMARKS
INSPECTION - CONTINUED
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety 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. Flashpoint for
type #1 drycleaning solvent is 100°F (38°C) and for type #2 is 138°F (59°C). If you
become dizzy while using 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.
Failure to observe these precautions could cause serious injury or death to personnel.
Particles blown by compressed air are hazardous. Make certain the air stream is
directed away from user and other personnel in the area. Compressed air used for
cleaning purposes shall not exceed 30 psi (207 kPa). User must wear safety goggles or
face shield to prevent personnel injury.
NOTE
Steps 11, 12, and 13 are typical for all rocker arms.
11.
Fuel injector
rocker arm (1)
a. Wipe clean with rag and inspect for
breaks and clogged oil passages.
If oil passages (2) are clogged, clean
with drycleaning solvent and use
compressed air to thoroughly clean oil
passages.
b. Check for cracks and imperfections by
visual and magnetic inspection.
If broken or cracked, replace.
12. Fuel injector
rocker arm (1)
Socket seat (3)
Inspect as follows:
a. Coat new injector link ball end (4) with
prussian blue.
b. Place injector link ball end (4) into
socket seat and rotate using hand
pressure.
c. Check socket seat wear area.
If socket seat wear area is not 80percent blued, replace socket seat.
13. Fuel injector
rocker arm (1)
Socket seat (3)
Remove as follows:
a. Using 3/8-inch electric drill and 9/32inch drill bit, drill hole through rocker
arm above socket seat.
b. Using 16-ounce ball-peen hammer and
1/4-inch pin punch, drive out socket
seat.
2-246
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
c.
Install plug in hole and stake in place.
Install new socket seat. See step 24.
WARNING
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety 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. Flashpoint for
type #1 drycleaning solvent is 100°F (38°C) and for type #2 is 138°F (59°C). If you
become dizzy while using 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.
Failure to observe these precautions could cause serious injury or death to personnel.
Particles blown by compressed air are hazardous. Make certain the air stream is
directed away from user and other personnel in the area. Compressed air used for
cleaning purposes shall not exceed 30 psi (207 kPa). User must wear safety goggles or
face shield to prevent personnel injury.
NOTE
Steps 14 and 15 are typical for all intake and exhaust rocker arms.
14.
Exhaust rocker
arm (5)
a. Wipe clean with rag and inspect for
breaks and clogged oil passages.
If oil passages (8) are clogged, clean
with drycleaning solvent and use
compressed air to thoroughly clean oil
passages.
b. Check for cracks and imperfections by
visual and magnetic inspection.
If broken or cracked, replace.
15.
Exhaust rocker
arm (5)
Check exhaust rocker arm-to-crosshead
contact surface (7).
If worn or damaged, replace.
2-247
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
INSPECTION - CONTINUED
NOTE
Steps given are typical for all push rods.
16.
Push rod (1)
a. Wipe clean with rag and inspect for
cracks and bends.
If cracked or bent, replace.
b. Coat ball end of adjusting screw (2)
with prussian blue.
c. Place ball end of adjusting screw (2)
into push rod socket (3) and rotate
using hand pressure.
d. Check push rod socket (3) wear area.
If push rod socket (3) wear area is
not 80-percent blued, replace push
rod.
17.
Push rod (1)
a. Using 5/16-inch radius gage, check ball
end (4) for wear.
If ball end (4) diameter is not 0.623
to 0.625 inch, replace push rod.
b. Check for loose push rod socket ends
(3) or ball ends (4).
If socket ends or ball ends are loose,
replace push rod.
NOTE
Steps given are typical for adjusting screws and adjusting bolts.
18.
2-248
Six adjusting
screws (5) and six
new locknuts (6)
Wipe clean and screw locknut down full
length of threads by hand.
If locknut binds on threads, replace
adjusting screw or adjusting bolt (7).
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
LOCATION
19.
ACTION
REMARKS
ITEM
Using 1/4-inch radius gage, check ball
end (8) for flat spots and roundness.
If out-of-round, or flat spots are
noticed, replace.
Six adjusting
screws (5)
WARNING
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety 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. Flashpoint for
type #1 drycleaning solvent is 100°F (38°C) and for type #2 is 138°F (59°C). If you
become dizzy while using 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.
Failure to observe these precautions could cause serious injury or death to personnel.
20.
Rocker arm shaft (9)
a. Using drycleaning solvent, clean oil
passages (10).
b. Using a 1- to 2-inch micrometer,
measure outside diameter at several
points for wear. Visually inspect for
scratches.
If scratched, or outside diameter is
less than 1.122 inch (28.50 mm),
replace.
2-249
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
21.
2-250
Rocker arm
housing (1)
a. Wipe clean with rag and Inspect for
cracks, breaks, dents, or distorted
mating surfaces.
If cracked, broken, dented, or mating
surfaces distorted, replace.
b. Inspect rocker arm shaft bores (2) for
scratches. Using dial bore gage, measure diameter of shaft bores (2) at
several points.
If shaft bores (2) are scratched, or
if diameter Is not 1.1238 to 1.1246
inches (28.545 to 28.565 mm)
replace.
c. Visually inspect edges of shaft bore (2)
for nicks and burrs.
Remove sharp edges, nicks, and
burrs using emery cloth.
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY
CAUTION
Make sure that all parts are free from dirt and dust.
NOTE
Step 22 is typical for fuel injector and exhaust rocker arms only.
Step 23 is typical for Intake rocker arm only.
22. Rocker arm (3)
Rocker arm
bushing (4)
a. Place on rocker arm, alining oil hole
(5) with crosshead nose oil hole (6).
b. Using arbor press and ST-691 mandrel
and block, press in.
23. Intake rocker
arm (7)
Rocker arm
bushing (8)
a. Place on intake rocker arm, alining slot
hole (9) with adjusting screw oil
hole (10).
b. Using arbor press and ST-691 mandrel
and block, press in.
2-251
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
ASSEMBLY - CONTINUED
24. Fuel injector
rocker arm (1)
a. Place in position on rocker arm.
b. Using arbor press and ST-691 mandrel
and block, press in.
Socket seat (2)
NOTE
Step 25 is typical for intake and exhaust rocker arms only.
Step 26 is typical for fuel injector rocker arms only.
25. Rocker arm (3)
Adjusting screw (4)
and new locknut (5)
a. Screw adjusting screw into rocker arm
until bottom threads are flush with
bottom of rocker arm.
b. Hand tighten locknut onto adjusting
screw until snug with rocker arm.
26. Fuel injector
rocker arm (6)
Adjusting bolt (7)
and new locknut (5)
a. Screw adjusting bolt into rocker arm
until bottom threads are flush with
bottom of rocker arm.
b. Hand tighten locknut onto adjusting bolt
until snug with rocker arm.
27. Rocker arm
housing (8)
Rocker arm shaft (9)
and six rocker
arms (10)
a. Coat rocker arm shaft with clean lubricating oil and start rocker arm shaft
into rocker arm housing.
b. Install six rocker arms on rocker arm
shaft as it is pushed through rocker arm
housing.
Note tag numbers on rocker arms for
correct location.
2-252
TM 5-2815-241-34&P
ROCKER ARM HOUSING AND PUSH ROD - CONTINUED
ACTION
REMARKS
LOCATION
ITEM
Rocker arm shaft (9)
Two new preformed
packing (11)
a. Coat with lubricating oil.
b. With rocker arm shaft extended 1/2 inch
from rocker arm housing (8), install one
packing on rocker arm shaft.
c. Push rocker arm shaft through rocker
arm housing (8) until other end extends
1/2 inch from rocker arm housing (8)
and install one packing on rocker arm
shaft.
29. Rocker arm
housing (8)
Setscrew (12)
a. Center rocker arm shaft (9) in rocker
arm housing.
b. Squeeze two rocker arms (10) together
to rotate rocker arm shaft (9) to aline
rocker arm shaft locking hole (13) with
rocker arm housing locking hole (14).
c. Using 5/32-inch hex key, install setscrew in rocker arm housing locking hole
(14), screw in and tighten.
30.
Rocker arms (10)
Check for freedom of movement.
28.
NOTE
FOLLOW-ON MAINTENANCE:
(page 2-73).
Install rocker arm housing (2-82) and push rods
TASK ENDS HERE
2-253
TM 5-2815-241-34&P
CAM FOLLOWER ASSEMBLY
This task covers:
c. Inspection (page 2-256)
d. Assembly (page 2-260)
a. Disassembly (page 2-254)
b. Cleaning (page 2-256)
INITIAL SETUP
Materials/Parts
Tools
Cloth, emery (item 1, appendix B)
Oil, lubricating (item 12, appendix B)
Pin, roll (nine required)
Plugs, cup (two required)
Prussian blue (item 13, appendix B)
Rags, wiping (item 14, appendix B)
Solvent, drycleaning (item 16, appendix B)
Tags, marker (item 17, appendix B)
Cutter, 60-degree angle (chamfering
cutter)
Gage, plug, ST-195
Gage, bore, dial
Gage, thickness
Goggles, safety
Hammer, ball-peen, 16-ounce
Hone, bushing, 0- to 1-inch
Mandrel and block, ST-249
Mandrel, plug driving, ST-970
Mandrel, plug driving, ST-1053
Micrometer, 0- to 1-inch
Micrometer, 1- to 2-inch
Press, arbor
Press, drill, suitable
Punch, center
Punch, drive-pin, 3/32-inch
Screwdriver, flat-tip, 1/4-inch
LOCATION
Equipment Condition
Cam follower housing removed
(page 2-47).
References
TM 55-1500-335-23, Inspection Methods,
Non-Destructive
ACTION
REMARKS
ITEM
DISASSEMBLY
NOTE
Steps given are typical for all three cam follower assemblies.
1. Cam follower
housing (1)
2-254
Change 1
Cam follower
levers (2)
Tag and number for location.
TM 5-2815-241-34&P
CAM FOLLOWER ASSEMBLY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
2. Cam follower
housing (1)
Two lockscrews (3)
Using 1/4-inch flat-tip screwdriver,
unscrew and take out.
3.
Two cup plugs (4)
Using 16-ounce ball-peen hammer and
center punch, knock out.
Discard.
CAUTION
When removing cam follower shafts, center drive pin on cam follower shaft and tap
lightly. Striking housing or cam followers will cause damage.
NOTE
When removing cam follower shaft, remove and set aside cam followers as they become
free from cam follower shaft.
4.
Using arbor press and ST-1053 plug driving
mandrel, press out of cam follower
housing (1).
Cam follower
shafts (5)
NOTE
Steps 5 and 6 are typical for all cam follower levers.
2-255
TM 5-2815-241-34&P
CAM FOLLOWER ASSEMBLY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY - CONTINUED
5. Cam follower
lever (1)
Roll pin (2)
Using 16-ounce ball-peen hammer and
3/32-inch drive-pin punch, drive out.
Discard roll pin.
6.
Cam follower roller
pin (3)
a. Using arbor press and ST-970 plug driving mandrel, press out of cam follower
lever (1).
b. Remove cam follower roller (4).
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
INSPECTION
WARNING
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety 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. Flashpoint for type
#1 drycleaning solvent is 100°F (38°C) and for type #2 is 138°F (59°C). If you become
dizzy while using 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. Failure to
observe these precautions could cause serious injury or death to personnel.
Particles blown by compressed air are hazardous. Make certain the air stream is
directed away from user and other personnel in the area. Compressed air used for
cleaning purposes shall not exceed 30 psi (207 kPa). User must wear safety goggles or
face shield to prevent injury.
7.
2-256
Cam follower
lever (1)
Wipe clean with rag and inspect for breaks or
clogged oil passages. Check for cracks and
imperfections by visual and magnetic
inspection.
If broken or cracked, replace. If
oil passages are clogged, clean with
drycleaning solvent and use compressed air to thoroughly clean oil
passages.
TM 5-2815-241-34&P
CAM FOLLOWER ASSEMBLY - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
8.
Cam follower
roller pin (3)
a. Inspect for breaks, cracks, or out-ofround condition.
If broken, cracked, or out-of-round,
replace.
b. Using 0- to 1-inch micrometer, measure outside diameter.
If outside diameter is less than
0.497 inch (12.82 mm), replace.
New roller pins should measure
0.4995 to 0.500 inch (12.89 to
12.70 mm).
9.
Injector cam
follower roller (4)
a. Inspect for breaks, cracks, or out-ofround condition.
If broken, cracked, or out-of-round,
replace.
b. Using dial bore gage, measure inside
diameter of injector cam follower
roller at several points for wear.
If lager than 0.505 inch (12.83
mm), replace.
New roller inside diameter should be
0.503 to 0.504 inch (12.78 to
12.80 mm).
c. Using a 1- to 2-inch micrometer, measure outside diameter of injector cam
follower roller at several points for
wear.
If smaller than 1.2485 inches (31.71
mm), replace.
New roller outside diameter should be
1.2490 to 1.251 inches (31.72 to
31.77 mm).
2-257
TM 5-2815-241-34&P
CAM FOLLOWER ASSEMBLY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
INSPECTION - CONTINUED
10. Cam follower
lever (1)
Valve cam follower
roller (2)
a.
Inspect for breaks, cracks, or out-ofround condition.
If broken, cracked, or out-of-round,
replace.
b. Using dial bore gage, measure inside
diameter at several points for wear.
If larger than 0.503 Inch (12.83
mm), replace.
New valve cam follower roller inside
diameter should be 0.5005 to 0.5015
inch (12.713 to 12.738 mm).
c. Using a 1- to 2-inch micrometer,
measure outside diameter at several
points.
If smaller than 1.248 inches (31.71
mm), replace.
New valve cam follower roller outside
diameter should be 1.2490 to 1.2500
inches (31.72 to 31.75 mm).
NOTE
Steps 11 to 14 are typical for all cam follower rollers, bushings, and levers.
11.
Valve cam follower
roller (2)
a. Using 0- to 1-inch micrometer, check
inside and outside diameters for
roundness.
If more than 0.002 inch (0.05 mm),
out of round, replace.
b. Using 0- to 1-inch micrometer, measure ends of roller for squareness to
inside diameter and parallelism to each
other.
If more than 0.004 inch (0.10 mm),
replace.
12.
Cam follower
bushing (3)
Using dial bore gage, measure Inside
diameter.
If more than 0.752 inch (19.10 mm),
using arbor press and ST-249 mandrel and block, remove and discard.
13.
Roller pin bore (4)
Using dial bore gage, measure inside diameter of roller pin bore.
If more than 0.4997 inch (12.892
mm), replace.
2-258
TM 5-2815-241-34&P
CAM FOLLOWER ASSEMBLY - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
14. Cam follower
lever (1)
Cam follower
socket (5)
Inspect cam follower socket as follows:
a. Coat new push rod ball end (6) with
prussian blue.
b. Place push rod ball end (6) into cam
follower socket and rotate using hand
pressure.
c. Check cam follower socket wear area.
If cam follower socket wear area is not
80-percent blued, replace cam
follower socket.
d. Using 16-ounce ball-peen hammer and
3/32-inch drive-pin punch, drive out.
Install new cam follower socket, see
step 18.
15.
Two cam follower
shafts (7)
a. Using 0- to 1-inch micrometer, measure outside diameter of cam follower
shafts.
If 0.748 inch (19.00 mm) or lass,
replace.
b. Visually inspect around lockscrew end
to make sure grooves are clean. Check
for cracks, breaks, bends, galling, or
surface imperfections.
If cracked, broken, galled, bent, or
surface is damaged, replace.
2-259
TM 5-2815-241-34&P
CAM FOLLOWER ASSEMBLY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
INSPECTION - CONTINUED
16.
Cam follower
housing (1)
a.
Inspect for cracks, breaks, and
damaged mating surfaces.
If cracked, broken, or mating surfaces damaged, replace.
b. Inspect edges of cup plug holes (2)
for sharp edges, nicks, or burrs.
Using emery cloth, remove sharp
edges, nicks, burrs and chamfer
edge of holes to aid in installation of
cup plug.
ASSEMBLY
WARNING
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety 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. Flashpoint for
type #1 drycleaning solvent is 100°F (38°C) and for type #2 is 138°F (59°C). If you
become dizzy while using 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.
Failure to observe these precautions could cause serious injury or death to personnel.
CAUTION
Make sure that all parts are free from dust and dirt.
2-260
TM 5-2815-241-34&P
CAM FOLLOWER ASSEMBLY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps 17 to 19 are typical for all cam follower levers.
17. Cam follower
lever (3)
a. Place on cam follower lever, alining
oil hole (5) with oil hole (6).
b. Using arbor press and ST-970 plug driving mandrel, press in.
c. Using 60-degree angle cutter and suitable drill press, chamfer each end of
cam follower bushing.
d. Using 0- to 1-inch bushing hone, hone
cam follower bushing to 0.7495 to
0.7505 inch (19.037 to 19.063 mm).
Clean with drycleaning solvent, after
honing, to remove all grit.
Use ST-195 plug gage to check bore
diameter.
Cam follower
bushing (4)
NOTE
If new cam follower sockets are installed in cam follower levers, new push rods must be
used when engine is reassembled.
18.
Cam follower
socket (7)
a. Place in position in cam follower
lever (3).
b. Using arbor press and ST-249 mandrel
and block, press in.
2-261
TM 5-2815-241-34&P
CAM FOLLOWER ASSEMBLY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY - CONTINUED
19. Cam follower
lever (1)
a. Place roller in cam follower lever.
b. Using thickness gage, check between
cam follower lever and roller for clearance of 0.006 inch (0.15 mm).
c. Install roller pin through lever and
aline with roller.
d. Aline roller pin hole (5) with hole (6) in
lever.
e. Using arbor press and ST-970 plug driving mandrel, press in.
f. Position roll pin in cam follower lever.
g. Using 16-ounce ball-peen hammer and
3/32-inch drive-pin punch, drive roll
pin thru roller pin.
Check roller for free movement.
Roller (2), roller
pin (3), and new
roll pin (4)
NOTE
When performing next step, position two cam follower levers with screw slots facing
toward ends of cam follower housing.
20. Cam follower
housing (7)
Two cam follower
shafts (8) and six
cam follower levers (9)
a. Coat two cam follower shafts with clean
lubricating oil and start through each
side of cam follower housing.
Aline lockscrew holes in shafts with
lockscrew holes in cam follower
housing.
b. Install cam follower levers onto shafts as
they are pressed through cam follower
housing.
Note tag numbers on cam follower
levers.
c. Using arbor press and ST-1053 plug
driving mandrel, press in.
NOTE
A dummy screw is installed at this point to prevent lock screw breakage. Lock screws
have a tendency to break due to very close cam follower housing-to-cam follower shaft
fit, which causes the cup plugs to act as a ram when driven into place.
21.
2-262
Two dummy
screws (10)
Using 1/4-inch flat-tip screwdriver, install
and tighten.
TM 5-2815-241-34&P
CAM FOLLOWER ASSEMBLY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
22.
Two new
cup plugs (11)
Using arbor press and ST-1053 plug driving
mandrel, press in until flush with end of cam
follower housing (7) or 0.010 inch (0.25
mm) below edge of hole.
23.
Two dummy screws
(10) and two lockscrews (12)
a. Using 1/4-inch flat-tip screwdriver,
remove two dummy screws.
b. Using 1/4-inch flat-tip screwdriver,
install and tighten two lock screws.
NOTE
FOLLOW-ON MAINTENANCE:
Install cam follower housing (page 2-70).
TASK ENDS HERE
2-263
TM 5-2815-241-34&P
Section X. ENGINE LUBRICATION SYSTEM MAINTENANCE
Page
Lubricating Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-264
Page
Lubricating Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-264
LUBRICATING OIL FILTER
For lubricating oil filter maintenance, refer to TM 5-3805-254-20.
LUBRICATING OIL PUMP
This task covers:
a. Disassembly (page 2-265)
b. Cleaning (page 2-266)
c. Inspection/Repair (page 2-267)
d. Assembly (page 2-270)
INITIAL SETUP
Tools
Extension, 6-inch, 3/8-inch drive
Gage, bore, dial
Gage, thickness
Hammer, plastic-faced
Handle, ratchet, 3/8-inch drive
Machine, boring
Mandrel
Mandrel, bushing, ST-1158
Mandrel, spacer, ST-1157
Micrometer, 0- to 1-inch
Pliers, round-nose, 6-inch
Press, arbor
Puller, dowel, ST-1134
Puller, gear
Screwdriver, flat-tip, 3/8-inch
Socket, 1/2-inch, 3/8-inch drive
2-264
Tools - Continued
Socket, 9/16-inch, 3/8-inch drive
Wrench, box-end, 9/16-inch
Wrench, hex-head, 1/2-inch
Wrench, torque, 0 to 100 ft lb (0 to 140 N•m),
3/8-inch drive
Materials/Parts
Bushing (if required)
Gasket, adapter housing to oil pump body
Lockwasher, adapter housing (eight required)
Oil, lubricating (item 12, appendix B)
Equipment Condition
Lubricating oil pump removed (page 2-40).
TM 5-2815-241-34&P
LUBRICATING OIL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY
1. Adapter housing (1)
Eight screws (2)
and eight lockwashers (3)
Using 3/8-inch drive 1/2-inch socket, 6inch extension, and ratchet handle, loosen
and take out.
Discard lockwashers.
2. Oil pump body (4)
Adapter housing (1)
a. Using plastic-faced hammer, tap lightly
to loosen from oil pump body.
b. Pull apart.
3.
Gasket (5)
Take off.
Discard.
4.
Idler gear (6)
Pull out.
5. Drive shaft (7)
Main drive gear (8)
and key (9)
a. Using gear puller, pull gear from drive
shaft.
b. Take off key.
6. Oil pump body (4)
Drive shaft (7)
Pull out from rear.
2-265
TM 5-2815-241-34&P
LUBRICATING OIL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY - CONTINUED
Pressure regulator spring is under tension. Maintain pressure on retaining yoke to
prevent injury.
7. Oil pump body (1)
Lock plate (2),
screw (3), and retaining yoke (4)
a. Using 3/8-inch flat-tip screwdriver,
bend back lock plate tabs.
b. Using 9/16-inch box-end wrench, loosen and take retaining yoke off slowly.
8.
Pressure regulator
cap (5), spring (6),
plunger (7) and
pipe plug (8)
a. Pull out cap, spring and plunger.
b. Using 1/2-inch hex-head wrench, unscrew and take out plug.
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
2-266
TM 5-2815-241-34&P
LUBRICATING OIL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION/REPAIR
Oil pump body (1)
and adapter housing (8)
a. Inspect all gasket mating surfaces for
flatness, nicks, or burrs.
If uneveness, nicks, or burrs exist,
discard.
b. Inspect for pitting or cracks.
If pitting or cracks exist, discard.
c. Inspect for damaged threads.
If thread damage exists, discard.
d. Inspect bushings (9, 10, and 11).
If worn or scored, discard.
10.
Drive gear (12) and
idler gear (13)
Inspect for worn or broken teeth, pitting, or
cracks.
If broken teeth, pitting, or cracks
exist, discard.
11.
Dowel pins (14)
Inspect for damaged dowel pins.
If dowel pin damage exists, use
ST-1134 dowel puller, remove
damaged dowel pin, and replace with
new.
12.
Drive shaft (15)
Inspect for nicks, burrs, scores, or
damaged splines.
Replace if damaged.
9.
2-267
TM 5-2815-241-34&P
LUBRICATING OIL PUMP - CONTINUED
ITEM
LOCATION
ACTION
REMARKS
INSPECTION/REPAIR - CONTINUED
Idler shaft (2)
a. Using 0- to 1-inch micrometer, check
outside diameter.
If outside diameter is less than 0.873
inch (22.17 mm), continue with steps
b and c. If outside diameter is 0.873
to 0.875 inch (22.17 to 22.22 mm),
proceed to step 14.
b. Using arbor press and mandrel, press
idler shaft from oil pump body and
discard.
c. Using arbor press and deep end of ST1157 spacer mandrel, press stamped
end of new idler shaft into oil pump body
until idler shaft protrudes 0.955 inch
(24.26 mm) above oil pump body.
14.
Drive shaft (3)
a. Using 0- to 1-inch micrometer, check
outside diameter.
If outside diameter is less than 0.873
Inch (22.17 mm), continue with steps
b and c. If outside diameter Is 0.873
to 0.875 inch (22.17 to 22.22 mm),
proceed to step 15.
b. Using arbor press and mandrel, press
drive shaft from drive gear (4) and
discard.
c. Using shallow end of ST-1157 spacer
mandrel, press drive gear (4) onto
new drive shaft until drive shaft protrudes
from drive gear 1.035 to 1.055 inch
(26.29 to 26.80 mm).
15. Oil pump body (1),
adapter housing (5),
and idler gear (6)
Bushings (7)
a. Inspect for damage and, using dial bore
gage, check inside diameter.
If damage exists, or if inside diameter
is greater than 0.879 inch (22.33
mm), continue with steps b, c, and
d. If bushing is serviceable, proceed
to step 16.
13.
2-268
Oil pump body (1)
TM 5-2815-241-37&P
LUBRICATING OIL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
b. Using arbor press and ST-1158 bushing
mandrel, press out bushing.
Discard.
c. Using arbor press and ST-1158 bushing
mandrel, press in new bushing from
flush to 0.020 inch (0.51 mm) below
surface of gear, oil pump body, or
adapter housing.
d. Using boring machine, bore new bushing to size of 0.8767 to 0.8777 inch
(22.268 to 22.293 mm).
16. Drive shaft (3)
Main drive gear (8)
Inspect for worn or broken teeth, pitting,
or cracks.
If broken teeth, wear, pitting, or
cracks exist, replace gear.
2-269
TM 5-2815-241-34&P
LUBRICATING OIL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY
17. Oil pump body (1)
Drive shaft (2) and
drive gear (3)
Lubricate with clean lubricating oil and
position into oil pump body.
18.
Key (4) and main
drive gear (5)
a. Position key in drive shaft and aline with
main drive gear.
b. Support drive shaft on arbor press and
press drive gear on drive shaft.
c. Using thickness gage, leave 0.002 to
0.004 inch (0.05 to 0.10 mm) clearance between drive gear surface and
bottom of gear pocket in oil pump body.
Also, clearance between main drive
gear and oil pump body must not be
greater than 0.012 inch (0.30 mm).
Idler gear (6)
Lubricate with clean lubricating oil and
position on idler shaft (7).
19.
Drive shaft (2) and
drive gear (3)
NOTE
Before installing adapter housing to oil pump body, make sure all gears, shafts, and
bushings are well lubricated with clean lubricating oil.
2-270
TM 5-2815-241-34&P
LUBRICATING OIL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
20.
Adapter housing (8)
and new gasket (9)
Install new gasket and position adapter
housing on oil pump body (1).
21.
Eight capscrews (10)
and eight new
lockwashers (11)
Using 3/8-inch drive 0 to 100 ft lb (0 to 140
N•m) torque wrench, 6-inch extension,
and 1/2-inch socket screw in and tighten to
30 to 35 ft Ibs (42 to 49 N•m).
22.
Pressure regulator
cap (12), spring
(13), and plunger (14)
Place in oil pump body.
Make sure spring is in open end of
plunger.
23.
Screw (15), lock
plate (16), retaining yoke (17), and
pipe plug (18)
a. Install over pressure regulator cap (12),
screw in screw, and, using 3/8-inch
drive 0 to 100 ft lb (0 to 140 N•m) torque
wrench and 9/16-inch socket, tighten to
30 to 35 ft Ibs (42 to 49 N•m).
b. Using 6-inch round-nose pliers, bend
lock plate.
c. Using 1/2-inch hex-head wrench,
screw in and tighten plug.
NOTE
FOLLOW-ON MAINTENANCE:
Install lubricating oil pump (page 2-88).
TASK ENDS HERE
2-271
TM 5-2815-241-34&P
Section Xl. MANIFOLD MAINTENANCE
Page
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . ..
Page
2-272
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD
This task covers:
a. Disassembly
b. Cleaning/Inspection
c. Assembly
INITIAL SETUP
Equipment Condition
Exhaust manifold removed (page 2-14).
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY
1. Manifold assembly
Front section (1),
center section (2),
and rear section (3)
Pull three sections apart,
CLEANING/INSPECTION
NOTE
For general cleaning and inspection procedures, see General Maintenance Instructions, page 2-3.
ASSEMBLY
2-272
Change 1
2-274
TM 5-2815-241-34&P
EXHAUST MANIFOLD - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
Aline all exhaust ports and push three
sections together.
Manifold front
section (1), center
section (2), and
rear section (3)
2.
NOTE
FOLLOW-ON MAINTENANCE:
Install exhaust manifold (page 2-134).
TASK ENDS HERE
Change 1
2-273
TM 5-2815-241-34&P
INTAKE MANIFOLD
This task covers:
c. Assembly (page 2-275)
a. Disassembly (page 2-274)
b. Cleaning/Inspection (page 2-274)
INITIAL SETUP
Equipment Condition
Tools
Wrench, box-end, 9/16-inch
Wrench, box-end, 7/8-inch
Wrench, box-end, 1 1/4-inch
Intake manifold removed (page 2-26).
Materials/Parts
Gasket, preheater assembly
Lockwasher, intake manifold (five
required)
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY
NOTE
Disassembly is limited to the removal of the glow plug and preheater assembly.
1. Intake manifold (1)
Five screws (2) and
five lockwashers (3)
Using 9/16-inch box-end wrench, unscrew
and take out.
Discard lockwashers.
2.
Glow plug and preheater assembly (4)
and gasket (5)
Lift off and remove.
Discard gasket.
3. Glow plug and preheater assembly (4)
Glow plug (6) and
preheater nozzle (7)
a. Using 7/8-inch box-end wrench, unscrew and take out glow plug.
b. Using 1 1/4-inch box-end wrench, unscrew and take out preheater nozzle.
CLEANlNG/INSPECTlON
NOTE
For general cleaning and inspection procedures, see General Maintenance Instructions, page 2-3.
2-274
TM 5-2815-241-34&P
INTAKE MANIFOLD - CONTINUED
LOCATION
4. Glow plug and preheater assembly (4)
ACTION
REMARKS
ITEM
Glow plug (6) and
preheater nozzle (7)
Inspect for stripped threads, cracked
porcelain or cracked preheater nozzle.
If stripped or cracked, replace.
5. Glow plug and preheater assembly (4)
Glow plug (6) and
preheater nozzle (7)
a. Using 7/8-inch box-end wrench, screw
in glow plug and tighten.
b. Using 1 1/4-inch box-end wrench,
screw in preheater nozzle and tighten.
6. Intake manifold (1)
New gasket (5) and
glow plug and preheater assembly (4)
Place in position.
7. Glow plug and preheater assembly (4)
Five screws (2)
and five new
lockwashers (3)
Using 9/16-inch box-end wrench, install
and tighten.
ASSEMBLY
NOTE
FOLLOW-ON MAINTENANCE:
Install intake manifold (page 2-119).
TASK ENDS HERE
2-275
TM 5-2815-241-34&P
Section XII. ACCESSORY DRIVE MAINTENANCE
Page
Accessory Drive . . . . . . . . . . . . . . . . . . . . . . . .. ..
2-276
Page
Accessory Drive Pulley . . . . . . . . . . . . . . . .
2-280
ACCESSORY DRIVE
This task covers:
a. Disassembly (page 2-276)
b. Cleaning (page 2-277)
c. Inspection/Repair (page 2-277)
d. Assembly (page 2-279)
INITIAL SETUP
Tools
Materials/Parts
Driver, bushing
Extension, 3-inch, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Micrometer, 1- to 2-inch
Micrometer, inside, 1- to 2-inch
Press, arbor
Puller, gear, coupling, ST-1249
Screwdriver, 1/4-inch, flat-tip
Socket, 1 5/16-inch, 1/2-inch drive
LOCATION
Bushing (if required)
Key (two required)
Equipment Condition
Accessory drive removed (page 2-43).
ITEM
ACTION
REMARKS
DISASSEMBLY
1. Accessory drive
shaft (1)
Self-locking nut (2)
Using 1/2-inch drive 1 5/16-inch socket,
3-inch extension, and ratchet handle,
loosen and remove.
2.
Coupling gear (3)
Using ST-1249 coupling gear puller, pull
from accessory drive shaft (1).
3.
Washer (4) and
thrust washer (5)
Take off.
4. Housing (6)
Accessory drive
shaft (1)
Pull out.
5. Accessory drive
shaft (1)
Gear (7) and thrust
washer (8)
Using arbor press, press off.
2-276
TM 5-2815-241-34&P
ACCESSORY DRIVE - CONTINUED
LOCATION
6. Accessory drive
shaft (1)
ACTION
REMARKS
ITEM
Two keys (9)
Using 1/4-inch flat-tip screwdriver, pry
out.
Discard.
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
INSPECTION/REPAIR
7.
Accessory drive
shaft (1)
Using 1- to 2-inch micrometer, check outside diameter at bushing area, (10).
If accessory drive shaft measures
less than 1.310 inch (33.27 mm),
discard accessory drive shaft.
2-277
TM 5-2815-241-34&P
ACCESSORY DRIVE - CONTINUED
ITEM
LOCATION
ACTION
REMARKS
INSPECTION/REPAIR - CONTINUED
8.
Housing (1)
Inspect for damage caused by bushing rotating in housing.
If bushing has rotated in housing,
discard housing.
9. Housing (1)
Sleeve bearing (2)
a. Inspect for damage.
If bearing is damaged, perform steps
d and e.
If bearing is serviceable, proceed to
step 10.
b. Using a 1- to 2-inch inside micrometer,
check inside diameter, (3).
If inside diameter is greater than
1.321 inch (33.55 mm) proceed to
steps d and e.
If inside diameter is less than 1.321
inch (33.55 mm), proceed to
step c.
c. Using a 1- to 2-inch inside micrometer,
check for out-of-round condition.
If bearing is out-of-round, more than
0.002 inch (0.05 mm), perform steps
d and e.
If bearing is out-of-round less than
0.002 inch (0.05 mm), proceed to
step 10.
d. Using bearing driver and arbor press,
push out.
e. Using bearing driver and arbor press,
press in new bearing.
2-278
TM 5-2815-241-34&P
ACCESSORY DRIVE - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY
10. Accessory drive
shaft (3)
Two new keys (4)
Place in shaft.
11.
Thrust washer (5)
and gear (6)
Using arbor press, put on until gear is
against shoulder on accessory drive shaft.
CAUTION
Grooved sides of thrust washers are to be installed away from the housing. Incorrect
installation of these thrust washers will result in excessive wear and increased end play,
which will cause failure of the accessory drive.
12. Accessory drive
housing (7)
Accessory drive
shaft (3)
Put in.
13. Accessory drive
shaft (3)
Thrust washer (8)
and washer (9)
Put on.
TA 242525
2-279
TM 5-2815-241-34&P
ACCESSORY DRIVE - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
14.
Coupling gear (1)
Using arbor press, install on accessory
drive shaft (2).
15.
Self-locking nut (3)
Using 1/2-inch drive 1 5/16-inch socket,
3-inch extension, and ratchet handle, put
on and tighten.
16. Housing (4)
Accessory drive
shaft (2)
Check to make sure end clearance is between 0.005 and 0.010 inch (0.13 to
0.25 mm).
NOTE
FOLLOW-ON MAINTENANCE:
Install accessory drive (page 2-84).
TASK ENDS HERE
ACCESSORY DRIVE PULLEY
This task covers:
a. Cleaning (page 2-281)
b. Inspection/Repair (page 2-281)
INITIAL SETUP
Tools
Equipment Condition
Chisel, cold, 3/8-inch
Hammer, ball-peen, 16-ounce
Mandrel, oil seal sleeve
Press, arbor
Accessory drive pulley removed from engine
(page 2-43).
TA 242526
2-280
Change 1
TM 5-2815-241-34&P
ACCESSORY DRIVE PULLEY
LOCATION
ACTION
REMARKS
ITEM
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
INSPECTlON/REPAIR
a. Inspect for cracks and chips in hub,
web, and groove areas.
If cracks or chips exist, discard
accessory drive pulley.
b. Inspect for wear in grooves and oil seal
sleeve (2).
If wear exists in grooves, discard
accessory drive pulley.
If wear exists in oil seal sleeve,
proceed with step 2.
Accessory drive
pulley (1)
1.
NOTE
The following step is for replacing oil seal sleeve on accessory drive pulley.
2. Accessory drive
pulley (1)
Oil seal sleeve (2)
FOLLOW-ON MAINTENANCE:
TASK ENDS HERE
a. Using 3/8-inch cold chisel and 16ounce ball-peen hammer, split worn oil
seal sleeve. Be sure not to damage accessory drive pulley hub.
b. Remove oil seal sleeve.
c. Using arbor press and oil seal sleeve
mandrel, press new oil seal sleeve into
accessory drive pulley hub, until flush or
0.015 inch (0.38 mm) below face of
accessory drive pulley hub.
NOTE
Install accessory drive pulley (page 2-90).
TA 242527
2-281
TM 5-2815-241-34&P
Section XIII. ENGINE COMPRESSION BRAKE MAINTENANCE
ENGINE COMPRESSION BRAKE HOUSING
This task covers:
a. Disassembly (page 2-282)
b. Cleaning (page 2-284)
c. Inspection (page 2-284)
d. Assembly (page 2-286)
INITIAL SETUP
Tools
Materials/Parts
Pliers, needle-nose
Pliers, snap-ring
Press, arbor
Screwdriver, flat-tip, 3/8-inch
Wrench, box-end, 7/16-inch
Wrench, hex, 5/32-inch
Wrench, solenoid
Oil, lubricating (item 12, appendix B)
Seal, ring, center
Seal, ring, lower
Seal, ring, upper
Equipment Condition
Engine compression brake housing removed
(page 2-28).
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY
NOTE
Steps given are typical for multiple components on each of three engine brake housings.
1. Housing (1)
(topside up)
Screw (2) and
control valve cover
plate (3)
a. Using 5/32-inch hex wrench, unscrew
and take out.
b. Take off control valve cover plate.
2.
Control valve
spring (4)
Using needle-nose pliers, take out.
3.
Control valve (5)
Using needle-nose pliers, take out.
4. Solenoid valve (6)
Screw (7), washer
(8), and wire (9)
Using 3/8-inch flat-tip screwdriver, unscrew and take off wire.
Install screw and washer to prevent
loss.
5.
Solenoid valve (6)
Using solenoid wrench, unscrew and take
out.
2-282
TM 5-2815-241-34&P
ENGINE COMPRESSION BRAKE HOUSING - CONTINUED
LOCATION
6.
ACTION
REMARKS
ITEM
Upper ring seal
(10), center ring
seal (11), and lower
ring seal (12)
Take off and discard.
NOTE
Leadout terminal bushing (13) is replaced only if terminal ends are broken.
TA 242528
2-283
TM 5-2815-241-34&P
ENGINE COMPRESSION BRAKE HOUSING - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY - CONTINUED
7. Housing (1)
(topside down)
Screw (2), flatwasher (3), and
master piston
spring (4)
Using 7/16-inch box-end wrench, unscrew
and take off.
8.
Master piston (5)
Take out.
WARNING
Slave piston spring is under tension. Care must be taken when removing retaining ring,
spring retainer, and slave piston spring to prevent injury.
9.
Spring retainer (6)
and retaining ring (7)
a. Using arbor press, push down on spring
retainer.
b. Using snap-ring pliers, close retaining
ring and take off.
c. Carefully release arbor press tension.
10.
Slave piston spring
(8) and slave
piston (9)
Take out.
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
INSPECTION
11. Housing (1)
(topside down)
Slave piston (9)
a. Place into slave piston bore (10) and
check for freedom of movement.
If binding is found, check for dirt or
damage.
b. Wipe slave piston and slave piston bore
clean and recheck for freedom of
movement.
Replace slave piston if damaged.
12.
Slave piston spring
(8), retaining ring
(7), and spring
retainer (6)
a. Check for cracks, breaks, or other
damage.
b. Check for worn slave piston spring.
Replace parts if damaged.
2-284
TM 5-2815-241-34&P
ENGINE COMPRESSION BRAKE HOUSING - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
13.
Master piston (5)
a. Place into master piston bore (11) and
check for freedom of movement.
If binding is found, check for dirt or
damage.
b. Wipe master piston and master piston
bore clean and recheck for freedom of
movement.
Replace master piston if damaged.
14.
Master piston
spring (4)
Check for wear, cracks or breaks.
Replace if damaged.
TA 242529
2-285
TM 5-2815-241-34&P
ENGINE COMPRESSION BRAKE HOUSING - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
15. Housing (1)
(topside up)
Solenoid valve (2)
a. Check for cracks, breaks, or damaged
threads.
b. Check for broken electrical connector.
Replace solenoid valve if damaged.
16.
Control valve (3)
a. Place into control valve bore (4) and
check for freedom of movement.
If binding is found, check for dirt or
damage.
b. Wipe control valve and control valve bore
(4) clean and recheck for freedom of
movement.
Replace control valve if damaged.
17.
Control valve spring
(5) and control
valve cover plate (6)
a. Check for cracks or breaks.
b. Check for worn control valve spring.
Replace parts if damaged.
18. Housing (1)
(topside up)
Control valve (3)
and control valve
spring (5)
Put into control valve bore (4).
19.
Control valve cover
plate (6) and
screw (7)
a. Put in place.
b. Using 5/32-inch hex wrench, tighten.
20. Solenoid valve (2)
New upper ring seal
(8), new center ring
seal (9), and new
lower ring seal (10)
a. Apply a coat of lubricating oil.
b. Push onto solenoid valve in correct
order.
21. Housing (1)
(topside up)
Solenoid valve (2)
a. Screw into solenoid valve bore (11).
b. Using solenoid wrench, tighten.
ASSEMBLY
2-286
TM 5-2815-241-34&P
ENGINE COMPRESSION BRAKE HOUSING - CONTINUED
LOCATION
22.
ACTION
REMARKS
ITEM
Screw (12), washer
(13), and wire (14)
a. Using 3/8-inch flat-tip screwdriver, unscrew and take off.
b. Put wire washer and screw in place.
c. Using 3/8-inch flat-tip screwdriver,
tighten.
NOTE
Make sure other end of wire (14) is connected to leadout terminal bushing (15).
TA 242530
2-287
TM 5-2815-241-34&P
ENGINE COMPRESSION BRAKE HOUSING - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY - CONTINUED
23. Housing (1)
(topside down)
Put into master piston bore (3).
Master piston (2)
NOTE
When performing next step, position master piston spring (4) as shown in illustration.
23.
Master piston spring
(4), flatwasher (5),
and screw (6)
a. Put in place.
Aline master piston spring (4) on
master piston (2).
b. Using 7/16-inch box-end wrench,
tighten.
24.
Slave piston (7) and
slave piston spring (8)
Put into slave piston bore (9).
WARNING
Slave piston spring will be under tension when installing. Extreme care must be taken to
prevent injury.
25.
2-288
Spring retainer (10)
and retaining
ring (11)
a. Position spring retainer in housing
grooves and on top of slave piston
spring.
b. Using arbor press, push down on spring
retainer.
c. Using snap-ring pliers, close retaining
ring and place into position.
Make sure retaining ring is seated in
groove.
d. Carefully release arbor press tension.
TM 5-2815-241-34&P
ENGINE COMPRESSION BRAKE HOUSING - CONTINUED
NOTE
FOLLOW-ON MAINTENANCE:
(page 2-116).
Install engine compression brake housing
TASK ENDS HERE
Section XIV. FUEL SYSTEM MAINTENANCE
Page
Page
Aneroid Control Valve ..................................
Fuel Injector ..................................................
Fuel Pump Calibration .................................
2-398
2-352
2-333
Fuel Pump ...............................................
Turbocharger ..........................................
2-289
2-384
FUEL PUMP
This task covers:
a. Cleaning (page 2-291)
b. Disassembly (page 2-291)
c. Filter Screen Inspection
(page 2-294)
d. Gear Pump Repair (page 2-295)
e. Pulsation Damper Repair
(page 2-301)
f.
g.
h.
i.
j.
k.
I.
Shutdown Valve Repair (page 2-304)
Front Cover Assembly Repair (page 2-308)
Fuel Pump Housing Repair (page 2-322)
Governor Plunger Repair (page 2-325)
Governor Spring Pack Repair (page 2-328)
Throttle Shaft Repair (page 2-329)
Fuel Pump Assembly (page 2-330)
TA 242531
2-289
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
INITIAL SETUP
Tools
Assembly tool, ST-419
Bit, drill, 1/4-inch
Bit, drill, 11/64-inch
Bit, screwdriver, flat-tip, 3/16-inch,
3/8-inch drive
Block, support (two required)
Chisel, gouge, 1/2-inch
Drill, electric, 3/8-inch
Driver, ST-853
Gage, bore
Gage, pressure, oil 0 to 600 psi
(0 to 4136 kPa)
Gage, thickness
Goggles, safety
Hammer, ball-peen, 16-ounce
Hammer, plastic-faced
Handle, ratchet, 3/8-inch drive
Handle, ratchet, 1/2-inch drive
Key, hex, 3/16-inch
Key, hex, 5/32-inch
Mandrel
Mandrel, seal driving
Micrometer, 0- to 1-inch
Micrometer, depth, 0- to 1-inch
Mittens, cloth, heat-protective
Ohmmeter
Pliers, diagonal-cutting, 8-inch
Pliers, slip-joint, 6-inch
Pliers, snapring
Power supply, 12 vdc
Press, arbor
Puller, ST-709
Puller, dowel, ST-667
Puller, gear, ST-1231
Punch, center
Punch, driftpin, brass, 3/16-inch
Reamer
Scale, machinist’s, 6-inch
Screwdriver, flat-tip, 3/8-inch
Screwdriver, flat-tip, 1/4-inch
Scribe, machinist’s
Socket, 3/16-inch hex-head, 1/2inch drive
Socket, 7/16-inch, 3/8-inch drive
Socket, 7/16-inch, 1/2-inch drive
Socket, 1/2-inch, 1/2-inch drive
V-blocks
Vise, soft-jawed
Wrench, box-end, 7/16-inch
2-290
Tools - Continued
Wrench, open-end, 7/16-inch (two required)
Wrench, open-end, 1/2-inch
Wrench, open-end, 5/8-inch
Wrench, open-end, 15/16-inch
Wrench, open-end, 1-inch
Wrench, torque, 0 to 150 in. lb (0 to 16.9
Nl m), 3/8-inch drive
Wrench, torque, 0 to 150 ft lb (0 to 210 N lm),
1/2-inch drive
Materials/Parts
Cloth, emery (item 1, appendix B)
Gasket, fuel pump housing
Gasket, gear pump
Gasket, governor spring pack cover
Grease, extreme-pressure (item 10,
appendix B)
Key, coupling, front cover
Lockwasher, front cover (two required)
Lockwasher, fuel pump housing (seven
required)
Lockwasher, gear pump (four required)
Lockwasher, governor spring pack cover
(four required)
Lockwasher, pulsation damper (six
required)
Lockwasher, shutdown valve (six required)
Lockwasher, throttle lever (two required)
Oil, lubricating (item 12, appendix B)
Oil, fuel (item 11, appendix B)
Seal, cap, fuel pump housing
Packing, preformed, pulsation damper (two
required)
Packing, preformed, shutdown valve (two
required)
Packing, preformed, throttle shaft (two
required)
Packing, preformed, pulsation damper
(two required)
Packing, preformed, shutdown valve
Prussian blue (item 13, appendix B)
Seal, oil, front cover (four required)
Seal, oil, pulsation damper
Shaft, shutdown valve
Tags, marker (item 17, appendix B)
Washer, nylon, pulsation damper
Wire, locking (item 21, appendix B)
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
Equipment Condition
Fuel pump assembly removed (page 2-41).
LOCATION
ACTION
REMARKS
ITEM
CLEANING
CAUTION
Do not use chemical or caustic solutions or solvents that may damage aluminum or
aluminum alloy parts. Serious damage to parts will occur.
Do not use wire brushes or stiff-bristle brushes on fuel pump parts for cleaning. Wire or
stiff bristle brushes will cause serious damage to parts.
NOTE
For general cleaning procedures, see General Maintenance Instructions (page 2-30).
DISASSEMBLY
1. Fuel pump
assembly (1)
Aneroid control feed
line (2) and return
line (3)
Using 5/8-inch open-end wrench, unscrew and remove.
2.
Filter screen cover
(4), preformed packing (5), spring (6),
and filter screen
assembly (7)
a. Using 3/8-inch flat-tip screwdriver, unscrew and remove filter screen cover.
b. Remove packing.
Discard packing.
c. Lift out spring and filter screen
assembly.
TA 242532
2-291
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY - CONTINUED
3. Fuel pump
assembly (1)
Four screws (2),
four lockwashers
(3), four flat
washers (4), two
preformed packings
(5), and pulsation
damper (6)
a. Using 3/16-inch hex key, unscrew and
remove four screws and four lockwashers.
Discard lockwashers.
b. Using plastic-faced hammer, tap shoulders of pulsation damper to loosen.
c. Take off pulsation damper and packing.
Discard packing.
4.
Four screws (7),
four lockwashers (8),
gear pump (9), and
gasket (10)
a. Using 3/16-inch hex key, unscrew and
remove four screws and four lockwashers.
Discard lockwashers.
b. Using plastic-faced hammer, tap shoulders of gear pump to loosen.
c. Take off gear pump and gasket.
Discard gasket.
5.
Shutdown valve (11),
two screws (12), two
lockwashers (13), and
gasket (14)
a. Using 3/16-inch hex key, unscrew and
remove two screws and two lockwashers.
Discard lockwashers.
b. Take off shutdown valve and gasket.
Discard gasket.
Lock wire (15), fuel
pump regulator seal
(16), four screws
(17), four lockwashers
(18), four flat washers
(19), governor
spring pack cover (20),
gasket (21), and
bracket (22)
a. Using 8-inch diagonal-cutting pliers,
cut lock wire.
b. Take off fuel pump regulator seal and
lock wire.
Discard lock wire.
c. Using 7/16-inch box-end wrench, unscrew and take out four screws, four
lockwashers, four flat washers, and
bracket.
Discard lockwashers.
d. Using plastic-faced hammer, tap shoulders of governor spring pack cover to
loosen.
e. Take off governor spring pack cover
and gasket.
Discard gasket.
2-292
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
7.
Front cover (23),
screw (24), six
screws (27), seven
lockwashers (25),
seven flat washers
(26), and gasket (28)
a. Using 5/32-inch hex key, unscrew and
remove screw (24), lockwasher, and
flat washer.
b. Using 7/16-inch box-end wrench, unscrew and remove six screws (27),
lockwashers, and flat washers.
Discard lockwashers.
c. Using plastic-faced hammer, tap cover
and seal to loosen.
d. Take off cover and seal and gasket.
Discard gasket.
8.
Throttle lever (29),
throttle lever screw
(30), flat washer (31),
two lockwashers
(32), and nut (33)
a. Using two 7/16-inch open-end
wrenches, loosen, unscrew, and take
off nut.
b. Take off lockwashers and flat washer.
Discard lockwashers.
c. Take out throttle lever screw.
d. Remove throttle lever.
9.
Snapring (34),
throttle shaft cover
(35), snapring (36),
and throttle shaft
assembly (37)
a. Using 6-inch slip-joint pliers, take out
snapring (34).
b. Remove throttle shaft cover.
c. Using snapring pliers, take out
snapring (36).
d. Pull out throttle shaft assembly.
Handle throttle shaft carefully.
TA 242533
2-293
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
FILTER SCREEN INSPECTION
NOTE
For fuel pump filter screen removal, see step 2 (page 2-291).
10. Filter screen
cover (1)
Inspect for damage or wear.
Discard, If damaged or worn.
Cap seal (2)
WARNING
Particles blown by compressed air are hazardous. Make certain the airstream is
directed away from user and other personnel in the area. Compressed air used for
cleaning purposes shall not exceed 30 psi (207 kPa). User must wear safety goggles or
face shield to prevent injury.
11.
Filter screen
cover (1)
a. Clean in fuel oil and blow dry with compressed air.
b. Inspect for damage or wear.
Discard if damaged or worn.
12.
Filter screen (3)
a. Inspect for holes or imbedded foreign
particles.
b. Clean in fuel oil and blow dry with compressed air.
c. Remove any metal particle buildup from
magnet inside filter screen.
Discard if damaged or clogged.
13.
Spring (4)
Inspect for damage or wear.
Discard if damaged or worn.
TA 242534
2-294
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
GEAR PUMP REPAIR
NOTE
For gear pump removal procedures, see steps 3 and 4 (page 2-292).
14. Gear pump
assembly
Elbow check
valve (5)
a. Using 1/2-inch open-end wrench, unscrew and remove.
b. Check for one way flow operation.
Discard if not operational.
15.
Gear pump
cover (6) and
gaskets (7)
a. Using 16-ounce ball-peen hammer, tap
gear pump cover from gear pump
housing (8).
b. Take off gasket.
Discard gasket.
16. Gear pump
housing (8)
Drive gear and
shaft (9) and
driven gear and
shaft (10)
Lift drive gear and shaft and driven gear
and shaft from gear pump housing.
17. Gear pump
cover (6)
Bushing sleeve (11)
a. Inspect for nicks, burrs, wear, or
scoring.
Discard if worn or scored.
b. Using emery cloth, polish out nicks and
burrs.
TA 242535
2-295
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
GEAR PUMP REPAIR - CONTINUED
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
18.
Gear pump housing
(1) and gear pump
cover (2)
a. Check gear pump housing and gear
pump cover for scoring or wear.
Discard if scored or worn.
b. Using 0- to 1-inch depth micrometer,
measure depth of gear pump housing
gear pocket.
Gear pocket depth should be 0.7478
to 0.7483 inch (18.994 to 19.006
mm). Discard if depth exceeds
0.7483 inch (19.006 mm).
c. Using bore gage, measure shaft bore
diameters in gear pump housing and
gear pump cover. Shaft bore should be
0.5013 to 0.5016 inch (12.733 to
12.740 mm).
Discard if shaft bores exceed 0.5016
inch (12.740 mm).
19.
Drive gear and shaft
(3) and driven gear
and shaft (4)
a. Inspect shafts for wear or scoring.
Discard if worn or scored.
b. Using 0- to 1-inch micrometer, measure diameter of shafts.
Shafts should be 0.4998 to 0.5001
inch (12.695 to 12.703 mm). Discard
if worn smaller than 0.4998 inch
(12.703 mm).
c. Check gears for damage.
Discard if worn.
d. Using 0-to 1-inch micrometer, measure width of drive gear and driven gear.
Gear width should be 0.7483 to
0.7486 inch (19.006 to 19.014 mm).
Discard gears if smaller than 0.7483
inch (19.006 mm).
2-296
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Steps 20 and 21 are for replacement of gear or shaft. If gear or shaft replacement is not
necessary, proceed to step 22. Step 20 is for driven gear and shaft assembly only. Step
21 is typical for both drive and driven gear and shaft assemblies.
20.
Spur gear and idler
shaft assembly (4)
Using prussian blue, mark shaft on gear
pump housing side.
21.
Shaft (5) and
gear (6)
a. Support gear and, using arbor press and
mandrel, press out shaft.
b. Lubricate shaft with extreme-pressure
grease.
c. Position shaft in gear and, using arbor
press and mandrel, press shaft into
gear until gear face is 0.680 to 0.690
inch (17.27 to 17.53 mm) from gear
pump housing end of shaft.
TA 242536
2-297
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
GEAR PUMP REPAIR - CONTINUED
NOTE
Steps 22 and 23 are for gear pump cover or dowel ring replacement only. If gear pump
cover or dowel ring replacement is not required, proceed to step 24.
22.
23.
Gear pump cover (1)
Bushing sleeve (2)
Remove.
Bushing sleeve (2)
a. Lubricate dowel ring with extremepressure grease.
b. Position dowel ring over drive gear and
shaft bore in gear pump cover and,
using arbor press and mandrel, press
in.
NOTE
Make sure all parts are clean before assembly, paying particular attention to lubricating
holes in gear pump cover and gear pump housing.
24.
2-298
Drive gear and shaft
(3), spur gear and
idler shaft (4), and
gear pump housing (5)
a. Using 0- to 1-inch micrometer, measure width of drive gear and driven gear.
Write down measurement indicated by
micrometer.
b. Using 0- to 1-inch depth micrometer,
measure depth of gear pocket in gear
pump housing.
Write down measurement indicated by
depth micrometer.
c. Subtract measurement obtained in step b
from measurement obtained in step a.
The result will indicate which gasket must
be used, for assembly, to obtain proper
end clearance for gear pump gears.
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
25. Gear pump
housing (5)
Drive gear and shaft
(3) and spur gear
and idler shaft (4)
a. Lubricate gear pump housing, drive gear
and shaft, and driven gear and shaft with
lubricating oil.
b. Clean prussian blue from gear pump
housing end of driven gear and shaft,
and position driven gear and shaft into
gear pump housing.
c. Position drive gear and shaft into gear
pump housing.
d. Using thickness gage, check gear backlash as shown.
Backlash must not exceed 0.004 inch
(0.102 mm).
26.
New gasket (6) and
gear pump cover (1)
a. Install red, 0.002-inch (0.51 mm), or
purple, 0.0015-inch (0.38 mm), new
gasket as determined in step 24.
b. Position gear pump cover on gear pump
housing (5), making sure dowels and
dowel holes are alined, and press
together.
c. Check that pump turns freely by finger
pressure only.
TA 242537
2-299
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
GEAR PUMP REPAIR - CONTINUED
27. Gear pump
assembly (1)
Using 6-inch machinist’s scale, measure
from end of drive gear and shaft (2) to gear
pump cover (3).
Distance should be 2.370 to 2.412
inches (60.2 to 61.3 mm).
28.
Drive gear and
shaft (2)
Using dial indicator, check end clearance.
End clearance should be 0.0009 to
0.0015 inch (0.0228 to 0.0377 mm).
28.
Elbow check
valve (4)
Using 1/2-inch open-end wrench, screw
in and tighten so open end of elbow check
valve faces away from fuel inlet port (5)
on gear pump body.
30.
New gear pump
gasket (6)
Install new gear pump gasket to gear pump
cover.
TA 242538
2-300
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
PULSATION DAMPER REPAIR
NOTE
For pulsation damper removal procedures, see step 3, page 2-292.
31. Pulsation damper
assembly (7)
Fuel inlet connection (8), locknut (9),
and preformed
packing (10)
a. Using 1-inch and 15/16-inch open-end
wrenches, loosen locknut.
b. Unscrew and remove fuel inlet connection and packing.
Discard packing.
32.
Elbow (11)
Using 7/16-inch open-end wrench, unscrew and remove.
33.
Two screws (12), two
lockwashers (13),
two flat washers
(14), and cover (15)
a. Using 7/16-inch open-end wrench,
unscrew and remove two screws, two
lockwashers, and two flat washers.
b. Take off cover.
Discard lockwashers.
34. Cover (15)
Preformed
packing (16)
Take out.
Discard.
TA 242539
2-301
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
PULSATION DAMPER REPAIR - CONTINUED
35. Pulsation damper
assembly (1)
Nylon washer (2),
plate (3), and preformed packing (4)
Take out nylon washer, plate, and preformed packing.
Discard nylon washer and preformed
packing.
CAUTION
Do not use chemical or caustic solutions or solvents that may damage aluminum or
aluminum alloy parts. Serious damage to parts will occur.
Do not use wire brushes or stiff bristle brushes on aluminum or aluminum alloy parts.
Wire or stiff bristle brushes will cause serious damage to parts.
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
36.
Cover (5)
Inspect for corrosion, wear, cracks, or
damage.
Discard if corroded, worn, cracked,
or damaged.
37.
Plate (3)
a. Inspect for corrosion or wear.
Discard if corroded or worn.
b. Visually check for cracks.
Discard if cracked.
38. Pulsation damper
assembly (1)
New preformed packing (4), plate (3),
new nylon washer (2),
new oil seal (6),
and new O-ring (7)
a. Install new preformed packing in groove.
b. Coat diaphragm with lubricating oil and
place in position.
c. Place new nylon washer in position.
d. Install new seal and new O-ring in end
of body.
2-302
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
39. Pulsation damper
assembly (1)
Cover (5), new preformed packing (8),
two screws (9), two
new lockwashers
(10), and two flat
washers (11)
a. Install new preformed packing in groove
of cover.
b. Position cover on pulsation damper
assembly.
c. Install one new lockwasher and one flat
washer on each screw.
d. Using 7/16-inch box-end wrench,
screw in and tighten two screws.
40.
Elbow (12)
Using 7/16-inch open-end wrench,
screw in and tighten so open end of elbow
faces up.
41.
Fuel inlet connection (13), new preformed packing (14),
and locknut (15)
a. Put in new packing on fuel inlet
connection.
b. Screw in by hand and face open end of
fuel inlet connection away from cover.
c. Using 1-inch and 15/16-inch open-end
wrenches, tighten locknut on fuel inlet
connection.
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ACTION
REMARKS
ITEM
SHUTDOWN VALVE REPAIR
NOTE
For shutdown valve removal procedures, see step 5, page 2-292.
42. Shutdown valve
housing (1)
Four machine screws
(2) and four lockwashers (3)
Using 1/4-inch flat-tip screwdriver, unscrew and remove.
Discard lockwashers.
43.
Coil assembly (4)
Remove.
44.
Access cover plate
(5), spring washer
(6), preformed packing (7), disk
valve (8)
Remove.
Discard packing.
45.
Override knob (9)
Pull off.
46.
Shaft (10), preformed packing (11)
and O-ring (12)
Using 1/4-inch flat-tip screwdriver, unscrew and remove shaft and preformed
packing from coil end.
Discard shaft, preformed packing
and O-ring.
47.
Pipe plug (13)
Using 7/16-inch open-end wrench, unscrew and remove.
CAUTION
Do not wet coil assembly with solvents or cleaners. Solvents or cleaners will cause
damage to coil.
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
48.
2-304
Coil assembly (4)
Using ohmmeter, check coil resistance.
Resistance should be 7.5 ohms ± 0.5
ohms.
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
49.
Disk valve (8)
Inspect disc valve for wear, bonding failure,
surface cuts, separations, or corrosion.
Discard if worn, cut, corroded, or
bonding has failed or separated.
50.
Shutdown valve
housing (1)
a. Inspect for wear, damage, or corrosion.
Discard if worn, damaged, or
corroded.
b. Inspect valve seating area for wear or
damage.
Discard if worn or damaged.
c. Using 6-inch machinist’s scale, measure width of valve seat.
Minimum valve seat width should be
0.015 inch (0.38 mm).
TA 242541
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LOCATION
ACTION
REMARKS
ITEM
SHUTDOWN VALVE REPAIR - CONTINUED
NOTE
Make sure all parts are clean before assembly.
51. Shutdown valve
housing (1)
New shaft (2) and
new preformed
packing (3)
a. Install new preformed packing on new
shaft and coat with lubricating oil.
b. Screw new shaft into bore of shutdown
valve housing until it reaches bottom.
c. Using 0- to 1-inch depth micrometer set
at 0.118 inch (2.997 mm), place depth
micrometer on face of shutdown valve
housing (1), and screw new shaft out
until tip touches spindle of depth
micrometer.
Do not move shaft after 0.118 inch
(2.997 mm) depth is attained.
52.
Override knob (4)
Press on until override knob contacts
shutdown valve housing.
53.
Disk valve (5)
Install with rubber side toward shutdown
valve housing.
54.
New preformed
packing (6)
Coat new packing with lubricating oil and
install in groove in shutdown valve housing.
55.
Spring washer (7)
Place spring washer on disk valve (5), with
concave side up, and in position around
locator on valve.
56.
Access cover plate
(8), coil assembly
(9), four machine
screws (10), and
four new lockwashers (11)
a. Place access cover plate and coil assembly on shutdown valve housing and
install four machine screws.
b. Using 3/8-inch drive 3/16-inch flat-tip
screwdriver bit and 0 to 150 in. lb (0 to
16.9 Nlm) torque wrench, screw in and
torque four machine screws to 25 to 35
in. lb (3 to 5 Nlm).
2-306
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FUEL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
New O-ring (12)
Install on bottom of shutdown valve.
58.
Pipe plug (13)
Using 7/16-inch open-end wrench, screw
in and tighten.
59.
Shutdown valve
housing (1)
a. Using 12 vdc power supply, and oil
pressure gage, 0 to 600 psi (0 to 4136
kPa) hook up shutdown valve and attach
lines to shutdown valve inlet and outlet.
b. Energize coil and pump test fluid through
valve at 300 psi (2068 kPa) maximum.
c. Deenergize valve and check to be sure
valve holds 300 psi (2068 kPa) load with
no leakage.
If shutdown valve does not hold
specified pressure, check shutdown
valve housing to access cover plate
mating surface for damage. Also
check rubber on access cover plate
for swelling or damage, and replace
as necessary.
57.
Shutdown valve
housing (1)
TA 242542
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FUEL PUMP - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
FRONT COVER ASSEMBLY REPAIR
NOTE
For front cover assembly removal procedures, see step 7, page 2-292.
Steps 60 thru 101 contain repair procedures for the front cover, drive shaft, and weight
carrier.
Weight carrier (2)
Check for excessive weight carrier shaft
bushing wear by moving weight carrier shaft
(3) from side to side in bushing (4).
There is excessive wear if weight
carrier shaft can be moved from side
to side in weight carrier shaft bushing.
Tag for replacement if wear is
observed.
61.
Drive shaft gear (5)
and spur gear (6)
Using thickness gage, check gear
backlash.
Backlash should be 0.005 to 0.009
inch (0.13 to 0.23 mm).
62.
Weight assist plunger (7), weight assist
shim (8), and weight
assist spring (9)
Remove.
60.
Front cover (1)
NOTE
When removing weight carrier, retaining ring (10) may be pulled from weight carrier
shaft (3) leaving bushing (4) in front cover. If snapring is pulled from weight carrier
shaft (3), weight carrier may also be pulled from shaft.
63.
Weight carrier (2)
Using ST-709 puller, pull weight carrier
from front cover (1).
NOTE
Perform step 64 only if weight carrier shaft remains in front cover when removing weight
carrier.
2-308
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FUEL PUMP - CONTINUED
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64.
Front cover (1)
ACTION
REMARKS
ITEM
Using ST-667 dowel puller, pull out.
Weight carrier
shaft (3)
NOTE
Perform step 65 only if bushing (4) remains in front cover when removing weight carrier
and weight carrier shaft.
65.
Bushing (4)
Using ST-709 puller, pull bushing from
front cover (1).
66. Weight carrier (2)
Retaining ring (10)
and bushing (4)
Using snapring pliers, take retaining ring off
bushing.
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ITEM
ACTION
REMARKS
FRONT COVER ASSEMBLY REPAIR - CONTINUED
67. Front cover (1)
Tachometer drive
housing (2), screw
(3), and lockwasher (4)
a. Using 3/8-inch flat-tip screwdriver,
unscrew and remove.
Discard lockwasher.
b. Lift off tachometer drive housing.
68.
Tachometer drive
shaft assembly (5),
two oil seals (6),
and spacer (7)
a. Using ST-667 dowel puller, remove
tachometer drive shaft assembly.
b. Take out oil seals and spacers.
Discard oil seals.
69.
Coupling screw (8),
coupling lockwasher
(9), and flat
washer (10)
Using 1/2-inch drive 1/2-inch socket and
ratchet handle, unscrew and take out.
Discard lockwasher.
70. Drive shaft
assembly (11)
Drive coupling (12)
and coupling key (13)
a. Using ST-709 puller, pull off drive
coupling.
b. Remove coupling key.
Discard coupling key.
71.
Tachometer drive
gear (14)
Using ST-1231 gear puller, remove.
72.
Snapring (15) and
drive shaft
assembly (11)
a. Using 6-inch slip-joint pliers, remove
snapring.
b. Remove drive shaft assembly.
TA 242544
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73.
Front cover (1)
ACTION
REMARKS
ITEM
Using arbor press and mandrel, press out.
Discard.
Two oil seals (16)
CAUTION
Do not use chemical or caustic solutions or solvents that may damage aluminum or
aluminum alloy parts. Serious damage to parts will occur.
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
74.
Front cover (1)
a.
Inspect for cracks, wear, or corrosion.
Discard if cracked, worn, or
corroded.
b. Inspect all mating surfaces for scratches, nicks, or burrs.
Remove small scratches, nicks, and
burrs with emery cloth.
c. Inspect shaft bores and bearing bores for
out-of-round condition.
Discard if out-of-round.
75.
Weight carrier
shaft bushing (17)
a. Using bore gage, measure inside
diameter.
Discard if worn more than 0.504 inch
(12.80 mm).
b. Inspect thrust face (18) for excessive
wear.
Discard if excessively worn or
scratched.
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ACTION
REMARKS
ITEM
FRONT COVER ASSEMBLY REPAIR - CONTINUED
NOTE
Step 76 covers procedures for inspecting cast weight carrier. These procedures also
apply to welded weight carrier with the following exception. If welded weight carrier is
found to be worn, discard entire weight carrier. Only cast weight carrier has replaceable
parts.
76. Weight carrier (1)
Governor weight
pins (2)
a. Place 1/4-inch drill bit under governor
weights (3).
b. Try to place 11/64-inch drill bit between
governor weights (3).
Replace governor weight pins if
11/64-inch drill bit does not fit
between weights.
NOTE
Perform step 77 only if governor weight pins (2) are to be replaced.
77. Weight carrier (1)
Two governor weight
pins (2) and two
governor weights (3)
a. Using 3/16-inch brass driftpin punch
and 16-ounce ball-peen hammer, tap
out two governor weight pins.
Discard governor weight pins.
b. Take out governor weights.
78.
Two governor
weights (3)
Inspect for wear or damage.
Discard if worn or damaged.
79.
Weight carrier (1)
Inspect for wear or damage.
Discard if worn or damaged.
80. Weight carrier (1)
Two governor weights
(3) and two new
governor weight
pins (2)
Position governor weights in weight carrier and using 3/16-inch brass drift-pin
punch and 16-ounce ball-peen hammer,
drive in two new governor weight pins.
Center new governor weight pins in
weight carrier.
2-312
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FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
Weight carrier shaft
(4) and spur
gear (5)
81.
Inspect for wear, scratches, nicks, burrs,
and damaged gear teeth.
Tag weight carrier shaft or spur gear
for replacement if worn, scratched,
nicked, burrs are noted, or gear teeth
are missing or damaged.
NOTE
Perform step 82 only if spur gear (5) or weight carrier shaft (4) is to be replaced.
82. Weight carrier (1)
Weight carrier shaft
(4) and spur
gear (5)
Support weight carrier (1) on support
blocks and, using arbor press and mandrel,
press out weight carrier shaft.
Discard weight carrier shaft or spur
gear as determined in step 81.
TA 242546
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ACTION
REMARKS
ITEM
FRONT COVER ASSEMBLY REPAIR - CONTINUED
NOTE
Step 83 covers assembly of weight carrier shaft. If old parts came off shaft during
disassembly and are to be used again, weight carrier shaft must be a minimum of
0.0005 inch (0.013 mm) larger than spur gear bore and weight carrier bore for an
interference fit.
83. Weight carrier (1)
Weight carrier shaft
(2) and spur gear (3)
a. Support weight carrier on support blocks
and, using arbor press and mandrel,
press weight carrier shaft into weight
carrier until it is 0.005 inch (0.13 mm)
to flush with weight side of weight
carrier.
b. Support weight carrier and shaft assembly in ST-1231 gear puller and, using
arbor press and mandrel, press weight
carrier shaft into spur gear.
Make sure rough edge of gear is
facing weight carrier.
84.
Drive shaft
assembly (4)
Inspect drive shaft (5), drive gear (6),
drive coupling (7), and ball bearing (8) for
wear or damage.
Tag worn or damaged parts for
replacement.
NOTE
Steps 85 thru 88 are for drive shaft, drive gear, drive coupling, and ball bearing
replacement only. If no replacement is necessary, proceed to step 90.
TA 242547
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ACTION
REMARKS
ITEM
CAUTION
Press drive gear away from ball bearing. Pressing drive gear towards ball bearing will
cause serious damage to parts.
85. Drive shaft (5)
Drive gear (6) and
drive coupling (7)
Using arbor press and mandrel, press drive
shaft from drive gear and drive coupling.
86.
Ball bearing (8)
a. Support inner race, and using arbor
press and mandrel, press drive shaft
(5) from ball bearing.
b. Lubricate drive shaft (5) with extremepressure grease.
c. Position ball bearing on drive shaft (5),
and, using arbor press and mandrel
against inner race, press into place.
87.
Drive gear (6)
Position on drive shaft (5) and, using arbor
press and mandrel, press until drive gear
reaches shoulder on drive shaft (5).
88.
Drive coupling (7)
a. Lubricate drive shaft (5) with extremepressure grease.
b. Position on drive shaft (5) and, using
arbor press and mandrel, press against
drive gear (6).
TA 242548
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FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
FRONT COVER ASSEMBLY REPAIR - CONTINUED
89.
Tachometer drive
housing (1)
Inspect for damage or wear.
Discard if damaged or worn.
90.
Assembled tachometer
drive shaft and
gear (2)
Inspect for wear, scoring, nicks, or broken
gear teeth.
Tag worn, scored, nicked, and broken parts for replacement.
NOTE
Perform steps 91 thru 94 only if tachometer drive shaft, bushing, or gear are to be
replaced. If none of these parts are to be replaced, proceed to step 95.
91. Tachometer drive
shaft (3)
Tachometer gear (4)
and tachometer
bushing (5)
a. Using arbor press and mandrel, or
ST-1231 gear puller, press or pull
tachometer gear from tachometer drive
shaft.
b. Remove tachometer bushing.
NOTE
Steps 92 and 93 cover inspection for tachometer drive shaft and tachometer bushing.
Perform steps 92 and 93 only if these parts have not been tagged for replacement.
92.
Tachometer drive
shaft (3)
Using 0- to 1-inch micrometer, measure
tachometer drive shaft in several places.
Diameter should be 0.3950 to 0.3955 inch
(10.033 to 10.046 mm).
Discard if worn smaller than 0.3950
inch (10.033 mm).
93.
Tachometer
bushing (5)
Using bore gage, measure inside diameter
of tachometer bushing. Inside diameter
should be 0.3963 to 0.3970 inch (10.066 to
10.084 mm).
Discard if worn larger than 0.3970
inch (10.084 mm).
2-316
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
94. Tachometer drive
shaft (3)
ACTION
REMARKS
ITEM
Tachometer bushing
(5) and tachometer
gear (4)
a. Lubricate tachometer drive shaft with
extreme-pressure grease.
b. Install tachometer bushing with chamfered end towards tachometer gear.
c. Position tachometer gear on tachometer
shaft and, using arbor press and mandrel, press tachometer gear onto tachometer shaft until flush with end of
tachometer shaft.
d. Check to see that tachometer gear and
shaft turn freely in tachometer bushing.
e. Using thickness gage, measure clearance between tachometer bushing and
tachometer gear. Maximum clearance is
0.005 inch (0.127 mm).
NOTE
Make sure all parts and subassemblies are clean and free of dust and dirt before proceeding with assembly procedures.
TA 242549
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LOCATION
ITEM
ACTION
REMARKS
FRONT COVER ASSEMBLY REPAIR - CONTINUED
95. Front cover (1)
Retaining ring (2)
and drive shaft (3)
a.
96.
Two new oil
seals (6)
a. Position one new oil seal on drive
shaft (3) with lip towards rear of pump
and, using arbor press and seal driving
mandrel, press into place.
b. Position second new oil seal on drive
shaft (3) with lip towards front of pump
and using arbor press and seal driving
mandrel, press into place.
97.
Tachometer shaft and
gear assembly (7),
spacer (8), two new
oil seals (9), tachometer drive housing
(10), new lockwasher
(11), and screw (12)
a. Aline oil groove on top of tachometer
bushing with fuel pump drive shaft.
b. Press tachometer shaft and gear assembly into front cover (1) until bushing
bottoms in its bore.
c. Position spacer on bushing with slotted
edge down.
d. Position two new oil seals on top of
spacer with spring side down, and cover
with a thin coat of lubricating oil.
e. Place tachometer drive housing on front
cover (1) and using 3/8-inch drive
3/16-inch flat-tip screwdriver bit and
ratchet handle, screw in and tighten
screw and new lockwasher.
2-318
Position retaining ring on drive shaft
between tachometer drive gear (4) and
ball bearing (5).
b. Lubricate ST-419 assembly tool with
lubricating oil and install over drive
shaft.
c. Position drive shaft in front cover,
alining ball bearing (5) with bore in front
cover and, using arbor press, press in
until ball bearing (5) is seated in front
cover.
d. Using 6-inch slip-joint pliers, secure
retaining ring in groove in front cover.
Look through holes in drive gear to
make sure retaining ring is fully
seated.
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
98.
ITEM
New coupling key
(13), tachometer
drive gear (4),
drive coupling (14),
flat washer (15), new
coupling lockwasher
(16), and coupling
screw (17)
ACTION
REMARKS
a. Position new coupling key on drive
shaft (3).
b. Lubricate drive shaft (3) with extremepressure grease and, using arbor press
and mandrel, press tachometer drive
gear and drive coupling into place.
Make sure tachometer drive gear and
tachometer gear teeth are alined.
c. Position new coupling lockwasher and
flat washer on coupling screw. Using
1/2-inch drive 1/2-inch socket and
ratchet handle, screw on and tighten.
Hold drive coupling or drive shaft in
soft-jawed vise while tightening coupling screw.
TA 242550
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FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
FRONT COVER ASSEMBLY REPAIR - CONTINUED
CAUTION
Make sure gears mesh when pressing weight carrier assembly into front cover to avoid
damage to gear teeth.
99. Front cover (1)
Weight carrier (2),
weight carrier shaft
bushing (3), weight
carrier shaft (4),
and retaining
ring (5)
a.
b.
c.
d.
e.
100. Weight carrier (2)
2-320
Weight assist shims
(6), weight assist
spring (7), and weight
assist plunger (8)
Push retaining ring onto end of weight
carrier shaft.
Lubricate weight carrier shaft bushing
with extreme-pressure grease and position in front cover.
Lubricate weight carrier shaft with lubricating oil and position in weight carrier
shaft bushing.
Using arbor press and mandrel, center
mandrel against back of weight carrier
between weights, and with gears alined,
press weight carrier and weight carrier
shaft bushing into front cover until
bushing is seated.
Rotate weight carrier with weights
opened out to make sure it will turn
completely in housing.
a. Install items and in order given.
Make sure small end of weight assist
plunger is closest to weight carrier
assembly weights.
b. Using 0 to 1-inch depth micrometer,
place one leg of depth micrometer base
across weight carrier walls and measure
distance to front cover (1) mating
surface.
Record as measurement A.
c. Repeat step 100b for other side of weight
carrier.
Record as measurement B.
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
d. Add measurements A and B and divide
by 2.
Record finding C.
e. Using 0 to 1-inch depth micrometer,
center depth micrometer on weight
carrier over weight assist plunger and
measure distance to end of weight assist
plunger.
Do not depress weight assist spring.
Record measurement D.
f. Subtract measurement D from finding C.
The result is the weight assist protrusion. Weight assist protrusion should
be 0.840 inch (21.33 mm). If weight
assist protrusion is below 0.840 inch
(21.33 mm), add weight assist shims
(5). If weight assist protrusion is above
0.840 inch (21.33 mm), remove
shims (5), or if no shims are used,
grind small end of weight assist plunger.
Weight assist shims are available in
0.007 inch (0.178 mm) and 0.016 inch
(0.406 mm) thicknesses.
TA 242551
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FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
FUEL PUMP HOUSING REPAIR
NOTE
For fuel pump housing disassembly procedures, see steps 1 thru 10.
101.
Fuel pump
housing (1)
Inspect fuel pump housing for scratches,
nicks, burrs, and cracks.
Discard if cracked. Polish out
scratches, nicks, and burrs with
emery cloth.
102. Fuel pump
housing (1)
Throttle sleeve (2)
Inspect throttle sleeve for wear or
damage.
Throttle sleeve is a nonreplaceable
Item. If worn or damaged, replace
fuel pump housing, and throttle
sleeve.
103.
Drive shaft
bushing (3)
a. Inspect drive shaft bushing for damage.
Mark for replacement if damaged.
b. Using bore gage, measure inside diameter of drive shaft bushing. Inside
diameter should be no larger than
0.7525 inch (19.11 mm).
If worn to 0.7525 inch (19.11 mm) or
larger, mark for replacement.
Spring pack
housing (4)
104.
Inspect for any signs of wear or damage.
Mark for replacement if worn or
damaged.
NOTE
Steps 105 to 111 are for drive shaft bushing or governor barrel replacement only. If
these parts are not to be replaced, proceed to step 114.
105. Fuel pump
housing (1)
Drive shaft
bushing (3)
Using 1/2-inch gouge chisel and 16-ounce
ball-peen hammer, remove.
Discard.
106.
New drive shaft
bushing (3)
Lubricate with extreme-pressure grease
and, using arbor press and mandrel, press
in until flush with end of drive shaft bushing
bore.
2-322
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FUEL PUMP - CONTINUED
LOCATION
107.
ACTION
REMARKS
ITEM
Sleeve bearing (3)
Lubricate 0.750 inch (19.05 mm) reamer
with lubricating oil and ream sleeve bearing to 0.7495 to 0.750 inch (19.04 to
19.06 mm).
WARNING
Heat-protective cloth mittens must be worn to prevent serious injury to hands when
handling heated parts.
108.
Spring pack housing
(4) and clip (5)
a. Using lock wire, hook through plug hole
in bottom of fuel pump housing (1) and
pull out clip.
b. Heat fuel pump housing (1) to 300°F
(149 oC) and, using arbor press and
mandrel, press out spring pack
housing.
109.
Fuel pump housing
(1), spring pack
housing (4), and
barrel assembly (6)
a. Inspect spring pack housing bore and
barrel assembly for scoring or damage.
Polish out score marks using emery
cloth. If deeply scored or damaged,
discard.
b. Using bore gage, measure inside diameter of spring pack housing bore.
c. Using 0 to 1-inch micrometer, measure
outside diameter of new spring pack
housing.
Outside diameter of spring pack housing should be 0.002 inch (0.051 mm)
larger than spring pack housing bore.
TA 242552
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FUEL PUMP - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
FUEL PUMP HOUSING REPAIR - CONTINUED
WARNING
Heat-protective cloth mittens must be worn to prevent serious injury to hands when
handling heated parts.
110. Fuel pump
housing (1)
Spring pack housing
(2) and barrel
assembly (3)
a. Aline spring pack housing fuel passages
with fuel passages in spring pack housing bore and scribe a center line on
spring pack housing and spring pack
housing bore.
b. Heat fuel pump housing using machinist’s scribe to 300oF (149oC). Drop in
barrel assembly and, using arbor press
and mandrel, press in spring pack housing, with scribe marks alined, until it
bottoms against barrel assembly.
Make sure clip hole is towards bottom
of fuel pump housing.
111.
Clip (4)
Using ST-853 driver, install clip into bottom
of spring pack housing (2) with slot towards
front of fuel pump housing (1).
TA 242553
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FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
GOVERNOR PLUNGER REPAIR
CAUTION
Do not remove torque spring by pulling it straight off. This will stretch it beyond its elastic
limit so it has to be replaced.
NOTE
Remove governor plunger from fuel pump housing if not previously removed.
112. Governor plunger
assembly (5)
a. Take torque spring off by twisting.
b. Take off shims.
Torque spring (6)
and shims (7)
NOTE
Step 113 is for determining new governor plunger to be used if spring pack housing has
been replaced. If spring pack housing has not been replaced, proceed to step 114.
113. Fuel pump
housing (1)
Governor plunger
assembly (5)
a. Attempt to fit governor plunger in spring
pack housing.
b. If governor plunger enters, try the next
larger size governor plunger.
c. Keep trying larger sizes until one will
not enter.
d. Select a governor plunger two sizes
smaller than the last governor plunger
that does fit inside spring pack housing.
Do not force a governor plunger Into
the spring pack housing.
e. Mark spring pack housing with size of
governor plunger determined to be
used.
TA 242554
Change 1
2-325
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
GOVERNOR PLUNGER REPAIR - CONTINUED
114. Governor plunger
assembly (1)
Thrust washer (2)
Inspect thrust washer for wear or damage.
Tag for replacement if worn or
damaged.
115.
Governor plunger (3)
Inspect governor plunger for excessive
wear or scoring.
Tag for replacement if worn or
scored.
NOTE
Steps 116 thru 120 are for governor plunger, thrust washer, driver, and stop sleeve
replacement only. Proceed to step 121 only if these parts do not need to be replaced.
116.
Retainer pin (4),
stop sleeve (5),
driver (6), and
thrust washer (2)
a. Support governor plunger assembly in Vblocks and drive retainer pin from stop
sleeve, governor plunger (3), and
driver.
b. Take out driver and thrust washer.
Replace parts as necessary.
117.
Stop sleeve (5)
Using arbor press and mandrel, press stop
sleeve from governor plunger (3).
Replace parts as necessary.
Stop sleeve (5)
a.
Thrust washer (2),
driver (6), and
retainer pin (4)
Place thrust washer and driver in position
and, with governor plunger supported on
V-blocks, drive in retainer pin.
Chamfered side of thrust washer must
be next to driver.
118.
119.
2-326
Governor plunger (3)
Lubricate governor plunger with
extreme-pressure grease and position
over stop sleeve with retainer pin-holes
alined.
b. Using arbor press and mandrel, press in
governor plunger until flush with face
of stop sleeve.
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
When installing shims, number of shims may vary to obtain proper clearance.
120. Governor plunger
assembly (1)
Torque spring (7)
and shims (8)
a. Install shims as required.
b. Install torque spring with small end
towards shoulder end of plunger by
twisting.
Replacement torque spring Is color
coded red-blue.
121.
Driver (6) and
thrust washer (2)
Using thickness gage, check clearance
between driver tang and thrust washer.
Clearance must be 0.002 to 0.005 inch
(0.05 to 0.13 mm).
If clearance does not meet these
dimensions, repair as necessary.
TA 242555
2-327
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
GOVERNOR SPRING PACK REPAIR
122. Governor barrel
assembly (1)
Retaining ring (2)
Using snapring pliers, take off.
123.
Spring retainer (3),
shims (4), and highspeed spring (5)
a. Take out.
b. Inspect for wear or damage.
Replace parts as necessary.
124.
Idle spring plunger
guide assembly (6)
Take out.
125. Idle spring plunger
guide (7)
Adjusting screw (8),
flat washer (9),
idle spring (10),
idle spring plunger
(11), and adapter (12)
a. Take out.
b. Inspect all parts for wear damage.
Replace parts as necessary.
126.
Adjusting screw (8),
flat washer (9),
idle spring (10),
idle spring plunger
(11), and adapter (12)
a. Screw in adjusting screw and place flat
washer over screw point inside idle
spring plunger guide.
b. Place idle spring inside, and install
idle spring plunger over idle spring.
c. Install adapter.
127. Governor barrel
assembly (1)
Idle spring plunger
guide assembly (6)
Install.
128.
High-speed spring
(5), shims (4),
spring retainer (3),
and retaining ring (2)
a. Install high-speed spring and shims as
required.
The final number of shims will be
determined during fuel pump
calibration.
b. Install spring retainer.
WARNING
Safety goggles must be worn to prevent possible eye injury when compressing barrel
assembly spring.
c. Compress governor barrel assembly
spring in governor barrel assembly
housing (1) and, using snapring pliers,
install retaining ring.
2-328
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
THROTTLE SHAFT REPAIR
129. Throttle shaft
assembly (13)
Preformed packing
(14) and ball (15)
a. Using center punch, 1/4-inch drill bit,
and 3/8-inch electric drill, drill out
ball.
b. Take off packing.
Discard packing and ball.
130.
Fuel adjusting
screw (16)
Using 1/4-inch flat-tip screwdriver, unscrew and take out.
131. Fuel adjusting
screw (16)
Preformed
packing (17)
Take off.
Discard.
NOTE
Throttle shafts vary with applications. Replace with same size and type if needed.
132.
Throttle shaft
assembly (13) and
fuel adjusting
screw (16)
Inspect for wear or damage.
Replace parts as necessary.
133. Throttle shaft
assembly (13)
Fuel adjusting screw
(16), new preformed
packing (17) and
new preformed
packing (14)
a. Lubricate with clean fuel oil and Install
packing (17) on fuel adjusting screw.
b. Screw in fuel adjusting screw about six
turns.
Do not restrict throttle shaft fuel port.
c. Lubricate with clean fuel oil and install
packing (14) on throttle shaft.
TA 242556
2-329
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
FUEL PUMP ASSEMBLY
134. Fuel pump
housing (1)
Filter screen (2),
spring (3), cap seal
(4) and filter
screen cover (5)
a. Install filter screen and spring.
b. Install cap seal on filter screen cover.
C. Screw in filter screen cover and, using
3/8-inch flat-tip screwdriver, tighten.
135.
Governor barrel
assembly cover (6)
a. Remove all traces of old gasket material.
b. Inspect for cracks or damage.
Discard If cracked or damaged.
136.
New cover gasket
(7), governor barrel
assembly cover (6),
bracket (8), four
screws (9), four
flat washers (10),
and four new lockwashers (11)
a. Install new cover gasket, governor barrel
assembly cover and bracket.
b. Install screws, lockwashers, and flat
washers.
C. Using 3/8-inch drive 7/16-inch socket
and 0 to 150 In. lb (0 to 16.9 N•m)
torque wrench, tighten to 108 to 132 in.
lb (1.02 to 1.24 N•m).
137.
Throttle shaft assembly (12), throttle
shaft cover (13), retaining ring (14),
and preformed
packing (15)
a. Install preformed packing and insert
throttle shaft assembly into fuel pump
housing (1) with fuel port facing down
and throttle stop slanted down.
b. Install throttle shaft cover.
C. Using 6-inch slip-joint pliers, install
retaining ring.
138.
Throttle lever (16),
throttle lever screw
(17), two new lockwashers (18), flat
washer (19), and
nut (20)
a. Install throttle lever on throttle shaft
assembly (11) making sure serrations
are alined and idle position of throttle
lever is near vertical.
b. Assemble throttle lever screw, flat
washer, lockwashers to throttle lever
and, using two 7/16-inch open-end
wrenches, screw on and tighten nut.
139.
Governor plunger
assembly (21)
Lubricate with lubricating oil and install in
spring pack housing.
2-330
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
LOCATION
140. Fuel pump
housing (1)
ITEM
Cover (22), new
gasket (23), six
screws (24) seven
new lockwashers (25)
seven flat washers
(26), and screw (27)
ACTION
REMARKS
a.
b.
C.
d.
e.
f.
g.
Position new gasket on fuel pump housing alining holes with dowels.
Position governor plunger driver and
weight carrier assembly horizontally.
Hold governor weight carrier assembly
weights in and ready to straddle governor
plunger drive, while assembling cover
to fuel pump housing.
Make sure tachometer drive gears
mesh properly.
Install six new lockwashers, six flat
washers, and six screws to fuel pump
housing through cover.
Using 7/16-inch box-end wrench,
tighten.
Install screw (27) new lockwasher, and
flat washer to fuel pump housing through
cover.
Using 5/32-inch hex key, screw in and
tighten.
TA 242557
2-331
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
ITEM
LOCATION
ACTION
REMARKS
FUEL PUMP ASSEMBLY - CONTINUED
141.
Fuel pump
assembly (1)
Turn drive coupling to be sure tachometer
drive gear is in mesh.
142. Fuel pump
assembly (1)
Gear pump (2), new
gear pump gasket
(3), four screws
(4), and four new
lockwashers (5)
a. Check new gear pump gasket against
gear pump to be sure all fuel pump holes
are on new gear pump gasket.
b. Position new gear pump gasket on fuel
pump assembly.
C. Install gear pump, four screws and four
new lockwashers to fuel pump housing.
d. Using 1/2-inch drive 3/16-inch hexhead socket and 0 to 150 ft lb (0 to 210
N•m) torque wrench, tighten in increments to 11 to 13 ft lb (15 to 18 N•m).
e. Turn drive coupling to make sure gear
pump turns freely.
143.
Pulsation damper
(6), four screws
(7), four new lockwashers (8),
and four flat
washers (9)
a. Check to make sure seal and O-ring are
in pulsation damper body and position
pulsation damper on gear pump.
b. Install four new lockwashers, four flat
washers, and four screws.
C. Using 3/8-inch drive 3/16-inch hexhead socket and 0 to 150 in. lb (0 to
16.9 N•m) torque wrench, tighten to
132 to 156 in. lb (1.24 to 1.47 N•m).
144.
Shutdown valve (10),
new gasket (11), two
new lockwashers
(12), and two
screws (13)
a.
145.
Aneroid control feed
line (14) and
return (15)
Using 5/8-inch open-end wrench, screw
on and tighten.
2-332
Position gasket and shutdown valve on
fuel pump assembly.
b. Install two new lockwashers and two
screws.
C. Using 3/16-inch hex key, screw in and
tighten.
TM 5-2815-241-34&P
FUEL PUMP - CONTINUED
NOTE
FOLLOW-ON MAINTENANCE:
Calibrate fuel pump (page 2-333).
TASK ENDS HERE
FUEL PUMP CALIBRATION
This task covers:
a. Cleaning (page 2-334)
b. Mounting Pump to Test Stand
(page 2-334)
c. Fuel Pump Run-In (page 2-338)
d. Pump Seal Testing (page 2-340)
e. Governor Cutoff RPM Testing
(page 2-340)
f. Throttle Testing and Adjusting
(page 2-342)
g. Idle Speed Testing and Adjusting
(page 2-344)
h. Throttle Lever Travel Checking and Adjusting
(page 2-345)
i. Pump Main Pressure Testing and Adjusting
(page 2-346)
j. Fuel Pressure Testing and Adjusting
(page 2-346)
k. Governor Fuel Pressure Testing and Adjusting
(page 2-347)
I. Governor Weight Setting Checking and
Adjusting (page 2-348)
m. Removing Pump from Test Stand
(page 2-349)
INITIAL SETUP
Tools
Adapter, fuel filter
Adjusting tool, spring pack, ST-984
Bit, drill, 1/4-inch
Drill, portable, electric, 3/8-inch
Protractor
Punch, center
Screwdriver, flat-tip, 1/8-inch
Straightedge
Template, travel
Tester, fuel injection (Test Stand,
ST-848, ST-775 or ST-445)
Wrench, box-end, 9/16-inch
Wrench, box-end, 7/16-inch
Materials/Parts
Gasket, pump
Grease, extreme-pressure (Item 10,
appendix B)
Oil, fuel (item 11, appendix B)
Test oil, injector (item 20, appendix B)
Equipment Condition
Fuel pump removed (page 2-41).
2-333
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
1.
Fuel pump (1)
Clean exterior surface thoroughly.
MOUNTING PUMP TO TEST STAND
2. Test stand (2)
Drive coupling (3)
and test stand
adapter plate (4)
Install proper drive coupling and adapter
plate to test stand as required.
3.
Fuel pump (1), four
screws (5) and four
flat washers (6)
Position fuel pump to adapter plate (4)
leaving 1/16 inch (1.5875 mm) between
fuel pump drive coupling and test stand drive
coupling (3), and secure with four screws
and four flat washers.
4.
Pump inlet adapter
assembly (7)
Install in pump inlet port (8).
5.
1/2-inch (12.7 mm)
flexible hose (9)
Connect from stand suction control valve
(10) to adapter elbow on pump inlet adapter
assembly (7).
TA 242560
2-334
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
6. Test stand (2)
1/4-inch (6.35 mm)
clear manifold
hose (11)
Connect from no. 2 manifold vacuum gage
(12) to 1/4-inch (6.35 mm) adapter (13)
on pump inlet adapter assembly (7).
7.
Pump discharge fitting assembly (14)
Install in pump fuel shutoff solenoid
valve (15).
8.
Fuel pressure
hose (16)
Install from test stand pressure gage outlet
(17) to pump discharge fitting
assembly (14).
9.
1/4-inch (6.35 mm)
flexible hose (18)
Install 1/4-inch (6.35 mm) flexible hose
(18) from test stand lube pressure connector (19) to test stand lube return
connector (20).
TA 242561
2-335
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
MOUNTING PUMP TO TEST STAND - CONTINUED
10. Test stand (1)
Fuel input hose (2)
Install from test stand fuel input connector
(3) to input discharge fitting (4).
11.
Fuel suction
hose (5)
Install from test stand fuel outlet connector
(6) to test stand fuel return connector (7).
12.
Leakage accumulator
hose (8)
Install to no. 1 accumulator cam (9) from
test stand leak test connector (10).
13.
1/4-inch (6.35 mm)
flexible hose (11)
Connect from small fitting (12) on fuel pump
(13) to auxiliary return connector (14).
TA
2-336
242618
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
14. Fuel pump (13)
Throttle lever
position holding
spring (15)
Install from top of throttle shaft lever (16) to
ring adapter assembly (17).
Spring will hold throttle lever to full fuel
position.
15.
Governor barrel
assembly cover plug
(18) and spring pack
adjusting tool (19)
a. Remove governor barrel assembly cover
plug.
b. Install ST-984 spring pack adjusting tool
into barrel assembly housing (20).
TA 242562
2-337
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
FUEL PUMP RUN-IN
16. Test stand (1)
Place in OPEN position.
Bypass valve (2),
suction valve (3)
and flow control
valve (4)
WARNING
Fuel is flammable and can explode. To avoid serious injury or death, keep fuel away
from open fire and keep extinguisher within easy reach when working with fuel. Smoking
is prohibited while working with fuel.
CAUTION
Make sure fuel pump screen is clean and fuel filter is installed with hole in filter facing
down. Foreign material in pump, or filter installed upside down, will cause fuel pump
damage.
Test stand motor switch is marked REVERSE and FORWARD. For all fuel tests for this fuel
pump, the test stand switch must be set to the REVERSE position.
NOTE
Seat all other test stand valves by opening one-quarter turn and reclosing, to make sure
they are in the closed position, to prevent leakage.
I
17. Fuel pump (5)
Fuel filter adapter
(8) and gasket (7)
Mount fuel filter adapter and gasket.
18.
Plug (8)
Using 9/16-inch box end wrench, remove
plug and fill fuel pump (5) with test oil or
fuel oil, and reinstall plug.
19.
Fuel shutoff valve
manual override
knob (9)
Open by turning fully clockwise.
20. Test stand (1)
Power switch (10)
Place in ON position.
21.
Fuel heat
switch (11)
Place in ON position.
Observe that fuel temperature gage
reads 90° to 100oF (32° to 38°C) for
test oil or diesel fuel.
22.
Selector valve (12)
Place in ROTAMETER position.
23.
Range crank (13)
Turn to HIGH range position.
2-338
Change 1
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
WARNING
Fuel is flammable and can explode. To avoid serious injury or death, keep fuel away
from open fire and keep extinguisher within easy reach when working with fuel. Smoking
is prohibited while working with fuel.
CAUTION
Do not hold throttle in idle position any longer than necessary to complete test. Pump
may overheat, since fuel flow is used to cool the pump.
NOTE
Pump must pick up fuel at 500 rpm without priming. If no fluid pickup is indicated at
rotameter, check fuel filter for improper installation and motor switch for correct
rotation, Make sure open suction valve, hose, and gear pump connections are tight.
Check rotameter for air in fuel flow. If air bubbles are present, work pump throttle lever
from fuel full open to idle several times, to relieve trapped air in pump.
If air bubbling persists, it is an indication of an air leak in the system. Turn test stand off
and check the line for loose connections between tank and pump, mating of gear pump
housing, and full fuel supply tank.
If pump is new or has been disassembled or reassembled, run pump slightly over rated
speed for 5 minutes to allow bearings and seals to seat, and to purge air from system.
24. Test stand (1)
Speed control buttons (14 and 15)
a. Start test stand by depressing start
button (18) until 2130 to 2150 rpm
is indicated on test stand
tachometer (17).
Depress and release FAST (14) or
SLOW (15) button to maintain 2130 to
2150 rpm.
b. At end of 5-minute period, reduce fuel
pump speed to 500 rpm.
TA
242563
2-339
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
PUMP SEAL TESTING
25. Test stand (1)
Check oil seals for leaks as follows:
a. With test stand operating at 500 rpm,
close suction valve (3).
b. Place fuel flow control valve (4) to OPEN
position.
If 25-inch (83.5 mm) vacuum is not
obtained, check all test stand hose
connections.
c. Place bypass valve (5) in closed
position.
d. Place a small amount of extremepressure grease over the vent of weep
hole (8).
e. If extreme-pressure grease is pulled into
weep hole (8) at 25-inch (83.5 mm)
vacuum, the seal is defective.
To replace seal, see Fuel Pump,
page 2-289.
Fuel pump (2)
CAUTION
Do not hold throttle lever in idle position any longer than necessary to complete test.
Pump may overheat, since fuel flow is used to cool the pump.
28.
Fuel pump tachometer
drive seal (7)
Check as follows:
a. With test stand (1) operating at 500
rpm, remove tachometer drive cap (8).
Depress and release FAST (9) or
SLOW (10) button to maintain 500
rpm.
b. Fill tachometer seal bore with test oil or
diesel fuel from test stand (1).
c. If fuel is drawn into pump at 25-inch
(83.5 mm) vacuum setting, the seal is
defective.
To replace seal, see Fuel Pump,
page 2-289.
GOVERNOR CUTOFF RPM TESTING
NOTE
Test stand must be shut off to change shims in spring pack.
When pump is opened to make adjustments, it must be purged of air before retest. With
fuel pump at 2100 rpm, move throttle back and forth until the rotameter shows no air.
2-340
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
Once 8-inch HG vacuum setting is obtained, do not change setting. Readings will
fluctuate during other tests. Note the increases or decreases as they occur.
27.
Fuel pump (2)
Test governor cutoff rpm as follows:
a. Open fuel flow control valve (4)
completely.
b. Increase pump speed to 2000 rpm.
Depress and release FAST (9) or
SLOW (10) button to obtain 2000
rpm.
c. Adjust fuel flow control valve (4) to
obtain 8-inch (20.32 mm) HG vacuum
on no. 2 vacuum gage (11).
d. Increase pump speed to 2100 rpm.
e. Open the fuel flow control valve (4) and
place the selector valve (12) in
ROTAMETER position.
f. Increase pump speed until the fuel
pressure drops. Test stand tachometer
(13) reading should be 2130 to 2150
rpm.
TA 242564
2-341
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
GOVERNOR CUTOFF RPM TESTING - CONTINUED
27. Continued
Fuel pump (1)
g. If cutoff rpm is too low, remove barrel
assembly cover (2) and add shims. If
cutoff rpm is too high, remove shims.
(See Fuel Pump, page 2-289.)
Each 0.001 in. (0.025 mm) shim
thickness will change speed approximately two rpm. Shims are available in
0.005-, 0.007-, 0.010-, and
0.020-inch (0.13, 0.18, 0.25, and
0.51 mm) thickness.
CAUTION
Do not hold throttle lever in idle position any longer than necessary to complete test.
Pump may overheat, since fuel flow is used to cool the pump.
h . Air must be purged from fuel pump. With
fuel pump at 500 rpm, move throttle lever
(3) back and forth until rotameter shows
no air, and recheck governor cutoff
rpm.
THROTTLE TESTING AND ADJUSTING
CAUTION
Do not hold throttle lever in idle position any longer than necessary to complete test.
Pump may overheat, since fuel flow is used to cool the pump.
NOTE
This setting controls fuel leakage inside fuel pump, to control deceleration time, and
keeps fuel in all lines during closed throttle position, preventing air locks.
A test cycle is one-half minute duration.
28. Test stand (4)
2-342
Fuel pump (1) and
throttle lever (3)
Test and adjust throttle leakage as
follows:
a. Increase fuel pump speed to 2100 rpm.
b. Place selector valve (5) to ROTAMETER
position.
This is to see if any air is In system.
c. Set fuel flow control valve (8) for 315
lb/hr reading.
At 2100 rpm, fuel flow should be 315
Ib/hr.
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
d. Place selector valve (5) to LEAKAGE
TEST position.
e. Place COUNT SELECTOR SWITCH (7) to
the 100 position.
f. Pull out dumping lever (8) to retain fuel
in no. 1 burette (9).
g. Remove throttle spring (10) and manually position throttle lever (3) to idle
position.
h. Push dumping lever (8) inward.
Burette must be cleared of fuel to
prevent overflow at this time.
i. Depress pulse counter button (11) to fill
no. 1 burette (9).
j. At the end of a cycle, read the amount of
fuel in no. 1 burette (9) on the scale.
For one-half minute cycle, fuel
delivery is 37 cc.
k. If throttle leakage is not as specified,
using 7/16-inch box-end wrench and
1/8-inch flat-tip screwdriver, adjust
front throttle screw (12) in or out until cc
delivery comes to specifications.
I. Check leakage with light and heavy
throttle lever (3) load. If leakage is
decreased by additional pressure on
throttle lever in closed position, set
leakage under these conditions.
TA
242565
2-343
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
IDLE SPEED TESTING AND ADJUSTING
NOTE
If pressure is low and the adjusting screw bottoms, stop the test stand, add shims to the
spring end of the adjusting screw (see Fuel Pump, page 2-289) and retest cutoff rpm
and throttle leakage, steps 27 and 28.
Each time governor barrel assembly cover or spring pack adjusting tool is removed, run
pump until purged of air.
29. Test stand (1)
Fuel pump (2)
governor barrel
assembly cover (3)
Test and adjust idle speed as follows:
a. Place selector valve (4) in IDLE
position.
b. Increase fuel pump speed to 500 rpm.
C. Pull throttle lever (5) to idle position.
Fuel pressure gage should read 28 psi
(179.27 kPa).
d. If fuel pressure is not 28 psi (179.27
kPa), adjust idle screw using ST-984
barrel assembly adjusting tool.
e. After proper adjustment is made, stop
test stand (1) and remove ST-984 barrel
assembly adjusting tool.
f. Install barrel assembly cover plug (8).
g. Purge fuel pump of air (see step 24).
TA 242566
2-344
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
THROTTLE LEVER TRAVEL CHECKING AND ADJUSTING
NOTE
Do not adjust front throttle screw from valve set under throttle leakage. The front throttle
screw has already been set to provide the proper deceleration time for the engine. Any
changes at this point will require recalibration of throttle leakage.
Travel template no. 3375355 or protractor will be used to set fuel pump throttle lever
travel adjustment. Make sure the combination of the first and third or second and fourth
holes on the template are used. Any other combination will result in an inaccurate reading. Correct travel is 27 to 29 degrees.
The throttle lever may be repositioned on throttle shaft as required, to line up throttle
lever and template holes.
30. Fuel pump (2)
Throttle lever (5)
Check and adjust throttle travel as follows:
a. Place travel template no. 3375355 (7)
against fuel pump housing as shown.
b. Move throttle lever to idle position.
c. Line up travel template no. 3375355 (7)
idle hole with center of throttle lever.
Use straightedge to aline.
d. Move throttle lever to full throttle
position.
e. Aline travel template no. 3375355 (7)
MAX holes with hole in throttle lever.
f. If throttle lever travel is incorrect, using
7/16-inch box-end wrench and 1/8inch flat-tip screwdriver, adjust rear
throttle stop screw (8) to obtain 27- to
29-degrees travel.
TA 242567
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FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
PUMP MAIN PRESSURE TESTING AND ADJUSTING
Test and adjust pump main pressure as
follows:
a. With vacuum set at &inch (203.2 mm)
HG on no. 2 vacuum gage (2) and throttle lever (3) wide open, adjust speed to
2100 rpm.
b. Place selector valve (4) to ROTAMETER
position.
c. Set fuel flow to 315 pph with fuel flow
control valve (5).
Fuel pressure should be 172 to 178 psi
(1188 to 1227 kPa).
d. If 172 to 178 psi (1186 to 1227 kPa) fuel
pressure does not read on pressure
gage (6) adjust pressure.
Test stand (1)
31.
FUEL PRESSURE TESTING AND ADJUSTING
CAUTION
Be careful not to damage bore of throttle shaft when drilling out ball.
NOTE
Throttle shaft internal adjusting screw is covered by a soft steel ball in end of throttle
shaft, and must be removed if not previously removed. Perform step 32 only if ball has
not been previously removed.
32. Fuel pump (7)
throttle shaft (8)
Ball (9)
Using center punch, 1/4-inch drill bit, and
3/8-inch portable electric drill, drill out
ball.
33. Test stand (1)
Fuel pump (7)
throttle shaft (8)
Test and adjust fuel pressure as follows:
Set fuel pressure to 172 to 178 psi (1186 to
1227 kPa).
Screw Internal fuel adjusting screw In
throttle shaft in to Increase pressure,
or out to decrease pressure.
2-346
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
GOVERNOR FUEL PRESSURE TESTING AND ADJUSTING
34. Test stand (1)
Fuel pump (7)
Test and adjust fuel pump governor, operating pressure as follows:
a. Adjust fuel pump speed to 1500 rpm.
b. Place selector valve (4) to ROTAMETER
position.
c. Place fuel throttle lever (3) to wide open
position.
d. Set fuel flow to 230 pph with the fuel flow
control valve (5).
Fuel pressure should be 100 to 106 psi
(989 to 730 kPa).
e. If fuel pressure is not 100 to 106 psi (689
to 730 kPa), check governor cutoff rpm
(see step 28).
TA
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TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
GOVERNOR WEIGHT SETTING CHECKING AND ADJUSTING
NOTE
Shims are available in 0.007 and 0.015 inch (0.18 and 0.38 mm) thicknesses. Do not
change setting more than 0.020 inch (0.508 mm) from specification.
35. Test stand (1)
Fuel pump (2)
Check fuel pump governor weight setting as
follows:
a. Adjust fuel pump speed to 1000 rpm.
b. Place throttle lever (3) to wide open
position.
c. Place selector valve (4) in ROTAMETER
position.
d. Set fuel flow to 150 pph with fuel flow
control valve (5).
Fuel pressure should be 50 to 58 psi
(335 to 399 kPa).
e. If fuel pressure is not 50 to 58 psi (335 to
399 kPa), adjust.
To increase or decrease pressure,
add or remove shims as necessary on
governor plunger. (See Fuel Pump,
page 2-289.)
TA 242569
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FUEL PUMP CALIBRATION - CONTINUED
ITEM
LOCATION
ACTION
REMARKS
REMOVING PUMP FROM TEST STAND
36. Test stand (1) and
fuel pump (2)
1/4-inch (6.35 mm)
flexible hose (6)
Remove flexible hose from small fitting (7)
on fuel pump and auxiliary return fitting (8)
on test stand.
37. Test stand (1)
Leakage accumulator
hose (9)
Remove from no. 1 accumulator cam (10)
and test stand leak test connector (11).
38.
Fuel suction
hose (12)
Remove from test stand (I), fuel outlet
connector (13) and test stand fuel return
connector (14).
39.
Fuel input hose (15)
Remove from test stand (1), fuel input
connector (16), and fuel pump discharge
fitting (17).
40.
1/4-inch (6.35 mm)
flexible hose (18)
Remove from test stand lube pressure (19)
and test stand lube return (20).
TA 242570
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TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
REMOVING PUMP FROM TEST STAND - CONTINUED
41. Test stand (1)
Fuel pressure
hose (2)
Remove from test stand pressure gage outlet
(3) and fuel pump discharge fitting (4).
42.
Fuel pump discharge
fitting (4)
Remove fuel pump discharge fitting from
fuel pump shutdown valve (5).
43.
1/4-inch (6.35 mm)
clear manifold
hose (6)
Remove from no. 2 manifold vacuum gage
(7) and 1/4-inch (6.35 mm) adapter on
pump inlet adapter assembly (8).
44.
1/2-inch (12.7 mm)
flexible hose (9)
Remove from test stand suction control valve
(10) and adapter elbow on pump inlet
adapter assembly (8).
45.
Pump inlet adapter
assembly (8)
Remove from pump inlet port (11).
46. Fuel pump (12)
Fuel filter adapter
(13) and gasket (14)
Remove.
47.
Fuel shutdown valve
manual override
knob (15)
Close fully by turning counterclockwise.
48. Test stand (1)
Fuel pump (12) four
screws (16) and four
lockwashers (17)
a. Remove four screws and four lockwashers from fuel pump and ring adapter
assembly (18).
b. Remove fuel pump from test stand.
49.
Fuel pump (12)
Plug all fuel pump ports to prevent entry of
dirt and foreign matter.
2-350
TM 5-2815-241-34&P
FUEL PUMP CALIBRATION - CONTINUED
NOTE
FOLLOW-ON MAINTENANCE:
Install fuel pump (page 2-86).
TASK ENDS HERE
TA 242571
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TM 5-2815-241-34&P
FUEL INJECTOR
This task covers:
a. Disassembly (page 2-352)
b. Cleaning (page 2-356)
c. Inspection (page 2-356)
d. Assembly (page 2-363)
e. Testing (page 2-366)
INITIAL SETUP
Tools
Tools - Continued
Adapter, injector
Adapter, tool, burnishing, ST-708
Detector, leakage, ST-990
Extension, plunger, ST-1089
Gage, size, orifice, ST-1332
Gage, thickness
Glass, magnifying
Handle, hinged, 1/2-inch drive
Injector, master, ST-1210
Key, hex, 5/64-inch
Plate, lapping
Stand, injector test, ST-790
Socket, crowsfoot, 1 1/4-inch,
1/2-inch drive
Tester, spray angle, ST-668
Tester, spring
Wrench, body, no. 3375102
Wrench, box-end, 1 1/4-inch
Wrench, open-end, 1-inch
LOCATION
Wrench, retainer, ST-995
Wrench, torque, 0 to 150 in. lb (0 to 16.9
N•m), 3/8-inch drive
Wrench, torque, 0 to 175 ft lb (0 to 245 N•m),
1/2-inch drive
Materials/Parts
Cutting fluid, lapping (item 5, appendix B)
Gasket, orifice plug (if required)
Gasket (two required)
Oil, fuel (item 11, appendix B)
O-ring
Prussian blue (Item 13, appendix B)
Test oil, injector (item 20, appendix B)
Equipment Condition
Fuel injectors removed (page 2-34).
ITEM
ACTION
REMARKS
DISASSEMBLY
1. Injector (1)
2-352
Injector detent
plunger link (2)
Pull out from injector.
Set aside to prevent damage.
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
Injector barrel and plunger are a matched set (class fit). Do not interchange.
Do not touch internal parts unless hands are clean and moistened with fuel oil. Acids
from skin can corrode internal parts and affect their close tolerances.
2.
Plunger (3) and
spring (4)
Pull out from injector.
Store plunger by standing on coupling
end.
3.
Preformed packing
(5) and two
gaskets (6)
Roll off injector (1).
Discard packing and gaskets.
4.
Strainer element
clip (7) and strainer
element (8)
Remove and inspect for damage.
Discard if damaged.
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FUEL INJECTOR - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
DISASSEMBLY - CONTINUED
Do not remove orifice plug from inlet groove.
5.
Injector (1)
Insert injector into loading fixture (2).
6. Injector (1)
Body wrench (3)
a. Install body wrench over flats on injector
and tighten special screw (4), to hold
injector in place.
b. Using ST-995 retainer wrench (5), 1/2inch drive 1 1/4-inch crowsfoot socket,
and hinged handle, loosen, but do not
remove cup retainer.
c. Loosen special screw (4). Remove tools
from injector and remove injector from
loading fixture.
NOTE
Another method of loosening cup retainer is to use a 1 1/4-inch box-end wrench on
ST-995 retainer wrench and a 1-inch open-end wrench on injector.
TA 242573
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TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
When handling injector, use care not to drop or lose any parts. Do not lose check ball.
7. Injector adapter (6)
Cup retainer (7)
Stand Injector upright. Screw off cup
retainer (7) and remove injector cup (8).
CAUTION
Do not touch internal parts unless hands are clean and moistened with fuel oil. Acids
from skin can corrode internal parts and affect their close tolerances.
8.
Injector barrel (9)
and injector
adapter (6)
a. Hold together and set barrel end down.
b. While holding injector barrel, lift
injector adapter straight up.
9.
injector barrel (9)
Lift up and tilt until check ball (10) falls out.
Set check ball in a safe place.
TA 242574
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TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CLEANING
CAUTION
Do not touch internal parts unless hands are clean and moistened with fuel oil. Acids
from skin can corrode internal parts and affect their close tolerances.
Do not clean cup spray holes with wire brush, drills, or other similar instruments that will
alter the size of spray holes.
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
Ultrasonic cleaning is recommended for cleaning injector barrel, plunger, and cup.
A clean shop, clean tools, and good cleaning practices are essential to good injector
repair. Most injector failures occur because of dirt. Clean all parts before assembly.
INSPECTION
10.
Injector detent
plunger link (1)
Check for excessive wear on ends.
If the wear can be seen or felt, replace
injector detent plunger link.
TA 242575
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FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
Handle injector plunger with care to prevent damage that would render it useless.
11.
Plunger (2)
a. Inspect machined surfaces for pitting or
wear.
Bright spots or surface disruption at
top of machined area and on opposite
sides at bottom of plunger, or at midpoint, are normal results of rocker
arm action. If metal is displaced or
wear is measurable at these points,
replace plunger and barrel. Narrow
streaks running the length of plunger
are normal. If pitted or worn, replace
plunger and barrel.
b. Inspect machined surfaces for cracks or
looseness where plunger is connected
to coupler.
If cracks or looseness exist, replace
plunger and barrel.
c. Inspect for metal seizure.
If metal seizure Is present, replace
plunger and barrel.
d. Inspect socket for wear or cracking.
If wear or cracking Is present in
socket, replace plunger and barrel.
TA
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FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
12. Barrel (1)
Plunger bore (2)
and check ball
seat (3)
a. Using magnifying glass, inspect plunger
bore for scoring.
If scoring exists, replace plunger and
barrel.
b. Inspect surface at each end for burrs or
scratches.
If burrs or scratches exist, replace
plunger and barrel.
c. Inspect check ball seat for nicks or
burrs.
If nicks or burrs exist, replace plunger
and barrel.
d. Inspect fuel passage plugs for looseness, and barrel for cracks.
If looseness or cracks exist, replace
plunger and barrel.
13.
Check ball (4)
Inspect check ball for any wear or damage.
If damage or wear exists, replace the
check ball.
TA 242577
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FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
Do not use crocus cloth or wire brush on barrel contact area surfaces.
14.
Barrel (1)
Using lapping plate and cutting fluid, lap
slightly to check barrel surfaces for mutilation and flatness in area shown by black area
in illustration below.
After lapping slightly, If mutilation or
unevenness exists, replace plunger
and barrel.
CUP CONTACT AREA OF BARREL
A-DIAMETER
IN. (MM)
0.400
(10.16)
B-DIAMETER
IN. (MM)
0.540
(13.72)
C-DIAMETER
IN. (MM)
0.710
(18.03)
D-DIAMETER
IN. (MM)
0.820
(20.83)
TA 242578
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TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
ITEM
LOCATION
ACTION
REMARKS
INSPECTION - CONTINUED
15.
Injector cup (1)
CONTINUOUS PATTERN
GOOD SEAT
a. Using magnifying glass, and comparing
with new injector cup (1), inspect injector cup for abrasive wear, corrosion
damage, and enlarged or distorted
spray holes.
If abrasive wear, corrosion damage,
or enlarged or distorted spray holes
exist, replace Injector cup.
b. Using prussian blue on a new plunger,
insert plunger into injector cup (1) and
rotate 90 degrees.
If plunger seat pattern in Injector cup
does not cover a 40-percent continuous area around the injector cup
cone, as illustrated below, replace
injector cup.
STAR PATTERN
BAD SEAT
c.
BROKEN PATTERN
BAD SEAT
Using lapping plate and cutting fluid, lap
slightly to check injector cup barrel surface for mutilation and flatness in the
areas shown by black in the illustration
below.
After lapping slightly, if mutilation or
unevenness exists, replace Injector
cup.
TA 242579
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TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
16. Injector cup
retainer (2)
ITEM
Injector cup threads
(3), cone (4) and
cup seating ledge (5)
ACTION
REMARKS
a. Inspect injector cup threads for
damage.
If threads are damaged, replace In.
jector cup retainer.
b. Inspect outside area of cone for nicks or
burrs that could prevent proper seating
of injector sleeve in cylinder head.
If nicks or burrs exist, replace injector
cup retainer.
c. Inspect inside of cone area on cup seating ledge for nicks or burrs that could
prevent injector cup seating.
If nicks or burrs exist, replace injector
cup retainer.
TA 242580
2-361
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
17.
Injector adapter (1)
Orifice plug (2)
and cup retainer
threads (3)
a.
b.
c.
d.
e.
Inspect orifice plug for burrs.
If burrs exist, replace Injector
adapter.
Inspect cup retainer threads for
damage.
If damage exists, replace Injector
adapter.
Inspect O-ring and gasket grooves (4)
for nicks or burrs that could damage Oring or gaskets during installation.
If nicks or burrs exist, replace injector
adapter.
Inspect both fuel passages (5).
Make sure fuel passages are open, If
fuel passages are plugged, see
general cleaning procedures
(page 2-3).
Using a lapping plate and cutting fluid,
lap slightly to check barrel mating surface (6) for nicks or burrs.
If nicks or burrs exist, replace injector
adapter.
TA 242581
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TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
a. Inspect injector spring for excessive
wear or mutilation.
If excessive wear or mutilation exists,
replace injector spring.
b. Using spring tester, test injector spring.
Compare to specifications in table
below.
If injector spring compresses to
dimensions shown below, at less than
load indicated under worn limit,
replace injector spring.
18. Injector spring
INJECTOR SPRING DATA
LOAD REQUIRED TO COMPRESS SPRINGS TO LENGTH
APPROXIMATE
FREE LENGTH
IN. (MM)
1.95
(49.7)
LENGTH
IN. (MM)
1.663
(42.2)
NEW MINIMUM
LB (KG)
143.25
(65)
NEW MAXIMUM
LB (KG)
WORN LIMIT
LB (KG)
158.75
(72)
138
(63)
ASSEMBLY
WARNING
Fuel is flammable and can explode. To avoid serious injury or death, keep fuel away
from open fire and keep fire extinguisher within easy reach when working with fuel.
Smoking is prohibited while working with fuel.
CAUTION
Do not touch internal parts unless hands are clean and moistened with fuel oil. Acids
from skin can corrode internal parts and affect their close tolerances.
Lubricate parts only with clean fuel oil before assembly. Do not use lubricating oil.
Lubricating oil can crystalize under excessive heat, causing damage to injector
components.
Make sure that all mating surfaces are free of burrs or other imperfections which could
result in incorrect fuel flow or torque.
NOTE
If the two barrel location pins were removed, install new spiral pins into the barrel.
2-363
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
ASSEMBLY - CONTINUED
19. Barrel (1)
Check ball (2)
Place check ball into top of barrel, in check
ball seat.
20.
Injector adapter (3)
Place injector adapter onto top of barrel.
21.
Injector adapter (3)
Plunger (4)
Immerse plunger in clean injector test
oil, and install into injector adapter
without injector spring.
22.
Injector adapter (3)
and barrel (1)
Injector cup (5)
Turn the injector adapter and barrel with
the barrel up. Place the injector cup on
the barrel.
23.
Injector adapter (3)
Injector cup (5) and
cup retainer (6)
Lubricate the injector cup contact area and
the cup retainer threads with clean fuel oil.
Screw down finger tight and loosen onequarter turn.
TA
2-364
242582
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
24.
Injector (7)
Place into loading fixture (6).
25. Injector (7)
Body wrench
no. 3375102 (9)
Install over flats on injector, tighten
special screw (10) just enough to hold
injector.
26. Loading fixture (8)
Special screw (10)
Using 3/8-inch drive 0 to 150 in. lb (0 to
17.5 N•m) torque wrench, tighten to 75 in.
lb (8.5 N•m) to aline injector cup and
plunger (4).
27. Injector (7)
Cup retainer (6)
Using ST-995 retainer wrench (11), 1/2inch drive 1 1/4-inch crowsfoot socket
(12), and 0 to 175 ft lb (0 to 245 N•m)
torque wrench (13) tighten to 50 ft lb (70
N-m).
28. Loading fixture (8)
Injector (7)
Loosen special screw (10) and remove from
loading fixture.
29.
Injector (7)
Remove all tools from injector.
TA 242583
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FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY - CONTINUED
WARNING
Fuel is flammable and can explode. To avoid serious injury or death, keep fuel away
from open fire and keep fire extinguisher within easy reach when working with fuel.
Smoking is prohibited while working with fuel.
When fuel is forced from injector spray holes, keep hands and body away from spray
stream. High-pressure fuel may pierce the skin.
30.
Injector (1)
a. Check injector cup to plunger alinement,
remove plunger, and coat with clean fuel
oil. Install ST-1089 plunger extension on
plunger (2).
b. Hold injector in vertical position (injector
cup down) and allow plunger to drip a
few drops of fuel oil into injector cup.
c. Insert plunger about 1/2 inch (12.7
mm) into barrel to be certain plunger
is started straight.
d. Using palm of hand, press plunger into
injector cup and rotate 90 degrees while
holding plunger firmly against injector
cup seat.
e. Turn injector so injector cup faces upward. Plunger should slide out when injector is lifted quickly.
If plunger does not slide out, remove
plunger, coat tip with fuel oil, and
repeat test.
If plunger sticks because of misalinement, loosen cup retainer, rotate injector cup one-quarter turn, and
retorque.
f. Remove ST-1089 plunger extension.
Plunger (2)
WARNING
When fuel is forced from injector spray holes, keep hands and body away from spray
stream. High-pressure fuel may pierce the skin.
NOTE
Step 31 must be performed on test injector before continuing with steps 32 thru 35.
2-366
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
31.
Injector (1)
a. Check plunger leakage on ST-990 leakage detector. See steps 36 thru 60.
b. Check injector cup spray pattern on
ST-668 spray angle tester. See steps 61
thru 72.
c. Check check ball seating, see steps 73
thru 83.
d. Test injector on ST-790 injector test
stand. (See steps 84 thru 99.)
32.
Plunger (2)
Take out plunger and install injector
spring (3). Reinstall plunger.
33. Injector grooves (4)
New preformed
packing (5) and
two new gaskets (6)
Lubricate with fuel oil and put on if damaged
after testing.
34. Injector (1)
Strainer element
clip (7) and strainer
element (8)
Put in.
35.
Injector (1)
Put detent plunger link (9) into injector
and store injector in clean, dry area until
ready for installation in cylinder head.
TA 242584
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FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
TESTING
WARNING
When fuel is forced from injector spray holes, keep hands and body away from spray
stream. High-pressure fuel may pierce the skin.
NOTE
The following testing procedures are based on use of the ST-990 leakage detector,
ST-668 spray angle tester, and ST-790 injector test stand.
36. ST-990 leakage
detector (1)
Pressure
regulator (2)
Set air pressure at 60 psi (414 kPa).
37.
Cylinder actuation
valve (3)
Operate three times, then reset pressure
regulator (2) at precisely 60 psi (414 kPa).
38.
Retraction lever (4)
Place in position A.
39.
Load cell (5)
Position on leakage detector as shown.
40. Load cell (5)
Knob (6)
Adjust until load cell reads 200 psi
(1379 kPa).
41.
Locknut (7)
Place thickness gage (8) between knob (6)
and locknut.
Adjust only when load cell Is used.
42.
Load cell (5)
Remove from ST-990 leakage detector.
TA 242585
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FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
43. Injector (9)
Plunger (10) and
spring (11)
Take out.
44.
ST-1089 plunger
extension (12)
Push in plunger and place into injector (9).
45.
Strainer element
clip (13) and
strainer element (14)
Take out if not previously removed.
46.
ST-708 burnishing
tool adapter (15)
a. Aline injector orifice plug (16) with hole
(17) on ST-708 burnishing tool adapter.
b. Insert and tighten locating screw (18) in
locating screw hole (19).
TA 242586
2-369
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FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
TESTING - CONTINUED
47.
Injector (1)
Install on support plate (2) and clamp into
position.
Support plate may be tilted for easier
Installation.
48.
Knob (3)
Adjust to obtain proper clearance with
thickness gage (4) between knob and
locknut (5).
49.
Transfer line (6)
Screw in and tighten in injector drain
port (7).
50.
T-handle clamp (8)
Tighten.
51.
Retraction lever (9)
Shift from position A to position B, making
sure plunger (10) retracts.
52.
Plunger (10)
Rotate in clockwise direction by small lncrements, observing airflow meter (11). Stop
rotation when highest reading is obtained.
If airflow meter indicates in excess of
4.5, replace injector barrel and
plunger.
53.
Retraction lever (9)
Shift from position B to position A.
54.
T-handle clamp (8)
Loosen.
This applies 200 lb (90.8 kg) load to
plunger.
55.
Bubble checker (12)
Observe.
If bubbles occur In 10 seconds, or If
time Interval between consecutive
bubbles exceeds 5 seconds, replace
injector cup.
56.
Transfer line (6)
Unscrew and remove from injector drain
port.
57.
Pressure
regulator (13)
Release air pressure.
2-370
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
58.
ST-708 burnishing
tool adapter (14)
Remove from leakage detector (15).
59. ST-708 burnishing
tool adapter (14)
Locating screw (16)
and transfer line (6)
Remove.
60.
Injector (1)
Remove.
TA 242587
2-371
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
TESTING - CONTINUED
61.
Spray angle
tester (1)
Locate on or near ST-790 injector test
stand (2).
Any other suitable source of 22 psi
(152 kPa) constant fuel pressure can
be used.
62. ST-790 injector
test stand (2)
Inlet hose (3)
Attach to adapter (4) from ST-790 injector
test stand.
63.
Drain hose (5)
Attach to adapter base (6) and place loose
end in ST-790 injector test stand drain area.
64.
Injector (7)
a. Check injector markings. See the following illustration and select the appropriate
target ring (8) and install injector on
ST-668 spray angle tester.
b. Select correct size plunger bore plug
and rubber seal, and install in injector
plunger bore.
65.
Plug (9)
Install in adapter drain opening.
66.
Injector (7)
Place in ST-668 spray angle tester seat,
adjust holddown bracket (10), and secure
with thumbscrew (11).
Be sure plunger bore plug and seal
are thoroughly sealed.
WARNING
When fuel is forced from injector spray holes, keep hands and body away from spray
stream. High-pressure fuel may pierce the skin.
67.
ST-790 injector
test stand (2)
Apply 22 psi (152 kPa) fuel pressure
68.
Target ring (8)
a. Shift so one spray stream hits on number
1 or index window.
This Is the tallest window and pro.
vides ± 3 degrees tolerance on
injector spray stream location.
b. Each spray stream must hit a window in
target ring.
If spray stream Is off 2 degrees of
window, replace injector cup.
2-372
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
69. ST-668 spray angle
tester (1)
Holddown
bracket (10)
Loosen thumbscrew (11).
70.
Injector (7)
Remove from ST-668 spray angle tester.
71.
Plug (9)
Remove from adapter drain opening.
72.
Injector (7)
Remove from adapter.
INJECTOR DATA MARKINGS ON INJECTOR ADAPTER
MARKING 12 - INJECTOR FLOW
MARKING 13 -PERCENT FLOW
MARKING 14 - NUMBER OF HOLES
MARKING 15 - SIZE OF HOLES
MARKING 16 - DEGREE OF HOLES
TA 242588
2-373
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
TESTING - CONTINUED
NOTE
Perform steps 73 thru 83 to test check ball seating.
73.
Plunger (1)
Place in injector (2) without spring.
74.
Preformed packing
(3) and two
gaskets (4)
Place on injector.
75.
ST-708 burnishing
tool adapter (5)
Lubricate inside with fuel oil.
CAUTION
Injector inlet port and ST-708 burnishing tool adapter inlet hole must be alined to prevent
damage to the burnishing tool point, when installed later.
76.
Injector (2)
a.
77.
ST-790 injector test
stand inlet line (7)
and drain line (8)
Connect to ST-708 burnishing tool adapter.
2-374
Position in ST-708 burnishing tool
adapter (5) so that injector inlet port and
adapter inlet holes aline.
b. Secure by tightening locating screw (6)
on ST-708 burnishing tool adapter.
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
NOTE
When testing check ball seating, hold injector in hand. Do not place in ST-790 injector
test stand holding device.
78. Injector (2)
Plunger (1)
Hold plunger down in injector.
79. ST-790 injector
test stand (9)
Motor switch (10)
Place in start position.
Check temperature gage (11). Test
oil testing temperature should be 90°
to 95°F (32° to 35°C).
80.
Regulator knob (12)
Adjust by turning until pressure gage (13)
reads 150 psi (1034 kPa).
81.
ST-708 burnishing
tool adapter orifice
plug opening (14)
Check for leakage. A slight see page of + 1 or
-2cc from the flow code stamped on the injector is acceptable.
If leakage exceeds specifications,
replace check ball. See steps 1 thru 7
and 17 thru 27.
82.
Motor switch (10)
Place in stop position.
83.
ST-790 injector test
stand inlet line (7)
and drain line (8)
Disconnect from ST-708 burnishing tool
adapter (5).
TA 242590
2-375
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
TESTING - CONTINUED
84. Injector (1)
Plunger (2)
Pull out.
85.
Injector spring (3)
Slide onto plunger and place in injector.
86.
Retainer plate (4)
Place on ST-708 burnishing tool adapter (5)
and secure with pins (6).
87.
Test stand link (7)
Place in ST-708 burnishing tool
adapter (5).
Use test stand link 6.5 Inches (185
mm) long marked ST 790-331.
88.
Injector (1)
Place in ST-790 injector test stand making
sure Injector is in injector seat (8).
89.
Burnishing tool (9)
Install into injector inlet connector (10) on
ST-790 injector test stand.
TA 242591
2-376
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
90. Burnishing tool (9)
ACTION
REMARKS
ITEM
Retract by pulling out small knob (12).
Burnishing tool
needle (11)
NOTE
With burnishing tool needle retracted, burnishing tool may be left in inlet connector
during all test operations.
91. ST-790 injector
test stand
Injector inlet
connector (10)
Connect by screwing in large knob section
(13) to ST-708 burnishing tool adapter (5)
inlet hole.
92.
Drain line (14)
Screw into ST-708 burnishing tool
adapter (5).
TA 242592
2-377
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
TESTING - CONTINUED
93. ST-790 injector
test stand (1)
Air valve (2)
Open to clamp injector in place.
Make sure ST-790 injector test stand
link is alined.
94.
Hydraulic valve (3)
Close to lock injector in place.
95.
Motor switch (4)
Place in start position.
Check temperature gage (5). Test oil
testing temperature should be 90° to
95°F (32° to 35°C).
96.
Regulator knob (6)
Adjust by turning until pressure gage (7)
reads 120 psi (827 kPa).
97.
Flow start
switch (8)
Press in until counter (9) reads the same
number of strokes as ST-1210 master
injector.
98.
Vial (10)
Observe reading.
Correct reading Is 182 to 183 cc at 120
psi (827 kPa).
NOTE
If vial reading Is greater than 183 cc, proceed with steps 99 thru 103 to install new orifice
plug, and recheck delivery steps 95 thru 98. If vial reading is less than 182 cc, proceed
with steps 103 and 104 to burnish orifice plug, and recheck delivery steps 95 thru 96.
If vial reading is correct at 182 to 183 cc, proceed with steps 105 thru 113.
99. ST-708 burnishing
tool adapter (11)
2-378
Injector inlet connectar (12) and
burnishing tool (13)
Remove by turning large knob section (14)
out until assembly is free.
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
100. Injector (15)
Orifice plug (16)
and gasket (17)
Using 5/64-inch hex key, remove orifice
plug.
Discard gasket.
101.
Orifice plug (16)
Using orifice size gage ST-1332, measure
orifice plug at the base end, not the
wrench end.
NOTE
Compare orifice plug inside diameter to table on page 2-380. Choose new orifice plug
with inside diameter one size smaller than orifice plug removed.
TA 242593
2-379
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
TESTING - CONTINUED
NOTE
New orifice plugs contain enough stock in inside diameter so that a small displacement
of metal by burnishing will increase delivery. Amount of displacement is limited so
several orifice plugs are required.
INJECTOR ORIFICE PLUGS
PART NUMBER
163065
163066
163067
146338
163068
163069
163070
163071
149726
163072
163073
163074
163075
163076
163077
163078
163079
128132
128133
128134
128135
131092
131093
131094
131095
131096
131097
131098
2-380
INSIDE DIAMETER
IN. (MM)
0.015 (0.38)
0.016 (0.41)
0.017 (0.43)
0.018 (0.46)
0.019 (0.48)
0.020 (0.51)
0.021 (0.53)
0.022 (0.56)
0.023 (0.58)
0.024 (0.61)
0.025 (0.64)
0.026 (0.66)
0.027 (0.68)
0.028 (0.71)
0.029 (0.74)
0.030 (0.76)
0.031 (0.79)
0.032 (0.81)
0.033 (0.64)
0.034 (0.66)
0.035 (0.89)
0.036 (0.91)
0.037 (0.94)
0.038 (0.97)
0.039 (0.99)
0.040 (1.02)
0.041 (1.04)
0.042 (1.07)
PART NUMBER
132800
132801
132802
131099
131100
131101
131102
131103
131104
131105
131106
131107
131108
132803
132804
132805
132806
132807
132808
132809
132810
132811
132812
132813
132814
132815
132816
132817
INSIDE DIAMETER
IN. (MM)
0.043 (1.09)
0.044 (1.12)
0.045 (1.14)
0.046 (1.17)
0.047 (1.19)
0.048 (1.22)
0.049 (1.24)
0.050 (1.27)
0.051 (1.29)
0.052 (1.32)
0.053 (1.35)
0.054 (1.37)
0.055 (1.40)
0.056 (1.42)
0.057 (1.45)
0.058 (1.47)
0.059 (1.50)
0.060 (1.52)
0.061 (1.55)
0.062 (1.57)
0.063 (1.60)
0.064 (1.63)
0.065 (1.65)
0.066 (1.68)
0.067 (1.70)
0.068 (1.73)
0.069 (1.75)
0.070 (1.78)
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
102. Injector (1)
New gasket (2) and
orifice plug (3)
a. Place gasket in injector.
b. Screw into injector.
c. Using 3/8-inch drive, 0 to 150 in. lb
(0 to 17.5 N•m) torque wrench and
5/64-inch hex key, tighten orifice plug
to 8 to 10 in. lb (0.9 to 1.1 N•m).
103. ST-790 injector
test stand (4)
injector inlet connector (5) and
burnishing tool (6)
Screw into ST-708 burnishing tool adapter
(7) by turning large knob section (8) until
secure.
TA 242594
2-381
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
TESTING - CONTINUED
CAUTION
When seating burnishing tool, use care not to push small knob in too hard, or overtighten indicator knob. Damage to injector and burnishing tool will occur.
NOTE
ST-790 injector test stand must be running while burnishing.
104. ST-790 injector
test stand (1)
Burnishing tool (2)
a. Turn indicator knob (3) until spaced
3/8 inch (9.5 mm) from large
knob (4).
b. Slowly push small knob (5) in until slight
contact is made in injector (6).
c. Turn small knob (5) counterclockwise to
lock with large knob (4) and indicator
knob (3).
d. Slowly turn indicator knob (3) in until
slightly seated in injector (6). Do not
overtighten.
e. Index indicator knob (3) with mark on
large knob (4).
f. Advance indicator knob (3) one mark,
and back off until spaced 3/8 inch
(9.5 mm).
NOTE
Follow steps 95 thru 98 and recheck fuel delivery. If delivery is lower than 182 cc, repeat
step 104. if delivery is higher than 183 cc, repeat steps 98 thru 104. If delivery is 182 to
183 cc, proceed to step 105.
105.
Motor switch (7)
Place in stop position.
106.
Injector inlet
connector (8)
Remove from ST-708 burnishing tool adapter (9) by screwing out large knob (4) on
burnishing tool.
107.
Drain connector (10)
and burnishing
tool (2)
Remove from ST-708 burnishing tool
adapter (9).
2-382
TM 5-2815-241-34&P
FUEL INJECTOR - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
108.
Hydraulic valve (11)
Open.
109.
Air valve (12)
Close.
110.
Injector (6)
Remove from ST-790 injector test stand.
111.
Test stand link (13)
Slide out of ST-708 burnishing tool
adapter (9).
112.
Retainer plate (14)
Remove from ST-708 burnishing tool
adapter (9) by removing two pins (15).
113.
ST-708 burnishing
tool adapter (9)
Remove from injector.
114.
Injector (6)
Proceed with steps 31 thru 35 for injector
final assembly.
NOTE
FOLLOW-ON MAINTENANCE:
Install injectors in cylinder head (page 2-78).
TASK ENDS HERE
TA 242595
2-383
TM 5-2815-241-34&P
TURBOCHARGER
This task covers:
a. Disassembly (page 2-385).
b. Cleaning (page 2-388)
c. Inspection (page 2-389)
d. Assembly (page 2-393)
e. Final Inspection (page 2-397)
INITIAL SETUP
Materials/Parts
Tools
Brush, soft-bristle
Cleaner, parts (with fluid)
Extension, 6-inch, 1/2-inch drive
Gage, bore
Gage, thickness
Hammer, ball-peen, 16-ounce
Hammer, plastic-faced
Handle, hinged, 1/2-inch drive
Handle, ratchet, 1/2-inch drive
Indicator, dial
Mandrel
Micrometer 0- to l-inch
Micrometer, 1- to 2-inch
Micrometer, 3- to 4-inch
Micrometer, 5- to 6-inch
Press, arbor
Puller, ST-647
Socket, 7/16-inch, 3/8-inch drive
Socket, 7/16-inch, 1/2-inch drive
Socket, deep, 3/4-inch, 1/2-inch
drive
Socket, ST-1095
Straightedge
Support, bearing, ST-881
Wrench, box-end, 7/16-inch
Wrench, box-end, 5/8-inch
Wrench, box-end, 3/4-inch
Wrench, box-end, 1 3/8-inch
Wrench, torque, 0 to 150 in. lb (0 to
16.9 N•m), 3/8-inch drive
Wrench, torque, 0 to 150 ft lb (0 to
210 N•m), 1/2-inch drive
2-384
Change 1
Cloth, emery (item 1, appendix B)
Compound, antiseize (item 2, appendix B)
Dye, leak-detection (item 7, appendix B)
Insert, bearing
Lockwasher, diffuser plate (eight required)
Nut, self-locking, retaining strap (two
required)
Oil, lubricating (item 12, appendix B)
Packing, preformed, bearing housing
Packing, bearing housing
Ring, oil control
Ring, seal, diffuser plate
Ring, sealing (two required)
Screw, retaining strap (two required)
Tape, masking (item 19, appendix B)
Washer, flat, retaining strap (four required)
Equipment Condition
Turbocharger removed (page 2-12).
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
DISASSEMBLY
NOTE
Exterior of turbocharger should be cleaned before disassembly. Mark compressor casing, diffuser plate, turbine casing, bearing housing, and clamps to make certain that
parts are assembled in the same position.
1. Turbocharger (1)
Tape (2)
Remove.
Discard.
2. Bearing housing (3)
Oil line inlet
fitting (4)
Using 5/8-inch box-end wrench, unscrew
and take off.
3.
Oil line outlet
fitting (5)
Using 1 3/8-inch box-end wrench, unscrew
and take off.
4. Rotor shaft (6)
Self-locking nut (7)
and turbine wheel
shaft (8)
a. Using ST-1095 socket and 1/2-inch
drive hinged handle, hold turbine wheel
from turning.
b. Using 1/2-inch drive 3/4-inch deep
socket, ratchet handle, and 6-inch extension, unscrew and take off nut (7).
TA 242596
2-385
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY - CONTINUED
5. Retaining strap (1)
Two screws (2), four
flat washers (3),
and two self-locking
nuts (4)
Using 7/16-inch box-end wrench, 1/2-inch
drive 7/16-inch socket, and ratchet handle,
unscrew and take off.
Discard screws, flat washers, and
self-lucking nuts.
6. Turbocharger (5)
Retaining strap (1)
Using 16-ounce ball-peen hammer, tap
loose and take off.
7.
Compressor housing a. Using ST-647 puller, take off compressor housing from shaft (7).
(6) and ST-647
b. Remove ST-647 puller.
puller (8)
8. Compressor
housing (6)
Eight screws (9)
and eight
lockwashers (10)
Using 7/16-inch box-end wrench, unscrew
and take off.
Discard lockwashers.
9.
Diffuser plate (11)
and seal ring (12)
Using plastic-faced hammer, tap free and
remove sealing ring and impeller (13).
Discard seal ring.
TA 242597
2-386
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
10. Diffuser plate (11)
Turbocharger
sleeve (14)
Take out.
11. Bearing housing and
turbine housing (15)
Preformed packing
(16), bearing insert
(17), and floating
bearing (18)
Take out.
Discard packing and bearing insert.
CAUTION
When pressing wheel and shaft from bearing housing, do not allow wheel and shaft to
drop. Damage to wheel and shaft will occur.
12.
Wheel and shaft (19)
and bearing
housing (20)
Position ST-881 bearing support over
bearing housing and against turbine housing
(15). Using arbor press, press wheel,
shaft, and bearing housing from turbine
housing.
TA 242598
2-387
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY - CONTINUED
Wheel and shaft (2)
Tap end of wheel and shaft lightly on work
bench.
Remove wheel and shaft from bearing
housing.
Two sealing
rings (3)
Take off.
Discard.
15. Bearing housing (1)
Heat shield (4) and
packing (5)
Take off.
Discard packing.
16. Turbocharger
sleeve (6)
Oil control ring (7)
Take off.
Discard.
13. Bearing housing (1)
14.
Wheel and shaft (2)
CLEANING
WARNING
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety 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. Flashpoint for
type #1 drycleaning solvent is 100oF (38°C) and for type #2 is 138°F (59°C). If you
become dizzy while using solvent, get fresh air immediately, and get medical aid. If
contact with eyes is made, flush your eyes with water, and get medical aid immediately.
Failure to observe these precautions could cause serious injury or death to personnel.
Particles blown by compressed air are hazardous. Make certain the air stream is
directed away from user and other personnel in the area. Compressed air used for
cleaning purposes shall not exceed 30 psi (207 kPa). User must wear safety goggles or
face shield to prevent injury.
TA 242599
2-388
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
CAUTION
Do not use glassbeading or sandblasting cleaning methods on parts to remove nearby
deposits of carbon or glazed carbon. Serious damage to parts will occur.
Do not use chemical or caustic solutions or solvents that may damage aluminum or
aluminum alloy parts. Serious damage to parts will occur.
Do not use wire brushes or stiff-bristle brushes on turbocharger parts for cleaning. Wire
or stiff-bristle brushes will cause serious damage to parts.
a. Place all parts in parts cleaner for
soaking. Keep parts separated and do
not stack parts.
b. Using a soft-bristle brush, brush heavy
carbon and dirt deposits from parts.
C. Pump parts cleaner fluid through oil
passages to flush out loose particles of
dirt or carbon.
d. Drain off parts and steam clean thoroughly. Make sure oil passages are
clean.
See General Maintenance instructions, page 2-3 for cleaning
procedures.
e. Blow off excess water and dry parts
thoroughly using moisture free compressed air.
All parts
17.
INSPECTION
CAUTION
Move parts to clean and dry area for inspection and assembly procedures. Do not stack
or bump parts together. Damage to parts may occur.
2-389
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
18.
Turbine housing (1)
a. Using straightedge, check mounting
flange area for cracks or distortion.
if cracked or distorted, discard.
b. Inspect turbine wheel side of turbine
housing for cracks and distortion or
wheel to housing contact.
if cracked or distorted, discard. if
scratches are deep, discard housing.
Small scratches and nicks can be
polished out with emery cloth.
19.
Turbine casing (2)
a. Inspect casing for cracks or distortion.
If cracked or distorted, discard.
b. Inspect impeller side of casing for
cracks, scratches, nicks, or scoring.
if cracked, deeply scratched, or
scored, discard. Small scratches,
nicks, or scoring can be polished out
with emery cloth.
20.
Bearing housing (3)
a.
2-390
Inspect for cracks in oil passages, inlet
and outlet, and pitting or distortion on
turbine end.
Discard if cracked, pitted, or
distorted.
b. Check for cracks where ribs meet bearing housing and bearing housing bore.
Discard if cracked.
c. Using bore gage, measure inside diameter of bearing housing bore. Bore
diameter should be 1.274 to 1.278
inches (32.36 to 32.46 mm).
Discard housing if bore exceeds 1.278
inches (32.38 mm).
d. Using 5- to 6-inch micrometer, measure turbine housing seating area diameter. Diameter should be 5.049 to 5.055
inches (128.25 to 128.40 mm).
Discard if diameter does not meet
these specifications. New bearing
housing should be 5.050 to 5.052
inches (128.27 to 128.32 mm).
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
21.
ITEM
ACTION
REMARKS
Bearing housing (3)
e. Using dial indicator, measure length of
bearing housing from compressor stop
to turbine stop, at several points.
Maximum length is 2.994 inches
(76.05 mm).
Discard if less than 2.986 inches
(75.84 mm) or measurements indicate bearing housing is distorted.
Floating bearing (4)
a. inspect for cracks and chips.
Discard if cracked or chipped.
b. Using 1- to 2-inch micrometer, measure outside diameter at several places.
Discard if micrometer does not indicate 1.272 to 1.273 inches (32.31 to
32.33 mm).
c. Using bore gage, measure inside diameter of bearing.
Discard if bore gage does not indicate
0.7520 to 0.7525 inch (19.101 to
19.114 mm).
d. Using 3- to 4-inch micrometer, measure length of bearing.
Discard if micrometer does not indicate 3.078 to 3.080 inches (78.18 to
78.23 mm).
TA 242600
2-391
TM 5-2915-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
22.
Diffuser plate (1)
a.
23.
Turbocharger sleeve
(2) and new oil control ring (3)
a. Inspect for indications of wear.
Discard if worn.
b. Using thickness gage and new oil control
ring, insert oil control ring into groove
on sleeve and measure clearance with
thickness gage.
Discard if clearance exceeds .009
inch (0.23 mm).
24.
Heat shield (4)
Inspect for cracks, distortion, or burned
condition.
Discard if distorted, burned, or
cracks exceed 1/2 inch (12.7 mm) in
length.
25.
Compressor wheel (5)
Inspect for broken vanes or indications of
contact with turbine housing. Using leakdetection dye check for cracks.
Discard if cracked, broken, or contact with compressor housing is
indicated.
26.
Wheel and shaft (6)
a. Using leak-detection dye, check wheel
for cracks.
Discard if cracked.
b. Inspect sealing ring grooves for
grooves, scratches, or nicks.
Discard if grooves, scratches, or
nicks cannot be removed with emery
cloth.
2-392
Inspect for cracks, burrs, or distortion.
Discard if cracked or distorted.
Smooth out burrs with emery cloth.
b. Using bore gage, measure inside diameter of turbocharger sleeve bore.
Discard if bore gage does not Indicate
0.999 to 1.004 inches (25.37 to
25.50 mm).
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
27.
ACTION
REMARKS
ITEM
Wheel and shaft (6)
c. Inspect shaft bearing thrust shoulder for
scratches or scoring.
Discard if scratches or scoring cannot
be removed with emery cloth.
d. Using O-to l-inch micrometer, measure shaft bearing journal diameters.
if micrometer does not indicate
0.7495 to 0.7505 inch (19.04 to
19.06 mm), discard wheel and shaft.
Retaining strap (7)
Inspect for cracks or distortion.
Discard if cracked or distorted.
ASSEMBLY
CAUTION
The work area and all parts must be free of grease, dust, dirt, and abrasive particles
that may get into turbocharger during assembly, and cause premature turbocharger
failure.
TA 242601
2-393
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY - CONTINUED
28. Wheel and shaft (1)
Floating bearing (2)
a. Coat shaft bearing journals with lubricating oil, and slide bearing into
position.
b. Using mandrel on shaft shoulder, check
bearing end clearance using thickness
gage.
Clearance should be 0.006 to 0.010
inch (0.15 to 0.25 mm).
c. Remove bearing.
29. Bearing housing (3)
New packing (4) and
heat shield (5)
Position new packing on turbine end of bearing housing and install heat shield.
30. Wheel and shaft (1)
Two new sealing
rings (6)
Apply a light coat of lubricating oil to sealing
ring grooves on shaft, and install two new
sealing rings.
CAUTION
Care must be taken when starting sealing rings in chamfer of bore, to allow sealing rings
to compress properly.
NOTE
Make sure end caps of sealing rings are 180 degrees from each other when installing
wheel and shaft.
31. Bearing housing (3)
Wheel and shaft (1)
Coat bore of bearing housing with lubricating oil and install wheel and shaft.
32.
Floating bearing (2)
Coat wheel and shaft and bearing with
lubricating oil, and insert bearing over shaft
in bearing housing.
2-394
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
33.
New bearing
insert (7)
Position new bearing insert over shaft to
flange on bearing.
34.
New preformed
packing (8)
Lubricate new packing with lubricating oil
and install in groove on compressor end of
bearing housing.
35. Seal (9)
Piston ring (10)
Coat seal and piston ring with lubricating oil
and install piston ring on seal.
36. Diffuser plate (11)
Seal (9) and piston
ring (10)
Install seal assembly from inside of diffuser
plate with piston ring towards outside of
diffuser plate.
37.
New seal ring (12)
Lubricate new seal ring with lubricating oil
and install on lip of diffuser plate.
38. Bearing housing
assembly (13)
Diffuser plate
assembly (14)
Coat bearing housing bore with lubricating
oil and place diffuser plate over shaft. Aline
retainer on diffuser plate so that retainer
covers side of bearing flange.
TA 242602
2-395
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY - CONTINUED
39. Bearing housing
assembly (1)
Compressor wheel (2)
a. Lubricate shaft with lubricating oil and
position compressor wheel on shaft.
b. Using arbor press and mandrel, press
compressor wheel against seal.
CAUTION
Do not overtorque self-locking nut as this will deform turbine wheel and shaft.
40.
Self-locking nut (3)
Using 3/4-inch box-end wrench, ST-1095
socket, and 1/2-inch drive 0 to 150 ft lb (0
to 210 N•m) torque wrench, install and
tighten self-locking nut to 20 to 24 ft lb (27 to
33 N•m).
41.
Compressor housing
(4), eight screws
(5), and eight new
lockwashers (6)
a. install compressor housing on bearing
housing assembly, and aline index
marks made in disassembly.
b. Install new lockwashers on screws and
screw into compressor housing.
C. Using 3/8-inch drive 7/16-inch socket
and 0 to 150 in. lb (0 to 16.9 N•m)
torque wrench, tighten to 60 to 84 in. lb
(6.7 to 9.7 N•m).
42. Turbine housing (7)
Bearing housing
and compressor
assembly (8)
a.
43. Turbocharger
assembly (9)
Retaining straps
(10), two new screws
(11), four new flat
washers (12) and two
new self-locking
nuts (13)
a. Position retaining straps around bearing
housing and center retaining strap
openings over oil supply and drain
holes.
b. Install one new flat washer on each new
screw and install through retaining
straps.
C. Install one new flat washer on each new
screw and screw on new self-locking
nut.
d. Using 7/16-inch box-end wrench, 1/2inch drive 7/16-inch socket, and 0 to
150 ft lb torque wrench, tighten to 32 to
36 ft lb (3.6 to 4.1 N•m).
2-396
Lubricate turbine housing bore with antiseize compound.
b. Position bearing housing and compressor assembly into turbine housing and
aline index marks made in disassembly.
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
44.
Oil line inlet
fitting (14)
Screw in and tighten using 5/8-inch boxend wrench.
45.
Oil line outlet
fitting (15)
Screw in and tighten using 1 3/8-inch boxend wrench.
FINAL INSPECTION
46. Turbocharger
assembly
Check radial clearance of diffuser plate and
compressor wheel as follows: Push shaft
toward side of bore, and using thickness
gage, measure minimum distance between
wheel vanes and housing.
Clearance should be 0.006 to
0.028 inch (0.15 to 0.71 mm) for
compressor wheel and 0.008 to
0.043 inch (0.20 to 1.09 mm) for
turbine wheel.
TA 242603
2-397
TM 5-2815-241-34&P
TURBOCHARGER - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
FINAL INSPECTION - CONTINUED
47.
Using a dial indicator, measure total end
clearance of wheels and shaft by pushing
shaft down all the way, and then moving
back again.
End clearance should be 0.006 to
0.018 inch (0.15 to 0.46 mm).
48.
Spin rotor by hand to make sure no interference is present.
49.
Cover all openings in turbocharger with
masking tape.
FOLLOW-ON MAINTENANCE:
Install turbocharger on engine (page 2-136).
TASK ENDS HERE
ANEROID CONTROL VALVE
This task covers:
a. Disassembly (page 2-399)
b. Cleaning (page 2-400)
c. Inspection (page 2-400)
d. Assembly (page 2-402)
INITIAL SETUP
Tools
Hammer, plastic-faced
Pan, drain, 2-gallon
Pliers, diagonal-cutting
Screwdriver, flat-tip, 1/4-inch
Wrench, box-end, 7/16-inch
Wrench, box-end, 9/16-inch
Wrench, hex, 3/16-inch
Wrench, open-end, 7/8-inch
Materials/Parts
Cover, side, aneroid control valve
Lockwasher, bellows
Lockwasher, bellows cover (three required)
Packing, preformed (two required)
Oil, lubricating (item 12, appendix B)
Wire, locking (item 21, appendix B)
Equipment Condition
Aneroid control valve removed (page 2-25).
2-398
TM 5-2815-241-34&P
ANEROID CONTROL VALVE - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
DISASSEMBLY
1. Aneroid control
valve (1)
Pipe plugs (2 and 3)
a. Using 3/16-inch hex wrench, unscrew
and take out.
b. Drain oil into drain pan.
2.
Tubing nut (4) and
tubing (5)
Using 9/16-inch box-end wrench, loosen
and take off.
3.
Lead seal (6) three
screws (7) three
lockwashers (8)
and lock wire (9)
a. Using diagonal-cutting pliers, cut lock
wire and take off.
b. Using 7/16-inch box-end wrench, unscrew and take out.
Discard lockwashers and lock wire.
4.
Bellows cover (10)
Using plastic-faced hammer, tap gently and
take off.
5.
Screw (11) and
lockwasher (12)
Using 7/16-inch box-end wrench, unscrew
and take off.
Discard lockwasher.
TA 242604
2-399
TM 5-2815-241-34&P
ANEROID CONTROL VALVE - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
DISASSEMBLY - CONTINUED
6. Aneroid control
valve (1)
Bellows washer (2)
bellows (3), piston
(4), and spring (5)
Take off.
7.
Side control
cover (6)
Using 1/4-inch flat-tip screwdriver, pry
out.
Discard side cover.
8.
Bellows actuating
shaft (7), shaft
valve (8), and preformed packing (9)
a. Lift up bellows actuating shaft and pull
out shaft valve.
b. Take off packing.
Discard.
9.
Check valve (10),
gasket (11), and
air filter (12)
a. Using 7/8-inch open-end wrench, unscrew check valve and take out.
b. Take off gasket.
Discard gasket.
C. Using 7/16-inch box-end wrench, unscrew air filter and take out.
CLEANING
WARNING
Drycleaning solvent P-D-680 is toxic and flammable. Wear safety 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. Flashpoint for
type #1 drycleaning solvent is 100oF (38°C) and for type #2 is 138°F (59°C). If you
become dizzy while using 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.
Failure to observe these precautions could cause serious injury or death to personnel.
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
INSPECTION
10.
2-400
Bellows cover (10)
Check for cracks, chips, or warpage.
Discard if cracked, chipped, or
warped.
TM 5-2815-241-34&P
ANEROID CONTROL VALVE - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION - CONTINUED
11.
Bellows (3)
Check for cracks, wrinkles, or dryness.
Discard if cracked, wrinkled, or dry.
12.
Spring (5)
Check for cracks, breaks, or loss of
tension.
Discard if cracked, broken, or weak.
13.
Bellows actuating
shaft (7)
Check for bent shaft or damaged threads.
Discard if bent or damaged.
14.
Aneroid control
valve body (1)
Check for cracks, chips, warpage, or damaged screw holes.
Discard if defective.
15.
Air filter (12)
Check for clogged screen.
Discard if defective.
TA 242605
2-401
TM 5-2815-241-34&P
ANEROID CONTROL VALVE - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY
16. Aneroid control
valve (1)
New gasket (3) and
check valve (4)
a. install new gasket on check valve.
b. Put check valve into position, and using
7/8-inch open-end wrench, tighten.
17.
Air filter (2)
Put in position, and using 7/16-inch boxend wrench, tighten.
18.
Shaft valve (5)
and new preformed
packing (6)
Put new packing on shaft valve.
19.
Side cover (7)
Put in position and, using plastic-faced
hammer, tap in place.
20.
Shaft valve (5) and
bellows actuating
shaft (8)
Lower bellows actuating shaft into aneroid
control valve body (1) alining hole (9) with
pin (10) on shaft valve as shown.
NOTE
Before performing step 21, dip bellows in lubricating oil to ensure pliability when
assembling.
TA 242606
2-402
TM 5-2815-241-34&P
ANEROID CONTROL VALVE - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
Bellows (11), piston
(12), spring (13),
and bellows actuating
shaft (8)
Place bellows, piston, and spring on
bellows actuating shaft.
22.
Bellows washer (14),
new lockwasher (15)
and screw (16)
a. Place bellows washer on bellows (11).
b. Position new lockwasher and screw, and
using 7/16-inch box-end wrench,
tighten.
23.
Bellows cover (17)
Aline bellows (11) and bellows cover with
holes in aneroid control valve (1).
24.
Three screws (18),
and three new
lockwashers (19)
Position new lockwashers and screws as
shown, and using 7/16-inch box-end
wrench, tighten.
25.
Lead seal (20),
tubing (21), tubing
nut (22), and new
lock wire (23)
a. Connect new lock wire to screws and
crimp on lead seal.
b. Position tubing, and using 9/16-inch
box-end wrench, tighten tubing nut.
26.
Pipe plug (24), pipe
plug hole (25), and
pipe plug (26)
a. Using 3/16-inch hex wrench, screw in
and tighten pipe plug (24).
b. Fill pipe plug hole with lubricating oil
until oil leaks from hole.
c. Using 3/16-inch hex wrench, screw in
and tighten pipe plug (26).
21.
Aneroid control
valve body (1)
TA 242607
2-403
TM 5-2815-241-34&P
ANEROID CONTROL VALVE - CONTINUED
NOTE
FOLLOW-ON MAINTENANCE:
Install aneroid control valve (page 2-132).
TASK ENDS HERE
Section XV. COOLING SYSTEM MAINTENANCE
Page
Page
idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-404
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-408
IDLER PULLEY
This task covers:
c. Inspection (page 2-405)
d. Assembly (page 2-406)
a. Disassembly (page 2-404)
b. Cleaning (page 2-405)
INITIAL SETUP
Materials/Parts
Tools
Oil, lubricating (item 12, appendix B)
Packing, preformed, shouldered shaft
Seal, oil, idler shaft
Chisel, cold, 1/2-inch
Hammer, ball-peen, 16-ounce
Mandrel
Mandrel, ST-658
Pliers, snapring
Press, arbor
Puller, bearing
Wrench, box-end, 7/8-inch
Wrench, hex, 5/32-inch
Wrench, open-end, 1 1/16-inch
LOCATION
Equipment Condition
Water pump removed (page 2-37).
ITEM
ACTION
REMARKS
DISASSEMBLY
1. Water pump (1)
Fan adjusting
screw (2)
Using 7/8-inch box-end wrench, unscrew
and take out.
2.
Nut (3) and
flat washer (4)
a. Using 1 1/16-inch open-end wrench,
unscrew and take off.
b. Remove idler pulley (5) with attached
parts.
2-404
TM 5-2815-241-34&P
IDLER PULLEY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
3. Idler pulley (5)
with attached parts
Sleeve spacer (6),
oil seal (7), and
preformed packing (8)
a. Using 16-ounce ball-peen hammer and
1/2-inch cold chisel, drive bearing
spacer (6) off shouldered shaft (9).
b. Take out oil seal and packing.
Discard.
4.
Retaining ring (10)
Using snapring pliers, take off.
5. Idler pulley (5)
Screw (11) and
flat washer (12)
Using 5/32-inch hex wrench, unscrew and
take out.
6.
Shouldered shaft (9)
and bearing (13)
Using bearing puller, pull out.
7. Bearing (13)
Shouldered shaft (9)
Using arbor press, press out.
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
TA 242608
2-405
TM 5-2815-241-34&P
IDLER PULLEY - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
INSPECTION
8.
Bearing (1) and
shouldered shaft (2)
a.
Inspect bearing for excessive wear or
binding (page 2-444).
b. Inspect shaft for straightness, galling,
or pitting on bearing surface, or dam.
aged threads.
Discard bearing or shaft if defective.
9.
Idler pulley (3)
Inspect pulley groove for excessive wear,
chips, cracks, or burrs.
Discard if defective.
10.
Shouldered shaft (2)
and bearing (1)
a. Using lubricating oil, lubricate idler
shaft.
b. Using arbor press and mandrel, press
bearing onto shouldered shaft until inner
race of bearing touches idler shaft
flange.
11.
Idler pulley (3) and
bearing (1)
Using arbor press, press bearing with idler
shaft (2) into idler pulley until bearing
bottoms.
12.
Retaining ring (4)
Using snapring pliers, put in.
13. Idler pulley (3)
Screw (5) and
flat washer (6)
a. Put in place.
b. Using 5/32-inch hex wrench, tighten.
14. Shouldered shaft (2)
New oil seal (7) and
new preformed
packing (8)
a. Using lubricating oil, lubricate lip of new
oil seal and new packing.
b. Position new packing into groove on idler
shaft.
c. Using arbor press and ST-658 mandrel,
press new oil seal into idler pulley (3).
ASSEMBLY
2-406
TM 5-2815-241-34&P
IDLER PULLEY - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
15.
Bearing spacer (9)
a. Position on idler shaft (2).
b. Using arbor press and mandrel, press
bearing through oil seal (7) until
bottomed against bearing inner race.
16. Water pump (10)
Idler shaft (2), nut
(11), flat washer
(12), and fan adjusting screw (13)
a. Position shaft in adjusting slot (14).
b. Put on nut and flatwasher.
Do not tighten.
c. Screw fan adjusting screw into idler
shaft.
Do not tighten.
NOTE
Adjustments will be made when installing belts.
TASK ENDS HERE
TA 242609
2-407
TM 5-2815-241-34&P
WATER PUMP
This task covers:
a. Disassembly (page 2-408)
b. Cleaning (page 2-409)
c. Inspection (page 2-409)
d. Assembly (page 2-410)
INITIAL SETUP
Tools
Materials/Parts
Disassembly tool, bearing, ST-1114
Driver, wear sleeve, ST-1159
Gage, bore
Hammer, ball-peen, 16-ounce
Mandrel
Mandrel, seal, ST-1191-2 and - 3
Mandrel ST-658
Micrometer, 0- to 1-inch
Pliers, snapring
Press, arbor
Puller, ST-647
Punch, straight, 3/16-inch
Straightedge, 12-inch
Wrench, box-end, 1/2-inch
LOCATION
Grease, extreme-pressure (item 10,
appendix B)
Oil, lubricating (item 12, appendix B)
Packing, preformed, water by-pass tube
Seal, carbon-faced
Seal, oil, front
Seal, oil, rear
Seat and seal, ceramic
Sleeve, wear (if required)
Equipment Condition
Water pump removed (page 2-37).
ITEM
ACTION
REMARKS
DISASSEMBLY
1. Water pump body (1)
Pulley (2) and
impeller (4)
Using ST-647 puller, pull from shaft (3).
2.
Ceramic seat and
seal (5), front oil
seal (6), and bearing retaining
ring (7)
a. Take out ceramic seat and seal from
impeller side of water pump.
Discard.
b. Take out front oil seal from pulley side of
water pump.
Discard.
c. Using snapring pliers, take out retaining
ring.
3.
Shaft assembly
(items 3 and 8
thru 11)
Support pulley side of water pump and,
using arbor press and mandrel, press shaft
assembly from water pump.
4. Shaft (3)
Outer bearing (8)
and bearing
spacer (9)
Using ST-1114 bearing disassembly tool,
press shaft through outer bearing and bearing spacer.
2-408
TM 5-2815-241-34&P
WATER PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
5.
Retaining ring (10)
and inner
bearing (11)
a. Using snapring pliers, take off retaining
ring.
b. Support inner bearing on inside race
and using arbor press and mandrel,
press out shaft (3).
6. Water pump body (1)
Carbon-faced seal
(12) and rear oil
seal (13)
Take out.
Discard.
7.
Screw (14), clamp
(15), water by-pass
tube (16), and preformed packing (17)
a. Using 1/2-inch box-end wrench, unscrew and take out screw and clamp.
b. Pull water by-pass tube from water pump
body.
c. Take off packing.
Discard.
CLEANING
NOTE
For general cleaning procedures, see General Maintenance Instructions, page 2-3.
INSPECTION
8.
Outer bearing (8)
bearing spacer (9),
and inner bearing (11)
a. Inspect inner bearing and outer bearing for wear, roughness, and damage.
Discard if worn, rough, or damaged.
b. Inspect bearing spacer for wear or
damage.
Discard if worn or damaged.
2-409
TM 5-2815-241-34&P
WATER PUMP - CONTINUED
ACTION
REMARKS
ITEM
LOCATION
INSPECTION - CONTINUED
Impeller(l), shaft
(2), and pulley (3)
a. Using bore gage, measure bore diameter of impeller and pulley.
b. Using O-to l-inch micrometer, measure shaft diameters that carry pulley
and impeller.
There must be a minimum of 0.001
inch (.025 mm) press fit between
bore diameters and shaft diameters.
10.
Impeller (1)
Inspect for cracks and corrosion.
Discard if cracked or corroded.
11.
Shaft (2)
a. Using 12-inch straightedge, check for
straightness.
Discard if bent.
b. Inspect all press fit mating surfaces.
Discard if scored.
12.
Pulley (3)
Inspect for cracks, bends, or excess wear in
grooves.
Discard if cracked, bent, or worn.
13.
Water pump body (4)
Inspect for cracks, damage from bearings
warpage, or damaged mating surfaces.
Discard if defective.
14. Pulley (3)
Wear sleeve (5)
Inspect for grooves or excessive wear.
Replace if worn or if grooves are
noted. (See steps 16 and 17).
9.
ASSEMBLY
NOTE
Perform steps 15 and 16 only if wear sleeve is to be replaced.
15.
Pulley (3) and
wear sleeve (5)
a. Using 3/16-inch straight punch and 16
ounce ball-peen hammer, drive wear
sleeve out of pulley.
b. Discard wear sleeve.
16. Pulley (3)
New wear sleeve (5)
a. Position new wear sleeve in pulley hub.
b. Using ST-1159 wear sleeve driver, drive
in new wear sleeve.
2-410
TM 5-2815-241-34&P
WATER PUMP - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
17. Shaft (2)
Inner bearing (6)
and retaining
ring (7)
a.
Lubricate shaft with extreme-pressure
grease and position inner bearing on
shaft.
b. Using arbor press and ST-658 mandrel
seated on inner race, press inner
bearing until seated on shoulder of
shaft.
c. Using snapring pliers, install retaining
ring.
18.
Bearing spacer (8)
Install.
19.
Outer bearing (9)
Using arbor press and ST-658 mandrel
seated on inner race, press on outer
bearing until seated against bearing
spacer (8).
Check inner bearing and outer bearing
for free rotation.
TA 242611
2-411
TM 5-2815-241-34&P
WATER PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ASSEMBLY - CONTINUED
20. Water pump body (1)
New rear oil
seal (2)
a. Position new rear oil seal on pulley side
of water pump body with lip opposite
impeller (3).
b. Using ST-l 191-2 seal mandrel, press
into water pump body.
CAUTION
Keep seal face free from grease or other foreign material to prevent damage to seat.
New carbon-faced
seal (4)
21.
a. Position new carbon-faced seal on impeller side of water pump body (1) with
lip facing impeller (3).
b. Using ST-658 mandrel, press into water
pump body until seal bottoms.
CAUTION
Do not support water pump body on thin section of impeller cavity when installing shaft
assembly or damage to water pump body may occur.
22.
Shaft assembly (5)
and bearing retaining ring (6)
a. Using arbor press and ST-658 mandrel,
press shaft assembly into water pump
body until inner bearing bottoms on rear
oil seal.
b. Using snapring pliers, install retaining
ring.
23.
New front oil
seal (7)
Using arbor press and ST-1191-3 seal
mandrel, press in.
24. Water pump body (1)
New ceramic seat
and seal (8)
a.
2-412
Lubricate bore with clean lubricating
oil.
b. Install new ceramic seat on shaft with
dimples facing away from carbon-face
seal.
c. Install seal on shaft against ceramic seat
with flat side toward impeller end of
shaft.
TM 5-2815-241-34&P
WATER PUMP - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
25.
Impeller (3)
a. Support water pump (1) on pulley end of
shaft (5).
b. Using arbor press and mandrel, press
on impeller, maintaining 0.020 to
0.040 inch (0.5 to 1.01 mm) clearance
between impeller and cavity.
26.
Pulley (9)
a. Support water pump (1) on impeller end
of shaft (5).
b. Using arbor press and mandrel, press
pulley on shaft until pulley hub is
flush with shoulder on shaft.
Check assembly for freedom of
rotation.
27.
New preformed packing (10) and by-pass
pipe (11)
Lubricate packing with clean lubricating oil
and slide into groove on by-pass pipe.
28.
By-pass pipe (11),
clamp (12), and
screw (13)
Position in water pump and, using 1/2-inch
box-end wrench, tighten.
NOTE
FOLLOW-ON MAINTENANCE:
Install water pump (page 2-121).
TASK ENDS HERE
TA 242612
2-413
TM 5-2815-241-34&P
Section XVI. FINAL TESTING, ADJUSTMENTS, AND TROUBLESHOOTING ON ENGINE
TEST STAND
Page
Final Testing and Adjustments.. .............
Scope ........................................................
2-414
2-414
Page
Troubleshooting on Engine
Test Stand.. .............................................
2-424
SCOPE
Engine testing and break-in are performed on a suitable engine test stand. Make sure engine test
stand capacity is sufficient to allow testing at 100 percent engine horsepower. Engine testing and
break-in are accomplished simultaneously. Break-in on a rebuild engine is necessary to provide an
operating period for moving parts and mating surfaces to reach a full seat. Final testing helps detect
potential problems and establishes a period for final adjustment for best engine performance. During
final testing make the following checks frequently. Lubricating oil pressure should remain at a constant figure with engine at speed and load after operating temperature has been reached. Abnormally
high or low oil pressure may indicate a problem. Oil temperature should not rise above 225°F
(107°C). Shut down engine and diagnose problem(s) before restarting engine. Do not allow oil to go
above high mark or below low mark on oil level dipstick.
After engine is started, add coolant as necessary to completely fill cooling system and replace entrapped air. Coolant should not exceed 200°F (93°C), or drop below 160°F (71ºC) during engine
operation. Allow engine to idle for a few minutes before shutting down after a load run. Engine blowby
readings must be taken frequently during run-in to note any blowby increase at a given speed and
load. If there is any indication of blowby increase, engine speed must be reduced for a few minutes
and then brought back to the original setting. During each power check, if blowby pressure rises,
more run-in is required. With engine running at governed speed at 96 to 100 percent rated horsepower, crankcase pressure should not exceed 12 inches (30.48 cm) of water. If crankcase pressure
exceeds this figure, operate engine at 96 to 100 percent rated load and rpm for 30 minutes, If there is
no rapid change in excess of 2 inches (50.8 mm) of water, and reading does not exceed 12 inches
(30.48 cm) of water, blowby is acceptable. Engine troubleshooting is included to further aid in
locating faults found during final testing.
FINAL TESTING AND ADJUSTMENTS
This task covers:
a. Procedures Before Starting
(page 2-415)
b. Starting (page 2-418)
c. Engine testing (page 2-419)
INITIAL SETUP
Tools
Tools - Continued
Hammer, ball-peen, 8-ounce
Handle, ratchet, 1/2-inch drive
Measuring device, fuel consumption,
ST-1190
Pump, priming
Punch, 1/4-inch
Screwdriver, flat-tip, 1/4-inch
Socket, hex key, 1/2-inch, 1/2-inch drive
2-414
Change 1
Test stand, engine
Tool, blowby checking, ST-487
Wrench, box-end, 9/16-inch
Wrench, open-end, 9/16-inch
Wrench, open-end, 5/8-inch
Wrench, open-end, 3/4-inch
TM 5-2815-241-34&P
FINAL TESTING AND ADJUSTMENTS - CONTINUED
INITIAL SETUP - CONTINUED
Materials/Parts
Materials/Parts - Continued
Ball, sealing
Coolant, antifreeze (item 3,
appendix B)
Filter, fuel
Oil, fuel (item 11, appendix B)
Oil, lubricating (item 12,
appendix B)
Seal, lead
Wire, locking (item 21, appendix B)
Equipment Condition
Engine mounted on suitable engine test stand.
ACTION
REMARKS
ITEM
LOCATION
PROCEDURES BEFORE STARTING
WARNING
Fuel is flammable and can explode. To avoid serious injury or death, keep fuel away
from open fire and keep fire extinguisher within easy reach when working with fuel.
Smoking is prohibited while working with fuel.
1. Engine mounted on
engine test stand
Fuel filter (1)
a. Fill with clean fuel oil.
b. Put on and tighten.
2.
Fuel pump (2)
a. Using 9/16-inch box-end wrench, loosen and take out plug (3) next to tachometer drive (4).
b. Fill with clean fuel oil.
C. Using 9/16-inch box-end wrench, put in
and tighten plug (3) next to tachometer
drive (4).
TA 242613
2-415
TM 5-2815-241-34&P
FINAL TESTING AND ADJUSTMENTS - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
PROCEDURES BEFORE STARTING - CONTINUED
3. Engine mounted on
engine test stand
Cooling system
Fill with clean coolant.
4.
Oil filter (1)
Fill with lubricating oil.
5.
Turbocharger (2)
a. Using 3/4-inch and 5/8-inch open-end
wrenches, loosen and take off oil inlet
line (3).
b. Lubricate bearing with 2 to 3 ounces (60
cc) of clean lubricating oil.
C. Using 3/4-inch and 5/8-inch open-end
wrenches, put on and tighten oil inlet
line.
6.
Oil filler cap (4)
a. Take out of rocker arm cover (5).
b. Fill crankcase with lubricating oil to low
mark on dipstick (6).
C. Put in rocker arm cover.
7.
Gearcase (7)
a. Using 1/2-inch drive 1/2-inch hex key
socket and ratchet handle, loosen and
take out priming passage plug (8).
b. Install priming pump from source of
clean lubricating oil to plug boss in
gearcase.
C. Prime system until a 30 psi (207 kPa)
maximum pressure is developed.
d. Crank engine at least 15 seconds with
fuel shutoff closed, while maintaining
oil pressure at a minimum of 15 psi
(103.5 kPa).
e. Remove priming pump.
f. Using 1/2-inch drive 1/2-inch hex key
socket and ratchet handle, put in and
tighten priming passage plug.
g . Clean area of any lubricating oil spilled
while priming.
2-416
TM 5-2815-241-34&P
FINAL TESTING AND ADJUSTMENTS - CONTINUED
LOCATION
ITEM
ACTION
REMARKS
8.
Oil filler cap (4)
a. Take out of rocker arm cover.
b. Fill crankcase with clean lubricating
oil to high mark on dipstick (6).
c. Put in rocker arm cover.
9.
ST-1190 fuel consumption measuring
device
Attach to engine.
10.
ST-487 blowby
checking tool
a. Attach to crankcase breather opening in
rocker arm cover.
b. Close all openings that would allow blowby pressure to escape.
11.
Aneroid control
valve (9)
a. Using 9/16-inch and 5/8-inch openend wrenches, disconnect fuel pressure
and fuel return lines (10).
b. Plug lines.
TA 242614
2-417
TM 5-2815-241-34&P
FINAL TESTING AND ADJUSTMENTS - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
STARTING
WARNING
EXHAUST GAS CAN KILL YOU
Exhaust gas is without color or smell, but can kill you. Breathing exhaust gas produces
symptoms of headache, dizziness, loss of muscular control, a sleepy feeling, and
coma. Brain damage or death can result from heavy exposure of exhaust fumes of fuelburning internal combustion engines. Exhaust gases can become dangerously concentrated under conditions of no air movement. Precautions must be followed to ensure
crew safety when the engine of any vehicle is operated for any purpose.
1.
DO NOT operate vehicle engine inside building unless ample ventilation is available.
2.
DO NOT idle engine for long periods without ventilator blower operating.
3.
DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment doors removed unless necessary for maintenance purposes.
4.
BE ALERT at all times during vehicle operation for exhaust odors and exposure symp
toms If either is present, IMMEDIATELY VENTILATE personnel compartments. If
symptoms persist, remove affected crew to fresh air; keep warm; DO NOT PERMIT
PHYSICAL EXERCISE; and, if necessary, give artificial respiration.
5.
FOR ARTIFICIAL RESPIRATION, REFER TO FM 21-11.
6.
BE AWARE; the field protective mask for chemical-biological-radiological (CBR)
protection will not protect you from exhaust gas fumes.
THE BEST DEFENSE AGAINST ENGINE EXHAUST FUMES IS GOOD VENTILATION.
CAUTION
To prevent damage to the turbocharger, do not accelerate the engine above 1000 rpm
until the reading on the oil pressure gage indicates normal oil pressure at idle speed.
12. Fuel pump (1)
Throttle (2)
Set for idle speed.
CAUTION
After engine starts, run at approximately 800 rpm, disconnect turbocharger oil drain
line, and observe oil drain. Oil should flow in 10 to 15 seconds. If no oil flows in 30
seconds, shut down engine and correct fault. Reconnect oil drain line when flow is
established.
NOTE
The manual override knob on forward end of electric shutdown valve allows valve to be
opened if power is not available during testing. To use, open valve by turning knob fully
clockwise. Each time engine is started, see Preliminary Starting Procedures,
page 2-3.
2-418
TM 5-2815-241-34&P
FINAL TESTING AND ADJUSTMENTS - CONTINUED
LOCATION
13.
ITEM
ACTION
REMARKS
Engine mounted on
engine test stand
a. Apply 12 volts to fuel shutdown valve (3)
to open.
b. Start engine (page 2-3). Allow to idle at
approximately 800 rpm.
If engine gives no Indication of
starting, see engine test stand
troubleshooting, page 2-424.
Engine mounted on
engine test stand
a. Operate at 800 rpm for 5 to 10 minutes.
b. Check oil pressure.
Shut down engine if not between 10
and 70 psi, and correct fault. See
engine test stand troubleshooting,
page 2-424.
c. Restart engine (page 2-3).
d. Check water temperature.
Shut down engine If above 200°F
(93°C) and correct fault. See engine
test stand troubleshooting,
page 2-424.
e. Restart engine (page 2-3).
f. Check all filters, gaskets, connections,
and hoses for leaks.
Shut down engine, repair or replace
all leaking filters, gaskets, connections, and hoses.
g. Restart engine (page 2-3).
h. Shut down engine. Check oil level.
Refill to high mark.
ENGINE TESTING
14.
TA
242615
2-419
TM 5-2815-241-34&P
FINAL TESTING AND ADJUSTMENTS - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ENGINE TESTING - CONTINUED
NOTE
Each time engine is started see Preliminary Starting Procedures, page 2-3.
15.
Engine (1) mounted
on engine test stand
a. Restart engine (page 2-3).
b. Apply load to 145 horsepower (± 10%)
at 1575 rpm (±5%) until full operating
temperature is reached.
c. Check crankcase pressure on ST-487
blowby checking tool.
NOTE
If blowby reading steadily decreases with each different load applied, reduce run-in time
at that load by half. Otherwise, run engine for time period specified.
d. Shut down engine and check oil level.
Refill to high mark.
e. Restart engine (page 2-3).
f. Apply load to 218 horsepower (±10%)
at 2100 rpm (±5%) for 15 minutes.
g. Set engine governed speed by adding or
removing shims under the high-speed
governor spring.
See fuel pump maintenance,
page 2-289.
h. Set fuel rate using ST-1190 fuel consumption measuring device.
i. Allow engine to idle. Adjust engine
idle to 600 rpm (±20) by removing
pipe plug (2) from spring pack cover (3)
and, using 1/4-inch flat-tip screwdriver, turning the idle adjustment
screw (4).
See fuel pump maintenance,
page 2-289.
Apply
load to 247 horsepower (±10%)
j.
at 2100 rpm (±5%) for 15 minutes.
If blowby rises, reduce load to
specifications In step f and run for 30
minutes. Return to load specified In
step j.
k. Apply load to 261 horsepower (±10%)
at 2100 rpm (±5%) for 15 minutes.
2-420
TM 5-2815-241-34&P
FINAL TESTING AND ADJUSTMENTS - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
I.
Check all filters, gaskets, connections,
and hoses for leaks.
m. Shut down engine.
Check for leaks and repair as
necessary.
n. Using appropriate tools, tighten all
exposed capscrews.
NOTE
Valve and injector readjustment, after one hour of operation, is necessary to ensure
lowest smoke potential and to avoid excessive injector train loads.
o. Restart engine (page 2-3) and run for
one hour at 1200 RPM.
p. Shut down engine.
q. Check valve and injector adjustments.
Adjust valves to hot specifications:
0.008 Inch (0.20 mm) clearance for
intake valves, 0.023 Inch (0.58 mm)
clearance for exhaust valves, and
0.170 Inch (4.32 mm) for Injector
plunger travel. See valve and Injector
adjustment, page 2-106.
TA 242616
2-421
TM 5-2815-241-34&P
FINAL TESTING AND ADJUSTMENTS - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
ENGINE TESTING - CONTINUED
NOTE
Each time engine is started see Preliminary Starting Procedures, page 2-3.
15. Continued
Engine (1) mounted
in engine test stand
r.
s.
18. Engine (1) mounted
in engine test stand
Aneroid control
valve (2)
a.
17. Fuel pump (4)
Sealing ball (5)
Using 1/4-inch punch and 8-ounce ballpeen hammer, hit into end of throttle
shaft (6).
18.
Locking wire (7)
a. Thread through pipe plug (8) and two
hex head cover screws (9). Twist locking wire until secure.
b. Install lead seal (10) onto twisted wire
ends.
2-422
Restart engine (page 2-3).
Run engine at approximately 800 rpm for
5 to 10 minutes until full operating temperature is obtained.
t. Apply load to 278 horsepower (±10%)
at 2100 rpm (±5%) for 5 minutes.
Engine should develop 278 to 290
horsepower at standard fuel rate of
105 Ib/hr.
u. Check blowby pressure.
If blowby pressure exceeds 12 inches
(30.48 cm) of water, reduce engine
speed and load as specified in step k.
v. Repeat steps s, t, and u until engine
develops a minimum of 278 horsepower
at standard fuel rate within permissible
blowby pressure.
w. Shut down engine.
Remove plugs from fuel pressure and
fuel return lines (3).
b. Using 9/16-inch and 5/8-inch openend wrenches, connect fuel pressure
and fuel return lines.
TM 5-2815-241-34&P
FINAL TESTING AND ADJUSTMENTS - CONTINUED
LOCATION
ACTION
REMARKS
ITEM
19. Engine (1) mounted
on engine test stand
Engine coolant
Drain from engine cooling system.
20.
ST-1190 fuel consumption measuring
device
Disconnect from engine.
21.
ST-487 blowby
checking tool
a.
Disconnect from crankcase breather
opening.
b. Clear all openings closed previously in
step 10.
NOTE
Disconnect all electrical wiring, water lines, fuel lines, and oil lines between engine and
engine test stand. Disconnect exhaust and intake air piping, and all engine test stand
gages and controls from engine.
22.
Engine (1)
Remove from engine test stand.
NOTE
Engine storage procedures are at discretion of repair facility.
TASK ENDS HERE
TA 242617
2-423
TM 5-2815-241-34&P
TROUBLESHOOTING ON ENGINE TEST STAND
GENERAL
The information contained in this paragraph is provided to help in identifying malfunctions that may
occur after assembly and during engine test stand final adjustments of the NTC-290 diesel engine.
The troubleshooting table lists common malfunctions which can occur. You should perform the tests
or inspections and corrective actions in the order listed.
This paragraph cannot list all malfunctions that may occur, or all tests, inspections, and corrective
actions. If a malfunction is not presented, or is not corrected by the listed corrective action, notify
your supervisor.
EXPLANATION OF COLUMNS
MALFUNCTION. Visual or operational indication that something is wrong with the NTC-290 diesel
engine.
TEST OR INSPECTION. Procedure to isolate the problem to a component or system.
CORRECTIVE ACTION. Procedure to correct the problem.
SYMPTOM INDEX
The symptom index is provided as a quick way to get you to the part of the troubleshooting table that will
help solve your problem. It lists all malfunctions covered in the troubleshooting table.
To use the symptom index, find the problem you are having listed in the index. Then go to the page
indicated for the troubleshooting procedure needed to help you find and correct your problem.
SYMPTOM
Page
Coolant temperature high .....................................................................................................................
Coolant temperature low .......................................................................................................................
Engine cannot reach governed rpm.. ....................................................................................................
Engine crankcase dilution.. ...................................................................................................................
Engine stops.. .........................................................................................................................................
Engine fails to start (cranking system working) ..................................................................................
Engine hard to start (cranking system working). .................................................................................
2-424
2-425
2-426
2-426
2-426
2-426
2-427
2-427
TM 5-2815-241-34&P
TROUBLESHOOTING ON ENGINE TEST STAND - CONTINUED
Page
Engine misses at high idle ....................................................................................................................
Engine misses at idle.. ...........................................................................................................................
Engine misses under load .....................................................................................................................
Engine surges at governed rpm ............................................................................................................
Excessive black smoke at idle ..............................................................................................................
Excessive black smoke under load.. .....................................................................................................
Excessive crankcase pressure.. ............................................................................................................
Excessive noise.. ....................................................................................................................................
Excessive smoke under acceleration ...................................................................................................
Excessive vibration ................................................................................................................................
Excessive white smoke at idle.. ............................................................................................................
Fuel knocks (combustion noise). ..........................................................................................................
Low oil pressure.. ...................................................................................................................................
Mechanical knocks.. ..............................................................................................................................
Oil temperature too high.. ......................................................................................................................
Sluggish engine acceleration.. ..............................................................................................................
2-427
2-428
2-428
2-429
2-429
2-429
2-430
2-430
2-431
2-431
2-431
2-432
2-432
2-433
2-433
2-433
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. COOLANT TEMPERATURE HIGH.
Step 1.
Step 2.
Step 3.
Step 4.
Check coolant level.
Refill to proper level.
Check engine oil level.
Refill crankcase to proper level.
Remove and test thermostat.
Replace defective thermostat.
Remove water pump (page 2-37). Inspect for incorrect or damaged impeller
(page 2-408).
Replace damaged or incorrect impeller.
2-425
TM 5-2815-241-34&P
TROUBLESHOOTING ON ENGINE TEST STAND - CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
2. COOLANT TEMPERATURE LOW.
Step 1.
Step 2.
Remove and test thermostat.
Replace defective thermostat.
Remove water pump (page 2-37). Inspect for incorrect impeller.
Replace incorrect impeller (page 2-408).
3. ENGINE CANNOT REACH GOVERNED RPM.
Step 1.
Step 2.
Check specifications for high-speed governor setting.
Reset high-speed governor setting.
Check injector timing (page 2-106).
Reset injector timing.
4. ENGINE CRANKCASE DILUTION.
Step 1.
Step 2.
Step 3.
Check gaskets and fuel lines for internal or external leaks.
Repair or replace leaking gaskets and fuel lines.
Remove injectors (page 2-34). Check for cracked injector cups or damaged
O-rings (page 2-289).
a. Replace cracked injector cups.
b. Replace damaged preformed packing.
Check cylinder head gaskets for internal and external leaks. Inspect cylinder
head for porous casting.
a. Replace defective gaskets (page 2-36).
b. Replace defective cylinder head (page 2-36).
5. ENGINE STOPS.
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
2-426
Check fuel shutoff valve for correct operation.
Replace defective fuel shutoff valve (page 2-289).
Check filters, gaskets, connections, and suction lines for air leaks.
Replace defective filters, leaking gaskets, hoses, and suction lines.
Remove fuel pump (page 2-41). Check for broken fuel pump drive shaft
(page 2-289).
Replace broken fuel pump drive shaft.
Disassemble fuel pump (page 2-289). Check for correct idle spring assembly.
Correct idle spring assembly and reassemble.
Disassemble fuel pump (page 2-289). Check for correct governor weight
assembly.
Correct governor weights and reassemble.
Perform engine compression check for cylinder head gasket leakage.
Replace leaking gasket.
TM 5-2815-241-34&P
TROUBLESHOOTING ON ENGINE TEST STAND - CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
6. ENGINE FAILS TO START (CRANKING SYSTEM WORKING).
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Check fuel shutoff valve for correct operation.
Replace defective fuel shutoff valve.
Check filter, gaskets, connections, and lines for air leaks.
Replace defective filter, leaking gaskets, connections, and suction
lines.
Check injector timing (page 2-106).
Reset injector timing.
Check valve adjustment (page 2-106).
Readjust valves.
Remove injectors (page 2-34). Check for damaged O-rings (page 2-289).
Replace damaged preformed packing.
7. ENGINE HARD TO START (CRANKING SYSTEM WORKING).
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Step 7.
Check filters, gaskets, connections, and lines for air leaks.
Replace defective filter, leaking gaskets, connections, and suction
lines.
Check all fuel lines for bends, breaks, or damage causing restriction.
Repair or replace all restricted fuel lines.
Check intake and exhaust manifolds for gasket leaks.
Replace leaking gaskets (page 2-272).
Check injector timing (page 2-106).
Readjust injector timing.
Check valve adjustment (page 2-106).
Readjust valves.
Remove injectors (page 2-34). Check for damaged preformed packing or
cracked injector cups (page 2-289).
Replace damaged packing.
Replace cracked injector cups.
Check engine for excessive blowby and wetness in exhaust caused by
broken or damaged rings.
Isolate damaged cylinders and replace broken or damaged rings.
8. ENGINE MISSES AT HIGH IDLE.
Step 1.
Step 2.
Step 3.
Check filter, gaskets, connections, and suction lines for air leaks.
Replace defective filter, leaking gaskets, connections, and suction
lines.
Check injector timing (page 2-106).
Reset injector timing.
Check valve adjustment (page 2-106).
Readjust valves.
2-427
TM 5-2815-241-34&P
TROUBLESHOOTING ON ENGINE TEST STAND - CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8. ENGINE MISSES AT HIGH IDLE - CONTINUED.
Step 4.
Step 5.
Remove injectors (page 2-34). Check for damaged preformed packings or
cracked injector cups (page 2-289).
Replace damaged packings.
Replace cracked injector cups.
Check engine for excessive blowby and wetness in exhaust caused by
broken or damaged rings.
Isolate damaged cylinders and replace broken or damaged rings.
9. ENGINE MISSES AT IDLE.
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Check idle speed according to specifications.
Adjust idle speed.
Check filter, gaskets, connections, and suction lines for air leaks.
Replace defective filter, leaking gaskets, connections, and suction
lines.
Check valve adjustment (page 2-106).
Readjust valves.
Check injector timing (page 2-106).
Reset injector timing.
Remove injectors (page 2-34). Check for damaged preformed packings
(page 2-289).
Replace damaged packings.
Check engine for excessive blowby and wetness in exhaust caused by broken or
damaged rings.
Isolate damaged cylinders and replace broken or damaged rings.
10. ENGINE MISSES UNDER LOAD.
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
2-428
Check all fuel lines for bends, breaks, or damage causing restriction.
Repair or replace all restricted fuel lines.
Check filter, gaskets, connections and suction lines for air leaks.
Replace defective filter, leaking gaskets, connections, and suction
lines.
Check valve adjustment (page 2-106).
Readjust valves.
Check injector timing (page 2-106).
Reset injector timing.
Remove injectors (page 2-34). Check for damaged preformed packings
(page 2-289).
Replace damaged packings.
TM 5-2815-241-34&P
TROUBLESHOOTING ON ENGINE TEST STAND – CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
10.
ENGINE MISSES UNDER LOAD – CONTINUED.
Step 6.
Step 7.
Step 8.
11.
ENGINE SURGES AT GOVERNED RPM.
Step 1.
Step 2.
12.
Check filter, gaskets, connections, and suction lines for air leaks.
Replace defective filter, leaking gaskets, connections, and suction
lines.
Perform engine compression test. Check for cylinder head gasket leakage.
Replace leaking gasket.
EXCESSIVE BLACK SMOKE AT IDLE.
Step 1.
Step 2.
Step 3.
Step 4.
13.
Check engine for excessive blowby and wetness in exhaust caused by broken or
damaged rings.
Isolate damaged cylinder and replace broken or damaged rings.
Perform engine compression test. Check for cylinder head gasket leakage.
Replace leaking head gasket.
Check intake and exhaust gaskets for leakage.
Replace leaking gaskets.
Remove injectors (page 2-34). Check for correct injector cup size
(page 2-289).
Replace incorrect injector cups.
Check for cracked injector cups (page 2-289).
Replace damaged injector cups.
Check injector timing (page 2-106).
Reset injector timing.
Check engine for excessive blowby and wetness in exhaust caused by broken or
damaged rings.
Isolate damaged cylinders and replace broken or damaged rings.
EXCESSIVE BLACK SMOKE UNDER LOAD.
Step 1.
Step 2.
Step 3.
Step 4.
Check for excessive exhaust back pressure.
Repair or replace defective turbocharger.
Check all fuel lines for bends, breaks, or damage causing restriction.
Repair or replace restricted fuel lines.
Remove injectors (page 2-34). Check for correct injector cup size
(page 2-289).
Replace incorrect injector cups.
Check for cracked injector cups (page 2-289).
Replace damaged injector cups.
2-429
TM 5-2815-241-34&P
TROUBLESHOOTING ON ENGINE TEST STAND – CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
13.
EXCESSIVE BLACK SMOKE UNDER LOAD – CONTINUED.
Step 5.
Step 6.
Step 7.
Step 8.
Step 9.
Check for damaged fuel injector preformed packings (page 2-289).
Replace damaged packings.
Check valve adjustment (page 2-106).
Readjust valves.
Check injector timing (page 2-106).
Reset injector timing.
Check engine for excessive blowby and wetness in exhaust caused by broken or
damaged rings.
Isolate damaged cylinders and replace broken or damaged rings.
Perform engine compression test. Check for cylinder head gasket leakage.
Replace leaking gasket.
14. EXCESSIVE CRANKCASE PRESSURE.
Step 1.
Step 2.
Check engine for excessive blowby and wetness in exhaust caused by broken or
damaged rings.
Isolate damaged cylinders and replace broken or damaged rings.
Perform engine compression test. Check for cylinder head gasket leakage.
Replace leaking gasket.
15. EXCESSIVE NOISE.
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
2-430
Check vibration damper and flywheel for damage or improper installation.
Replace damaged vibration damper and flywheel.
Reinstall vibration damper and flywheel correctly.
Check valve adjustment (page 2-106).
Readjust valves.
Check injector timing (page 2-106).
Reset injector timing.
Check push tubes or cam followers for damage.
Replace damaged push tubes (page 2-33) and cam followers
(page 2-47).
Check for scored pistons and cylinder sleeves.
Replace scored pistons and cylinder sleeves (page 2-214).
TM 5-2815-241-34&P
TROUBLESHOOTING ON ENGINE TEST STAND – CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
16.
EXCESSIVE SMOKE UNDER ACCELERATION.
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Step 7.
Step 8.
Step 9.
Step 10.
Check for excessive exhaust back pressure.
Repair or replace defective turbocharger (page 2-12).
Check fuel drain lines for restrictions.
Repair or replace restricted fuel drain lines.
Check for defective aneroid control valve (page 2-289).
Replace defective aneroid control valve.
Check intake and exhaust gaskets for leakage.
Replace leaking gaskets (page 2-272).
Check injector timing (page 2-106).
Reset injector timing.
Check valve adjustment (page 2-106).
Readjust valves.
Remove injectors (page 2-34). Check for correct injector cup size
(page 2-289).
Replace incorrect injector cups.
Check push tubes or cam followers for damage.
Replace damaged push tubes (page 2-33) and cam followers
(page 2-47).
Perform engine compression test. Check for cylinder head gasket leakage.
Replace leaking cylinder head gasket.
Check for scored pistons and cylinder sleeves.
Replace scored pistons and cylinder sleeves.
17. EXCESSIVE VIBRATION.
Inspect vibration damper and flywheel for damage or improper installation.
a. Replace damaged vibration damper and flywheel.
b. Reinstall vibration damper and flywheel.
18.
EXCESSIVE WHITE SMOKE AT IDLE.
Step 1.
Step 2.
Step 3.
Step 4.
Check for starting fluid build up in intake manifold.
Remove built up starting fluid.
Check for raw fuel in intake manifold.
Repair starting aid (page 2-289) and remove excess fuel.
Check for low coolant temperature or defective thermostat.
Replace defective thermostat.
Check injector timing (page 2-106).
Reset injector timing.
2-431
TM 5-2815-241-34&P
TROUBLESHOOTING ON ENGINE TEST STAND – CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
18.
EXCESSIVE WHITE SMOKE AT IDLE – CONTINUED.
Step 5.
Step 6.
19.
Check valve adjustment (page 2-106).
Readjust valves.
Remove injectors (page 2-34). Check for correct injector cup size
(page 2-289).
Replace incorrect injector cups.
FUEL KNOCKS (COMBUSTION NOISE).
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Step 7.
Check for starting fluid build up in intake manifold.
Remove built up starting fluid.
Check for excess fuel in intake manifold from starting aid.
Repair starting aid (page 2-289) and remove excess fuel.
Check filter, gaskets, connections, and suction lines for air leaks.
Replace defective filter, leaking gaskets, connections, and lines.
Check for low coolant temperature or defective thermostat.
Replace defective thermostat.
Check injector timing (page 2-106).
Reset injector timing.
Check valve adjustment (page 2-106).
Readjust valves.
Remove injectors (page 2-34). Check for damaged preformed packings
(page 2-289).
Replace damaged packings.
20. LOW OIL PRESSURE.
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
2-432
Check crankcase oil level.
Refill to proper level.
Check oil suction line for restrictions.
Repair or replace restricted line.
Check for high engine temperature or defective thermostat.
a. Replace defective thermostat.
b. Refill coolant to proper level.
Check bypass filter orifice for correct size (page 2-264).
Replace orifice with correct size.
Check for correct main and connecting rod bearing clearance (page 2-214).
Replace bearings with proper size. Repair crankshaft.
Check for main and connecting rod bearing damage (page 2-214).
a. Repair cause of damage.
b. Replace damaged main and connecting rod bearing. Repair
crankshaft.
TM 5-2815-241-34&P
TROUBLESHOOTING ON ENGINE TEST STAND – CONTINUED
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
21. MECHANICAL KNOCKS.
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
22.
Check vibration damper and flywheel for looseness and damage.
Tighten loose bolts.
Replace damaged vibration damper or flywheel.
Check push tubes and cam followers for damage.
Replace damaged push tubes (page 2-33) and cam follower
(page 2-47).
Check for broken piston rings.
Replace broken piston rings (page 2-220).
Check for scored pistons and cylinder sleeves.
Replace scored pistons (page 2-220) or cylinder sleeves
(page 2-140).
Check for correct main and connecting rod bearing clearance.
Replace bearings with proper size. Repair crankshaft (page 2-214
or 2-220).
Check for excessive crankshaft end play.
Replace thrust bearing with oversize, repair crankshaft (page 2-214).
OIL TEMPERATURE TOO HIGH.
Step 1.
Step 2.
Step 3.
Check crankcase oil level.
Refill to proper level and drain excess oil.
Check for high engine temperature or defective thermostat.
Replace defective thermostat.
Check all hoses, connections, and gaskets for leaks, allowing air into cooling
system.
Repair or replace leaking hoses, connections, and gaskets.
23. SLUGGISH ENGINE ACCELERATION.
Step 1.
Step 2.
Step 3.
Check filter, gaskets, connections, and suction lines for air leaks.
Replace defective filter, leaking gaskets, connections, and lines.
Check all fuel lines for bends, breaks, or damage causing restriction.
Repair or replaced restricted fuel lines.
Check injector timing (page 2-106).
Reset injector timing.
2-433
TM 5-2515-241-34&P
Section XVII. ENGINE SPECIFICATIONS
OVERVIEW
This section provides quick location of specifications and wear limits needed to maintain, repair, or
overhaul the diesel engine and its components. Wear limits indicate that a part may be reused at the
worn limit but must be discarded if worn limit is exceeded. Specifications are given in US standard and
metric measurements.
This section is numerically structured in repair section number order to aid in locating pertinent information for a specific system. Example: SECTION V, CRANKCASE AND CYLINDER BLOCK; SECTION
VI, CYLINDER HEAD AND VALVES, etc.
Page
Section V, Crankcase and Cylinder
Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section VI, Cylinder Head and
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section VII, Crankshaft . . . . . . . . . . . . . . . . . . . .
Section VIII, Pistons and Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section IX, Camshaft and Timing
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-434
2-436
2-437
2-438
Page
Section X, Engine Lubrication
System . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section XI, Manifolds . . . . . . . . . . . . . . . . .
Section XII, Accessory Drive . . . . . . . . . . .
Section XIII, Engine Brake . . . . . . . . . . . . .
Section XIV, Fuel System . . . . . . . . . . . . . .
Section XV, Cooling System . . . . . . . . . .
2-441
2-442
2-442
2-443
2-443
2-444
2-439
SECTION V, CRANKCASE AND CYLINDER BLOCK
WEAR LIMITS – INCH (MM)
PART OR LOCATION
Installed Camshaft Bushing Inside Diameter
Camshaft Bushing Bore in Block
Cylinder Sleeve Counterbore
Inside Diameter
Counterbore Depth
Sleeve Protrusion
Sleeve-to-Block Clearance
Lower Bore
Cylinder Block Lower Sleeve Bore
Main Bearing Bore
2-434
NEW
MINIMUM
NEW
MAXIMUM
1.999
(50.77)
2.1285
(54.064)
2.0005
(50.813)
2.1295
(54.089)
2.0015
(50.838)
2.1305
(54.115)
6.5615
(166.662)
0.350
(8.89)
0.003
(0.08)
6.5635
(166.713)
0.352
(8.94)
0.006
(0.15)
0.412
(10.46)
0.002
(0.05)
6.124
(155.55)
4.7485
(120.612)
0.008
(0.20)
6.126
(155.60)
4.750
(120.65)
WORN
LIMIT
4.7505
(120.663)
TM 5-2815-241-34&P
SECTION V, CRANKCASE AND CYLINDER BLOCK – CONTINUED
PART OR LOCATION
Cylinder Block Height From Main Bearing
Bore Center Line
From Top of Alinement Bar
Cylinder Sleeve Counterbore
Cylinder Sleeve Counterbore Shims
Part No. 143938
Part No. 143939
Part No. 143946
Part No. 143947
Part No. 143948
Part No. 143949
Cylinder Sleeve Inside Diameter
WORN
LIMIT
NEW
MINIMUM
NEW
MAXIMUM
19.004
(482.70)
16.629
(422.38)
0.350
(8.89)
19.006
(482.75)
16.631
(422.43)
0.352
(8.94)
18.994
(482.45)
16.619
(422.12)
0.412
(10.46)
0.0063
(0.160)
0.0072
(0.183)
0.0081
(0.206)
0.018
(0.46)
0.028
(0.71)
0.056
(1.42)
5.4995
(139.687)
0.007
(0.18)
0.0088
(0.223)
0.0099
(0.251)
0.022
(0.56)
0.034
(0.86)
0.068
(1.73)
5.501
(139.73)
5.505
(139.83)
NOTE
New cylinder sleeves dimensions at 60° to 70°F (160° to 21 °C); may be 0.0002 to
0.0006 inch (0.005 to 0.015 mm) smaller than indicated due to lubrite coating.
Cylinder Sleeve Protrusion
Camshaft
Journal Diameter
Camshaft Support Bushing
Camshaft Outboard Bearing Support
Gearcase Cover
Accessory Drive Bushing
Part No. 132770
Part No. 132771
Part No. 132772
0.003
(0.08)
0.006
(0.15)
1.997
(50.72)
1.3725
(34.861)
1.751
(44.48)
1.998
(50.75)
1.3755
(84.938)
1.754
(44.55)
1.996
(50.70)
1.370
(34.80)
1.757
(44.63)
1.565
(39.75)
1.555
(39.41)
1.545
(39.24)
1.569
(39.85)
1.559
(39.60)
1.549
(39.34)
1.571
(39.90)
1.561
(39.65)
1.551
(39.40)
2-435
TM 5-2815-241-34&P
SECTION V, CRANKCASE AND CYLINDER BLOCK – CONTINUED
TORQUE LIMITS – FT LB (KGM)
PART OR LOCATION
Main Bearing Capscrews
1. Tighten to
2. Advance to
3. Loosen
4. Tighten to
5. Advance to
Piston Cooling Nozzles Capscrews
MINIMUM
MAXIMUM
145 (20.05)
300 (41.49)
All
140 (19.36)
300 (41.49)
16 (22)
155 (21.44)
310 (42.87)
All
145 (20.95)
310 (42.87)
21 (28)
SECTION VI, CYLINDER HEAD AND VALVES
WEAR LIMITS – INCH (MM)
PART OR LOCATION
Height
Injector Sleeve
Top Inside Diameter
Injector Cup Protrusion
NEW
MINIMUM
NEW
MAXIMUM
4.370
(111.00)
4.380
(111.25)
1.145
(29.09)
0.060
(1.52)
1.155
(29.34)
0.070
(1.78)
Valve Seat Insert
Run-out
Valve Crossheads and Guides
Crosshead Stem Inside Diameter
Guide Outside Diameter
Guide Assembled Height
Depth Valve Stem Pocket
Valve, Guides and Springs
Valve Stem Outside Diameter
Valve Guide Inside Diameter
Valve Guide Protrusion
2-436
WORN
LIMIT
4.340
(110.24)
0.002
(0.05)
0.434
(11.02)
0.433
(10.99)
1.860
(47.24)
0.120
(3.05)
0.436
(11.07)
0.4335
(11.011)
1.880
(47.75)
0.140
(3.56)
0.440
(11.18)
0.432
(10.97)
0.450
(11.43)
0.4525
(11.493)
1.315
(33.40)
0.451
(11.46)
0.4532
(11.511)
1.325
(33.65)
0.449
(11.40)
0.455
(11.56)
TM 5-2815-241-34&P
SECTION VI, CYLINDER HEAD AND VALVES – CONTINUED
TORQUE LIMITS – PT LB (N•M)
PART OR LOCATION
Cylinder Head Capscrews
(Tighten in sequence)
Step 1
Step 2
Step 3
Step 4
MINIMUM
MAXIMUM
80 (108)
180 (244)
280 (380)
25 (34)
100 (136)
200 (271)
300 (407)
SECTION VII, CRANKSHAFT
WEAR LIMITS – INCH (MM)
PART OR LOCATION
Bearings
Standard Size (Thickness)
Main Bearing (All)
Connecting Rods (855 Series)
Journal Clearance
Main
Connecting Rods
Crankshaft Thrust Washer Thickness
Part No. 157280
Part No. 157281
Part No. 157282
Crankshaft End Clearance
Vibration Dampers
Misalinement of Index Marks
WORN
LIMIT
NEW
MINIMUM
NEW
MAXIMUM
0.123
(3.12)
0.0724
(1.839)
0.1238
(3.144)
0.0729
(1.852)
0.1215
(3.086)
0.071
(1.80)
0.0015
(0.038)
0.0015
(0.038)
0.005
(0.13)
0.0045
(0.114)
0.067
(0.18)
0.007
(0.18)
0.245
(6.22)
0.255
(6.48)
0.265
(6.73)
0.007
(0.18)
0.247
(6.27)
0.257
(6.53)
0.267
(6.78)
0.017
(0.43)
0.022
(0.56)
0.0625
(1.587)
2-437
TM 5-2815-241-34&P
SECTION VIII, PISTONS AND CONNECTING RODS
WEAR LIMITS – INCH (MM)
PART OR LOCATION
Piston Pin Bushing
Connecting Rod Length
Center to Center
NEW
MINIMUM
NEW
MAXIMUM
2.001
(50.83)
2.0015
(50.838)
11.998
(304.75)
12.000
(304.80)
Connecting Rod Alinement
Without Bushing
Twist
Without Bushing
0.020
(0.51)
0.010
(0.25)
With Bushing
Pilot OD
Bolthole Inside Diameter Pilot
855 Series Rod
Cap
Piston and Piston Rings
Piston Pin Bore
Aluminum
Piston Pin Diameter
Piston
Skirt Diameter at 70°F (21°C)
Piston Pin Bore
Inside Diameter at 70°F (21°C)
Piston Pin
Outside Diameter
2-438
2.0025
(50.863)
0.008
(0.20)
0.004
(0.10)
With Bushing
Connecting Rod Bolt (855 CID Series)
Minimum OD
WORN
LIMIT
0.541
(13.74)
0.6245
(15.852)
0.545
(13.84)
0.625
(15.87)
0.540
(13.72)
0.6243
(15.857)
0.6246
(15.865)
0.6248
(15.870)
0.6251
(15.877)
0.6249
(15.872)
0.6252
(15.880)
1.9985
(50.762)
1.9988
(50.769)
1.9989
(50.772)
1.999
(50.77)
1.999
(50.77)
1.9978
(50.754)
5.487
(139.37)
5.488
(139.40)
5.483
(139.27)
1.9985
(50.762)
1.9990
(50.775)
1.999
(50.775)
1.99875
(50.768)
1.9990
(50.775)
1.9978
(50.754)
TM 5-2815-241-34&P
SECTION VIII, PISTONS AND CONNECTING RODS – CONTINUED
PART OR LOCATION
NEW
MINIMUM
NEW
MAXIMUM
0.023
(0.58)
0.019
(0.48)
0.028
(0.71)
0.010
(0.25)
0.033
(0.85)
0.029
(0.74)
0.038
(0.97)
0.020
(0.51)
WORN
LIMIT
Piston Ring
(Gap in Ring Travel Area of Liner)
Part No. 147670
Part No. 132880
Part No. 168680
Part No. 194610
* Add 0.003-inch (0.08 mm) ring gap to new maximum limit for 0.001 (0.03) wear in cylinder liner
wall.
TORQUE LIMITS – FT LB (N•M)
PART OR LOCATION
MINIMUM
MAXIMUM
70 (95)
*140 (190)
75 (102)
*150 (203)
Completely
30 (41)
75 (102)
*150 (203)
Connecting Rod Capscrews
Step
Step
Step
Step
Step
Step
1
2
3
4
5
6
Tighten to
Advance to
Loosen all
Tighten to
Advance to
Advance to
25 (34)
70 (95)
*140 (190)
* Torque to 100 ft lb (136 N•m) with lock plates.
SECTION IX, CAMSHAFT AND TIMING SYSTEM
WEAR LIMITS – INCH (MM)
PART OR LOCATION
Camshaft Journal
Outside Diameter
NEW
MINIMUM
NEW
MAXIMUM
1.997
(50.72)
1.998
(50.75)
WORN
LIMIT
1.996
(50.70)
2-439
TM 5-2815-241-34&P
SECTION IX, CAMSHAFT AND TIMING SYSTEM – CONTINUED
WEAR LIMITS – INCH (MM) – CONTINUED
PART OR LOCATION
Rocker Arm Bushing
Inside Diameter
Rocker Arm Shaft
Outside Diameter
Cam Follower Shaft
Outside Diameter
Cam Follower Bushing
Inside Diameter
Injector Cam Roller
Inside Diameter
Injector Cam Roller
Outside Diameter
Valve Cam Rollers
Inside Diameter
Valve Cam Rollers
Outside Diameter
Cam Roller Pins
Outside Diameter
Push Rods
Ball End Radius
Push Rod Socket
Spherical Inside Diameter
NEW
MINIMUM
NEW
MAXIMUM
1.1245
(28.562)
1.1275
(28.639)
1.1286
(28.664)
1.123
(28.52)
1.124
(28.55)
1.122
(28.50)
0.7485
(19.012)
0.749
(19.02)
0.748
(19.00)
0.7495
(19.037)
0.7505
(19.063)
0.7515
(19.088)
0.503
(12.78)
0.504
(12.80)
0.505
(12.83)
1.249
(31.72)
1.251
(31.78)
1.247
(31.67)
0.5005
(12.713)
0.5015
(12.738)
0.503
(12.78)
1.249
(31.72)
1.250
(31.75)
1.247
(31.67)
0.4995
(12.687)
0.500
(12.70)
0.497
(12.62)
0.623
(15.82)
0.625
(15.87)
0.505
(12.83)
0.520
(13.21)
WORN
LIMIT
TORQUE LIMITS – FT LB (N•M)
PART OR LOCATION
Valve Crosshead Nuts Using ST669 Adapter
Rocker Arm Housing Capscrews
Rocker Arm Shaft Plugs
Straight
Tapered
2-440
MINIMUM
MAXIMUM
22 (30)
55 (75)
26 (35)
65 (88)
20 (27)
20 (27)
25 (34)
30 (41)
TM 5-2815-241-34&P
SECTION IX, CAMSHAFT AND TIMING SYSTEM – CONTINUED
PART OR LOCATION
Cam Follower Capscrews
MINIMUM
MAXIMUM
30 (41)
35 (47)
SECTION X, ENGINE LUBRICATION SYSTEM
WEAR LIMITS – INCH (MM)
PART OR LOCATION
Single Lubricating Oil Pump
(Double Capacity)
Bushing Inside Diameter
Drive Shaft
Outside Diameter
Idler Shaft
Outside Diameter
NEW
MINIMUM
NEW
MAXIMUM
WORN
LIMIT
0.8767
(22.268)
0.8777
(22.293)
0.879
(22.33)
0.8745
(22.212)
0.875
(22.22)
0.873
(22.17)
0.8745
(22.212)
0.875
(22.22)
0.873
(22.17)
0.012
(0.30)
0.002
(0.05)
0.008
(0.020)
Drive Gear to Body
Drive Shaft End Play
Idler Shaft
Protrusion Above Body to Cover Face
Driven Gear and Driving Gear Shaft
Protrusion
Piston Cooling Nozzle Tube
Protrusion Above Body Mounting Face
0.955
(24.26)
1.035
(26.29)
1.055
(26.80)
2.970
(75.44)
3.000
76.20)
TORQUE LIMITS – FT LB (N•M)
PART OR LOCATION
Oil Pump Mounting Capscrew
Piston Cooling Nozzle Capscrew
MINIMUM
MAXIMUM
35 (47)
16 (22)
45 (61)
21 (28)
2-441
TM 5-2815-241-34&P
SECTION Xl, MANIFOLDS
TORQUE LIMITS – FT LB (N•M)
PART OR COMPONENT
Exhaust Manifold Capscrews
7/16-inch Capscrew with Washer
3/8-inch Stud
Intake Manifold
MINIMUM
MAXIMUM
20 (27)
20 (27)
40 (54)
25 (34)
25 (34)
SECTION XII, ACCESSORY DRIVE
WEAR LIMIT – INCH (MM)
PART OR LOCATION
Accessory Drive Bushing
Inside Diameter
Accessory Drive Shaft
Outside Diameter
End Clearance
NEW
MINIMUM
NEW
MAXIMUM
1.312
(33.32)
1.315
(33.40)
1.31
(33.55)
1.3115
(33.312)
0.005
(0.13)
1.312
(33.32)
0.010
(0.25)
1.310
(33.27)
Accessory Drive Bushing
Out-of-Round
WORN
LIMIT
0.002
(0.05)
TORQUE LIMIT – FT LB (N•M)
PART OR COMPONENT
Accessory Drive Pulley
Accessory Drive Capscrews
2-442
MINIMUM
MAXIMUM
90 (122)
40 (54)
loo (136)
45 (61)
TM 5-2815-241-34&P
SECTION XIII, ENGINE BRAKE
ADJUSTMENT – INCH (MM)
PART OR COMPONENT
MINIMUM
MAXIMUM
.018 (.46)
Slave Piston and Crosshead Clearance
TORQUE – FT LB (N•M)
PART OR COMPONENT
Adjusting Screw Locknut
Rocker Arm Housing Stud
Engine Brake Housing Nuts
MINIMUM
MAXIMUM
15 (20.3)
65 (88)
55 (75)
18 (24.4)
75 (102)
60 (81)
SECTION XIV, FUEL SYSTEM
TORQUE LIMITS – FT LB (NOM)
PART COMPONENT
Fuel Pump
Spring Pack Capscrews
Fuel Filter
Brass Filter Fittings
Gear Pump Capscrew
Filter Bracket Capscre
Mounting Capscrews
Throttle Shaft Plug
Fuel Injector
cups
Mounting Capscrews
Orifice Plug
MINIMUM
MAXIMUM
9 (12)
20 (27)
30 (41)
11 (15)
20 (27)
30 (41)
40 in. lb (4.5)
11 (15)
25 (34)
40 (54)
13 (18)
30 (41)
35 (47)
55 in. lb (6.2)
10 (14)
8 in. lb (0.9)
55 (75)
12 (16)
10 in. lb (1.1)
2-443
TM 5-2815-241-34&P
SECTION XV, COOLING SYSTEM
WEAR LIMITS – INCH (MM)
NEW
MINIMUM
PART OR COMPONENT
NEW
MAXIMUM
WORN
LIMIT
Water Pump Impeller to Shaft
Press Fit
0.001
(0.03)
Impeller to Body
Clearance
Fan Hub
End Clearance
0.020
(0.51)
0.040
(1.02)
0.003
(0.08)
0.010
(0.25)
Bearing to Shaft
Press Fit
0.001
(0.03)
Idler Pulley Bearing to Shaft
0.003
(0.51)
THERMOSTAT OPERATING RANGES
RANGE
BEGINS
OPENING
Low
Medium
High
160°F (71°C)
175°F (79°C)
180°F (82°C)
FULLY
OPEN
175°F (79°C)
185°F (85°C)
195°F (91°C)
TORQUE LIMITS – FT LB (N•M)
PART OR LOCATION
Water Pump Capscrews
Water Header Plates
Idler Pulley
Water Manifold
2-444
MINIMUM
MAXIMUM
30 (41)
8 (11)
12 (16)
30 (41)
35 (47)
10 (14)
15 (20)
35 (47)
TM 5-2815-241-34&P
APPENDIX A
REFERENCES
A-1.
SCOPE.
This appendix lists forms, field manuals, technical manuals, and other publications referenced in this manual and
which apply to direct and general support maintenance of NTC-290 Diesel Engine.
A-2.
PUBLICATION INDEX.
DA Pam 25-30, Consolidated Index of Army Publications and Blank Forms, should be consulted frequently for latest
changes or revisions and for new publications relating to materiel covered in this technical manual.
A-3.
FORMS.
Refer to DA Pam 738-750, The Army Maintenance Management System (TAMMS) for instructions on the use of
Maintenance Forms.
Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Log Assembly (Records) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Request Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Material Condition Status Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Processing and Deprocessing Record for Shipment, Storage
and Issue of Vehicles and Spare Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Changes to Equipment Technical Publications . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Changes to Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4.
FM 55-30
FM 21-10
FM 21-11
FM 10-16
FM 3-3
FM 3-5
FM 3-4
FM 9-207
TECHNICAL BULLETINS.
Color, Marking, and Camouflage Painting of Military Vehicles,
Construction Equipment, and Materials Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Improvement Report and Maintenance Digest
(U.S. Army Tank-Automotive Command) Tank Automotive Equipment Series . . . . . . . . . . . . .
Maintenance in the Desert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soldering Methods and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-6.
DD Form 1397
SF 368
DA Form 2028-2
DA Form 2028
FIELD MANUALS.
Army Motor Transport Units and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Hygiene and Sanitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid for Soldiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Fabric Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NBC Contamination Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NBC Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NBC Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation and Maintenance of Ordnance Materiel in Cold Weather (O° to –65°F) . . . . . . . . . .
A-5.
DA Form 2404
DA Form 2408
DA Form 2407
DA Form 2406
TB 43-0209
TB 43-0001-39
TB 43-0239
TB SIG 222
TECHNICAL MANUALS.
Inspection Methods, Non-Destructive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection, Care, and Maintenance of Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM 55-1500-335-23
TM 9-214
Change 1
A-1
TM 5-2815-241-34&P
A-6.
TECHNICAL MANUALS-Continued.
Materials Used for Cleaning, Preserving, Abrading, and Cementing
Ordnance Materiel and Related Items Including Chemicals . . . . . . . . . . . . . . . . . . . . . .
Organizational Support Maintenance Manual, Truck, Dump, 20-Ton, 6x4 . . . . . . . . . . . . . . . . . .
Organizational Maintenance Repair Parts and Special Tools Lists, Truck, Dump,
20-Ton,6x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Support and General Support Maintenance Manual, Truck, Dump,
20-Ton,6x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Support and General Support Maintenance Repair Parts and
Special Tools Lists, Truck, Dump, 20-Ton, 6x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator’s Manual for Welding Theory and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Painting Instructions for Army Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use . . . . . . . . .
Storage and Materials Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-7.
TM 9-247
TM 5-3805-254-20
TM 5-3805-254-20P
TM 5-3805-254-34
TM
TM
TM
TM
TM
5-3805-254-34P
9-237
43-0139
750-244-6
743-200-1
OTHER PUBLICATIONS.
Army Logistics Readiness and Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 700-138
Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items) . . . . . CTA 50-970
Lubrication Order, Truck, Dump, 20-Ton, 6x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LO 5-3805-254-12
A-2
Change 1
TM 5-2815-241-34&P
APPENDIX B
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Section I. INTRODUCTION
B-1.
SCOPE.
This appendix lists expendable/durable supplies and materials you will need to operate and maintain the
semitrailers. This listing is for informational purposes only and is not authority to requisition the listed items. These
items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V, Repair Parts, and
Heraldic Items), or CTA 8-100, Army Medical Department Expendable/Durable Items.
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” of maintenance paragraphs or narrative instructions to identify the material needed (e.g., Dry cleaning
solvent, Item 16, Appendix B).
b. Column (2), Level. This column identifies the lowest level of maintenance that requires the listed item.
C - Operator/Crew
O - Organizational Maintenance
F - Direct Support Maintenance
H -General Support Maintenance
c. Column (3), National Stock Number. This is the National Stock Number assigned to the item. Use it to
request or requisition the item.
d. Column (4), Description. Indicates the Federal item name and, if required, a description to identify the
item. me last line for each item indicates the Commercial and Government Entity (CAGE) Code in parentheses
followed by the part number, if applicable.
e. Column (5), Unit of Measure (U/M). Indicates the measure used in performing the actual maintenance
function. This measure is expressed by a two-character 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 your requirements.
Change 1
B-1
TM 5-2815-241-34&P
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
(1)
(2)
(3)
(4)
(5)
Item
dumber
Level
National
Stock Number
Description
(CAGE) Part Number
U/M
1
O
5350-00-192-5050
Cloth: Abrasive
50-Sheet Package
(58536) A-A-1048
ea
2
O
9150-00-398-4170
Grease: Special Purpose and Lubricant
1-Pound Can
(07644) 25-10MS
lb
3
O
6850-00-181-7929
Antifreeze: Permanent, Ethylene Glycol, Inhibited
(81348) MIL46153
gal
4
O
5350-00-221-0872
Cloth: Abrasive
50-Sheet Package
(81348) A-A-1206
sh
5
F
9150-00-663-1360
Cutting Fluid: Lapping
1-Quart Can
(92663) KS9595
St
6
O
7930-00-282-9699
Detergent: Liquid, GP, WS
1-Gallon Can
(81349) MIL-D-16791
gal
7
F
6820-00-0014192
Dye: Leak-Detection
1-Gallon Can
(81349) MIL-D-81298
gal
8
O
9150-00-698-2382
Fluid: Transmission, Automatic (AFT)
A-A Service Protection
1-Quart Can
(12204) 4271243
St
9
O
9150-00-270-0067
Oil: Gear, GO 85W/140
5-Gallon Can
(81348) VV-L-765
gal
10
F
9150-01-147-3600
Grease: Extreme-Pressure
16-Ounce Aerosol Can
(52203) 91491
02
11
O
9140-00-286-5294
Fuel: Diesel DF-2 Regular
(81348) VV-F-800
gal
B-2
Change 1
TM 5-2815-241-34&P
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST-Continued
(1)
(2)
(3)
(4)
(5)
Item
Number
Level
National
Stock Number
Description
(CAGE) Part Number
U/M
12
0
Oil: Lubricating, OE/HDO 30
(81349) MIL-L-2104C
9150-00-186-6681
9150-00-188-9858
9150-00-189-6729
1 -Quart Can Type 1
5-Gallon Can
55-Gallon Drum
qt
gal
gal
13
F
8010-00-652-3626
Paste: Prussian Blue
(81349) MIL-P-30501
OZ
14
C
7920-00-205-1711
Rags: Wiping 50-Pound Bale
(58536) A-A-2522
ea
15
C
9150-00-281-1893
Soap: Lubricating
1 Package Quantity, Stick, Package Type
(24446) 181A8705POO1
OZ
16
O
Solvent: Dry Cleaning, Type II
(81348) P-D-680
6850-00-281-1985
6850-00-285-8012
1-Gallon Can
55-Gallon Can
gal
gal
17
O
9905-00-537-8954
Tags: Marker
Box of 50
(81349) MIL-T-12755
ea
18
O
8030-00-889-3535
Tape: Antiseizing, Pipe-Joint Sealer
1/2-inch Wide, 260 inches Long
(76381) 4B
ft
19
O
7510-00-473-9513
Tape: Pressure Sensitive, Adhesive
e-inch Wide
(81349) MIL-T-23397
ft
20
F
4910-00-779-6851
Oil: Test, Injector
(33287) J-26400-5B
OZ
21
F
9505-00-684-4843
Wire: Locking
1-Pound Roll
(72452) 1459-262
lb
Change 1
B-3/(B-4 blank)
TM 5-2815-241-34&P
APPENDIX C
REPAIR PARTS AND SPECIAL TOOLS LISTS
Section I. INTRODUCTION
C-1.
SCOPE.
This RPSTL lists and authorizes spares and repair parts; special tools; special test, measurement, and
diagnostic equipment (TMDE); and other special support equipment required for performance of Direct Support and
General Support Maintenance of the Diesel Engine. It authorizes the requisitioning, issue, and disposition of spares,
repair parts and special tools as indicated by the source, maintenance and recoverability (SMR) codes.
C-2. GENERAL.
in addition to Section I, Introduction, this Repair Parts and Special Tools List is divided into the following
sections:
a. Section ii. Repair Parts List. A list of spares and repair parts authorized by this RPSTL for use in the
performance of maintenance. The list also includes parts which must be removed for replacement of the authorized
parts. Parts lists are composed of functional groups in ascending alphanumeric sequence, with the parts in each group
listed in ascending figure and item number sequence. Bulk materiels are listed in item name sequence. Repair parts
kits are listed separately in their own functional group within Section Ii. Repair parts for reparable special tools are also
listed in this section. Items listed are shown on the associated iIiustration(s)/figure(s).
b. Section iii. Special Tools List. A list of special tools, special TMDE, and other special support equipment
authorized by this HPSTL [as indicated by Basis of issue (BOI) information in the DESCRIPTION AND USABLE ON
CODE column] for the performance of maintenance.
c. Section IV. Cross-reference indexes. A list, in National Item Identification Number (NIIN) sequence, of
ail National stock numbered items appearing in the listing, followed by a list in alphanumeric sequence of all part
numbers appearing in the listings. National stock numbers and part numbers are cross-referenced to each
illustration/figure and item number appearance. The figure and item number index lists figure and item numbers in
alphanumeric sequence and cross-references NSN, CAGE, and part numbers.
C-3.
EXPLANATION OF COLUMNS (SECTIONS ii AND iii).
a.
ITEM NO. [Column (1)]. indicates the number used to identify items called out In the illustration.
b. SMR CODE (Column (2)]. me Source, Maintenance, and Recoverability (SMR) code is a 5-position code
containing supply/requisitioning information, maintenance category authorization criteria, and disposition instruction,
as shown in the following breakout:
*Complete Repair: Maintenance capacity, capability, and authority to perform all corrective maintenance tasks of the “Repair” function in a
use/user environment in order to restore serviceability to a failed item.
Change 1
C-1
TM 5-2815-241-34&P
C-3.
EXPLANATION OF COLUMNS (SECTIONS II AND Ill) – Continued.
(1) Source Code. The source code tells you how to get an item needed for maintenance, repair, or
overhaul of an end item/equipment. Explanations of source codes follow:
Code
PA
PB
PC**
PD
Application/Explanation
Stocked items; use the applicable NSN to request/requisition Items
with these source codes. They are authorized to the category
indicated by the code entered in the 3d position of the SMR code.
PE
PF
PG
** Items coded PC are subject to deterioration
........................................................
KD
KF
KB
Items with these codes are not to be requested/requisitioned
Individually. They are pan of a kit which is authorized to the
maintenance category indicated In the 3d position of the SMR code.
The complete kit must be requisitioned and applied.
........................................................
MO - Made at UM/AVUM
Level
MF - Made at DS/AVUM
Level
MH - Made at GS Level
MD - Made at Depot
items with these codes are not to be requested/requisitioned
individually. They must be made from bulk materlel which is Identified
by the part number in the DESCRIPTION AND USABLE ON CODE
(UOC) column and listed in the bulk materiel group of the repair parts
list in this RPSTL. If the item is authorized to you by the 3d position
code of the SMR code, but the source code indicates it is made at a
higher level, order the item from the higher level of maintenance.
........................................................
AO - Assembled by UM/
AVUM Level
AF - Assembled by DS/
AVUM Level
AH - Assembled by GS
Level
AD - Assembled at Depot
Items with these codes are not to be requested/requisitioned
individually. The pans that make up the assembled item must be
requisitioned or fabricated and assembled at the level of maintenance
indicted by the source code. If the 3d position code of the SMR code
authorizes you to replace the item, but the source code indicates that
the item is assembled at a higher level, order the item from the higher
level of maintenance.
NOTE
Cannibalization or controlled exchange, when authorized, may be used as a source of
supply for items with the above source codes, except for those source coded ‘XA.”
XA - DO NOT requisition an ‘XA-coded item. Order its next higher assembly.
XB - If an “XB” item is not available from salvage, order it using the CAGE and pan number given.
C-2
Change 1
TM 5-2815-241-34&P
C-3.
EXPLANATION OF COLUMNS (SECTIONS II AND Ill) –Continued.
XC - Installation drawing, diagram, instruction sheet, field service drawing, that is identified by manufacturer’s part
number.
XD - Item is not stocked. Order an “XD”-coded item through normal supply channels using the CAGE and part
number given, if no NSN is available.
(2) Maintenance Code. Maintenance codes tell you the level(s) of maintenance authorized to use and
repair support items. The maintenance codes are entered in the third and fourth positions of the SMR code as follows:
(a)
The maintenance code entered in the third position tetls you the lowest maintenance level
authorized to remove, replace, and use an item. The maintenance code entered in the third
positlon will indicate authorization to one of the following levels of maintenance.
Application/Explanation
Code
- Crew or operator maintenance done within unit maintenance or aviation unit
maintenance.
- Unit maintenance or aviation unit can remove, replace, and use the item.
- Direct support or aviation intermediate level can remove, replace, and use
the Item.
- General support level can remove, replace, and use the item.
- Specialized repair activity can remove, replace, and use the item.
- Depot level can remove, replace, and use the item.
C
0
F
H
L
D
NOTE
Some limited repair may be done on the Item at a lower level of maintenance, If
authorized by the Maintenance Allocation Chart (MAC) and SMR codes.
(b)
Code
O
F
H
L
D
Z
B
The maintenance code entered In the fourth position tells whether or not the item is to be
repaired and identifies the lowest maintenance level with the capability to do complete repair
(i.e., perform all authorized “Repair” functions). This position will contain one of the following
maintenance codes:
Application/Explanation
- Unit maintenance or aviation unit is the lowest level that can do complete
repair of the item.
- Direct support or aviation intermediate is the lowest level than can do complete repair of the item.
- General support is the lowest level that can do complete repair of the item.
- Specialized repair activity is the lowest level that can do complete repair of
the item.
- Depot is the lowest level that can do complete repair of the item.
- Nonreparable. No repair is authorized.
- No repair is authorized. (No parts or special tools are authorized for the
maintenance of a “B”-coded item.) However, the item may be reconditioned
by adjusting, lubricating, etc., at the user level.
Change 1
C-3
TM 5-2815-241-34&P
C-3. EXPLANATION OF COLUMNS (SECTIONS II AND Ill) -Continued.
(3) Recoverability Code. Recoverability codes are assigned to items to indicate the disposition action
on unserviceable items. The recoverability code is entered in the fifth position of the SMR code as follows:
Code
Z
Application/Explanation
- Nonreparable item. When unserviceable, condemn and dispose of the
item at the level of maintenance shown in the 3d position of the SMR
code.
- Reparable item. When uneconomically reparable, condemn and dispose of the Item at unit maintenance or aviation unit level.
- Reparable item. When uneconomically reparable, condemn and dispose of the item at the direct support or aviation intermediate level.
- Reparable item. When uneconomically reparable, condemn and dispose of the item at the general support level.
- Reparable item. When beyond lower level repair capability, return to depot. Condemnation and disposal of item not authorized below depot
level.
- Reparable item. Condemnation and disposal of item not authorized below specialized repair activity (SRA).
- Item requires special handling or condemnation procedures because of
specific reasons (e.g., precious metal content, high dollar value, critical
material, or hazardous material). Refer to appropriate manuals/directives for specific instructions.
O
F
H
D
L
A
c. CAGEC [Column (3)]. The Commercial and Government Entity (CAGE) Code (C) is a 5-digit
alphanumeric code which is used to identify the manufacturer, distributor, or Government agency, etc., that supplies
the item.
NOTE
When you use an NSN to requisition an Item, the Item you receive may have a different
part number from the part ordered.
d. PART NUMBER [Column (4)]. Indicates the primary number used by the manufacturer (individual,
company, firm, corporation, or Government activity), which controls the design and characteristics of the item by
means of its engineering drawings, specifications standards, and inspection requirements to identify an item or range
of items.
e. DESCRIPTION AND USABLE ON CODE (UOC) [Column (5)]. This column includes the following
information:
(1)
The Federal item name and, when required, a minimum description to identify the item.
(2)
Physical security classification. Not Applicable.
(3)
Items that are included in kits and sets are listed below the name of the kit or set on Figure KIT.
(4)
item line entry.
Spare/repair parts that make up an assembled item are listed immediately following the assembled
(5) Pan numbers for bulk materiels are referenced in this column in the line item entry for the item to be
manufactured/fabricated.
(6) When the item is not used with all serial numbers of the same model, the effective serial numbers are
shown on the last line(s) of the description (before UOC). Not Applicable.
(7)
C-4
me usable on code, when applicable (see paragraph C-5, Special Information).
Change 1
TM 5-2815-241-34&P
C-3.
EXPLANATION OF COLUMNS (SECTIONS II AND Ill) -Continued.
(8) In the Special Tools List section, the Basis of Issue (BOI) appears as the last line(s) -in the entry for
each special tool, special TMDE, and other special support equipment. When density of equipments supported
exceeds density spread indicated in the Basis of Issue, the total authorization is increased proportionately.
(9) The statement “END OF FIGURE” appears just below the last item description in Column 5 for a given
figure in both Section II and Section Ill.
f. QTY [Column (6)]. The QTY (quantity per figure) column indicates the quantity of the item used in the
breakout shown on the illustration/figure, which is prepared for a functional group, subfunctional group, or an
assembly. A “V” appearing in this column in lieu of a quantity indicates that the quantity is variable and the quantity may
vary from application to application.
C-4.
EXPLANATION OF COLUMNS (SECTION IV).
a. National Stock Number (NSN) Index.
(1)STOCK NUMBER column. This column lists the NSN by National Item Identification Number (NIIN)
digits
of the
(i.e.,
NIIN
c o n s i s t s o f the
last
nine
NSN
sequence. The
NSN
5305-01-674-1467). When using this column to locate an item, ignore the first 4 digits of the NSN. HowevNIIN
er, the complete NSN should be used when ordering items by stock number.
(2) FIG. column. This column lists the number of the figure where the item is identified/located. The
figures are in numerical order in Section II and Section III.
(3) lTEM column. me item number identifies the item associated with the figure listed in the adjacent
FIG. column. This item is also identified by the NSN listed on the same line.
b. Part Number Index. Part numbers in this index are listed by part number in ascending alphanumeric
sequence (i.e., vertical arrangement of letter and number combination which places the first letter or digit of each group
in order A through Z, followed by the numbers 0 through 9 and each following letter or digit in like order).
(1) CAGEC column. The Commercial and Government Entity (CAGE) Code (C) is a 5-digit alphanumeric
code used to identify the manufacturer, distributor, or Government agency, etc., that supplies the item.
(2) PART NUMBER column. Indicates the primary number used by the manufacturer (individual, firm,
corporation, or Government activity), which controls the design and characteristics of the item by means of its
engineering drawings, specifications standards and inspection requirements to identify an item or range of items.
(3) STOCK NUMBER column. This column lists the NSN for the associated part number and
manufacturer identified in the PART NUMBER and CAGE columns to the left.
(4) FIG. column. This column lists the number of the figure where the item is identified/located in Section
II and Section Ill.
(5) lTEM column. me item number is that number assigned to the item as it appears in the figure
referenced in the adjacent figure number column.
c.
Figure and Item Number Index.
(1) FIG. column. This column lists the number of the figure where the item is identified/located in
Sections II and III.
(2) lTEM column. me item number is that number assigned to the item as it appears in the figure
referenced in the adjacent figure number column.
(3)
STOCK NUMBER column. This column lists the NSN for the item.
Change 1
C-5
TM 5-2815-241-34&P
C-4.
EXPLANATION OF COLUMNS (SECTION IV) – Continued.
(4) CAGE column The Commercial and Government Entity (CAGE) is a 5-digit alphanumeric code used
to identify the manufacturer, distributor, or Government agency, etc., that supplies the item.
(5) PART NUMBER column. Indicates the primary number used by the manufacturer (individual, firm,
corporation, or Government activity), which controls the design and characteristics of the item by means of its
engineering drawings, specifications standards and inspection requirements to identify an item or range of items.
C - 5 . SPECIAL INFORMATION.
a. Usable On Code. me usable on code appears in the lower left corner of the Description column heading.
Not Applicable.
b. Fabrication Instructions. Bulk materiels required to manufacture items are listed in the Bulk Materiel
Functional Group of this RPSTL. Part numbers for bulk materiels are also referenced in the DESCRIPTION column of
the line item entry for the item to be manufactured/fabricated. Detailed fabrication instructions for items source coded
to be manufactured or fabricated are found in Appendix D of this manual.
c. Assembly Instructions. Detailed assembly instructions for items source coded to be assembled from
component spare/repair parts are found in Chapter 2. Items that make up the assembly are listed immediately
following the assembly item entry or reference is made to an applicable figure.
d.
Kits. Line item entries for repair parts kits appear in group 9401 in Section II.
e. Index Numbers. Items which have the word BULK in the FIG. column will have an index number shown in
the item column. This index number is a cross-reference between the National Stock Number/Part Number Index and
the bulk materiel list in Section II.
f. Associated Publications. The publications listed below pertain to the NTC-290 Diesel Engine, the 20-Ton
Dump Truck, and their components:
Publication
LO 5-3805-254-12
TM 5-3805-254-10
TM 5-3805-254-20-1
TM 5-3805-254-20-2
TM 5-3805-254-20P
TM 5-3805-254-34
TM 5-3805-254-34P
C-6.
Short Title
Truck, Dump
IHC Model F-5070
Truck, Dump
IHC Model F-5070
Truck, Dump
IHC Model F-5070
Truck, Dump
IHC Model F-5070
Truck, Dump
IHC Model F-5070
Truck, Dump
IHC Model F-5070
Truck, Dump
IHC Model F-5070
(CCE)
(CCE)
(CCE)
(CCE)
(CCE)
(CCE)
(CCE)
HOW TO LOCATE REPAIR PARTS.
a. When National Stock Number or Part Number Is Not Known:
(1) First. Using the Table of Contents, determine the assembly group or subassembly group to which the
item belongs. This is necessary since figures are prepared for assembly groups and subassembly groups, and listings
are divided into the same groups.
(2)
Second. Find the figure covering the assembly group or subassembly group to which the item
(3)
Third. Identify the item on the figure and use the Figure and Item Number Index to find the NSN.
belongs.
C-6
Change 1
TM 5-2815-241-34&P
C-6.
HOW TO LOCATE REPAIR PARTS–Continued.
b. When National Stock Number or Part Number Is Known:
(1) First. Using the National Stock Number or Part Number Index, find the pertinent National Stock
Number or Part Number. The NSN Index Is in National Item Identification Number (NIIN) sequence [see paragraph
C-4.a(1)]. The part numbers in the Part Number Index are listed in ascending alphanumeric sequence (see paragraph
C-4.b). Both indexes cross-reference you to the illustration/figure and item number of the item you are looking for.
(2) Second. Turn to the figure and item number, verify that the item is the one you’re looking for, then
locate the item number in the repair parts list for the figure.
C-7. ABBREVIATIONS.
For standard abbreviations see MIL-STD-12D, Military Standard Abbreviations for Use on Drawings,
Specifications, Standards, and in Technical Documents.
Abbreviations
Explanation
NIIN . . . . . . . . . . . . . . . . . . National Item Identification Number
(consists of the last 9 digits of the NSN)
RPSTL . . . . . . . . . . . . . . . . Repair Parts and Special Tools Lists
Change 1
C-7
SECTION II
TM 5-2815-241-34&P CO1
FIGURE 1. ENGINE MOUNTING BRACKETS.
SECTION II
TM5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
(b)
ITEM
NO.
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
2
1
XDHHH
2
2
PAFZZ
2
3
2
(1)
ILLUSTRATION
(a)
FIG.
NO.
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0101-CRANKCASE, BLOCK, CYLINDRT HEAD
89346
AR09911
BLOCK, CYLINDER
EA
1
5305-00-942-2196
96906
MS18154-60
.SCREW, CAP, HEXAGON H
EA
4
PAHZZ
5310-00-261-340
96906
MS35338-8
.WASHER, LOCK
EA
4
4
PAFZZ
2815-00-404-2747
15434
158145
.COVER, ACCESS
EA
1
2
5
PAHZZ
2815-00-064-4398
15434
213740
.CYLINDER, SLEEVE
EA
6
2
5
XDHZZ
15434
202226
.SLEEVE, SALVAGE
EA
6
2
6
PAHZZ
5305-00-230-1939
15434
S118A
.SCREW
EA
12
2
7
PAHZZ
5310-00-159-6209
96906
MS122032
.WASHER, LOCK
EA
12
2
8
XDHZZ
89346
210895
.COVER WATER HEADER
EA
1
2
9
PAHZZ
5330-00-537-2382
15434
70089-1
.GASKET WATER HEADER COVER PART OF KIT P/N 3018762
EA
3
2
10
PAHZZ
5330-01-145-5377
15434
3007442
.PACKING, PREFORMED PART OF KIT P/N 3018762
EA
6
2
11
XDHZZ
89346
211475
.NOZZLE
EA
6
2
12
PAHZZ
96906
MS35338-45
.WASHER, LOCK
EA
6
2
13
XDHZZ
89346
S102A
.SCREW, CAP, HEXAGON HEAD
EA
6
2
14
PAHZZ
2930-00-799-0843
15434
132019
.COVER, WATER HEADER
EA
1
2
15
PAHZZ
4730-00-044-4715
15434
S962
.PLUG, PIPE
EA
1
2
16
XDHZZ
15434
191079
.SLEEVE, WATER, PASSAG
EA
V
2
17
PAHZZ
5315-00-014-1284
24617
141284
.PIN, STRAIGHT, HEADLE FLYWHEEL HOUSING
EA
2
2
18
PAHZZ
5315-00-014-1195
15434
658585
.PIN, STRAIGHR, HEADLE, CAM FOLLOWER TO BLOCK
HOUSING
EA
6
2
19
PAHZZ
2815-00-484-8359
15434
42645
EA
3
EA
3
EA
1
EA
14
EA
14
EA
2
EA
2
EA
2
EA
1
EA
1
5310-00-407-9566
.CAP, MAIN BEARING NO.1, 3, 5
2
19
PAHZZ
3130-00-408-9041
15434
42646
.CAP, PILLOW BLOCK NO. 2, 4, 6
2
19
PAHZZ
2815-00-484-8360
15434
42647
.CAP, MAIN BEARING NO.7
2
20
PAHZZ
5310-00-356-1447
15434
3009213
.LOCK, PLATE
2
21
PAHZZ
5306-00-804-2468
15434
105953
.BOLT, MACHINE HEAD MAIN BEARING CAP
2
22
PAHZZ
5315-00-532-9388
19207
5329388
.PIN, STRAIGHT, HEADLE MAIN BARING TO BLOCK
2
23
PAHZZ
4730-00-018-9566
15434
S911B
.PLUG, PIPE
2
24
PAHZZ
4730-00-801-8186
15434
S-915-A
.PLUG, PIPE
2
25
PAHZZ
5365-01-150-6257
15434
210884
.PLUG, MACHINE THREAD .875 THREAD
2
26
PAHZZ
2815-00-772-9434
15434
70653
.DOWEL, DIAMOND, GEAR COVER
C-9
TM 5-2815-241-34&P
(1)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
ILLUSTRATION
(b)
ITEM
NO.
(a)
FIG.
NO.
SECTION II
(2)
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
2
0101 (CONT)
2
27
PAHZZ
4730-00-057-5555
96906
MS49005-6
.PLUG, PIPE
EA
4
2
28
PAHZZ
5315-00-238-0882
15434
60408
.PIN, STRAIGHT, HEADLE GEAR COVER
EA
1
2
29
PAHZZ
5315-01-058-4551
15434
202903
.PIN, STRAIGHT HEXAGO
EA
2
2
30
PAHZZ
5315-00-281-7610
15434
68445
.PIN, GROOVED, HEADLE HEAD TO BLOCK
EA
6
2
31
PAHZZ
5330-00-058-1767
15434
149105PC183049
.PACKING, PREFORMED
EA
6
2
32
PAFZZ
5330-00-246-0309
79150
26384
.GASKET COVER TO BLOCK PART OF KIT P/N 3018762
EA
1
2
33
PAHZZ
5330-01-049-0466
15434
3008998
.PACKING
EA
6
2
34
PAHZZ
5330-00-064-4399
15434
215090
.GASKET
EA
6
2
35
XDHZZ
15434
153938
.SHIM .007 IN. THK
EA
1
2
35
PAHZZ
15434
3019956
.SPACER, RING .008 IN. THK
EA
1
2
35
XDHZZ
15434
143946
SHIM .009 IN., THK
EA
1
2
35
PAHZZ
15434
143947
SPACER, RING .020 IN. THK
EA
1
2
35
XDHZZ
15434
143948
SPACER, RING .031 IN. THK
EA
1
2
35
XDHZZ
15434
143919
SPACER, RING .062 IN. THK
EA
1
C-10/(11 blank)
5365-00-488-0799
5365-01-086-8214
TM 5-2815-241-34&P
FIGURE 3. CYLINDER HEAD.
C-12
SECTION II
(1)
TM1-1520-248-23P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
ILLUSTRATION
(a)
FIG.
NO.
(b)
ITEM
NO.
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0101 (CONT)
3
1
PAFHH
2815-01-080-0642
15434
300809
CYLINDER HEAD, DIESE
EA
3
3
2
PAFZZ
5310-00-962-5610
15434
69699
.WASHER, FLAT
EA
12
3
3
PAFZZ
5305-00-006-8411
15434
209700
.SCREW
EA
12
3
4
PAHZZ
5365-00-404-2934
15434
S965E
.PLUG, PIPE
EA
3
3
5
PAHZZ
4730-00-289-4770
15434
S995
.PLUG, PIPE
EA
6
3
6
PAHZZ
4730-00-044-4715
15434
S962
.PLUG, PIPE
EA
2
3
7
PAFZZ
5330-01-080-5021
15434
3036126
.GASKET CYLINDER HEAD PART OF KIT P/N 3801330
EA
1
3
8
PAFZZ
5330-00-129-9349
15434
193949
.GASKET
EA
21
3
9
PAHZZ
5340-00-721-5329
00905
H524018
.PLUG, FUSIBLE
EA
1
3
10
PAHZZ
4730-00-018-9566
15434
S911B
.PLUG, PIPE
EA
4
3
11
PAHZZ
2815-00-739-6048
15434
3008100
.CYLINDER HEAD, DIESE
EA
1
C-13
TM 5-2815-241-34&P
FIGURE 4. CRANKSHAFT, GEARS AND BEARINGS.
C-14
SECTION II
(1)
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
ILLUSTRATION
(a)
FIG.
NO.
(b)
ITEM
NO.
(7)
U/M
USABLE
ON
CODE
0102-CRANKSHAFT
4
1
XDFZZ
4
2
PAFZZ
4
3
XDFZZ
4
4
PAFZZ
4
5
4
15434
212113
SCREW, CAP, HEXAGON HEAD
96906
MS35338-50
WASHER, LOCK
15434
211914
DAMPER, VIBRATION
3020-01-077-4411
15434
211918
PULLLEY, GROOVE
PAHZZ
5330-00-361-2955
15434
40662A
GASKET REAR COVER PART OF KIT P/N 3018762
6
PAHZZ
2815-01-146-5925
15434
3006737
COVER, REAR CAMSHAFT
4
7
PAHZZ
5330-00-005-0858
96906
MS35338-8
SEAL REAR OIL PART OF KIT P/N 3018762
4
8
PAHZZ
5310-00-261-7340
15434
MS90726-64
WASHER, LOCK
4
9
PFHZZ
15434
3029348
SCREW, CAP, HEXAGON HEAD
4
10
PAHHH
2815-01-151-8772
15434
3014614
CRANKSHAFT, ENGINE ASSEMBLY
4
11
PAHZZ
3020-01-146-0107
15434
3024923
.GEAR, HELICAL
4
12
PAHHH
2815-01-083-3157
15434
3801261
.CRANKSHAFT, EBGUBE
4
13
PAHZZ
3120-01-143-9547
35434
3801262
.BEARING HALF SET. SL .010 INCH UNDERSIZE
4
13
PAHZZ
3120-01-144-8882
15434
3801263
.BEARING HALF SET. SL .020 INCH UNDERSIZE
4
13
PAHZZ
3120-01-145-9132
15434
3801260
.BEARING HALF SET. SL .030 INCH UNDERSIZE
4
13
PAHZZ
3120-01-132-9339
15434
H42693
.REARING SET STANDARD
4
14
PAHZZ
3120-00-349-6444
15434
H42693
..BEARING, HALF SLEEVE STADARD
4
15
PAHZZ
3120-00-318-8537
15434
H40496
..BEARING, HALF SLEEVE STADARD
4
16
3120-00-090-5504
15434
42690
..BEARING, HALF SLEEVE STADARD
4
17
PAHZZ
3120-01-214-7779
15434
157280
..WASHER, HALF TRUST STANDARD
4
18
PAHZZ
5315-01-058-4551
15434
202903
..PIN, STRAIGHT, HEXAGO
4
19
PAHZZ
3120-00-593-1507
15434
3019204
..BEARING, HALF SLEEVE STADARD
4
20
XDHZZ
15434
3019192
..BEARING, HALF SLEEVE STADARD
4
21
PAHZZ
3120-00-695-1232
15434
3019180
..BEARING, HALF SLEEVE STADARD
4
22
PAHZZ
5315-01-079-6740
15434
210179
.KEY, MACHINE
5310-00-820-6653
C-15
(8)
QTY
INC
IN
UNIT
TM 52815-241-34&P
FIGURE 5. FLYWHEEL HOUSING AND FLEXPLATE.
C-16
SECTION II
(1)
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
ILLUSTRATION
(a)
FIG.
NO.
(b)
ITEM
NO.
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0103-FLYWHEEL ASSEMBLY
5
1
PAFZZ
5
2
XDFZZ
5
3
PAFZZ
5
4
5
2815-01-122-8002
35434
10657
COVER, HOUSING BRASS
EA
1
15434
193717
HOUSING, FLYWHEEL
EA
1
5310-00-134-4368
15434
S601
WASHER, OIL PAN
EA
7
PAFZZ
5310-00-584-5272
96906
MS35338-48
WASHER, LOCK
EA
7
5
PAFZZ
5305-00-071-2070
96906
MS90728-114
SCREW. CAP HEXAGON HEAD
EA
4
5
6
PAFZZ
5305-00-795-9353
15434
188936
SCREW. CAP
EA
9
5
7
PAFZZ
5310-00-820-6653
96906
MS35338-50
WASHER, LOCK
EA
9
5
8
PAFZZ
5310-00-109-7638
15434
S658
WASHER, FLAT
EA
9
5
9
PAFZZ
5305-00-091-4009
15434
106289
SCREW, CAP, HEXAGON HEAD
EA
3
5
10
PAFZZ
2815-00-603-7264
15434
64482
LOCKWIRE, BOLT, FLYWH
EA
3
5
11
XDFZZ
15434
120448
SCREW, CAP HEXAGON HEAD
EA
3
5
12
XDFZZ
15434
123000
FLEXPLATE
EA
6
5
13
PAFZZ
5310-00-469-3998
15434
S200
NUT, PLAIN, HEXAGON
EA
1
5
14
PAFZZ
5315-00-014-1284
15434
141284
PIN, STRAIGHT, HEADLE
EA
3
5
15
PFFZZ
5330-00-478-2962
15434
199064
GASKET FLYWHEEL HOUSING PART OF KITP/N 3018762
EA
2
5
16
PAFZZ
5310-00-159-6209
96906
MSI22032
WASHER, LOCK PART OF KIT P/N 3018762
EA
1
5
17
XDFZZ
15434
70214
SCREW, MACHINE
EA
2
C-17
TM 5-2815-241-34&P
FIGURE 6. PISTON AND CONNECTING ROD.
C-18
SECTION II
(1)
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
ILLUSTRATION
(a)
FIG.
NO.
(b)
ITEM
NO.
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0104-PISTONS, CONNECTING RODS
6
1
PAHZZ
2815-01-086-2704
15434
3014149
RING SET, PISTON
EA
6
6
2
PAHZZ
2815-00-962-5618
15434
132880
.RING, PISTON COMPRESSION
EA
2
6
3
PAHZZ
2815-00-994-4427
15434
147670
.RING, PISTON COMPRESSION
EA
1
6
4
PAHZZ
2815-00-994-4429
15434
194610
.RING, PISTON OIL
EA
1
6
5
PFHHH
2815-00-004-8291
15434
AR08190
PISTON ASSEMBLY
EA
6
6
6
PAHZZ
5365-00-282-5030
15434
61908
.RING, RETAINING
EA
2
6
7
PAHZZ
2815-00-480-4347
15434
181970
.PIN, PISTON
EA
1
6
8
XDFZZ
15434
203090
.PISTON
EA
1
6
9
PAHZZ
3120-014-087-3004
15434
214950
BEARING, HALF SLEEVE
EA
12
6
10
PAHZZ
2815-00-753-0660
15434
3015523
CONNECTING ROD, PIST
EA
6
6
22
PAHHH
5310-00-134-4171
15434
200861
.WASHER, FLAT
EA
2
6
12
PAHZZ
5310-00-222-7240
15434
69936
.NUT, PLAIN, HEXAGON
EA
2
6
13
PAHZZ
2815-00-132-0273
15434
187420
.BUSHING, POSTON PIN STANDARD
EA
1
6
13
XDFZZ
15434
152770
.BUSHING, HEAVY WALL
EA
1
6
14
PAHZZ
15434
9195-3
.BOLT, CONNECTING ROD
EA
2
5306-00-041-0917
C-19
TM 5-2815-241-34&P
FIGURE 7. CAMSHAFT.
C-20
SECTION II
(1)
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
ILLUSTRATION
(b)
ITEM
NO.
(a)
FIG.
NO.
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0105-VALVES, CAMSHAFTS, AND TIMING
SYSTEMS
7
1
XDHHH
15434
3023177
CAMSHAFT, SERVICE AS
EA
1
7
2
XDFZZ
15434
3021601
.PLUG, VENT
EA
1
7
3
XDHZZ
15434
3023229
.CAMSHAFT, ENGINE
EA
1
7
4
PAHZZ
3120-00-339-5642
15434
BM27253
BEARING SET, SLEEVE CAMSHAFT
EA
1
7
5
PAHZZ
3120-00-573-0391
15434
100670
.BEARING, SLEEVE
EA
1
7
6
PAHZZ
3120-00-906-6657
15434
157870
.BEARING, SLEEVE
EA
1
7
7
PAHZZ
3120-00-374-4342
15434
9235-1
BEARING, WASHER THRU
EA
1
7
8
PFFZZ
5315-00-616-5527
96906
MS35756-18
KEY, WOODRUFF CAMSHAFT GEAR
EA
1
7
9
PAFZZ
2815-00-107-115
15434
156226
GEAR, CAMSHAFT
EA
1
C-21
TM 5-2815-241-34&P
FIGURE 8. GEARCASE COVER.
C-22
SECTION II
(1)
TM5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
ILLUSTRATION
(b)
ITEM
NO.
(a)
FIG.
NO.
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0105 (CONT)
8
1
PAFZZ
5305-01-165-3300
15434
S-119-C
SCREW CAP, HEXGON H TIMING GEAR COVER MTG
EA
1
8
2
PAFZZ
5310-00-209-0965
69606
MS35338-47
WASHER, LOCK
EA
13
8
3
PAFZZ
5330-00-005-0857
15434
30043316
SEAL OIL PART OF KIT P/N 3018762
EA
1
8
4
XDFZZ
15434
AR09473
COVER, GEARCASE
EA
1
8
5
PAFZZ
5330-01-046-0441
15434
210412
GASKET GEAR COVER PART KIT P/N 3018762
EA
1
8
6
PAFZZ
5305-00-709-8537
96906
MS90727-94
SCREW, CAP, HEXAGON H
EA
3
8
7
PAFZZ
5365-00-716-5496
15434
AR01176
SHIM SET CAMSHAFT TRUST
EA
1
8
8
PAFZZ
5365-01-086-7788
15434
185573
.SHIM INSERT
EA
1
8
8
PAFZZ
5365-01-147-0912
15434
65259-A
.SHIM .010 IN. THK
EA
1
8
8
PAFZZ
5365-01-147-0913
15434
65259-B
.SHIM .005 IN. THK
EA
1
8
8
PAFZZ
5365-00-507-3254
15434
65259C
.SHIM .002 IN. THK
EA
1
8
9
PAFZZ
5305-00-942-2196
96906
MS18154-60
SCREW, CAP, HEXAGON H
EA
3
8
10
PAFZZ
5310-00-261-7340
96906
MS35338-8
WASHER, LOCK
EA
3
8
11
PAFZZ
5310-00-080-6004
96906
MS27183-14
WASHER, FLAT
EA
3
8
12
PAFZZ
2815-00-242-2992
15434
150002
SUPPORT, CAMSHAFT
EA
1
8
13
PAFZZ
5330-00-005-0856
15434
3006736
SEAL CRANKSHAFT
EA
1
8
14
PAFZZ
5305-00-709-8542
69606
MS90727-91
SCREW, CAP, HEXAGON H
EA
9
C-23
TM 5-2815-241-34&P
FIGURE 9. VALVES, SPRINGS AND GUIDES.
C-24
SECTION II
(1)
TM5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
ILLUSTRATION
(b)
ITEM
NO.
(a)
FIG.
NO.
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
05105 (CONT)
9
1
PAFZZ
2815-00-933-3009
15434
170296
SEAL, HELICAL COMPRE
EA
24
9
2
PAFZZ
5340-01-143-6048
15434
127554
HALF-COLLET
EA
48
9
3
PAFZZ
5305-00-062-4378
15434
147389
SETSCREW, CROSSHEAD
EA
12
9
4
PAFZZ
5310-00-426-3990
15434
203131
NUT, PLAIN, HEXAGON
EA
12
9
5
PAFZZ
2815-00-300-0882
15434
3036065
CROSSHEAD, VALVE INTAKE
EA
6
9
5
PAFZZ
2815-01-085-3733
75078
011573
CROSSHEAD, VALVE EXHAUST
EA
6
9
6
PAFZZ
5305-00-477-6769
15434
70772
SCREW, ASSEMBLED
EA
8
9
7
PAFZZ
2910-00-928-3505
15434
147100
CROSSOVER, FUEL
EA
12
9
8
PAFZZ
5330-00-143-8485
15434
131026
PACKING, PREFORMED PART OF KIT P/N 3801330
EA
12
9
9
PAFZZ
2815-00-085-7434
15434
3017759
INSERT, VALVE SEAT EXHAUST, STANDART
EA
12
9
9
PAFZZ
2815-01-140-7421
15434
127935
INSERT, VALVE SEAT .005 INCH OVERSIZE
EA
12
9
9
PAFZZ
2815-00-132-0240
15434
3014622
SEAT, VALVE .010 INCH OVERSIZE
EA
12
9
9
PAFZZ
2815-01-127-1060
15434
3014623
INSERT, VALVE SEAT .020 INCH OVERSIZE
EA
12
9
9
PAFZZ
2815-01-127-3597
15434
3014624
INSERT, VALVE SEAT .030 INCH OVERSIZE
EA
12
9
9
PAFZZ
2815-01-127-3598
15434
3014625
INSERT, VALVE SEAT .040 INCH OVERSIZE
EA
12
9
10
PAFZZ
2815-00-962-5629
15434
145701
VALVE, POPPET, ENGINE EXHAUST
EA
12
9
10
PAFZZ
2815-00-739-6098
15434
135957
VALVE, POPPET, ENGINE
EA
12
9
11
PAFZZ
2815-01-085-2818
15434
3006456
GUIDE, VALVE STEM
EA
24
9
12
XDFZZ
15434
68803-A
SPACER, VALVE
EA
V
9
13
PAFZZ
2815-00-632-6239
15434
172034
SEAT, HELICAL, COMPRE
EA
24
9
14
PAFZZ
5360-00-009-9270
15434
211999
SPRING, HELICAL COMP
EA
24
9
15
PAFZZ
5330-00-406-4542
15434
196641
PACKING, PREFORMED PART OF KIT P/N 3801330
EA
6
9
16
PAFZZ
5315-00-866-5015
15434
123558
PIN, STRAIGHT HEADLE
EA
12
9
17
PAFZZ
2910-01-070-7979
15434
3011935
SLEEVE, COOLING, FUEL
EA
6
C-25
TM 5-2815-241-34&P
FIGURE 10. PUSH RODS AND CAM FOLLOWERS.
C-26
SECTION II
(1)
TM5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
ILLUSTRATION
(a)
FIG.
NO.
(b)
ITEM
NO.
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0105 (CONT)
10
1
XDFZZ
10
2
PAFZZ
10
3
10
15434
2010650
PUSH ROD, EXHAUST VA
EA
6
2815-00-590-7385
15434
3027215
ROD, INJECTOR
EA
6
PAFZZ
2815-00-705-9257
15434
BM47777
ROD, PUSH INTAKE
EA
6
4
PAFFF
2818-00-609-7115
15434
BM37625
HOUSING, ASSY CAM FO
EA
3
10
5
PAFFF
2815-00-505-5116
15434
BM37634
.CAM FOLLOWER LEVER INTAKE AND EXHAUST
EA
4
10
6
PAFZZ
5315-00-041-0916
15434
68513
..PIN, STRAIGHT, HEADLE
EA
1
10
7
PAFZZ
2815-00-311-2521
15434
9260-1
..ROLLER
EA
1
10
8
PAFZZ
5315-00-777-3544
15434
118939
..PIN, STRAIGHT, HEADLE
EA
1
10
9
PAFZZ
2815-00-505-5119
15434
107738
..SOCKET, CAM FOLLOWER
EA
1
10
10
XDFZZ
15434
120543
..CAM FOLLOWER LEVER AND BUSHING
EA
1
10
11
PAFZZ
3120-00-659-7808
15434
118378
..BEARING, SLEEVE
EA
1
10
12
PAFFF
2815-00-705-2851
15434
3018049
.CAM FOLLOWER INJECTOR
EA
2
10
13
PAFZZ
5315-00-041-0915
15434
68512
..PIN, STRAIGHT, HEADLE
EA
1
10
14
PAFZZ
2815-00-362-1780
15434
7348-2
..ROLLER, INJECTOR CAM
EA
1
10
15
PAFZZ
5315-00-777-3544
15434
118939
..PIN, STRAUGGTM HEADLE
EA
1
10
16
PAFZZ
2815-00-505-5119
15434
107738
..SOCKET, CAM FOLLOWER
EA
1
10
17
XAFZZ
15434
BM-37496
..CAM FOLLOWER LEVER AND BUSHING
EA
1
10
18
PAFZZ
3120-00-791-1440
15434
118377
..BEARING, SLEEVE
EA
1
10
19
PAFZZ
5305-00-339-1415
15434
69736
.SCREW, MACHINE
EA
6
10
20
PAFZZ
5340-00-485-0945
15434
175831
.PLUG, EXPANSION
EA
2
10
21
PAFZZ
2815-00-388-3126
15434
304731
.SHAFT, STRAIGHT
EA
2
10
22
PAFZZ
2815-00-375-9892
15434
BM73976
.HOUSING
EA
1
10
23
XDFZZ
15434
210685
SHAFT
EA
1
10
24
PAFZZ
5340-00-276-5847
15434
S719
PLUG, EXPANSION
EA
1
10
25
PAFZZ
5310-00-684-3463
96906
MS51092-1
WASHER, LOCK COPPER
EA
1
10
26
PAFZZ
5305-00-362-1536
15434
9237
SETSCREW SHAFT LOCK
EA
1
10
27
XDFZZ
15434
208411
BOLT, MACHINE CARRIAGE
EA
1
10
28
PAFZZ
5310-00-261-7340
96906
MS35338-8
WASHER, LOCK
EA
19
10
29
PAFZZ
5310-00-080-6004
96906
MS27183-14
WASHER, FLAT
EA
1
C-27
TM 5-2815-241-34&P
(1)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
ILLUSTRATION
(a)
FIG.
NO.
(b)
ITEM
NO.
SECTION II
(2)
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0105(CONT)
10
30
PAFZZ
5310-00-521-8595
15435
S223
NUT, HEXAGON
EA
1
10
31
PAFZZ
5330-00--886-2509
15434
43696
PACKING, PREFORMED
EA
1
10
32
XDFZZ
15434
208581
LEVER COMPRESSION RELEASE
EA
1
10
33
XDFZZ
15434
139289
SPRING
EA
1
10
34
PAFZZ
5310-00-407-9566
96906
MS35338-45
WASHER, LOCK
EA
1
10
35
PAFZZ
5306-00-225-9086
96906
MS90726-31
BOLT, MACHINE
EA
1
10
36
PAFZZ
5330-000-777-3545
15434
120819
GASKET .026 IN. THK PART OR KIT P/N 3018762
EA
1
10
36
PAFZZ
5330-00-175-6585
15434
9266
GASKET .015 IN. THK PART OR KIT P/N 3018762
EA
1
10
36
PAFZZ
5330-00-349-1219
15434
9266A
GASKET .007 IN. THK PART OR KIT P/N 3018762
EA
1
10
37
PAFZZ
3120-00-546-6698
15434
68586
BUSHING, SLEEVE
EA
1
10
38
PAFZZ
5305-00-546-6698
15434
S129
SCREW, CAP, HEXAGON H
EA
1
C-28/(29 blank)
TM 5-2815-241-34&P
FIGURE 11. ROCKER HOUSING COVER AND BREATHER.
C-30
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a)
FIG.
NO.
(b)
ITEM)
NO.
(2)
(3)
(4)
(5)
(6)
( 7 ) (8)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
QTY
U/M INC
IN
UNIT
USABLE
ON
CODE
0105(CONT)
11
1 PAOZZ
2815-00-590-7378
15434
101322
CAP,FILLER,OPENING
EA
1
11
2 PAFZZ
2815-01-159-1737
15434
3006187
COVER,ROCKER HOUSING
EA
1
11
3 PAFZZ
5305-00-782-9489
96906
MS90728-66
SCREW,CAP,HEXAGON H COVER MTG
EA
9
11
4 PAFZZ
5305-00-942-2196
96906
MS18154-60
SCREW,CAP,HEXAGON H COVER MTG
EA
6
11
5 PAFZZ
96906
MS35338-8
WASHER,LOCK COVER MTG
EA
15
11
6 PAFZZ
5310-00-080-6004
96906
MS27183-14
WASHER,FLAT
EA
15
11
7 PAFZZ
2815-01-142-1732
15434
3006183
COVER,ACCESS
EA
1
11
8 PAFZZ
2815-01-146-1024
15434
3006358
COVER,ROCKER ARM
EA
1
11
9 PAFZZ
5330-01-066-3908
73165
B90429
GASKET
EA
3
C-31
TM 5-2815-241-34&P
FIGURE 12. ROCKER ARMS AND HOUSING
C-32
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a) (b)
FIG. ITEM
NO. NO.
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7) (8)
USABLE
ON
CODE
QTY
U/M INC
IN
UNIT
0105(CONT)
15434
AR03307
HOUSING AND ROCKER
EA
3
2815-01-096-9198
15434
BM95161
.ROCKER,ARM,ENGINE P EXHAUST
EA
1
5310-00-732-0560
36906
MS51968-14
..NUT,ADJUSTING SCREW
EA
1
4 XDFZZ
15434
213109
..SCREW,ADJUSTING
EA
1
12
5 XDFFF
15434
169704
..ARM AND BUSHING ASSEMBLY,REAR
EA
1
12
6 PAFZZ
3120-00-589-3537
15434
140330
...BUSHING,SLEEVE
EA
1
12
7
PAFFF
2815-00-005-7431
15434
AR-2308
.LEVER INJECTOR FUEL
EA
2
12
8
PAFZZ
5310-00-732-0560
96906
MS51968-14
..NUT,ADJUSTING SCREW
EA
1
12
9 XDFZZ
15434
199239
..SCREW,lNJECTOR ARM ADJUSTING
EA
1
12
10 XDFFF
15434
218152
..LEVER ROCKER ARM
EA
1
12
11 PAFZZ
3120-00-589-3537
15434
140330
..BUSHING,SLEEVE
EA
1
12
12 PAFZZ
2815-00-404-2940
15434
194037
.SEAT,BALL SOCKET
EA
1
12
13 PAFFF
2815-00-195-5894
15434
AR51276
.ROCKER,ARM,ENGINE P
EA
2
12
14 PAFZZ
5310-00-732-0560
96906 MS51968-14
..NUT,ADJUSTING SCREW
EA
1
12
15 XDFZZ
15434
213109
..SCREW,ADJUSTING
EA
1
12
16
XDFFF
15434
168805
..ARM AND BUSHING
EA
1
12
17
PAFZZ
15434
140330
. . . BUSHING,SLEEVE
EA
1
12
18
XDFZZ
75078
2514
.WASHER,BEARING
EA
18
12
19
PAFZZ
5307-01-147-1316
75078
2856
.STUD,SHOULDERED INJECTOR
EA
2
12
19
PAFZZ
5307-01-147-2821
75078
1232
.STUD,SHOULDERED
EA
8
12
19
XDFZZ
75078
1199
.STUD,SHOULDERED
EA
8
12
20 KDFZZ
15434
199224
.NUT,ROCKER
EA
18
12
21
75078
011573
CROSSHEAD VALVE EXHAUST
EA
2
12
22 XDFZZ
75078
2680
.LOCKPLATE
EA
2
12
23
XDFZZ
15434
199216
.GASKET,HOUSING
EA
1
12
24
PAFFF
2815-00-851-7637
15434
BM95162
ROCKER,ARM,ENGINE P
EA
1
12
25
PAFZZ
5310-00-732-0560
96906
MS51968-14
.NUT,ADJUSTING SCREW
EA
1
12
26 XDFZZ
15434
213109
.SCREW,ADJUSTING
EA
1
12
27
15434
140330
..BUSHING,SLEEVE
EA
1
12
1 XDFFF
12
2
PAFFF
12
3
PAFZZ
12
PAFZZ
PAFZZ
3120-00-589-3537
2815-01-085-3733
3120-00-589-3537
C-33
TM 5-2815-241-34&P
(1)
ILLUSTRATION
(2)
SMR
( a ) ( b ) CODE
FIG. ITEM
NO. NO.
SECTION II
(3)
NATIONAL
STOCK
NUMBER
(4)
(5)
FSCM
(6)
PART
NUMBER
(7)
DESCRIPTION
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0105(CONT)
12
28
PAFFF
2815-00-195-5897
15434
BM95160
.ROCKER ARM,ENGINE P
EA
1
12
29
PAFZZ
5310-00-732-0560
96906
MS51968-14
..NUT,ADJUSTING SCREW
EA
1
12
30
KDFZZ
15434
213109
..SCREW,ADJUSTING
EA
1
12
31
KDFFF
15434
168803
..ARM AND BUSHING
EA
1
12
32
PAFZZ
15434
140330
. . . BUSHING,SLEEVE
EA
1
12
33
XDFZZ
15434
199220
.SEAL RING OIL SUPPLY SCREW
EA
1
12
34
PAFZZ
2520-01-085-6128
15434
199225
.SCREW,SHAFT LOCK
EA
1
12
35
PAFZZ
5340-00-365-5759
15434
62229
.PLUG,VENTILATOR
EA
1
12
36
KDFZZ
75078
2514
.WASHER
EA
6
12
37
PAFZZ
2815-00-230-0070
15434
3007242
.HOUSIING,ROCKER ARM
EA
1
12
38
PFFZZ
5330-01-133-8493
89346
187589
.GASKET HOUSING TO HEAD PART OF KIT P/N 3801330
EA
1
12
39
PAFFF
2815-01-079-1799
15434
140297
.SHAFT,STRAIGHT
EA
1
C-34/(35 blank)
3120-00-589-3537
TM 5-2815-241-34&P
FIGURE 13. OIL PAN AND DIPSTICK.
C-36
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a) (b)
FIG. ITEM
NO. NO.
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7) ( 8 )
USABLE
ON
CODE
QTY
U/M INC
IN
UNIT
0106-ENGINE LUBRICATION SYSTEM
15434 112593
SCREW,CAP,HEXAGON HEAD
EA
2
15434 197230
PACKING,PREFORMED
EA
2
15434 3019400
HOSE
EA
1
13
1 XDFZZ
13
2
13
3 XDFZZ
13
4
PAFZZ
2815-00-338-6839
15434 20622
STRAINER,ELEMENT OIL PAN
EA
1
13
5 PAFZZ
5305-00-804-6454
15434 S1354
SCREW HEAD STRAINER MTG
EA
4
13
6 PAFZZ
5330-00-351-6428
15434 3031469
GASKET OIL PAN PART OF KIT P/N 3018762
EA
1
13
7 XDDZZ
15434 204657
DIPSTICK OIL
EA
1
13
8 PAOZZ
5340-00-417-5800
15434 200064
CLAMP,LOOP
EA
1
13
9 PAOZZ
5310-00-637-9541
96906 MS35338-46
WASHER,LOCK
EA
1
13
10 PAOZZ
SCREW,CAP,HEXAGON
EA
1
13
11 XDOZZ
15434 211358
TUBE,DIPSTlCK OIL
EA
1
13
12 XDFZZ
15434 67347-1
BRACKET,OIL GAGE
EA
1
13
13 XDFZZ
15434 67346
GASKET OIL GAGE BRACKET
EA
1
13
14 PAOZZ
4730-00-801-8186 15434 S-915-A
PLUG,PIPE
EA
3
13
15 PAFZZ
5310-00-261-7340
96906 MS35338-8
WASHER,LOCK
EA
2
13
16 PAFZZ
5305-00-709-8523
96906 MS90727-87
SCREW,CAP,HEXAGON H
EA
2
13
17 PAOZZ
4730-00-203-0395
80218 10003
PLUG,DRAIN
EA
1
13
18 PAFZZ
5306-00-719-5467 15434 70349
BOLT,MACHINE
EA
34
13
19 PAFZZ
5310-00-209-0965
WASHER,LOCK
EA
38
13
20 PAFZZ
5310-00-562-6557 15434 S622
WASHER,FLAT
EA
34
13
21 XDFZZ
15434 208461
PAN,OIL
EA
1
13
22 PAFZZ
5305-00-463-0428
15434 185804
SCREW,CAP,HEXAGON HEAD
EA
4
13
23 PAFZZ
5310-00-562-6558
15434 S626
WASHER,FLAT
EA
4
13
24 PAFZZ
5310-00-768-0318
96906 MS51967-14
NUT,HEXAGON
EA
2
13
25 PAFZZ
5310-00-584-5272 96906 MS35338-48
WASHER,LOCK
EA
2
13
26 PAFZZ
5305-00-071-1769
96906 MS90725-115
SCREW,CAP,HEXAGON
EA
2
13
27 PAFZZ
5330-00-143-8376
15434 157551
GASKET SUCTION FLANGE PART OF KIT P/N 3018762
EA
1
13
28 PFFZZ
4730-01-211-1989 15434 3012527
FLANGE OIL SUCTION
EA
1
13
29 PAFZZ
5310-00-407-9566 96906 MS35338-45
WASHER,LOCK
EA
2
PFFZZ
5330-01-209-3583
5305-00-269-3209 96906 MS90725-48
96906 MS35338-47
C-37
TM 5-2815-241-34&P
FIGURE 14. ENGINE BREATHER ASSEMBLY.
C-38
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a)
FIG.
NO.
(b)
ITEM
NO.
(2)
SMR
CODE
(3)
NATIONAL
STOCK
NUMBER
(4)
FSCM
PART
NUMBER
(7)
(6)
(5)
DESCRIPTION
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0106(CONT)
14
1
PAFZZ
2815-00-405-1798
33457 2S7225S
BREATHER ASSEMBLY ENGINE
EA
1
C-39
TM 5-2815-241-34&P
FIGURE 15. ENGINE BREATHER HOSE.
C-40
SECTION II
(1)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
7
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
U/M
USABLE
ON
CODE
(8)
QTY
INC
IN
UNIT
0106(CONT)
15
1 XDFZZ
15434
390782C1
HOSE,HEATER
EA
1
15
2 XDFZZ
15434
274085R91
CLAMP,HOSE
EA
3
15
3 XDFZZ
15434
209862C1
STRAP,CABLE LOCK
EA
1
15
4 XDFZZ
15434
299263091
CLAMP,RUBBER CUSHIO
EA
1
15
5 MFFZZ
19207
8465575-44
HOSE MANUFACTURE FROM NSN 4720-00-846-5575
EA
1
15
6 XDFZZ
15434
364319C1
TUBE,HOSE
EA
1
C-41
TM 5-2815-241-34&P
FIGURE 16. ENGINE OIL FILTER COOLER.
C-42
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a) (b)
FIG. ITEM
NO. NO.
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7) ( 8 )
USABLE
ON
CODE
QTY
U/M INC
IN
UNIT
0106(CONT)
XDOOO
16
1
16
2 PAOZZ
16
3
COOLER,OlL
EA
1
5305-00-068-0511 96906 MS90728-62
.SCREW,CAP,HEXAGON H
EA
1
PAOZZ
5305-01-062-1054
45152 1816-HX-1
.SCREW,CAP,HEXAGON H
EA
10
16
4 PAOZZ
5310-00-261-7340
96906 MS35338-8
.WASHER,LOCK
EA
12
16
5
PAOZZ
4730-00-057-5555
96906 MS49005-6
.PLUG,PIPE
EA
1
16
6
XDOZZ
15434
.COVER
EA
1
16
7 PAOZZ
.GASKET OIL COOLER COVER PART OF KIT P/N 3018762
EA
1
16
8 XDOOO
.COOLER,OIL
EA
1
16
9 PAOZZ
2930-00-437-0567 15434 142616
..RETAINER,OIL COOLER
EA
2
16
10 XDOZZ
15434 148295
..PACKING,PREFORMED PART OF KIT P/N 3018762
EA
2
16
11 PAOZZ
2930-00-603-1625
46529 A331987
..CORE,OIL COOLER
EA
1
16
12
4730-00-057-5555 96906 MS49005-6
..PLUG,PIPE
EA
1
16
13 PAOZZ
4730-01-160-3579
..PLUG,PIPE
EA
1
16
14 PAOOO
2940-01-146-1995 15434 179063
..SEAT,BY-PASS FILTER
EA
1
16
15 PFOZZ
5360-01-200-0323 15434 202128
. . . SPRING,FILTER BY-PA
EA
1
16
16 XDOZZ
15434 201707
..DISC,BY-PASS
EA
1
16
17 PAOZZ
..PLUG,PIPE
EA
2
16
18 XAOZZ
15434 210832
..HOUSING,FlLTER AND
EA
1
16
19
96906 MS90728-70
.SCREW,CAP,HEXAGON H
EA
1
16
20 PAOZZ
2815-00-791-1453 15434 127558
.PLUNGER,OIL,PUMP
EA
1
16
21 PAOZZ
5360-00-664-5343 15434 68274
.SPRING,HELICAL,COMP
EA
1
16
22 PAOZZ
5365-00-197-9327
.SPACER,RING PART OF KIT P/N 3018762
EA
1
16
23 PAOZZ
5365-01-112-4281 15434 183913
.PLUG,MACHINE THREAD
EA
1
16
24 PAOZZ
5365-00-708-3434 15434 110907
.PLUG,MACHINE THREAD
EA
1
16
25 XDOZZ
15434 210967
.SUPPORT,COOLER
EA
1
16
26 PAOZZ
.GASKET OIL COOLER PART OF KIT P/N 3018762
EA
1
16
27
FILTER,OIL
EA
1
16
28 PAOZZ
5330-00-132-0248 15434 173368
.PACKING,PREFORMED PART OF KIT P/N 3018762
EA
1
16
29 PAOZZ
2940-00-073-3316 15434 158139
.FILTER,ELEMENT FLUI
EA
1
PAOZZ
PAOZZ
XDOOO
15434 AR09479
210858
5330-01-046-1991 15434 218245
15434 AR09478
15434 S-910-B
4730-00-018-9566 15434 S9118
5305-00-846-5703
15434 67946
5330-01-046-3144 15434 3010030
15434 AR-09265
C-43
TM 5-2815-241-34&P
(1)
ILLUSTRATION
(a)
(b)
FIG. ITEM
NO. NO.
(2)
SMR
CODE
(3)
NATIONAL
STOCK
NUMBER
SECTION II
(4)
(5)
(6)
FSCM
PART
NUMBER
DESCRIPTION
(7)
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0106(CONT)
16
30
XDOOO
15434
184387
.SHELL AND BOLT ASSY
EA
1
16
31
XDOZZ
15434
184386
..SHELL
EA
1
16
32
PAOZZ
79470
C3159X2
..PLUG,PIPE
EA
1
16
33
XCOZZ
15434
184388
..BOLT,SHELL
EA
1
16
34
PAOZZ
5310-00-080-6004
96906
MSS7183-14
WASHER,FLAT
EA
2
16
35
PAOZZ
5310-00-261-7340
96906
MS35338-8
WASHER,LOCK
EA
8
16
36
PAOZZ
5305-00-942-2196
96906
MS18154-60
SCREW,CAP,HEXAGON H
EA
2
16
37
PAOZZ
5305-01-203-6444
15434
S145
SCREW,CAP,HEXAGON H
EA
1
16
38
PAOZZ
5310-01-200-1318
15434
S608
WASHER,LOCK
EA
1
16
39
XDOZZ
15434
132756
WASHER,PLAIN
EA
1
16
40
XDOZZ
15434
210966
BRACE,COOLER
EA
1
16
41
PAOZZ
15434
212161
PACKING,PREFORMED
EA
2
16
42
XDOZZ
15434
210883
TUBE,WATER TRANSFER
EA
1
16
43
PAOZZ
5330-01-079-6514
15434
3008017
GASKET COOLER SUPPORT PART OF KIT P/N 3018762
EA
1
16
44
PAOZZ
5305-00-068-0511
96906
MS90728-62
SCREW,CAP,HEXAGON H
EA
2
16
45
PAOZZ
5305-00-165-8157
72582
450517
SCREW,CAP,HEXAGON H
EA
2
16
46
PAOZZ
5305-00-404-1388
15434
S199B
SCREW,CAP,HEXAGON H
EA
2
C-44/(45 blank)
4730-00-081-9618
5330-01-077-5228
TM 5-2815-241-34&P
FIGURE 17. LUBRICATING OIL PUMP.
C-46
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a)
(b)
FIG. ITEM
NO. NO.
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7) (8)
USABLE
ON
CODE
QTY
U/M INC
IN
UNIT
0106(CONT)
PUMP,OIL LUBRICATIN
EA
1
5315-00-043-1787 96906 1335756-34
.KEY,WOODRUFF
EA
1
3 PAFZZ
5305-01-140-9118
.SCREW,CAP,HEXAGON H
EA
1
17
4 PAFZZ
2815-00-406-8936 15434 109319
.LOCK PLATE
EA
1
17
5 PAFZZ
2815-00-828-7013 15434 126304
.YOKE,CAP RETAINING
EA
1
17
6 PAFZZ
5340-00-833-7966 15434 134596
.PLUG,BY-PASS VALVE
EA
1
17
7 PAFZZ
5360-01-038-4659 15434 211939
.SPRING,HELICAL,COMP
EA
1
17
8 PAFZZ
2815-00-705-2856 15434 109333
.PLUNGER,PRESSURE RE
EA
1
17
9 PAFZZ
4730-00-289-4770 15434 S995
.PLUG,PIPE
EA
2
17
10 PAFZZ
5310-00-209-0965
.WASHER,LOCK
EA
5
17
11 PAFZZ
5305-01-165-3300 15434 S-119-C
.SCREW,CAP,HEXAGON H
EA
1
17
12 PAFZZ
5310-00-261-7340 96906 MS35338-8
.WASHER,LOCK
EA
2
17
13 PAFZZ
5305-00-709-8282
.SCREW,CAP,HEXAGON H
EA
2
17
14 PAFZZ
5315-00-475-2574 15434 69519
.PIN,STRAIGHT,HEADLE
EA
11
17
15 PAFZZ
3040-01-079-1748 15434 199587
.GEARSHAFT,WORM WHEE
EA
1
17
16 PAFZZ
3020-01-084-9640
15434 3014783
.GEAR,SPUR
EA
1
17
17 XDFFF
15434 AR-03636
.GEAR AND BUSHING
EA
1
17
18 PAFZZ
3120-00-566-0480
15434 68365
..BUSHING,SLEEVE
EA
2
17
19 PAFZZ
3040-01-079-3469 15434 177419
.SHAFT,SHOULDERED
EA
1
17
20 XDFZZ
15434 117897
.CAPSCREW
EA
1
17
21 PAFZZ
5305-00-424-3571 15434 S101A
EA
2
17
22 PAFFF
2815-01-085-3734
.BODY,OIL PUMP WITH
EA
1
17
23 PAFZZ
3120-00-627-6697 15434 69521
..BEARING,SLEEVE
EA
1
17
24 PAFZZ
3020-01-085-3779 15434 204832
.GEAR,HELICAL
EA
1
17
25 PAFZZ
5330-01-066-3910 15434 203145
.GASKET COVER PART OF KIT P/N 3018762
EA
1
17
26 XDFFF
.HOUSING,ADAPTER
EA
1
17
27 PAFZZ
3120-00-627-6697 15434 69521
..BEARING,SLEEVE
EA
1
17
28 PAFZZ
5310-00-407-9566 96906 MS35338-45
.WASHER,LOCK
EA
8
17
29 PAFZZ
5305-00-225-9081 96906 MS90725-36
.SCREW,CAP,HEXAGON H
EA
1
17
1 PAFFF
2815-01-085-2573
17
2 PAFZZ
17
15434 AR10172
96906 MS90728-59
96906 MS35338-47
96906 MS90727-83
15434 AR09832
15434 AR08667
SCREW,CAP,HEXAGON H
C-47
TM 5-2815-241-34&P
(1)
ILLUSTRATION
(a) (b)
FIG. ITEM
NO.
NO.
SECTION II
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0106(CONT)
17
30
PAFZZ
5306-00-136-9751
15434
S-147-B
BOLT,MACHINE
EA
1
17
31
PAFZZ
5306-00-225-8499
96906
MS90725-34
BOLT,MACHINE
EA
6
17
32
XDFZZ
15434
121907
EA
1
C-48/(49 blank)
GASKET PART OF KIT P/N 3018762
TM 5-2815-241-34&P
FIGURE 18. INTAKE MANIFOLD.
C-50
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(2)
( a ) (b)
FIG. ITEM
NO. NO.
SMR
CODE
(3)
NATIONAL
STOCK
NUMBER
(4)
FSCM
(7)
(6)
(5)
DESCRIPTION
PART
NUMBER
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0108-MANIFOLDS
18
1 PAFZZ
4720-01-070-8149
55683
851-202994
HOSE,PREFORMED
EA
1
18
2
PAFZZ
4730-00-477-4160
15434
208326
CLAMP,HOSE
EA
2
18
3
XDFZZ
15434
3022205
CONNECTION,AIR CROS
EA
1
18
4
PAFZZ
5305-00-725-2317
96906 MS90728-64
CAPSCREW
EA
7
18
5
PAFZZ
5310-00-261-7340
96906
MS35338-8
WASHER,LOCK
EA
17
18
6
PAFZZ
5310-00-080-6004
96906
MS27183-14
WASHER,FLAT
EA
10
18
7
XDFZZ
15434
199568
GASKET PART OF KIT P/N 3801330
EA
1
18
8
PAFZZ
96906
MS18154-60
SCREW,CAP,HEXAGON H
EA
10
18
9
XDFZZ
15434
3019227
GASKET,PLATE
EA
1
18
10
PFFZZ
2815-00-070-2251
15434
141761
MANIFOLD,AIR INTAKE
EA
1
18
11
PAFZZ
5310-00-134-4169
15434
63842
WASHER,FLAT
EA
3
18
12
PAFZZ
5330-00-910-8736
15434
202961
GASKET,MANIFOLD
EA
3
5305-00-942-2196
C-51
TM 5-2815-241-34&P
FIGURE 19. EXHAUST MANIFOLD.
C-52
TM 5-2815-241-34&P
SECTION II
(2)
(1)
LLUSTRATION
(a) ( b )
FlG. ITEM
NO. NO.
SMR
CODE
(3)
(4)
(5)
(6)
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0108(CONT)
PAFZZ
5330-00-659-3178
15434
3020943
GASKET PART OF KIT P/N 3801330
6
1
EA
19
2815-00-920-8356
15434
151489
MANIFOLD,EXHAUST REAR
1
2
PAFZZ
EA
19
5340-00-132-3203
15434
200919
STRAP,RETAINING
2
3
PAFZZ
EA
19
PAFZZ
5310-00-887-8325
15434
114638
WASHER,KEY
4
4
EA
19
PAFZZ
5305-00-005-0666
15434
200908
SREW,CAP,HEXAGON H
4
5
EA
19
PAFZZ
2815-00-920-2073
15434
151478
MANIFOLD ENGINE FRONT
1
6
EA
19
2815-00-829-5227
15434
105199
DOWEL,MANIFOLD
4
7 PAFZZ
EA
19
8 PAFZZ
2815-01-077-4463
15434
200566
MANIFOLD,CENTER SEC
EA
1
19
9 PAFZZ
2815-00-767-4012
15434
116982
LOCKING PLATE,NUT A
EA
4
19
5305-01-028-8869
15434
S155
CAPSCREW
8
10 PAFZZ
EA
19
3120-01-079-6527
15434
109594
BEARING,SLEEVE
8
11 PAFZZ
EA
19
C-53
TM 5-2815-241-34&P
FIGURE 20. ACCESSORY DRIVE.
C-54
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a)
(b)
FIG. ITEM
N0.
N0.
(2)
SMR
CODE
(3)
NATIONAL
STOCK
NUMBER
(4)
FSCM
(7)
(6)
(5)
DESCRIPTION
PART
NUMBER
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0109-ACCESSORY DRIVING MECHANISMS
15434
191517
NUT,SELF-LOCKING,HE
EA
1
2 XDFZZ
15434
194380
WASHER,FLAT
EA
1
20
3 XDFFF
15434
4R09607
PULLEY FAN AND WATER PUMP DRIVE
EA
1
20
4 XAFZZ
15434
210926
.PULLEY
EA
1
20
5 PAFZZ
2930-00-401-9531
15434
190397
.SLEEVE,PULLEY,PUMP
EA
1
20
6 PAFZZ
5330-00-026-2931
15434
200809
GASKET
EA
1
20
7 XDFHH
15434
AR08366
DRIVE,ACCESSORY DRI
EA
1
20
8 PAFZZ
3020-00-160-9092
15434
142689
.GEAR,HELICAL
EA
1
20
9 PAHZZ
3120-01-147-5275
15434
3026556
.BEARING WASHER,THRU
EA
1
15434
AR08256
.HOUSING ASSEMBLY
EA
1
15434
116391
..BEARINC,SLEEVE
EA
1
15434
199338
..HOUSING
EA
1
20
1
20
PAFZZ
5310-00-442-6899
20
10
XDHHH
20
11
PAHZZ
20
12
XAHZZ
20
13
PAHZZ
4730-00-018-9566
15434
S911B
..PLUG,PIPE
EA
2
20
14
PFHZZ
3040-01-203-8549
15434
199969
.SHAFT,ACCESSORY DRI
EA
1
20
15
PAHZZ
5315-00-616-5522
96906
MS35756-12
.KEY
EA
1
20
16
PAHZZ
3120-00-086-8364
15434
116389
.BEARING WASHER,THRU
EA
1
20
17
PAHZZ
5310-00-081-9292
15434
116390
.WASHER,FLAT
EA
1
20
18
XDHZZ
15434
190769
.COUPLING
EA
1
20
19
PAHZZ
5310-00-442-6899
15434
191517
.NUT,SELF-LOCKING,HE
EA
1
20
20
PFFZZ
5315-00-616-5527
96906
MS35756-18
KEY,WODDRUFF PART OF KIT P/N 3018762
EA
1
20
21
PAFZZ
5310-00-209-0965
96906
MS35338-47
WASHER,LOCK
EA
5
20
22
PAFZZ
5305-00-071-1788
96906
MS90728-87
SCREW,CAP,HEXAGON H
EA
5
3120-00-792-9834
C-55
TM 5-2815-241-34&P
FIGURE 21. ENGINE COMPRESSION BRAKE.
C-56
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
( a ) (b)
FIG. ITEM
NO. NO.
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0112-ENGINE BRAKE
15434 199201
BRAKE,COMPRESSION ENGINE ASSEMBLY
EA
1
XDFZZ
15434 1484
PISTON,SLAVE
EA
2
3
XDFZZ
15434 1022
SPRING,SLAVE PISTON
EA
2
21
4
XDFZZ
15434 1289
RETAINER SLAVE PISTON SPRING
EA
2
21
5
XDFZZ
15434 1023
.RING,RETAINING
EA
2
21
6
XDFZZ
15434 1492
SCREW,CAP,HEXAGON HEAD SPRING RETAINER
EA
2
21
7
XDFZZ
15434 1030
WASHER,FLAT
EA
2
21
8
XDFZZ
15434 1011
SPRING MASTER PISTON
EA
2
21
9
XDFZZ
15434 1017
PISTON,MASTER
EA
2
21
10 XDFZZ
15434 2689
VALVE ASSEMBLY SOLENOID
EA
1
21
11
XDFZZ
15434 2390
HARNESS
EA
1
21
12
XDFZZ
15434 1081
SEAL,RlNG SOLENOID UPPER
EA
1
21
13
XDFZZ
15434 1082
SEAL,RING SOLENOID CENTER
EA
1
21
14
XDFZZ
15434 1083
.SEAL,RING SOLENOID LOWER
EA
1
21
15
XDFZZ
15434 1026
.NUT,PLAIN,HEXAGON ADJUSTING SCREW
EA
2
21
16
XDFZZ
15434 1031
.SETSCREW
EA
2
21
17
XDFZZ
15434 2299
.TERMINAL BUSHING LEADOUT
EA
1
21
18
XDFZZ
15434 1200
.SPOOL ASSEMBLY CONTROL VALVE
EA
1
21
19
XDFZZ
15434 1012
.SPRING,
EA
2
21
20
XDFZZ
15434 4136
.COVER,CONTROL VALVE
EA
2
21
21
XDFZZ
15434 1265
.SCREW,CAP,SOCKET HE AIR BLEED
EA
2
21
1 XDFFF
21
2
21
CONTROL VALVE
C-57
TM 5-2815-241-34&P
FIGURE 22. FUEL INJECTORS.
C-58
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a) (b)
FIG. ITEM
NO. NO.
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
GROUP 03-FUEL SYSTEM
0301- FUEL INJECTOR
22
1 PAFHH
2910-01-150-2631
15434 3018323
NOZZLE,FUEL INJECTI
EA
6
22
2 PAFZZ
5305-01-060-5958
15434 165006
.SCREW,CAP,HEXAGON H CLAMP MTG
EA
2
22
3 PAFZZ
5340-00-134-3529
15434 191218
.CLAMP
EA
1
22
4 PAHZZ
2910-00-238-5435
15434 191916
.PLUNGER,DETENT
EA
1
22
5 PAHZZ
2910-00-237-0056
15434 AR40065
.PARTS KIT,FUEL INJE
EA
1
22
6 PAHZZ
2910-01-070-9710
15434 167157
..BALL CHECK,FUEL INJ
EA
1
22
7 PAHZZ
5360-00-132-0245
15434 166009
.SPRING INJECTOR
EA
1
22
8 PAHZZ
2910-01-105-6457 15434 185139
.ADAPTER,INJECTOR
EA
1
22
9 PAHZZ
5365-00-815-1137 15434 174299
.CLIP,FILTER SCREEN
EA
1
22
10 PAHZZ
2815-00-815-1114 15434 174298
.STRAINER,ELEMENT,SE
EA
1
22
11 PAHZZ
5330-00-924-7757 96906
.PACKING,PREFORMED PART OF KIT P/N 3801330
EA
1
22
12 PAHZZ
5330-00-132-0276 15434 193736
.GASKET PART OF KIT P/N 3801330
EA
2
22
13 PAHZZ
5315-01-079-6506 15434 203426
.PIN,SPIRAL
EA
2
22
14 PAHZZ
2910-01-152-8531 15434 3012537
.CUP,INJECTOR
EA
1
22
15 PAHZZ
5340-01-079-4678 15434 185138
.RETAINER,CUP
EA
1
MS9241-024
C-59
TM 5-2815-241-34&P
FIGURE 23. FUEL PUMP HOUSING.
C-60
TM 5-2815-241-34&P
SECTION II
(2)
(1)
ILLUSTRATION
(a)
FIG.
NO.
(b)
ITEM
NO.
SMR
CODE
(3)
NATIONAL
STOCK
NUMBER
(4)
FSCM
(6)
(5)
(7)
DESCRIPTION
PART
NUMBER
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0302-FUEL PUMPS
FUEL PUMP ASSEMBLY
EA
1
MS9021-116
.PACKING,PREFORMED
EA
1
15434
139473
.PLUG,MACHINE THREAD
EA
1
15434
112076
.PLUG,FUEL,OUTLET
EA
1
15434
138782
.SPRING,TORQUE CONTR
EA
1
15434
BM79290
.HOUSING,FUEL PUMP
EA
1
15434
NM73902
..HOUSING ASSEMBLY
EA
1
2910-00-603-2835
15434
BM76665
...BARREL ASSEMBLY
EA
1
9 PAHZZ
5315-00-369-2588
15434
68549
.... PIN,STRAIGHT,HEADLE
EA
1
23
1 PAFHH
2910-01-047-6021
15434
3007300-2764
23
2 PAFZZ
5330-00-582-7484
96906
23
3 PAFZZ
5365-00-988-3668
23
4 PAFZZ
5365-01-160-1832
23
5 XDHZZ
23
6 PAHHH
23
7 XDHHH
23
8 PAHHH
23
2910-00-404-9999
23
10
PAHZZ
3120-00-810-6032
15434
100193
.... BEARING,SLEEVE
EA
1
23
11
PAHZZ
2910-00-400-5178
15434
163733
....CLIP,GOVERNOR
EA
1
23
12
PAHZZ
5315-00-844-0140
15434
118227
....PIN,HOLLOW
EA
1
23
13
PAHZZ
2910-00-829-5603
15434
140618
.... HOUSING,SPRING PACK
EA
1
23
14
PAHHH
2910-01-091-3204
15434
BM98430
..PLUNGER,GOVERNOR
EA
1
23
15
PAHZZ
5365-00-507-3224
15434
101841
...SHIM
EA
1
23
15
PAHZZ
5365-00-507-3225
15434
101842
...SHIM
EA
1
23
15
PAHZZ
5365-00-543-3744
15434
101843
...SHIM
EA
1
23
16
PAHZZ
2910-01-086-5544
15434
182530
...PLUNGER,DETENT
EA
1
23
17
PAHZZ
5315-00-907-0711
72962
590220940406
...PIN,SPRING
EA
1
23
18
PAHZZ
2910-00-829-5604
15434
144302
...SPACER,FUEL PUMP
EA
1
23
19
XDHZZ
15434
138905
...BEARING,SLEEVE
EA
1
23
20
PAHZZ
2990-00-772-1778
15434
70690
...DRIVER,PLUNGER
EA
1
23
21
PFHHH
2910-00-887-8354
15434
BM73718
.WEIGHT AND CARRIER
EA
1
23
22
PAHZZ
3120-00-904-9595
15434
163944
..BUSHING,GOVERNOR
EA
1
23
23
XDHHH
15434
AR-00796
..CARRIER ASSEMBLY
EA
1
23
24 PAHZZ
2910-00-451-8063
15434
146437
...WEIGHT,GOVERNOR
EA
2
23
25 PAHZZ
5360-00-081-8487
15434
143847
...SPRING,HELICAL,COMP
EA
1
23
26 PFHZZ
5310-00-727-8353
80205
NAS620-5L
...SHIM,WEIGHT ASSIST
EA
1
23
27 PAHZZ
5315-00-082-0448
15434
144178
...PIN,SHOULDER,HEADLE
EA
1
BARRE
C-61
TM 5-2815-241-34&P
(1)
ILLUSTRATION
(a) (b)
FIG. ITEM
NO. NO.
SECTION II
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
(8)
QTY
U/M INC
IN
USABLE
ON
UNIT
CODE
0302(CONT)
23
28
XDHZZ
23
29
PAHZZ
3020-00-701-11
15434
23
30
PFHZZ
5365-00-256-28
96906
23
31
PAFZZ
4820-00-130-4820
15434
C-62/(63 blank)
15434
142204
. . . PIN,WEIGHT PIVOT
113244
. . . GEAR,SPUR
MS16632-1050
... RING,RETAINER
175836
.VALVE,CHECK
EA
2
EA
1
EA
1
EA
1
TM 5-2815-241-34&P
FIGURE 24. MAINSHAFT COVER.
C-64
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
( a ) (b)
FIG. ITEM
NO.
NO.
(2)
(3)
(4)
(5)
(6)
(7)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
U/M
USABLE
ON
CODE
(8)
QTY
INC
IN
UNIT
0302(CDNT)
24
1 PAFZZ
3010-00-447-9799
15434
162426
INSERT,FLEXIBLE COU
EA
1
24
2 PAFHH
2990-00-237-0058
15434
BM69886
COVER ASSEMBLY MAIN
EA
1
24
3 PAHZZ
5306-00-019-4227
15434 69793
.BOLT,MACHINE
EA
1
24
4 PAHZZ
5310-00-261-7340
96906
.WASHER,LOCK COUPLING
EA
1
24
5 PAHZZ
5310-00-486-2505
15434 108330
.WASHER,FLAT
EA
1
24
6 PAHZZ
3040-00-695-3285
15434 101918
.COUPLING HALF,SHAFT
EA
1
24
7 PAHZZ
3020-00-567-4356
15434 101983
.GEAR,HELICAL
EA
1
24
8 PAFHH
2910-00-369-8240
15434 BM68879
.HOUSING COVER ASSEM
EA
1
24
9 PAHZZ
5330-00-010-8497
15434 104038
..SEAL,PLAIN ENCASED
EA
2
MS35338-8
24
10
PAHZZ
5315-00-695-3292
96906 MS20066-116
..KEY,MACHINE
EA
1
24
11
PAHHH
2910-00-567-4338
15434
AR51307
..GEARSHAFT,SPUR-WORM
EA
1
24
12
PAHZZ
2910-00-773-9369
15434
100192
. . . SHAFT,SHOULDERED DRIVE
EC
1
24
13
PAHZZ
3110-00-144-8499
24617 903302
...BEARING,BALL
El
1
24
14
PAHZZ
3020-00-562-1173
15434 103036
. . . GEAR,SPUR
El
1
24
15 PAHZZ
5365-00-721-7884
15434
70699
..RING,RETAINING
EA
1
24
16 PAFZZ
5330-00-506-4866
15434
100764
.GASKET COVER TO HOUSING PART OF KIT P/N BM68356
EA
1
24
17 PFFZZ
5305-00-071-2056
96906
MS90728-90
.CAPSCREW
EA
4
24
18
PAFZZ
5310-00-209-0965
96906
MS35338-47
.WASHER,LOCK
EA
4
24
19
PAFZZ
5310-00-562-6557
15434
S622
.WASHER,FLAT
EA
4
24
20
XDFZZ
15434
S274
NUT
EA
4
24
21
PAFZZ
5330-01-109-1283
15434
210374
GASKET PUMP TO COMPRESSOR PART OF KIT P/N 3018762
EA
1
24
22
PAFZZ
5305-00-161-0902
15434
118226
SCREW COVER TO HOUSING
EA
1
24
23
PFFZZ
5305-00-071-2241
96906
MS90725-10
.CAPSCREW
EA
6
24
24
PAFZZ
5310-00-159-6209
96906
MS122032
.WASHER,LOCK
EA
6
24
25
PAFZZ
5310-00-141-1795
88044
AN960-416
WASHER COVER TO HOUSING
EA
6
24
26
PAFZZ
5310-00-410-6756
15434
S606
.WASHER,LOCK
EA
1
24
27 PAFZZ
5310-00-014-5850
96906 MS27183-42
.WASHER,FLAT BODY TO COVER
EA
1
C-65
TM 5-2815-241-34&P
FIGURE 25. GEAR PUMP.
C-66
TM 5-2815-241-34&P
SECTION II
(2)
(1)
ILLUSTRATION
(b)
(a)
FIG. ITEM
NO. NO.
(3)
(4)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
(7)
(6)
(5)
DESCRIPTION
PART
NUMBER
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
25
1
PAFHH
2910-00-869-3428
15434
BM97502
.PUMP,FUEL
EA
1
25
2
PAHZZ
120-00-719-5719
15434
101468
..BUSHING,SLEEVE
EA
1
25
3 PAFHH
910-01-096-9200
15434
BM97497
..HOUSING
EA
1
25
4 PAHZZ
315-00-014-1244
30760
17300-1251
...PIN,STRAIGHT,HEADLE COVER TO HOUSING
EA
2
25
5 PAFZZ
365-00-716-6580
15434
68606
...PLUG,MACHINE THREAD
EA
1
25
6 PAHZZ
020-00-892-4704
15434
119363
..GEAR,SPUR
EA
2
25
7 PAHZZ
910-00-933-3012
15434
175864
..SHAFT,IDLER,GEA
EA
1
25
8 PAHZZ
910-00-567-4354
15434
100215
..SHAFT,SHOULDERED
EA
1
25
9 PAHZZ
330-00-567-3463
15434
110855
..GASKET COVER TO HOUSING PART OF KIT P/N BM68356
EA
1
ASSEMBLY,FU
25
10
PAHZZ
730-00-803-8353
15434
116936
..CHECK VALVE,ELBOW
EA
1
25
11
PAFZZ
5306-00-485-0790
15434
70790
.BOLT,MACHINE SOCKET HEAD
EA
4
25
12
PAFZZ
1310-00-484-1718
15434
181466
.WASHER,LOCK
EA
4
25
13
PAFZZ
5330-00-006-2494
15434
2‘10647
GASKET PART OF KIT P/N BM68356
EA
1
C-67
TM 5-2815-241-34&P
FIGURE 26. DAMPER.
C-68
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a)
(b)
FIG. ITEM
NO. NO.
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0302(CONT)
26
1 PAFHH
2910-00-828-7126
15434 B M 7 6 3 4 0
.DAMPENER,FLUID PRES
EA
1
26
2
5305-00-071-2241
96906 MS90725-10
..CAPSCREW
EA
2
26
3 PAFZZ
5310-00-159-6209 96906 MS122032
..WASHER,LOCK
EA
2
26
4 PAFZZ
5310-00-141-1795
..WASHER
EA
2
26
5 PAHZZ
2910-00-829-5616 15434 153336
..HOUSING,FUEL PUMP
EA
1
26
6 PAHZZ
5330-00-809-2667 15434 1 0 0 0 9 9
..PACKING,PREFORMED PART OF KIT P/N BM68356
EA
1
26
7 PAHZZ
2910-00-951-3536
15434 202897
..DISK,SOLID,PLAIN
EA
1
26
8 PAHZZ
5330-00-809-3276
15434 139988
..PACKING
EA
1
26
9 PAHZZ
5365-00-965-0870
15434 160514
..SPACER RING PART OF KIT P/N BM68356
EA
26
10 PAHZZ
2910-00-829-5617 15434
153338
..COVER,ACCESS
EA
1
26
11 PAFZZ
5310-00-141-1795
AN960-416
.WASHER
EA
1
26
12 PAFZZ
5310-00-484-1718 15434
181466
.WASHER,LOCK
EA
2
26
13 PAFZZ
5306-00-485-0790 15434
70790
.BOLT,MACHINE SOCKET HEAD
EA
2
26
14 PAFZZ
4730-01-078-9859 15434
203849
.ELBOW,TUBE TO BOSS
EA
1
26
15 PAHZZ
5330-00-252-8888 16954 691-10014
.GASKET PART OF KIT P/N BM68356
EA
1
26
16 PAFZZ
4730-00-803-8353 15434
.ELBOW,CONNECTION
EA
1
PAFZZ
88044 AN960-416
88044
116936
PART OF KIT P/N BM68356
1
C-69
TM 5-2815-241-34&P
FIGURE 27. SPRING PACK.
C-70
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a) ( b )
F I G . ITEM
NO. NO.
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7) ( 8 )
USABLE
ON
CODE
QTY
U/M INC
IN
UNIT
0302(CONT)
.PLUNGER,FUEL INJECT
EA
1
15434 BM69886
.COVER ASSEMBLY MAIN IDLING SPRING
EA
1
5360-00-082-0124
15434
144195
..SPRING,HELICAL,COMP
EA
1
4 PAFZZ
5310-00-507-3259
15434
70715
..WASHER,FLAT
EA
1
27
5 PAFZZ
2910-00-132-0769
15434 BM67416
..GLIDE,CLIP ASSEMBLY
EA
1
27
6 PAFZZ
5305-00-506-5722 15434 70716
..SETSCREW
EA
1
27
7 XDFFF
15434 BM74747
.SPRING ASSEMBLY
EA
1
27
8 PAFZZ
5360-00-461-5738
15434 143251
..SPRING,HELICAL,COMP
EA
1
27
9 PAFZZ
5365-00-507-3260
15434 70717
..SPACER RING
EA
1
27
9 PAFZZ
5365-00-507-3261 15434
70717A
..SHIM
EA
1
27
9 PAFZZ
5365-00-507-3262 15434 70717B
..SHIM
EA
1
27
9 PAFZZ
5365-00-462-4504 15434 189800
..SHIM GOVERNOR
EA
1
27
10 PAFZZ
5340-00-898-1497 15434 70713
.RING RETAINING
EA
1
27
11 PFFZZ
5365-00-807-2636 96906 MS16625-1100
.RING,RETAINING
EA
1
27
12 PAFZZ
5330-00-562-1176
.GASKET PART OF KIT P/N BM68356
EA
1
27
13 PAFZZ
2910-00-858-3522 15434 44678
.COVER,SPRING PACK
EA
1
27
14 PAFZZ
5310-00-141-1795 88044 AN960-416
.WASHER SPRING PACK COVER TO HOUSING
EA
4
27
15 PAFZZ
5310-00-484-1718 15434 181466
.WASHER,LOCK SPRING PACK COVER TO HOUSING
EA
4
27
16 PAFZZ
5305-01-072-8831
15434 203619
.SCREW SPRING PACK COVER TO HOUSING
EA
1
27
17 PAFZZ
5340-00-464-7064
15434 124020
.WIRE,SHAFT SEAL
EA
1
27
18 PAFZZ
2910-00-065-5544
15434 124019
.SEAL,FUEL PUMP REGU
EA
2
27
19 PAFZZ
4730-00-369-7824 15434 177999
.PLUG,PIPE
EA
1
27
20 PAFZZ 5305-00-071-2241
.CAPSCREW
EA
3
27
1 PAFZZ
2910-00-369-8251
15434
27
2 PAFFF
2990-00-237-0058
27
3 PAFZZ
27
140925
15434 70705
96906 MS90725-10
C-71
TM 5-2815-241-34&P
FIGURE 28. ANEROID CONTROL.
C-72
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
( a ) (b)
FIG. ITEM
NO. NO.
SMR
CODE
(3)
(4)
(5)
(6)
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7) (8)
U/M
USABLE
ON
CODE
QTY
INC
IN
UNIT
0302(CONT)
15434
AR-09454-00EF
CONTROL,ANEROID
EA
1
5310-00-159-6209
96906
MS122032
.WASHER,LOCK
EA
3
5305-00-071-2241
96906 MS90725-10
.CAPSCREW COVER TO HOUSING
EA
3
15434
114947
.COVER,BELLOWS
EA
1
15434
114739
.BELLOWS
EA
1
XDHZZ
15434
114755
.PISTON,BELLOWS
EA
1
7
XDHZZ
15434
115033
.SHAFT,BELLOWS ACTUA
EA
1
28
8
XAHZZ
15434
140357
.HOUSING,CONTROL
EA
1
28
9
XDHHH
15434
EM69381
.VALVE,LEVER AND PIN
EA
1
28
10
PAHZZ
15434
114791
..PACKING,PREFORMED PART OF KIT P/N BM68356
EA
1
28
11 XDHZZ
15434
140358
..VALVE
EA
1
28
12
XDHZZ
15434
115034
..LEVER
EA
1
28
13
XDHZZ
15434
114940
..PIN
EA
1
28
14
XDHZZ
15434
114773
.COVER,CONTROL
EA
1
28
15
PAHZZ
4730-00-018-9566
15434
S911B
.PLUG,PIPE
EA
2
28
16
PAHZZ
5305-00-063-5043
88044
AN565F428H24
.SCREW,ADJUSTING
EA
1
28
17
PAHZZ
5330-00-580-5327
15434
70815
.PACKING WITH RETAIN
EA
1
28
18
PAHZZ
5310-00-757-6367
15434
108074
.NUT,BELLOWS ACTUATING SHAFT
EA
1
28
19
XDHZZ
15434
114765
.PLUG,PLUNGER
EA
1
28
20
XDHZZ
15434
114764
.RETAINER,SPRING
EA
1
28
21
PAHZZ
91265
TS33-016
.GASKET SPRING RETAINER
EA
1
28
22
XDHZZ
15434
114745
.SPRING,PRESSURE VAL
EA
1
28
23
XDHZZ
15434
114795
.WASHER,PRESSURIZING
EA
1
28
24
XDHZZ
15434
140414
.PLUNGER,PRESSURE
EA
1
28
25
XDHZZ
15434
114921
.SHIM,SPRING
EA
V
28
26
XDHZZ
15434
124033
.SPRING,BELLOWS
EA
1
28
27
XDHZZ
15434
114754
.WASHER BELLOWS RETAINER
EA
1
28
28 XDFZZ
15434
208621
TUBE AIR SUPPLY
EA
1
28
29 PAFZZ
15434
144372
ELBOW,TUBE TO HOSE
EA
1
28
1
XDFHH
28
2
PAHZZ
28
3
PAHZZ
28
4
XDHZZ
28
5
PAHZZ
28
6
28
2910-00-767-4018
5330-00-816-8148
5330-00-951-3538
4730-01-157-8923
PART OF KIT P/N BM68356
C-73
TM 5-2815-241-34&P
(1)
ILLUSTRATION
(a)
FIG.
NO.
(b)
ITEM
NO.
(2)
SMR
CODE
SECTION II
(3)
NATIONAL
STOCK
NUMBER
(4)
(5)
(6)
PART
NUMBER
FSCM
(7)
DESCRIPTION
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0302(CONT)
28
30 PAFZZ
28
31 XDFZZ
28
32 PFFZZ
28
96906 MS39230-1
ELBOW
EA
2
15434 AS0501900SS
HOSE,CONTROL
EA
1
15434 AS0500760SS
HOSE,CONTROL
EA
1
33 XDFZZ
15434
ADAPTER
EA
1
28
34 XDFZZ
15434 NPN
ADAPTER
EA
1
28
35 PAFZZ
4730-00-196-0837
96906 MS51887-5
ADAPTER
EA
1
28
36 PAFZZ
5305-00-782-9489
96906 MS90728-66
SCREW,CAP,HEXAGON H
EA
2
28
37 PAFZZ 5310-00-261-7340
96906 MS35338-8
WASHER,LOCK
EA
4
28
38 XDFZZ
15434 204851
BRACKET
EA
1
28
39 PAFZZ
5310-00-080-6004
96906 MS27183-14
WASHER,FLAT
EA
2
20
40 PAFZZ
5305-00-942-2196
96906 MS18154-60
SCREW,CAP,HEXAGON H
EA
2
28
41 PAFZZ
5365-00-082-1193
15434
SPACER
EA
2
28
42 XDFZZ
FILTER,AIR
EA
1
C-74/(75 blank)
4730-00-287-1649
4720-01-169-7509
143950
63385
15434 213713
TM 5-2815-241-34&P
FIGURE 29. TURBOCHARGER.
C-76
TM 5-2815-241-34&P
SECTION II
(1)
ILLUSTRATION
(a) (b)
FIG. ITEM
NO. NO.
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0305-SUPERCHARGER, BLOWER,
TURBOCHARGER, OR ALTITUDE
COMPENSATOR
29
1 PAFFF
2990-01-046-0171
15434
AR12604
TURBOCHARGER
EA
1
29
2
PAFZZ
2950-00-275-3355
15434
195469
.HOUSING,TURBINE
EA
1
29
3
PFFZZ
5310-00-164-1904
15434
S222A
.NUT,SELF-LOCKING PART OF KIT P/N 3801098
EA
1
29
4
PAFZZ
2950-00-275-9344
15434
212563
.IMPELLER,TURBOCHARG
EA
1
29
5
PAFZZ
5330-00-237-6266
15434
156444
.SEAL PART OF KIT P/N 3801098
EA
1
29
6
PAFZZ
2950-00-275-8276
15434
211375
.RING,SEALlNG PART OF KIT P/N 3801098
EA
1
29
7
PAFZZ
2950-00-275-4658
15434
203294
.PLATE,DIFFUSER
EA
1
29
8
PAFZZ
5310-00-159-6209
96906
MS122032
.WASHER,LOCK
EA
8
29
9
PAFZZ
5305-00-230-1939
15434
S118A
.CAPSCREW
EA
8
29
10
PAFZZ
5340-00-103-9988
15434
156416
.STRAP,RETAINING
EA
2
29
11
PAFZZ
5305-00-411-9340
15434
194010
.SCREW
EA
2
29
12
PAFZZ
5310-00-562-6560
15434
S631
.WASHER,FLAT
EA
4
29
13
PAFZZ
5310-00-680-6874
72962
1801-040
.NUT,CLAMP
EA
2
29
14
PAFZZ
5330-00-426-2933
15434
202457
.PACKING,PREFORMED PART OF KIT P/N 3801098
EA
1
29
15
PAFZZ
5330-00-632-6182
15434
170510
.GASKET PART OF KIT P/N 3801098
EA
1
29
16
PAFZZ
3120-00-682-7706
15434
156420
.BEARING
EA
1
29
17
PAFZZ
2950-01-085-3580
15434
216802
.SLEEVE,TURBOCHARG PART OF KIT P/N 3801098
EA
1
29
18
PAFZZ
2950-00-432-1559
15434
202376
.HOUSING,BEARING
EA
1
29
19
PAFZZ
5330-00-406-7789
15434
202377
.PACKING,FLAT FIBER PART OF KIT P/N 3801098
EA
1
29
20
PAFZZ
2990-00-477-6159
15434
171570
.SHIELD,HEAT
EA
1
29
21
PAFZZ
5330-01-136-8431
15434
3022969
.RING,RETAINING PART OF KIT P/N 3801098
EA
2
29
22
PAFZZ
2950-00-275-9325
15434
AR10058
.WHEEL AND SHAFT
EA
1
29
23
PFFZZ
2815-01-136-5825
15434
202506
.CASING,TURBINE
EA
1
29
24
PAFZZ
2815-00-406-6737
15434
128936
.PLATE,NAME,TURBO
EA
1
29
25
PAFZZ
5305-00-804-6318
15434
S2286
.SCREW,DRIVE
EA
4
29
26
PFFZZ
5310-00-059-9264
96906
MS21045C6
NUT,LOCK PART OF KIT P/N 3801098
EA
4
29
27
PAFZZ
5330-00-194-8385
15434
190849
GASKET PART OF KIT P/N 3801330, 3801098
EA
1
29
28
PAFZZ
5307-00-922-2626
15434
3010915
STUD,EXHAUST MANIFO
EA
4
C-77
TM 5-2815-241-34&P
(1)
ILLUSTRATION
( a ) (b)
FIG. ITEM
NO.
NO.
SECTION II
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
USABLE
ON
CODE
(8)
QTY
U/M INC
IN
UNIT
0305(CONT)
29
29
PAOZZ
5340-00-400-3449
15434
108722
CLAMP,LOOP
EA
2
29
30
PAOZZ
4720-01-085-1316
15434
AC1600300NF
HOSE,NONMETALLIC
EA
1
29
31
XDOZZ
15434
213936
TUBE ASSEMBLY
EA
1
29
32
PAOZZ
4730-01-006-5103
15434
183669
ADAPTER,STRAIGHT
EA
1
29
33
PAOZZ
4730-09-494-9350
15434
197733
COUPLING,PIPE
EA
1
29
34
KDOZZ
15434
208668
ADAPTER
EA
1
29
35
XDOZZ
15434
209959
HOSE,TEFLON OIL INLET
EA
1
29
29
29
29
29
29
29
29
29
29
29
15434
3801098
3
5
6
14
15
17
19
21
26
27
KIT,TURBOCHARGER RE
NUT,SELF-LOCKING
SEAL
RING,SEALING
PACKING.PREFORMED
GASKET
SLEEVE,TURBOCHARG
PACKING,FLAT FIBER
RING,RETAlNlNG
NUT,LOCK
GASKET
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
1
1
1
1
1
1
1
1
2
4
1
PAFZZ
C-78/(79 blank)
2815-01-128-9187
TM 5-2815-241-34&P
TA242325
FIGURE 30. SHUT DOWN VALVE.
C-80
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0306-TANKS, LINES, FITTINGS, HEADERS
30
1
PAFHH
4810-00-695-3284
15434
3035342
VALVE SOLENOID
EA
1
30
2
PAFZZ
5355-00-082-1189
15434
129838
.KNOB OVERRIDE
EA
1
30
3
PAHZZ
2990-00-829-5600
15434
129826
.HOUSING, SHUT OFF VA
EA
1
30
4
PAFZZ
4730-00-011-3175
15434
70295
.PLUG, PIPE
EA
1
30
5
PAHZZ
4820-01-085-2616
15434
3000266
.STEM, FLUID VALVE
EA
1
30
6
PAHZZ
5330-00-132-0274
15434
190876
PACKING, PREFORMED PART OF KIT P/N BM68356
EA
1
30
7
PAHZZ
2910-01-146-1048
15434
3030970
.DISK, VALVE
EA
1
30
8
PAHZZ
5310-00-082-1888
15434
129768
.WASHER, SPRING TENSI
EA
1
30
9
PAHZZ
5330-00-081-9299
15434
129888
.PACKING, PREFORMED PART OF KIT P/N BM68356
EA
1
30
10
PAHZZ
2910-00-084-7787
15434
129839
.COVER PLATE, ACCESS
EA
1
30
11
PAHZZ
2920-01-121-8859
15434
134072
.COIL ASSEMBLY
EA
1
30
12
PAFZZ
5310-00-922-2017
24617
0120217
.WASHER, LOCK
EA
4
30
13
PAHZZ
5305-00-138-9848
15434
187556
.SCREW, MACHINE
EA
4
30
14
PAHZZ
5305-00-509-8106
15434
S189C
SCREW, CAP, SOCKET HE
EA
2
30
15
PAFZZ
5310-00-484-1718
15434
181466
WASHER, LOCK
EA
2
30
16
PAFZZ
5310-00-262-2986
15434
67684
WASHER, FLAT
EA
2
30
17
PAFZZ
5330-00-951-3538
91265
TS33-016
GASKET PART OF KIT P/N BM68356
.
EA
1
C-81
TM 5-2815-241-34&P
FIGURE 31. FUEL PUMP FILTER.
C-82
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0309-FUEL FILTERS
31
1
PAOZZ
5365-00-507-3271
15434
157088
PLUG, MACHINE THREAD
EA
1
31
2
PAOZZ
5330-00-961-9470
15434
154088
SEAL CAP PART OF KIT P/N BM68356
EA
1
31
3
PAOZZ
5360-00-597-4570
15434
70700
SPRING, HELICAL, COMP
EA
1
31
4
PAOZZ
2910-00-790-8736
15434
146483
FILTER ELEMENT, FLUI
EA
1
31
5
PAOZZ
2910-00-470-7075
79396
33341
FILTER, ELEMENT, FLUI
EA
1
C-83
TM 5-2815-241-34&P
TA242327
FIGURE 32. GLOW PLUG AND PREHEATER.
C-84
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0311-ENGINE STARTING AIDS
32
1
XDOZZ
15434
106452R91
PRIMER, HAND ASSEMBL
EA
1
32
2
XDOZZ
15434
AC9
PLUG, GLOW
EA
1
32
3
XDOZZ
15434
267627C2
HOUSING, PREHEATER
EA
1
32
4
XDOZZ
15434
236985R1
NOZZLE, PREHEATER
EA
1
C-85
TM 5-2815-241-34&P
FIGURE 33. THROTTLE SHAFT.
C-86
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
2
3
1
1
1
1
1
1
1
1
1
1
2
1
USABLE
ON
CODE
0312-ACCELERATOR, THROTTLE OR CHOKE
CONTROLS
33
1
PAOZZ
5350-00-774-4246
15434
109915
SCREW, THROTTLE ADJU
33
2
PAOZZ
5310-00-971-7989
96906
MS35691-5
NUT, PLAIN, HEXAGON LEVER AND THROTTLE ADJUSTING
33
3
XDFFF
15434
AR51317
THROTTLE SHAFT ASSE
33
4
PAFZZ
5330-00-081-9289
15434
100478
.PACKING, PREFORMED PART OF KIT P/N BM68356
33
5
PAFZZ
3040-00-085-7439
15434
149030
.SHAFT, SHOULDERED
33
6
PAFZZ
3110-01-079-8190
15434
213769
.PLUG, BALL
33
7
PAFZZ
5330-01-072-8983
15434
213768
.PACKING, PREFORMED
33
8
PAFZZ
5315-01-973-0414
15434
149040
.PIN, GROOVED, HEADED
33
9
PAFZZ
2990-00-858-3526
15434
148977
COVER, THROTTLE SHAF
33
10
PAFZZ
5365-00-786-0102
15434
S16206
RING, RETAINING
33
11
XDOZZ
15434
AR03034
LEVER, THROTTLE
33
12
PAOZZ
5305-00-493-3959
15434
S159B
SCREW, CAP, HEXAGON H
33
13
PAOZZ
5310-00-159-6209
96906
MS122032
WASHER, LOCK
33
14
PAOZZ
5310-00-141-1795
88044
AN960-416
WASHER
C-87
TM 5-2815-241-34&P
TA242329
FIGURE 34. THERMOSTAT HOUSING.
C-88
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
GROUP 05-COOLING SYSTEM
0503-WATER MANIFOLD, HEADERS,
THERMOSTATS AND HOUSING GASKET
34
1
XDOZZ
34
2
PAOZZ
34
3
XDOZZ
2930-0-732-5206
15434
102231
HOUSING, THERMOSTAT
EA
1
15434
145977
VALVE, TEMPERATURE R
EA
1
15434
215172
CONNECTION, WATER, OU
EA
1
C-89
TM
5-2815-241-34&P
TA242330
FIGURE 35. WATER MANIFOLD.
C-90
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0503 (CONT)
35
1
PAOZZ
5310-00-261-7340
96906
MS353368-8
WASHER, LOCK
EA
12
35
2
PAOZZ
2930-00-928-3596
15434
133342
MANIFOLD, WATER REAR
EA
1
35
3
PAOZZ
5305-00-068-0511
96906
MS90728-62
SCREW, CAP, HEXAGON H
EA
12
35
4
PAOZZ
5330-00-506-4874
15434
70624
PACKING, PREFORMED PART OF KIT P/N 3801330
EA
4
35
5
PAOZZ
4730-00-404-2906
15434
130394
COUPLING, TUBE
EA
2
35
6
PAOZZ
4730-00-289-4770
15434
S995
PLUG, PIPE
EA
1
35
7
PAOZZ
2930-00-928-3595
15434
130118
MANIFOLD, WATER CENTER
EA
1
35
8
PAOZZ
4730-00-801-8186
15434
S-915-A
PLUG, PIPE
EA
3
35
9
XDOZZ
15434
211016
MANIFOLD, WATER FRONT
EA
1
35
10
PAOZZ
5330-01-077-5228
15434
212161
PACKING, PREFORMED PART OF KIT P/N 3801330
EA
2
35
11
PAOZZ
5305-01-114-9279
15434
S110
SCREW, CAP, HEXAGON, H
EA
1
35
12
PAOZZ
5310-00-407-9566
96906
MS35338-45
WASHER, LOCK
EA
1
35
13
PAOZZ
4710-01-085-6130
15434
211027
TUBE, BENT, METALLIC
EA
1
35
14
PAOZZ
5330-00-143-8369
15434
148203
GASKET PART OF KIT P/N 3801330
EA
6
C-91
TM 5-2815-241-34&P
TA242331
FIGURE 36. WATER PUMP.
C-92
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0504-WATER PUMP
36
1
PAOZZ
5305-00-846-5703
96906
MS90728-70
SCREW, CAP, HEXAGON H
EA
2
36
2
PAOZZ
5310-00-261-7340
96906
MS35338-8
WASHER, LOCK
EA
15
36
3
PAOZZ
4730-00-801-8186
15434
S-915-A
PLUG, PIPE
EA
1
36
4
PAOZZ
4730-00-044-4715
15434
S962
PLUG, PIPE
EA
1
36
5
PAOZZ
5305-00-068-0511
96906
MS90728-62
SCREW, CAP, HEXAGON H
EA
3
36
6
XDOZZ
15434
210806
CONNECTION
EA
1
36
7
XDOZZ
15434
210805
GASKET
EA
1
36
8
PAOZZ
5310-00-486-2505
15434
108330
WASHER, FLAT
EA
3
36
9
PAOZZ
5305-00-725-2317
96906
MS90728-64
CAPSCREW
EA
1
36
10
XDOZZ
15434
214476
BRACKET, CONNECTION
EA
1
36
11
PAOZZ
5330-01-080-5020
15434
208132
GASKET
EA
1
36
12
PAOZZ
4730-00-909-8627
96906
MS35842-13
CLAMP, HOSE
EA
12
36
13
XDOZZ
15434
63495-D
HOSE
EA
1
36
14
XDOZZ
15434
209600
PIPE, WATER BY-PASS
EA
1
36
15
PAOZZ
15434
43463A
PACKING, PREFORMED PART OF KIT P/N 3801330
EA
2
5330-00-159-1464
BM68356
36
16
PAOZZ
5305-01-114-9279
15434
S110
SCREW, CAP, HEX, HD
EA
1
36
17
PAOZZ
5310-00-407-9566
96906
MS35338-45
WASHER, LOCK
EA
1
36
18
PAOZZ
5340-01-135-7250
15434
214617
CLAMP, RIM, CLENCHING
EA
1
36
19
PAOOO
15434
AR-045090
PUMP, WATER
EA
1
36
20
PAOZZ
15434
S911B
.PLUG, PIPE
EA
1
36
21
XDOZZ
15434
214173
.SEAL, WATER PUMP
EA
1
36
22
XDOOO
15434
AR08853
.IMPELLER
EA
1
36
23
PAOZZ
15434
3033677
..PACKING WITH RETAIN
EA
1
36
24
XAOZZ
15434
208134
..IMPELLER, WATER PUMP
EA
1
36
25
XAOZZ
15434
210238
.BODY, WATER PUMP
EA
1
36
26
PAOZZ
15434
203100
.GASKET, PUMP PART OF KIT P/N 3018762
EA
1
36
27
XDOZZ
15434
208138
.SHAFT, WATER PUMP
EA
1
36
28
PAOZZ
15434
S16073
.BEARING, BALLL, ANNULA
EA
2
2930-01-046-3493
4730-00-018-9566
5330-00-005-0407
5330-00-011-7939
3110-00-144-8519
C-93
TM 5-2815-241-34&P
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
SECTION II
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0504 (CONT)
36
29
PAOZZ
5365-00-420-9696
15434
112302
.RING, RETAINING
EA
1
36
30
PAOZZ
5365-01-132-1984
15434
196844
.SPACER
EA
1
36
31
PAOZZ
2815-00-815-0355
15434
S16255
.RING, BEARING RETAIN
EA
1
36
32
PAOZZ
5330-01-080-2992
15434
3038998
.SEAL, PLAIN, ENCASED
EA
1
36
33
XDOZZ
15434
AR08854
.PULLEY, WATER PUMP
EA
1
36
34
XDOOO
15434
AR08851
IDLER, WATER PUMP
EA
1
36
35
XDOZZ
15434
210860
.CAPSCREW, BUTTON HEA
EA
1
36
36
PAOZZ
15434
61623
.WASHER, FLAT
EA
1
36
37
XDOZZ
15434
208118
.PULLEY, IDLER
EA
36
38
PAOZZ
3040-01-079-3468
15434
208119
.SHAFT, SHOULDERED
EA
1
1
1
36
39
PAOZZ
3110-01-144-8519
15434
S16073
.BEARING, BALL, ANNULA
EA
1
36
40
PAOZZ
2815-00-815-0355
15434
S16255
.RING, BEARING RETAIN
EA
1
36
41
PAOZZ
5330-01-086-3991
15434
145506
.PACKING, PREFORMED
EA
1
36
42
PAOZZ
5330-01-080-2992
15434
3038998
.SEAL, PLAIN ENCASED
EA
1
36
43
PAOZZ
5365-01-080-0409
15434
208120
.SPACER, SLEEVE
EA
1
36
44
PAOZZ
5310-01-145-0762
15434
213082
.WAHSER, FLAT
EA
1
36
45
PAOZZ
5310-00-763-8920
96906
MS51967-20
.NUT, PLAIN, HEXAGON
EA
1
36
46
PAOZZ
5305-00-269-2811
96906
MS90726-67
SCREW, CAP, HEXAGON H
EA
5
36
47
XDOZZ
15434
137797
CAPSCREW
EA
2
36
48
XDOZZ
15434
210804
CONNECTION, WATER TRANSFER
EA
1
36
49
PAOZZ
5305-00-404-1390
15434
S149A
SCREW, CAP, HEXAGON H
EA
2
36
50
PAOZZ
5305-00-058-6604
15434
182706
SCREW, CAP, HEXAGON H
EA
1
36
51
PAOZZ
5330-00-106-6370
15434
130226
GASKET PART OF KIT P/N 3018762
EA
1
36
2
2
2
4
4
5
5
8
8
10
10
PAHZZ
5330-01-092-4143
15434
3018762
9
10
32
5
7
15
16
3
5
36
36
SET, GASKET
GASKET
PACKING, PREFORMED
GASKET
GASKET
SEAL
GASKET
WASHER, LOCK
SEAL
GASKET
GASKET
GASKET
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
1
2
6
1
1
1
1
2
1
1
1
1
C-94
5310-00-276-2816
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0504 (CONT)
10
13
13
16
16
16
16
16
16
17
17
20
24
36
36
36
6
27
7
10
22
26
28
43
25
32
20
21
26
51
36
3
9
9
12
18
19
22
22
29
35
35
35
36
7
8
15
38
7
1
11
12
27
4
10
14
15
36
24
25
25
26
26
26
26
27
28
28
30
30
30
31
33
36
16
9
13
6
8
9
15
12
10
17
6
9
17
2
4
15
GASKET
GASKET
GASKET
GASKET
PACKING, PREFORMED
SPACER, RING
GASKET
PACKING, PREFORMED
GASKET
GASKET
GASKET
KEY, WOODRUFF
GASKET
GASKET, PUMP
GASKET
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
PAFZZ
5330-01-149-9715
15434
3801330
GASKET AND SEAL SET
GASKET
PACKING, PREFORMED
PACKING, PREFORMED
GASKET
GASKET
GASKET
PACKING, PREFORMED
GASKET
GASKET
PACKING, PREFORMED
PACKING, PREFORMED
GASKET
PACKING, PREFORMED
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
1
1
8
6
1
1
6
1
2
1
4
2
6
2
PAHZZ
5330-00-888-4988
15434
BM68356
GASKET SET
GASKET
GASKET
GASKET
PACKING, PREFORMED
PACKING
SPACER RING
GASKET
GASKET
PACKING, PREFORMED
PACKING WITH RETAIN
PACKING, PREFORMED
PACKING, PREFORMED
GASKET
SEAL CAP
PACKING, PREFORMED
PACKING, PREFORMED
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
C-95
TM 5-2815-241-34&P
FIGURE 37. FAN HUB.
C-96
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
0505-FAN ASSEMBLY
37
1
XDOOO
15434
AR10142
HUB, FAN
EA
1
37
2
XDOZZ
15434
210996
.RETAINER
EA
1
37
3
PAOZZ
15434
145551
.PACKING, PREFORMED
EA
1
37
4
PAOZZ
5310-01-072-8821
15434
142176
.NUT, HUGLOCK
EA
1
38
5
PAOZZ
3110-01-073-2576
60038
ASSEMBLY90028
.BEARING, ROLLER, TAPE
EA
1
34
6
XDOZZ
15434
211869
.PULLEY
EA
1
37
7
PAOZZ
15434
200307
.SEAL, OIL
EA
1
37
8
XDOZZ
15434
AR10141
.BRACKET AND SHAFT
EA
1
37
9
PAOZZ
5330-00-719-5235
96906
MS90727-114
SCREW, CAP, HEXAGON H
EA
3
37
10
PAOZZ
5310-00-584-5272
96906
MS35338-48
WASHER, LOCK
EA
5
37
11
PAOZZ
5310-00-809-5997
96906
MS27183-17
WASHER, FLAT
EA
2
37
12
PAOZZ
5305-00-725-4183
96906
MS90726-113
SCREW, CAP, HEXAGON H
EA
2
37
13
PAOZZ
2930-01-098-0175
15434
208829
BRACKET, FAN SUPPORT
EA
1
37
14
PAOZZ
5310-00-470-6154
15434
S285
NUT, PLAIN, HEXAGON
EA
1
37
15
PAOZZ
5305-01-091-2498
15434
166777
SCREW
EA
1
5330-01-072-8822
C-97
TM 5-2815-241-34&P
TA242333
FIGURE 38. NAME PLATES.
C-98
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
GROUP 22-BODY CHASSIS AND ACCESSORY ITEMS
2210-DATA PLATES AND INSTRUCTION
HOLDERS
38
1
PAOZZ
9905-00-733-7622
15434
105375
PLATES DESIGNAT
EA
2
38
2
PAOZZ
5305-00-804-6318
15434
S2286
SCREW
EA
4
C-99/ (C-100 blank)
SECTION II
(1)
ILLUSTRATION
(b)
(a)
ITEM
FIG.
NO.
NO.
TM 5-2815-241-34&P
(2)
(3)
(4)
(5)
(6)
SMR
CODE
NATIONAL
STOCK
NUMBER
FSCM
PART
NUMBER
DESCRIPTION
(7)
U/M
(8)
QTY
INC
IN
UNIT
USABLE
ON
CODE
GROUP 95-GENERAL USE STANDARDIZED PARTS
9501-BULK MATERIEL
BULK
1
XDFZZ
89346
364359C1
HOSE, NONMETALLIC
FT
C-101/ (C-102 blank)
V
SECTION IV
TM 5-2815-241-34&P
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
NATIONAL
STOCK NUMBER
2815-00-004-8291
5330-00-005-0407
5305-00-005-0666
5330-00-005-0856
5330-00-005-0857
5330-00-005-0858
2815-00-005-7431
5330-00-006-2494
5305-00-006-8411
5360-00-009-9270
5330-00-010-8497
4730-00-011-3175
5330-00-011-7939
5315-00-012-0123
5315-00-014-1195
5315-00-014-1244
5315-00-014-1284
5315-00-014-1284
5310-00-014-5850
4730-00-018-9566
4730-00-018-9566
4730-00-018-9566
4730-00-018-9566
4730-00-018-9566
4730-00-018-9566
5306-00-019-4227
5330-00-026-2931
5330-00-026-2933
5315-00-041-0915
5315-00-041-0916
5306-00-041-0917
5315-00-043-1787
4730-00-044-4715
4730-00-044-4715
4730-00-044-4715
4730-00-057-5555
4730-00-057-5555
4730-00-057-5555
5330-00-058-1767
5305-00-058-6604
5310-00-059-9264
5305-00-062-4378
5305-00-063-5043
2815-00-064-4398
5330-00-064-4399
2910-00-065-5544
5305-00-068-0511
5305-00-068-0511
5305-00-068-0511
5305-00-068-0511
2815-00-070-2251
5305-00-071-1769
5305-00-071-1788
5305-00-071-2056
5305-00-071-2070
5305-00-071-2241
5305-00-071-2241
5305-00-071-2241
5305-00-071-2241
FIGURE
NO.
6
36
19
8
8
4
12
25
3
9
24
30
36
1
2
25
2
5
24
2
3
16
20
28
36
24
20
29
10
10
6
17
2
3
36
2
16
16
2
36
29
9
28
2
2
27
16
16
35
36
18
13
20
24
5
24
26
27
28
ITEM
NO.
5
23
5
13
3
7
7
13
3
14
9
4
26
14
18
4
17
14
27
23
10
17
13
15
20
3
6
14
13
6
14
2
15
6
4
27
5
12
31
50
26
3
16
5
34
18
2
44
3
5
10
26
22
17
5
23
2
20
3
NATIONAL
STOCK NUMBER
FIGURE
NO.
2940-00-073-3316
5310-00-080-6004
5310-00-080-6004
5310-00-080-6004
5310-00-080-6004
5310-00-080-6004
5310-00-080-6004
5360-00-081-8487
5330-00-081-9289
5310-00-081-9292
5330-00-081-9299
4730-00-081-9618
5360-00-082-0124
5315-00-082-0448
5355-00-082-1189
5365-00-082-1193
5310-00-082-1888
2910-00-084-7787
2815-00-085-7434
3040-00-085-7439
3120-00-086-8364
3120-00-090-5504
5305-00-091-4009
5340-00-103-9988
5330-00-106-6370
2815-00-107-1115
5310-00-109-7638
5330-00-129-9349
4820-00-130-4820
2815-00-132-0240
5360-00-132-0245
5330-00-132-0248
2815-00-132-0273
5330-00-132-0274
5330-00-132-0276
2910-00-132-0769
5340-00-132-3203
5340-00-134-3529
5310-00-134-4168
5310-00-134-4169
5310-00-134-4171
5306-00-136-9751
5305-00-138-9848
5310-00-141-1795
5310-00-141-1795
5310-00-141-1795
5310-00-141-1795
5310-00-141-1795
5330-00-143-8369
5330-00-143-8376
5330-00-143-8485
3110-00-144-8499
3110-00-144-8519
3110-00-144-8519
5330-00-159-1464
5310-00-159-6209
5310-00-159-6209
5310-00-159-6209
5310-00-159-6209
5310-00-159-6209
16
8
10
11
16
18
28
23
33
20
30
16
27
23
30
28
30
30
9
33
20
4
5
29
36
7
5
3
23
9
22
16
6
30
22
27
19
22
5
18
6
17
30
24
26
26
27
33
35
13
9
24
36
36
36
2
2
24
26
28
ITEM
NO.
29
11
29
6
34
6
39
25
4
17
9
32
3
27
2
41
8
10
9
5
16
16
9
10
51
9
8
8
31
9
7
28
13
6
12
5
3
3
3
11
11
30
13
25
4
11
14
14
14
27
8
13
28
39
15
7
16
24
3
2
C-103
TM 5-2815-241-34&P
SECTION IV
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
NATIONAL
STOCK NUMBER
FIGURE
NO.
5310-00-159-6209
5310-00-159-6209
3020-00-160-9092
5305-00-161-0902
5310-00-164-1904
5305-00-165-8157
5330-00-175-6585
5330-00-194-8385
2815-00-195-5894
2815-00-195-5897
4730-00-196-0837
5365-00-197-9327
4730-00-203-0395
5310-00-209-0965
5310-00-209-0965
5310-00-209-0965
5310-00-209-0965
5310-00-209-0965
5310-00-222-7240
5306-00-225-8499
5305-00-225-9081
5306-00-225-9086
2815-00-230-0070
5305-00-230-1939
5305-00-230-1939
2910-00-237-0056
2990-00-237-0058
2990-00-237-0058
5330-00-237-6266
5315-00-238-0882
2910-00-238-5435
2815-00-242-2992
5330-00-246-0309
5330-00-252-8888
5365-00-256-2846
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-262-2986
5305-00-269-2811
5305-00-269-3209
2950-00-275-3355
2950-00-275-4658
2950-00-275-8276
2950-00-275-9325
2950-00-275-9344
5310-00-276-2816
5340-00-276-5847
5315-00-281-7610
29
33
20
24
29
16
10
29
12
12
28
16
13
8
13
17
20
24
6
17
17
10
12
2
29
22
24
27
29
2
22
8
2
26
23
2
4
8
10
11
13
16
16
17
18
24
28
35
36
30
36
13
29
29
29
29
29
36
10
2
C-104
ITEM
NO.
8
13
8
22
3
45
36
27
13
28
35
22
17
2
19
10
21
18
12
31
29
35
37
6
9
5
2
2
5
28
4
12
32
15
30
3
8
10
28
5
15
4
35
12
5
4
37
1
2
16
46
10
2
7
6
22
4
36
24
30
NATIONAL
STOCK NUMBER
FIGURE
NO.
5365-00-282-5030
4730-00-287-1649
4730-00-289-4770
4730-00-289-4770
4730-00-289-4770
2815-00-300-0882
2815-00-311-2521
3120-00-318-8537
2815-00-338-6839
5305-00-339-1415
3120-00-339-5642
5330-00-349-1219
3120-00-349-6444
5330-00-351-6428
5310-00-356-1447
5330-00-361-2955
5305-00-362-1536
2815-00-362-1780
5340-00-365-5759
5315-00-369-2588
4730-00-369-7824
2910-00-369-8240
2910-00-369-8251
3120-00-374-4342
2815-00-375-9892
2815-00-388-3126
5340-00-400-3449
2910-00-400-5178
2930-00-401-9531
5305-00-404-1388
5305-00-404-1390
4730-00-404-2906
5365-00-404-2934
2815-00-404-2940
2815-00-404-2947
2910-00-404-9999
2815-00-405-1798
5330-00-406-4542
2815-00-406-6737
5330-00-406-7789
2815-00-406-8936
5310-00-407-9566
5310-00-407-9566
5310-00-407-9566
5310-00-407-9566
5310-00-407-9566
5310-00-407-9566
3130-00-408-9041
5310-00-410-6756
5305-00-411-9340
5340-00-417-5800
5365-00-420-9696
5305-00-424-3571
5310-00-426-3990
2950-00-432-1559
2930-00-437-0567
5310-00-442-6899
5310-00-442-6899
3010-00-447-9799
2910-00-451-8063
6
28
3
17
35
9
10
4
13
10
7
10
4
13
2
4
10
10
12
23
27
24
27
10
10
29
23
20
16
36
35
3
12
2
23
14
9
29
29
17
2
10
13
17
35
36
2
24
29
13
36
17
9
29
16
20
20
24
23
ITEM
NO.
6
30
5
9
6
5
7
15
4
19
4
36
14
6
20
5
26
14
35
9
19
8
1
7
22
21
29
11
5
46
49
5
4
12
4
6
1
15
24
19
4
12
34
29
28
12
17
19
26
11
8
29
21
4
18
9
1
19
1
24
SECTION IV
TM 5-2815-241-34&P
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
NATIONAL
STOCK NUMBER
FIGURE
NO.
5360-00-461-5738
5365-00-462-4504
5305-00-463-0428
5340-00-464-7064
5310-00-469-3998
5310-00-470-6154
2910-00-470-7075
5315-00-475-2574
4730-00-477-4160
2990-00-477-6159
5305-00-477-6769
5330-00-478-2962
2815-00-480-4347
5310-00-484-1718
5310-00-484-1718
5310-00-484-1718
5310-00-484-1718
2815-00-484-8359
2815-00-484-8360
5306-00-485-0790
5306-00-485-0790
5340-00-485-0945
5310-00-486-2505
5310-00-486-2505
5365-00-488-0799
5305-00-493-3959
4730-00-494-9350
2815-00-505-5116
2815-00-505-5119
2815-00-505-5119
5330-00-506-4866
5330-00-506-4874
5305-00-506-5722
5365-00-507-3224
5365-00-507-3225
5365-00-507-3254
5310-00-507-3259
5365-00-507-3260
5365-00-507-3261
5365-00-507-3262
5365-00-507-3271
5305-00-509-8106
5310-00-521-8595
5315-00-532-9388
5330-00-537-2382
5365-00-543-3744
5305-00-546-6698
3020-00-562-1173
5330-00-562-1176
5310-00-562-6557
5310-00-562-6557
5310-00-562-6558
5310-00-562-6560
3120-00-566-0480
5330-00-567-3463
2910-00-567-4338
2910-00-567-4354
3020-00-567-4356
3120-00-573-0391
5330-00-580-5327
27
27
13
27
5
37
31
17
18
29
9
5
6
25
26
27
30
2
2
25
26
10
24
36
2
33
29
10
10
10
24
35
27
23
23
8
27
27
27
27
31
30
10
2
2
23
10
24
27
13
24
13
29
17
25
24
25
24
7
28
ITEM
NO.
8
9
22
17
13
15
5
14
2
20
6
15
7
12
12
15
15
19
19
11
13
20
5
8
35
12
33
5
9
16
16
4
6
15
15
8
4
9
9
9
1
14
30
22
9
15
38
14
12
20
19
23
12
18
9
11
8
7
5
17
NATIONAL
STOCK NUMBER
FIGURE
NO.
5330-00-582-7484
5310-00-584-5272
5310-00-584-5272
5310-00-584-5272
3120-00-589-3537
3120-00-589-3537
3120-00-589-3537
3120-00-589-3537
3120-00-589-3537
2815-00-590-7378
2815-00-590-7385
3120-00-593-1507
5360-00-597-4570
2930-00-603-1625
2910-00-603-2835
2815-00-603-7264
2815-00-609-7115
5315-00-616-5522
5315-00-616-5527
5315-00-616-5527
3120-00-627-6697
3120-00-627-6697
5330-00-632-6182
2815-00-632-6239
5310-00-637-9541
5330-00-659-3178
3120-00-659-7808
3120-00-661-6646
5360-00-664-5343
5310-00-680-6874
3120-00-682-7706
5310-00-684-3463
3120-00-695-1232
4810-00-695-3284
3040-00-695-3285
5315-00-695-3292
3020-00-701-1112
2815-00-705-2851
2815-00-705-2856
2815-00-705-9257
5365-00-708-3434
5305-00-709-8282
5305-00-709-8523
5305-00-709-8537
5305-00-709-8542
5365-00-716-5496
5365-00-716-6580
5305-00-719-5235
5306-00-719-5467
3120-00-719-5719
5340-00-721-5329
5365-00-721-7884
5305-00-725-2317
5305-00-725-2317
5305-00-725-4183
5310-00-727-8353
5310-00-732-0560
5310-00-732-0560
5310-00-732-0560
5310-00-732-0560
5310-00-732-0560
23
5
13
37
12
12
12
12
12
11
10
4
31
16
23
5
10
20
7
20
17
17
29
9
13
19
10
10
16
29
29
10
4
30
24
24
23
10
17
10
16
17
13
8
8
8
25
37
13
25
3
24
18
36
37
23
12
12
12
12
12
ITEM
NO.
2
4
25
11
6
11
17
27
32
1
2
19
3
11
8
10
4
15
8
20
23
27
15
13
9
1
11
37
21
13
16
25
21
1
6
10
29
12
8
3
24
13
16
6
14
7
5
10
18
2
9
15
4
9
13
26
3
8
14
25
29
C-105
SECTION IV
TM 5-2815-241-34&P
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
NATIONAL
STOCK NUMBER
FIGURE
NO.
2930-00-732-5206
9905-00-733-7622
2815-00-739-6084
2815-00-739-6098
2815-00-753-0660
5310-00-757-6367
5310-00-763-8920
2815-00-767-4012
2910-00-767-4018
5310-00-768-0318
2990-00-772-1778
2815-00-772-9434
2910-00-773-9369
5305-00-774-4246
5315-00-777-3544
5315-00-777-3544
5330-00-777-3545
5305-00-782-9489
5305-00-782-9489
5365-00-786-0102
2910-00-790-8736
3120-00-791-1440
2815-00-791-1453
3120-00-792-9834
5305-00-795-9353
2930-00-799-0843
4730-00-801-8186
4730-00-801-8186
4730-00-801-8186
4730-00-801-8186
4730-00-803-8353
4730-00-803-8353
5306-00-804-2468
5305-00-804-6318
5305-00-804-6318
5305-00-804-6454
5365-00-807-2636
5330-00-809-2667
5330-00-809-3276
5310-00-809-5997
3120-00-810-6032
2815-00-815-0355
2815-00-815-0355
2815-00-815-1114
5365-00-815-1137
5330-00-816-8148
5310-00-820-6653
5310-00-820-6653
5310-00-820-6653
2815-00-828-7013
2910-00-828-7126
2815-00-829-5227
2990-00-829-5600
2910-00-829-5603
2910-00-829-5604
2910-00-829-5616
2910-00-829-5617
5340-00-833-7966
5315-00-844-0140
5305-00-846-5703
34
38
3
9
6
28
36
19
28
13
23
2
24
33
10
10
10
11
28
33
31
10
16
20
5
2
2
13
35
36
25
26
2
29
38
13
27
26
26
37
23
36
36
22
22
28
1
4
5
17
26
19
30
23
23
26
26
17
23
16
C-106
ITEM
NO.
2
1
11
10
10
18
45
9
5
24
20
26
12
1
8
15
36
3
36
10
4
18
20
11
6
14
24
14
8
3
10
16
21
25
2
5
11
6
8
12
10
31
40
10
9
10
4
2
7
5
1
7
3
13
18
5
10
6
12
19
NATIONAL
STOCK NUMBER
FIGURE
NO.
5305-00-846-5703
2815-00-851-7637
2910-00-858-3522
2990-00-858-3526
5315-00-866-5015
2910-00-869-3428
5330-00-886-2509
5310-00-887-8325
2910-00-887-8354
5330-00-888-4988
3020-00-892-4704
5340-00-898-1497
3120-00-904-9595
3120-00-906-6657
5315-00-907-0711
4730-00-909-8627
5330-00-910-8736
2815-00-920-2073
2815-00-920-8356
5310-00-922-2017
5307-00-922-2626
5330-00-924-7757
2910-00-928-3505
2930-00-928-3595
2930-00-928-3596
2815-00-933-3009
2910-00-933-3012
5305-00-942-2196
5305-00-942-2196
5305-00-942-2196
5305-00-942-2196
5305-00-942-2196
5305-00-942-2196
2910-00-951-3536
5330-00-951-3538
5330-00-951-3538
5330-00-961-9470
5310-00-962-5610
2815-00-962-5618
2815-00-962-5623
5365-00-965-0870
5310-00-971-7989
5315-00-973-0414
5365-00-988-3668
2815-00-994-4427
2815-00-994-4429
4730-01-006-5103
5305-01-028-8869
5360-01-038-4659
2990-01-046-0171
5330-01-046-0441
5330-01-046-1991
5330-01-046-3144
2930-01-046-3493
2910-01-047-6021
5330-01-049-0466
5315-01-058-4551
5315-01-058-4551
5305-01-060-5958
5305-01-062-1054
36
12
27
33
9
25
10
19
23
36
25
27
23
7
23
36
18
19
19
30
29
22
9
35
35
9
25
2
8
11
16
18
28
26
28
30
31
3
6
9
26
33
33
23
6
6
29
19
17
29
8
16
16
36
23
2
2
4
22
16
ITEM
NO.
1
24
13
9
16
1
31
4
21
KIT
6
10
22
6
17
12
12
6
2
12
28
11
7
7
2
1
7
2
9
4
36
8
40
7
21
17
2
2
2
10
9
2
8
3
3
4
32
10
7
1
5
7
26
19
1
33
29
18
2
3
SECTION IV
TM 5-2815-241-34&P
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
NATIONAL
STOCK NUMBER
FIGURE
NO.
5330-01-066-3908
5330-01-066-3910
2910-01-070-7979
4720-01-070-8149
2910-01-070-9710
5310-01-072-8821
5330-01-072-8822
5305-01-072-8831
5330-01-072-8983
3110-01-073-2576
3020-01-077-4411
2815-01-077-4463
5330-01-077-5228
5330-01-077-5228
4730-01-078-9859
3040-01-079-1748
2815-01-079-1799
3040-01-079-3468
3040-01-079-3469
5340-01-079-4678
5315-01-079-6506
5330-01-079-6514
3120-01-079-6527
5315-01-079-6740
3110-01-079-8190
5365-01-080-0409
2815-01-080-0642
5330-01-080-2992
5330-01-080-2992
5330-01-080-5020
5330-01-080-5021
2815-01-083-3157
3020-01-084-9640
4720-01-085-1316
2815-01-085-2573
4820-01-085-2616
2815-01-085-2618
2950-01-085-3580
2815-01-085-3733
2815-01-085-3733
2815-01-085-3734
3020-01-085-3779
2520-01-085-6128
4710-01-085-6130
2815-01-086-2704
5330-01-086-3991
2910-01-086-5544
5365-01-086-7788
5365-01-086-8214
3120-01-087-3004
5305-01-091-2498
2910-01-091-3204
5330-01-092-4143
2815-01-096-9198
2910-01-096-9200
2930-01-098-0175
2910-01-105-6457
5330-01-109-1283
5365-01-112-4281
5305-01-114-9279
11
17
9
18
22
37
37
27
33
37
4
19
16
35
26
17
12
36
17
22
22
16
19
4
33
36
3
36
36
36
3
4
17
29
17
30
9
29
9
12
17
17
12
35
6
36
23
8
2
6
37
23
36
12
25
37
22
24
16
35
ITEM
NO.
9
25
17
1
6
4
7
16
7
5
4
8
41
10
14
15
39
38
19
15
13
43
11
22
6
43
1
32
42
11
7
12
16
30
1
5
11
17
5
21
22
24
34
13
1
41
16
8
35
9
16
14
KIT
2
3
14
8
21
23
11
NATIONAL
STOCK NUMBER
FIGURE
NO.
5305-01-114-9279
2920-01-121-8859
2815-01-122-8002
2815-01-127-1060
2815-01-127-3597
2815-01-127-3598
2815-01-128-9187
5365-01-132-1984
3120-01-132-9339
5365-01-133-8271
5330-01-133-8493
5340-01-135-7250
2815-01-136-5825
5330-01-136-8431
2815-01-140-7421
5305-01-140-9118
2815-01-142-1732
5340-01-143-6048
3120-01-143-9547
3120-01-144-8882
5310-01-145-0762
5330-01-145-5377
3120-01-145-9132
3020-01-146-0107
2815-01-146-1024
2910-01-146-1048
2940-01-146-1995
2815-01-146-5925
5365-01-147-0912
5365-01-147-0913
5307-01-147-1316
5307-01-147-2821
3120-01-147-5275
5330-01-149-9715
2910-01-150-2631
5365-01-150-6257
2815-01-151-8772
2910-01-152-8531
4730-01-157-8923
2815-01-159-1737
5365-01-160-1832
4730-01-160-3579
5305-01-165-3300
5305-01-165-3300
4720-01-169-7509
5310-01-186-4361
5970-01-193-0895
5306-01-197-6194
5360-01-200-0323
5310-01-200-1318
5305-01-203-6444
3040-01-203-8549
5330-01-209-3583
4730-01-211-1989
3120-01-214-7779
36
30
5
9
9
9
29
36
4
1
12
36
29
29
9
17
11
9
4
4
36
2
4
4
11
30
16
4
8
8
12
12
20
36
22
2
4
22
28
11
23
16
8
17
28
1
1
1
16
16
16
20
13
13
4
ITEM
NO.
16
11
1
9
9
9
KIT
30
13
16
38
18
23
21
9
3
7
2
13
13
44
10
13
11
8
7
14
6
8
8
19
19
9
KIT
1
25
10
14
29
2
4
13
1
11
32
7
15
12
15
38
37
14
2
28
17
C-107
SECTION IV
TM 5-2815-241-34&P
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
FSCM
15434
15434
88044
88044
88044
88044
88044
88044
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
60038
15434
15434
46529
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
C-108
PART NUMBER
AC1600300NF
AC9
AN565F428H24
AN960-416
AN960-416
AN960-416
AN960-416
AN960-416
AR-00796
AR-03636
AR-045090
AR-09265
AR-09454-OOEF
AR-2308
AR01176
AR03034
AR03307
AR08190
AR08256
AR08366
AR08667
AR08851
AR08853
AR08854
AR09473
AR09478
AR09479
AR09607
AR09832
AR09911
AR10058
AR10141
AR10142
AR10172
AR12604
AR40065
AR51276
AR51307
AR51317
ASSEMBLY90028
AS0500760SS
AS0501900SS
A331987
BM-37496
BM27253
BM37625
BM37634
BM47777
BM67416
BM68356
BM68879
BM69381
BM69886
BM69886
BM73718
BM73902
BM73976
BM74747
BM76340
BM76665
NATIONAL
STOCK NUMBER
4720-01-085-1316
5305-00-063-5043
5310-00-141-1795
5310-00-141-1795
5310-00-141-1795
5310-00-141-1795
5310-00-141-1795
2930-01-046-3493
2815-00-005-7431
5365-00-716-5496
2815-00-004-8291
2815-01-085-3734
2950-00-275-9325
2815-01-085-2573
2990-01-046-0171
2910-00-237-0056
2815-00-195-5894
2910-00-567-4338
3110-01-073-2576
4720-01-169-7509
2930-00-603-1625
3120-00-339-5642
2815-00-609-7115
2815-00-505-5116
2815-00-705-9257
2910-00-132-0769
5330-00-888-4988
2910-00-369-8240
2990-00-237-0058
2990-00-237-0058
2910-00-887-8354
2815-00-375-9892
2910-00-828-7126
2910-00-603-2835
FIGURE ITEM
NO.
NO.
29
32
28
24
26
26
27
33
23
17
36
16
28
12
8
33
12
6
20
20
17
36
36
36
8
16
16
20
17
2
29
37
37
17
29
22
12
24
33
37
28
28
16
10
7
10
10
10
27
36
24
28
24
27
23
23
10
27
26
23
30
2
16
25
4
11
14
14
23
17
19
27
1
7
7
11
1
5
10
7
26
34
22
33
4
8
1
3
22
1
22
8
1
1
1
5
13
11
3
5
32
31
11
17
4
4
5
3
5
KIT
8
9
2
2
21
7
22
7
1
8
FSCM PART NUMBER
NATIONAL
STOCK NUMBER
15434
15434
15434
15434
15434
15434
15434
73165
79470
15434
15434
00905
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
2910-00-404-9999
2815-00-195-5897
2815-01-096-9198
2815-00-851-7637
2910-01-096-9200
2910-00-869-3428
2910-01-091-3204
5330-01-066-3908
4730-00-081-9618
3120-00-318-8537
3120-00-349-6444
5340-00-721-5329
5310-00-159-6209
5310-00-159-6209
5310-00-159-6209
5310-00-159-6209
5310-00-159-6209
5310-00-159-6209
5310-00-159-6209
5365-00-807-2636
5365-00-256-2846
5305-00-942-2196
5305-00-942-2196
5305-00-942-2196
5305-00-942-2196
5305-00-942-2196
5305-00-942-2196
5315-00-695-3292
5310-00-059-9264
5315-00-012-0123
5310-00-080-6004
5310-00-080-6004
5310-00-080-6004
5310-00-080-6004
5310-00-080-6004
5310-00-080-6004
5310-00-809-5997
5310-00-014-5850
5310-00-407-9566
5310-00-407-9566
5310-00-407-9566
5310-00-407-9566
5310-00-407-9566
5310-00-407-9566
5310-00-637-9541
5310-00-209-0965
5310-00-209-0965
5310-00-209-0965
5310-00-209-0965
5310-00-209-0965
5310-00-584-5272
5310-00-584-5272
5310-00-584-5272
5310-00-820-6653
5310-00-820-6653
5310-00-820-6653
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
BM79290
BM95160
BM95161
8195162
BM97497
BM97502
BM98430
B90429
C3159x2
H40496
H42693
H524018
MS122032
MS122032
MS122032
MS122032
MS122032
MS122032
MS122032
MS16625-1100
MS16632-1050
MS18154-60
MS18154-60
MS18154-60
MS18154-60
MS18154-60
MS18154-60
MS20066-116
MS21045C6
MS24665-355
MS27183-14
MS27183-14
MS27183-14
MS27183-14
MS27183-14
MS27183-14
MS27183-17
MS27183-42
1335338-45
MS35338-45
MS35338-45
MS35338-45
MS35338-45
MS35338-45
MS35338-46
MS35338-47
MS35338-47
MS35338-47
MS35338-47
MS35338-47
MS35338-48
MS35338-48
MS35338-48
MS35338-50
MS35338-50
MS35338-50
MS35338-8
MS35338-8
MS35338-8
MS35338-8
FIGURE ITEM
NO.
NO.
23
12
12
12
25
25
23
11
16
4
4
3
2
5
24
26
28
29
33
27
23
2
8
11
16
18
28
24
29
1
8
10
11
16
18
28
37
24
2
10
13
17
35
36
13
8
13
17
20
24
5
13
37
1
4
5
2
4
8
10
6
28
2
24
3
1
14
9
32
15
14
9
7
16
24
3
2
8
13
11
30
2
9
4
36
8
40
10
26
14
11
29
6
34
6
39
12
27
12
34
29
28
12
17
9
2
19
10
21
18
4
25
11
4
2
7
3
8
10
28
SECTION IV
TM 5-2815-241-34&P
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
FSCM PART NUMBER
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
15434
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
MS35338-8
MS35338-8
MS35338-8
MS35338-8
MS35338-8
MS35338-8
MS35338-8
MS35338-8
MS35338-8
MS35338-8
MS35691-5
MS35756-12
MS35756-18
MS35756-18
MS35756-34
MS35842-13
MS39230-1
MS49005-6
MS49005-6
MS49005-6
MS51092-1
MS51887-5
MS51967-14
MS51967-20
MS51968-14
MS51968-14
MS51968-14
MS51968-14
MS51968-14
MS9021-116
MS90725-10
MS90725-10
MS90725-10
MS90725-10
MS90725-115
MS90725-34
MS90725-36
MS90725-58
MS90726-113
MS90726-31
MS90726-64
MS90726-67
MS90727-114
MS90727-83
MS90727-87
MS90727-91
MS90727-94
MS90728-114
MS90728-59
MS90728-62
MS90728-62
MS90728-62
MS90728-62
MS90728-64
MS90728-64
MS90728-66
MS90728-66
MS90728-70
MS90728-70
MS90728-87
NATIONAL
STOCK NUMBER
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-261-7340
5310-00-971-7989
5315-00-616-5522
5315-00-616-5527
5315-00-616-5527
5315-00-043-1787
4730-00-909-8627
4730-00-287-1649
4730-00-057-5555
4730-00-057-5555
4730-00-057-5555
5310-00-684-3463
4730-00-196-0837
5310-00-768-0318
5310-00-763-8920
5310-00-732-0560
5310-00-732-0560
5310-00-732-0560
5310-00-732-0560
5310-00-732-0560
5330-00-582-7484
5305-00-071-2241
5305-00-071-2241
5305-00-071-2241
5305-00-071-2241
5305-00-071-1769
5306-00-225-8499
5305-00-225-9081
5305-00-269-3209
5305-00-725-4183
5306-00-225-9086
5305-00-269-2811
5305-00-719-5235
5305-00-709-8282
5305-00-709-8523
5305-00-709-8542
5305-00-709-8537
5305-00-071-2070
5305-01-140-9118
5305-00-068-0511
5305-00-068-0511
5305-00-068-0511
5305-00-068-0511
5305-00-725-2317
5305-00-725-2317
5305-00-782-9489
5305-00-782-9489
5305-00-846-5703
5305-00-846-5703
5305-00-071-1788
FIGURE ITEM
NO.
NO.
11
13
16
16
17
18
24
28
35
36
33
20
7
20
17
36
28
2
16
16
10
28
13
36
12
12
12
12
12
23
24
26
27
28
13
17
17
13
37
10
4
36
37
17
13
8
8
5
17
16
16
35
36
18
36
11
28
16
36
20
5
15
4
35
12
5
4
37
1
2
2
15
8
20
2
12
30
27
5
12
25
35
24
45
3
8
14
25
29
2
23
2
20
3
26
31
29
10
13
35
9
46
10
13
16
14
6
5
3
2
44
3
5
4
9
3
36
19
1
22
FSCM PART NUMBER
96906
96906
80205
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
MS90728-90
MS9241-024
NAS620-5L
NPN
S-119-C
S-119-C
S-147-B
S-910-B
S-915-A
S-915-A
S-915-A
S-915-A
S101A
S102A
S110
S110
S118A
S118A
S129
S1354
S145
S149A
S155
S159B
S16073
S16073
S16206
S16255
S16255
S189C
S199B
S200
S222A
S223
S2286
S2286
S274
S285
S601
S606
S608
S622
S622
S626
S631
S658
S719
S911B
S911B
S911B
S911B
S911B
S911B
S962
S962
S962
S965E
S995
S995
S995
NATIONAL
STOCK NUMBER
5305-00-071-2056
5330-00-924-7757
5310-00-727-8353
5305-01-165-3300
5305-01-165-3300
5306-00-136-9751
4730-01-160-3579
4730-00-801-8186
4730-00-801-8186
4730-00-801-8186
4730-00-801-8186
5305-00-424-3571
5305-01-114-9279
5305-01-114-9279
5305-00-230-1939
5305-00-230-1939
5305-00-546-6698
5305-00-804-6454
5305-01-203-6444
5305-00-404-1390
5305-01-028-8869
5305-00-493-3959
3110-00-144-8519
3110-00-144-8519
5365-00-786-0102
2815-00-815-0355
2815-00-815-0355
5305-00-509-8106
5305-00-404-1388
5310-00-469-3998
5310-00-164-1904
5310-00-521-8595
5305-00-804-6318
5305-00-804-6318
5310-00-470-6154
5310-00-134-4168
5310-00-410-6756
5310-01-200-1318
5310-00-562-6557
5310-00-562-6557
5310-00-562-6558
5310-00-562-6560
5310-00-109-7638
5340-00-276-5847
4730-00-018-9566
4730-00-018-9566
4730-00-018-9566
4730-00-018-9566
4730-00-018-9566
4730-00-018-9566
4730-00-044-4715
4730-00-044-4715
4730-00-044-4715
5365-00-404-2934
4730-00-289-4770
4730-00-289-4770
4730-00-289-4770
FIGURE ITEM
NO.
NO.
24
22
23
28
8
17
17
16
2
13
35
36
17
2
35
36
2
29
10
13
16
36
19
33
36
36
33
36
36
30
16
5
29
10
29
38
24
37
5
24
16
13
24
13
29
5
10
2
3
16
20
28
36
2
3
36
3
3
17
35
17
11
26
34
1
11
30
13
24
14
8
3
21
13
11
16
6
9
38
5
37
49
10
12
28
39
10
31
40
14
46
13
3
30
25
2
20
15
3
26
38
20
19
23
12
8
24
23
10
17
13
15
20
15
6
4
4
5
9
6
C-109
SECTION IV
TM 5-2815-241-34&P
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
FSCM PART NUMBER
91265
91265
75078
75078
24617
80218
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
C-110
TS33-016
TS33-016
011573
011573
0120217
10003
100099
100192
100193
100215
100478
100670
100764
1011
1012
101322
101468
1017
101841
101842
101843
101918
101983
1022
102231
1023
1026
1030
103036
1031
104038
105199
105375
105953
106289
106452R91
107738
107738
108074
1081
1082
1083
108330
108330
108722
109319
109333
109594
109915
110855
110907
112076
112302
112593
113244
114638
114739
114745
114754
114755
NATIONAL
STOCK NUMBER
5330-00-951-3538
5330-00-951-3538
2815-01-085-3733
2815-01-085-3733
5310-00-922-2017
4730-00-203-0395
5330-00-809-2667
2910-00-773-9369
3120-00-810-6032
2910-00-567-4354
5330-00-081-9289
3120-00-573-0391
5330-00-506-4866
2815-00-590-7378
3120-00-719-5719
5365-00-507-3224
5365-00-507-3225
5365-00-543-3744
3040-00-695-3285
3020-00-567-4356
3020-00-562-1173
5330-00-010-8497
2815-00-829-5227
9905-00-733-7622
5306-00-804-2468
5305-00-091-4009
2815-00-505-5119
2815-00-505-5119
5310-00-757-6367
5310-00-486-2505
5310-00-486-2505
5340-00-400-3449
2815-00-406-8936
2815-00-705-2856
3120-01-079-6527
5305-00-774-4246
5330-00-567-3463
5365-00-708-3434
5365-01-160-1832
5365-00-420-9696
3020-00-701-1112
5310-00-887-8325
2910-00-767-4018
FIGURE ITEM
NO.
NO.
28
30
9
12
30
13
26
24
23
25
33
7
24
21
21
11
25
21
23
23
23
24
24
21
34
21
21
17
5
21
12
17
6
12
10
8
4
5
16
8
19
1
2
9
15
15
15
6
7
3
1
5
21
21
15
7
24
21
24
19
38
2
5
32
10
10
28
21
21
21
24
36
29
17
17
19
33
25
16
23
36
13
23
19
28
28
28
28
14
16
9
7
1
21
9
1
9
16
18
12
13
14
5
8
29
4
8
11
1
9
24
4
29
1
29
4
5
22
27
6
FSCM PART NUMBER
NATIONAL
STOCK NUMBER
15434 114764
15434 114765
15434 114773
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
30760
15434
15434
15434
15434
15434
15434
15434
15434
75078
15434
15434
15434
15434
15434
15434
75078
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
114791
114795
114921
114940
114947
115033
115034
116389
116390
116391
116936
116936
116982
117300-1251
117897
118226
118227
118377
118378
118939
118939
119363
1199
1200
120448
120543
120819
121907
123000
1232
123558
124019
124020
124033
126304
1265
127554
127558
127935
1289
128936
129768
129826
129838
129839
129888
130118
130226
130394
131026
132019
132756
132880
133342
134072
134596
135957
5330-00-816-8148
3120-00-086-8364
5310-00-081-9292
3120-00-792-9834
4730-00-803-8353
4730-00-803-8353
2815-00-767-4012
5315-00-014-1244
5305-00-161-0902
5315-00-844-0140
3120-00-791-1440
3120-00-659-7808
5315-00-777-3544
5315-00-777-3544
3020-00-892-4704
5330-00-777-3545
5307-01-147-2821
5315-00-866-5015
2910-00-065-5544
5340-00-464-7064
2815-00-828-7013
5340-01-143-6048
2815-00-791-1453
2815-01-140-7421
2815-00-406-6737
5310-00-082-1888
2990-00-829-5600
5355-00-082-1189
2910-00-084-7787
5330-00-081-9299
2930-00-928-3595
5330-00-106-6370
4730-00-404-2906
5330-00-143-8485
2930-00-799-0843
2815-00-962-5618
2930-00-928-3596
2920-01-121-8859
5340-00-833-7966
2815-00-739-6098
FIGURE
NO.
28
28
28
28
28
28
28
28
28
28
20
20
20
25
26
19
25
17
24
23
10
10
10
10
25
12
21
5
10
10
17
5
12
9
27
27
28
17
21
9
16
9
21
29
30
30
30
30
30
35
36
35
9
2
16
6
35
30
17
9
ITEM
NO.
20
19
14
10
23
25
13
4
7
12
16
17
11
10
16
9
4
20
22
12
18
11
8
15
6
19
18
11
10
36
32
12
19
16
18
17
26
5
21
2
20
9
4
24
8
3
2
10
9
7
51
5
8
14
39
2
2
11
6
10
SECTION IV
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
FSCM
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
24617
24617
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
PART NUMBER
137797
138782
138905
139289
139473
139988
140297
140330
140330
140330
140330
140330
140357
140358
140414
140618
140925
141284
141284
141761
142176
142204
142616
142689
143251
143847
143938
143946
143947
143948
143949
143950
144178
144195
144302
144372
145506
145551
145701
145977
146437
146483
147100
147389
147670
148203
148295
1484
148977
149030
149040
149105PC183049
1492
150002
151478
151489
152770
153336
153338
154088
NATIONAL
STOCK NUMBER
5365-00-988-3668
5330-00-809-3276
2815-01-079-1799
3120-00-589-3537
3120-00-589-3537
3120-00-589-3537
3120-00-589-3537
3120-00-589-3537
2910-00-829-5603
2910-00-369-8251
5315-00-014-1284
5315-00-014-1284
2815-00-070-2251
5310-01-072-8821
2930-00-437-0567
3020-00-160-9092
5360-00-461-5738
5360-00-081-8487
5365-01-086-8214
5315-00-082-0448
5360-00-082-0124
2910-00-829-5604
4730-01-157-8923
5330-01-086-3991
2815-00-962-5623
2930-00-732-5206
2910-00-451-8063
2910-00-790-8736
2910-00-928-3505
5305-00-062-4378
2815-00-994-4427
5330-00-143-8369
2990-00-858-3526
3040-00-085-7439
5315-00-973-0414
5330-00-058-1767
2815-00-242-2992
2815-00-920-2073
2815-00-920-8356
2910-00-829-5616
2910-00-829-5617
5330-00-961-9470
FIGURE ITEM
NO.
NO.
36
23
23
10
23
26
12
12
12
12
12
12
28
28
28
23
27
2
5
18
37
23
16
20
27
23
2
2
2
2
2
28
23
27
23
28
36
37
9
34
23
31
9
9
6
35
16
21
33
33
33
2
21
8
19
19
6
26
26
31
47
5
19
33
3
8
39
6
11
17
27
32
8
11
24
13
1
17
14
10
4
28
9
8
8
25
35
35
35
35
35
33
27
3
18
29
41
3
10
2
24
4
7
3
3
14
10
2
9
5
8
31
6
12
6
2
13
5
10
2
FSCM PART NUMBER
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
72962
15434
15434
15434
15434
45152
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
89346
15434
15434
15434
15434
15434
156226
156416
156420
156444
157088
157280
157551
157870
158139
158145
160514
162426
163733
163944
165006
166009
166777
167157
168803
168805
169704
170296
170510
171570
172034
173368
174298
174299
175831
175836
175864
177419
177999
179063
1801-040
181466
181466
181466
181466
1816-HX-1
182530
182706
183669
183913
184386
184387
184388
185138
185139
185573
185804
187420
187556
187589
187893R1
188936
189800
190397
190769
190849
TM 5-2815-241-34&P
NATIONAL
STOCK NUMBER
2815-00-107-1115
5340-00-103-9988
3120-00-682-7706
5330-00-237-6266
5365-00-507-3271
3120-01-214-7779
5330-00-143-8376
3120-00-906-6657
2940-00-073-3316
2815-00-404-2947
5365-00-965-0870
3010-00-447-9799
2910-00-400-5178
3120-00-904-9595
5305-01-060-5958
5360-00-132-0245
5305-01-091-2498
2910-01-070-9710
FIGURE ITEM
NO.
NO.
7
29
29
29
31
4
13
7
16
2
26
24
23
23
22
22
37
22
12
12
12
9
2815-00-933-3009
29
5330-00-632-6182
29
2990-00-477-6159
9
2815-00-632-6239
16
5330-00-132-0248
22
2815-00-815-1114
22
5365-00-815-1137
10
5340-00-485-0945
23
4820-00-130-4820
25
2910-00-933-3012
17
3040-01-079-3469
27
4730-00-369-7824
16
2940-01-146-1995
29
5310-00-680-6874
25
5310-00-484-1718
26
5310-00-484-1718
27
5310-00-484-1718
30
5310-00-484-1718
16
5305-01-062-1054
23
2910-01-086-5544
36
5305-00-058-6604
29
4730-01-006-5103
16
5365-01-112-4281
16
16
16
22
5340-01-079-4678
22
2910-01-105-6457
8
5365-01-086-7788
13
5305-00-463-0428
2815-00-132-0273
6
30
5305-00-138-9848
12
5330-01-133-8493
1
5305-00-795-9353 5
5365-00-462-4504 27
2930-00-401-9531 20
20
5330-00-194-8385 29
9
10
16
5
1
17
27
6
29
4
9
1
11
22
2
7
16
6
31
16
5
1
15
20
13
28
10
9
20
31
7
19
19
14
13
12
12
15
15
3
16
50
32
23
31
30
33
15
8
8
22
13
13
38
8
6
9
5
18
27
C-111
TM 5-2815-241-34&P
SECTION
IV
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
FSCM PART NUMBER
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
33457
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
C-112
190876
191079
191218
191517
191517
191916
191970
193717
193736
193949
194010
194037
194380
194610
195469
19581R1
196641
196844
197230
197733
199064
199201
199216
199220
199224
199225
199239
199338
199568
199587
199969
2S7225S
200064
200307
200566
200809
200861
200908
200919
2010650
201124
201707
202128
202226
202376
202377
202457
202506
202897
202903
202903
202961
203090
203100
203131
203145
203294
203426
203619
203849
NATIONAL
STOCK NUMBER
5330-00-132-0274
5340-00-134-3529
5310-00-442-6899
5310-00-442-6899
2910-00-238-5435
2815-00-480-4347
5330-00-132-0276
5330-00-129-9349
5305-00-411-9340
2815-00-404-2940
2815-00-994-4429
2950-00-275-3355
5330-00-406-4542
5365-01-132-1984
5330-01-209-3583
4730-00-494-9350
5330-00-478-2962
2520-01-085-6128
3040-01-079-1748
3040-01-203-8549
2815-00-405-1798
5340-00-417-5800
5330-01-072-8822
2815-01-077-4463
5330-00-026-2931
5310-00-134-4171
5305-00-005-0666
5340-00-132-3203
5360-01-200-0323
2950-00-432-1559
5330-00-406-7789
5330-00-026-2933
2815-01-136-5825
2910-00-951-3536
5315-01-058-4551
5315-01-058-4551
5330-00-910-8736
5330-00-011-7939
5310-00-426-3990
5330-01-066-3910
2950-00-275-4658
5315-01-079-6506
5305-01-072-8831
4730-01-078-9859
FIGURE ITEM
NO.
NO.
30
2
22
20
20
22
6
5
22
3
29
12
20
6
29
1
9
36
13
29
5
21
12
12
12
12
12
20
18
17
20
14
13
37
19
20
6
19
19
10
37
16
16
2
29
29
29
29
26
2
4
18
6
36
9
17
29
22
27
26
6
16
3
1
19
4
7
2
12
8
11
12
2
4
2
13
15
30
2
33
15
1
23
33
20
34
9
12
7
15
14
1
8
7
8
6
11
5
3
1
9
16
15
5
18
19
14
23
7
29
18
12
8
26
4
25
7
13
16
14
FSCM PART NUMBER
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
204657
204832
204851
20622
208118
208119
208120
208132
208134
208138
208326
208411
208461
208581
208621
208668
208829
209600
209700
209862C1
209919
209959
210179
210238
210374
210412
210647
210685
210804
210805
210806
210832
210858
210860
210883
210884
210895
210926
210966
210967
210996
211016
211027
211358
211375
211475
211869
211914
211918
211939
211999
212113
212161
212161
212563
213082
213109
213109
213109
213109
NATIONAL
STOCK NUMBER
3020-01-085-3779
2815-00-338-6839
3040-01-079-3468
5365-01-080-0409
5330-01-080-5020
4730-00-477-4160
2930-01-098-0175
5305-00-006-8411
2815-01-146-5925
5315-01-079-6740
5330-01-109-1283
5330-01-046-0441
5330-00-006-2494
5365-01-150-6257
4710-01-085-6130
2950-00-275-8276
3020-01-077-4411
5360-01-038-4659
5360-00-009-9270
5330-01-077-5228
5330-01-077-5228
2950-00-275-9344
5310-01-145-0762
FIGURE ITEM
NO.
NO.
13
7
17 24
28 38
13
4
36 37
36 38
36 43
36 11
36 24
36 27
18
2
10 27
13 21
10 32
28 28
29 34
37 14
36 14
3
3
15
3
4
6
29 35
4
22
36 25
24 21
8
5
25 13
10 23
36 48
36
7
36
6
16 18
16
6
36 35
16 42
2
25
2
8
20
4
16 40
16 25
37
2
35
9
35 13
13 11
29
6
2
11
37
6
4
3
4
4
17
7
9
14
4
1
16 41
35 10
29
4
36 44
12
4
12 15
12 26
12 30
SECTION IV
TM 5-2815-241-34&P
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
FSCM PART NUMBER
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
75078
75078
89346
79150
15434
75078
15434
15434
75078
89346
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
213713
213740
213768
213769
213936
214173
214476
214617
214950
215090
215172
216802
218152
218245
2299
236985R91
2390
24874R1
2514
2514
25711R1
26384
267627C2
2680
2689
274085R91
2856
299227C3
299228C1
299263091
3000266
3004316
3006183
3006187
3006358
3006456
3006736
3006737
3007242
3007300-2764
3007442
3008017
3008089
3008100
3008998
3009213
3010030
3010915
3011935
3012527
3012537
3014149
3014614
3014622
3014623
3014624
3014625
3014783
3015523
3017759
NATIONAL
STOCK NUMBER
2815-00-064-4398
5330-01-072-8983
3110-01-079-8190
5340-01-135-7250
3120-01-087-3004
5330-00-064-4399
2950-01-085-3580
5330-01-046-1991
5330-00-246-0309
5307-01-147-1316
5970-01-193-0895
4820-01-085-2616
5330-00-005-0857
2815-01-142-1732
2815-01-159-1737
2815-01-146-1024
2815-01-085-2618
5330-00-005-0856
5330-00-005-0858
2815-00-230-0070
2910-01-047-6021
5330-01-145-5377
5330-01-079-6514
2815-01-080-0642
2815-00-739-6084
5330-01-049-0466
5310-00-356-1447
5330-01-046-3144
5307-00-922-2626
2910-01-070-7979
4730-01-211-1989
2910-01-152-8531
2815-01-086-2704
3020-01-146-0107
2815-00-132-0240
2815-01-127-1060
2815-01-127-3597
2815-01-127-3598
3020-01-084-9640
2815-00-753-0660
2815-00-085-7434
FIGURE ITEM
NO.
NO.
28
2
33
33
29
36
36
36
6
2
34
29
12
16
21
32
21
1
12
12
1
2
32
12
21
15
12
1
1
15
30
8
11
11
11
9
8
4
12
23
2
16
3
3
2
2
16
29
9
13
22
6
4
9
9
9
9
17
6
9
42
5
7
6
31
21
10
18
9
34
3
17
10
7
17
4
11
5
18
36
3
32
3
22
10
2
19
1
15
4
5
3
7
2
8
11
13
7
37
1
10
43
1
11
33
20
26
28
17
28
14
1
11
9
9
9
9
16
10
9
FSCM PART NUMBER
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
79396
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
89346
89346
89346
15434
15434
15434
15434
89346
15434
15434
89346
89346
15434
72582
89346
89346
19207
72962
15434
3018049
3018323
3018762
3019180
3019192
3019204
3019227
3019400
3019956
3020943
3021601
3022205
3022969
3023177
3023229
3024923
3026556
3027215
3029348
3030970
3031469
3033677
3035342
3036065
3036126
3038998
3038998
3047031
33341
364319C1
364359C1
3801098
3801260
3801261
3801262
3801263
3801330
390782C1
40662A
4136
414085C1
414089C1
424140C2
424141C2
42645
42646
42647
42690
427820C1
43463A
43696
441889C2
446002R1
44678
450517
465225C2
47686961
5329388
590220940406
60408
NATIONAL
STOCK NUMBER
FIGURE
NO.
2815-00-705-2851 10
2910-01-150-2631 22
5330-01-092-4143 36
3120-00-695-1232 4
4
3120-00-593-1507 4
18
13
5365-00-488-0799 2
5330-00-659-3178 19
7
18
5330-01-136-8431 29
7
7
2815-01-083-3157 4
3120-01-147-5275 20
2815-00-590-7385 10
2815-01-151-8772 4
2910-01-146-1048 30
5330-00-351-6428 13
5330-00-005-0407 36
4810-00-695-3284 30
2815-00-300-0882 9
5330-01-080-5021 3
5330-01-080-2992 36
5330-01-080-2992 36
2815-00-388-3126 10
2910-00-470-7075 31
15
BULK
2815-01-128-9187 29
3120-01-132-9339 4
3120-01-143-9547 4
3120-01-144-8882 4
3120-01-145-9132 4
5330-01-149-9715 36
15
5330-00-361-2955 4
21
5306-01-197-6194 1
5310-01-186-4361 1
2815-00-484-8359
3130-00-408-9041
2815-00-484-8360
3120-00-090-5504
2
2
2
4
5330-00-159-1464 36
5330-00-886-2509 10
2910-00-858-3522 27
5305-00-165-8157 16
5315-00-532-9388 2
5315-00-907-0711 23
5315-00-238-0882 2
ITEM
NO.
12
1
KIT
21
20
19
9
3
35
1
2
3
21
1
3
12
9
2
10
7
6
23
1
5
7
32
42
21
5
6
1
KIT
13
13
13
13
KIT
1
5
20
12
7
17
17
19
19
19
16
2
15
31
10
11
13
45
6
9
22
17
28
C-113
TM 5-2815-241-34&P
SECTION IV
NATIONAL STOCK NUMBER AND PART NUMBER INDEX
FSCM PART NUMBER
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
16954
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
19207
55683
24617
15434
15434
15434
C-114
61623
61908
62229
63385
63495-D
63842
64482
65259-A
65259-B
65259C
67346
67347-1
67684
67946
68274
68365
68445
68512
68513
68549
68585
68586
68606
68803-A
691-10014
69519
69521
69521
69699
69736
69793
69936
70089-1
70214
70295
70349
70624
70653
70657
70690
70699
70700
70705
70713
70715
70716
70717
70717A
707178
70772
70790
70790
70815
7348-2
8465575-44
851-202994
903302
9195-3
9235-1
9237
NATIONAL
STOCK NUMBER
5310-00-276-2816
5365-00-282-5030
5340-00-365-5759
5365-00-082-1193
5310-00-134-4169
2815-00-603-7264
5365-01-147-0912
5365-01-147-0913
5365-00-507-3254
5310-00-262-2986
5365-00-197-9327
5360-00-664-5343
3120-00-566-0480
5315-00-281-7610
5315-00-041-0915
5315-00-041-0916
5315-00-369-2588
5315-00-014-1195
3120-00-661-6646
5365-00-716-6580
5330-00-252-8888
5315-00-475-2574
3120-00-627-6697
3120-00-627-6697
5310-00-962-5610
5305-00-339-1415
5306-00-019-4227
5310-00-222-7240
5330-00-537-2382
4730-00-011-3175
5306-00-719-5467
5330-00-506-4874
2815-00-772-9434
2815-01-122-8002
2990-00-772-1778
5365-00-721-7884
5360-00-597-4570
5330-00-562-1176
5340-00-898-1497
5310-00-507-3259
5305-00-506-5722
5365-00-507-3260
5365-00-507-3261
5365-00-507-3262
5305-00-477-6769
5306-00-485-0790
5306-00-485-0790
5330-00-580-5327
2815-00-362-1780
4720-01-070-8149
3110-00-144-8499
5306-00-041-0917
3120-00-374-4342
5305-00-362-1536
FIGURE ITEM
NO.
NO.
36
6
12
28
36
18
5
8
8
8
13
13
30
16
16
17
2
10
10
23
2
10
25
9
26
17
17
17
3
10
24
6
2
5
30
13
35
2
5
23
24
31
27
27
27
27
27
27
27
9
25
26
28
10
15
18
24
6
7
10
36
6
35
41
13
11
10
8
8
8
13
12
16
22
21
18
30
13
6
9
18
37
5
12
15
14
23
27
2
19
3
12
9
17
4
18
4
26
1
20
15
3
12
10
4
6
9
9
9
6
11
13
17
14
5
1
13
14
7
26
FSCM PART NUMBER
NATIONAL
STOCK NUMBER
15434
15434
15434
89346
2815-00-311-2521 10 7
5330-00-175-6585 10 36
5330-00-349-1219 10 36
5365-01-133-8271 1 16
9260-1
9266
9266A
969783R1
FIGURE ITEM
NO.
NO.
SECTION
(1)
ITEM
NO
II
(2)
(3)
SMR
CODE CAGEC
TM 5-2815-241-34&P
(4)
PART
NUMBER
(5)
(6)
DESCRIPTION AND USABLE ON CODES (UOC) QTY
GROUP 01 ENGINE
GROUP 0100 ENGINE ASSEMBLY
FIG.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17
XDFZZ
XDFZZ
XDFZZ
PAFZZ
XDFZZ
XDFZZ
PFFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
PFFZZ
XDFZZ
PFFZZ
PFFZZ
PFFZZ
XDFZZ
XDFZZ
89346
89346
89346
96906
89346
89346
89346
89346
89346
89346
89346
89346
89346
96906
89346
89346
89346
89346
R99227C3
427820C1
25711R1
MS35338-50
24874R1
46522502
414089C1
187893R1
476669C1
441889C2
446002R1
414085C1
19581R1
MS24665-355
299228C1
96 97 83R1
424140C2
424141C2
1 ENGINE MOUNTING BRACKETS
BOLT, MACHINE
WASHER, FLAT
WASHER, FLAT
WASHER, LOCK
BOLT, HEXAGON HEAD
BRACKET
FRONT ENGINE MTG
SHOULDERED
NUT
WASHER, FLAT
WASHER, INSULATOR
CROSSMEMBER ENGINE FRONT MTG
WASHER, SPECIAL
HEAD
BOLT, SHOULDER
NUT, SLOTTED, HEXAGON
PIN, COTTER
REAR ENGINE MTG LOWER
INSULATOR
REAR ENGlNE MTG UPPER
INSULATOR
REAR ENGINE MTG LEST SIDE
BRACKET
REAR ENGINE MTG RIGHT SIDE
BRACKET
END OF FIGURE
1-1
2
4
8
8
8
1
2
2
4
1
2
2
2
2
2
2
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 2. CYLINDER BLOCK.
TM 5-2815-241-34&P
SECTION II
(1)
ITEM
NO
(4)
PART
NUMBER
(2)
(3)
SMR
CODE CAGEC
(5)
(6)
DESCRIPTION AND USABLE ON CODES(UOC) QTY
GROUP 0101 CRANKCASE, BLOCK,
CYLINDER HEAD
FIG.
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
24617
24617
89346
15434
AR-09912
68445
183049
3008998
215090
143938
143939
143946
143947
143948
143949
213740
202226
S-118-A
S-600
210895
70089-1
1
2
3
4
5
6
6
6
6
6
6
7
7
8
9
10
11
XDHHH
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
XDHZZ
PAHZZ
PAHZZ
PAHZZ
XDHZZ
PAHZZ
PAHZZ
XDHZZ
PAHZZ
12
13
14
15
16
PAHZZ 15434 112076
PAHZZ 15434 S-966E
PAHZZ 9 6 9 0 6 M S 3 5 6 4 8 - 8
PAHZZ 15434 6 9 9 0 1
PAHZZ 15434 9226
17
PAHZZ
15434
68585
18
18
19
19
19
20
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
15434
15434
15434
l5434
15434
19207
199064
9333-1
42645
42646
42647
5329388
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PAHZZ 15434
PAHZZ 1 5 4 3 4
PAHZZ 1 5 4 3 4
PAHZZ 15434
PAHZZ 15434
PAHZZ 15434
PAHZZ 15434
PAHZZ 15434
PAHZZ 15434
PAHZZ 1 5 4 3 4
PAHZZ 15434
PAHZZ 15434
PAHZZ 15434
PAHZZ 15434
3009213
105953
S129
S604
132648
67963
S-911-B
199067
210884
66292
3008468
70653
67622
3008469
2 CYLINDER BLOCK
BLOCK ,CYLINDER
HEAD TO BLOCK
. PIN, GROOVE, HEADLES
.PACKING,PREFORMED
.PACKING
.GASKET
0.007 IN. T H K
.SHIM
0.008 I N .
THK
SPACER,RING
.
0.008
IN.
THK
.SHIM
. SPACER, RING 0.020 IN. THK
0.031 IN. THK
.SHIM
0.062 IN. T H K
. SHIM
.CYLINDER SLEEVE
.SLEEVE, SALVAGE
. SCREW, ASSEMBLED W A S
. WASHER, LOCK
WATER HEADER
.COVER
WATER HEADER COVER PART OF
.GASKET
KIT P/N 3018762
.PLUG, FUEL OUTLET
.PLUG ,PIPE
.PLUG, EXPANSION
.PLUG, PIPE
FLYWHEEL
.PIN, STRAIGHT, HEADLE
HOUSING
.PIN, STRAIGHT, HEADLE CAM FOLLOWER
TO BLOCK HOUSING
.BASKET, HOUSING DRY
.GASKET, HOUSING WET
NO. 1,3,5
.CAP, MAIN BEARING
NO. 2,4,6
.CAP, PILLOW BLOCK
.CAP, MAIN BEARING NO. 7
MAIN
BEARING
.PIN, STRAIGHT, HEADLE
TO BLOCK
. WASHER, LOCK
.BOLT, MACHINE HEAD MAIN BEARING CAP
HEAD
.SCREW, CAP, HEXAGON H
.WASHER, LOCK
.FLANGE BLIND OIL
SUCTION FLANGE
.GASKET
.PLUG, PIPE
. PLUG, PIPE
.PLUG, MACHINE T H R E A D
. WASHER, FLAT
.PLUG,PIPE
COVER
.DOWEL, METALLIC
.PLUG, PIPE
.PLUG, PIPE
2-1
1
6
6
6
6
1
1
1
1
1
1
6
6
12
12
1
2
3
1
1
7
2
6
1
1
3
3
1
2
14
14
2
6
1
1
2
2
1
1
3
1
1
1
TM 5-2815-241-34&P
SECTION II
(1)
ITEM
NO
(4)
PART
NUMBER
(2)
(3)
SMR
CODE CAGEC
35
36
37
38
39
40
41
42
43
44
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
XDHZZ
PAHZZ
XDHZZ
PAHZZ
15434
15434
15434
15434
15434
15434
89346
15434
89346
15434
45
PAHZZ
15434
BM 427253
100670
157870
60408
S719
68445
3010395
S-605
3007976
3007442
(5)
(6)
DESCRIPTION AND USABLE ON CODES(UOC) QTY
.BEARING SET, SLEEVE
CAPSHAFT..
..BEARING,SLEEVE
. .BEARING,SLEEVE
.PIN, STRAIGHT ,HEADLE GEAR COVER
.PLUG, EXPANSION..
.PIN
STRAIGHT
HEXAGO
.SCREW,CAP,HEXAGON
HEAD
. WASHER,LOCK
. NOZZLE
.PACKING, PREFORMED PART OF KIT P/N
1
1
6
1
1
2
6
6
6
6
3018762
S962
.PLUG, PIPE
1
END OF FIGURE
2-2
SECTION II
TM 5-2815-241-34&P C01
TA508245
FIGURE 3. CYLINDER HEAD.
TM 5-2815-241-34&P
SECTION II
(1)
ITEM
NO
(2)
(3)
SMR
CODE CAGEC
(4)
PART
NUMBER
(6)
(5)
DESCRIPTION AND USABLE ON CODES(UOC) QTY
GROUP 0101 CRANKCASE, BLOCK
CYLINDER HEAD
FIG. 3 CYLINDER HEAD
1
2
3
4
5
PAFHH
PAHZZ
PAHZZ
PAHZZ
PAFZZ
15434
15434
15434
15434
15434
3007716
S965E
S995
216524
3047402
6
7
8
9
10
11
PAFZZ
PAHZZ
PAHZZ
PAFDD
PAFZZ
PAFZZ
15434
15434
15434
15434
15434
15434
193949
70459
S911B
3008100
69699
209700
CYLINDER H E A D , D I E S E
.PLUG, MACHINE THREAD
.PLUG, PIPE
.PLUG, PIPE
.GASKET CYLINDER HEAD PART
P/N 3801330
.GASKET
.PLUG, FUSIBLE
.PLUG, PIPE
.CYLINDER
HEAD,DIESE..
WASHER, FLAT
SCREW
END OF FIGURE
3-1
OF
KIT
3
3
6
2
1
21
1
4
1
12
12
SECTION II
TM 5-2815-241-34&P C01
TA508248
FIGURE 4. CRANKSHAFT, GEARS, AND BEARINGS.
TM 5-2815-241-34&P
(4)
PART
SECT ION II
(1)
ITEM
NO
(2)
(3)
SMR
CODE CAGEC
NUMBER
(5)
(6)
DESCRIPTION AND USABLE ON CODES(UOC) QTY
GROUP 0102 CRANKSHAFT
FIG. 4 CRANKSHAFT, GEARS, AM
BEARINGS
1
2
3
4
5
PAFZZ 15434
PAFZZ 15434
XDFZZ 15434
PAFZZ 15434
PAHZZ 15434
6 PAHZZ
7 PAHZZ
204165
127316
211915
211918
40662A
15434 209919
15434 204829
8
9
10
11
12
13
PAHZZ
PAHZZ
PAHHH
PAHZZ
PAHZZ
PAHZZ
15434
96934
15434
15434
15434
15434
S604
MS90727-64
3004165
215965
3000140
3801261
13
PAHZZ
15434
3801262
13
PAHZZ
15434
3801263
13
14
15
16
17
18
19
20
21
22
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
XDHZZ
PAHZZ
PAHZZ
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
AR-07110
44383
3019186
44387
3019218
202903
187680
3019192
3019180
210179
HEAD
SCREW, CAP, HEXAGON
WASHER, LOCK
DAMPER,
VIBRATION
PULLEY, GROOVE
GASKET REAR COVER PART OF KIT, P/N
3018762
COVER, TIMING GEAR,
SEAL REAR OIL PART OF KIT P/N
3O18762
WASHER, LOCK
HEAD
SCREW, CAP, HEXAGON H
CRANKSHAFT,
ENGINE
.GEAR, HELICAL
.CRANKSHAFT, ENGINE
.BEARING HALF SET, SL 0.010 INCH
UNDERSIZE
.BEARING HALF SET, SL 0.020 INCH
UNDER SIZE
BEARING HALF SET, SL 0.030 INCH
UNDER SIZE
.BEARING SET
STANDARD
STANDARD
..BEARING HALF, SLEEVE
STANDARD
. .BEARING HALF, SLEEVE
STANDARD
..BEARING HALF, SLEEVE
STANDARD
..BEARING, WASHER, THRU
STANDARD
..PIN STRAIGHT HEXAGO
STANDARD
..BEARING HALF, SLEEVE
STANDARD
..BEARING, HALF SLEEVE
STANDARD
..BEARING HALF, SLEEVE
.KEY, MACHINE
END
4-1
OF
FIGURE
6
6
1
1
1
1
1
8
8
1
1
1
1
1
1
1
3
3
1
4
2
1
3
3
1
SECTION II
TM 5-2815-241-34&P C01
TA508247
FIGURE 5. FLYWHEEL HOUSING AND FLEXPLATE.
SECTION II
(1)
ITEM
NO
(2)
(3)
SMR
CODE CAGEC
TM 5-2813-241-34&P
(4)
PART
NUMBER
(5)
(6)
DESCRIPTION AND USABLE ON CODES(UOC) QTY
GROUP 0103 FLYWHEEL ASSEMBLY
F I G . 5 FLYWHEEL HOUSING AND
FLEXPLATE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PAFZZ
XDFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
XDFZZ
XDFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PFFZZ
16
17
PAFZZ
PAFZZ
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
24617
15434
96906
96939
70657
193717
S601
MS35338-48
S106
64482
120448
123000
188936
S603
S658
106289
S200
141284
199064
MS122032
MS35204-239
BRASS
COVER,ACCESS
HOUSING,FLYWHEEL
WASHER, FLAT PAN
WASHER, LOCK
HEAD
SCREW,CAP,HEXAGON
LOCKWIRE,BOLT,FLYWH
SCREW,CAP,HEXAGON
HEAD
FLEXPLATE
SCREW,CAP
WASHER,LOCK
WASHER,FLAT
HEAD
SCREW,CAP,HEXAGON
H
NUT,PLAIN,HEXAGON
PIN,STRAIGHT,HEADLE
GASKET FLYWHEEL HOUSING PART OF KIT
P/N 3018762
WASHER,LOCK PART OF KIT P/N 3018762
SCREW, MACHINE
END OF FIGURE
5-1
1
1
7
7
4
3
6
1
9
9
9
3
3
2
1
2
2
SECTION II
TM 5-2815-241-34&P C01
TA508248
FIGURE 6. PISTON AND CONNECTING ROD.
TM 5-2815-241-34&P
SECTION II
(1)
ITEM
NO
(3)
(2)
SMR
CODE CAGEC
(4)
PART
NUMBER
(5)
(6)
DESCRIPTION AND USABLE ON CODES(UOC) QTY
GROUP 0104 PISTONS, CONNECTING RODS
FIG.
1
2
3
4
5
6
7
6
9
10
11
12
13
13
14
PAHZZ
PFHZZ
PAHZZ
PAHZZ
PFHHH
PFHZZ
PAHZZ
XDHZZ
PAHZZ
PAHHH
PAHZZ
PAHZZ
PAHZZ
XDHZZ
PAHZZ
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
3014149
132880
147670
194610
AR-08190
175755
191970
203090
214950
BM 52474
200861
69936
187420
152770
9195-3
6 PISTON AND CONNECTING ROD
RING SET,PISTON
.RING ,PISTON
.RING, PISTON
.RING, PISTON
PISTON ASSEMBLY
.RING, RETAINING
.PIN, PISTON
. PISTON
BEARING
CONNECTING
ROD,PIST
. WASHER, FLAT
.NUT, PLAIN, HEXAGON
.BUSHING,PISTON
PIN
.BUSHING,HEAVY WALL
.BOLT, CONNECTING ROD
END OF FIGURE
6-1
6
2
1
1
6
2
1
1
12
6
2
2
1
1
2
SECTION II
TM 5-2815-241-34&P C01
TA508249
FIGURE 7. CAMSHAFT.
SECTION II
(3)
(2)
(1)
ITEM
SMR
NO
CODE CAGEC
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTlON AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 6105 VALVES, CAMSHAFTS, AND
TIMING SYSTEM
FIG. 7 CAMSHAFT
1
2
3
4
5
6
XDHHH
PAFZZ
PAHZZ
PAHZZ
PFFZZ
PAFZZ
15434
15434
15434
15434
15434
15434
3023177
68193
143450
9235-1
69550
156226
CAMSHAFT, SERVICE AS
. PLUG, VENT
. CAMSHAFT, ENGINE
BEARING, WASHER, THRU
KEY, MACHINE CAMSHAFT GEAR
GEAR, CAMSHAFT
END OF FIGURE
7-1
1
1
1
1
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 8. GEARCASE COVER.
SECTION II
(3)
(l)
(2)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(5)
(6)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0105 VALVES, CAMSHAFTS, AND
TIMING SYSTEM
FIG. 8 GEARCASE COVER
1 PAFZZ 15434 S-119-C
2
3
4
5
PAFZZ
PAFZZ
PAFZZ
PAFZZ
96906
15434
15434
15434
MS35338-47
S622
3004316
210412
6
7
8
9
10
11
12
13
14
15
16
16
16
16
17
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
96906
15434
96906
15434
96906
15434
96906
15434
15434
15434
15434
15434
15434
15434
S-908
MS90727-94
60408
MS90727-91
70653
MS18154-60
S604
MS27183-14
150002
AR01176
185573
65259-A
65259-B
65259-C
215705
18
19
20
21
PAFZZ
XDFFF
PAFZZ
PAFZZ
15434
15434
15434
15434
3006736
AR09473
S-908
3029852
SCREW, CAP, HEXAGON HEAD, TIMING
GEAR COVER MTG
WASHER, LOCK
WASHER, FLAT
SEAL OIL PART OF KIT P/N 3018762
GASKET GEAR COVER PART OF KIT P/N
3018762
PLUG, PIPE
SCREW, CAP, HEXAGON H
PIN, STRAIGHT, HEADLE
SCREW, CAP, HEXAGON H
DOWEL, METALLLC
SCREW, CAP, HEXAGON H HEAD
WASHER, LOCK
WASHER, FLAT
SUPPORT, CAMSHAFT
SHlM SET CAMSHAFT THRUST
. SHIM INSERT
. SHIM 0.010 IN. THK
. SHIM 0.005 IN. THK
. SHIM 0.002 IN. THK
PACKING, PREFORMED PART OF KIT P/N
3018762
SEAL, PLAIN ENCASED CRANKSHAFT
COVER, GEAR CASE
. PLUG, PIPE
. BEARING , SLEEVE
END OF FIGURE
8-1
1
13
13
1
1
3
3
1
9
1
3
3
3
1
1
1
1
1
1
1
1
1
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 9. VALVES, SPRINGS, AND GUIDES.
SECTION II
(2)
(3)
(1)
ITEM
SMR
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0105 VALVES, CAMSHAFTS, AND
TIMING SYSTEM
FIG. 9 VALVES, SPRINGS, AND GUIDES
1
2
3
4
5
5
6
7
8
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
15434
15434
15434
75078
15434
15434
15434
170296
127554
147389
203131
3036065
17339
70772
147100
131026
9
9
9
9
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
15434
15434
3017759
127935
3014622
3014623
9 PAFZZ 15434 3014624
9 PAFZZ 15434 3014625
10
10
11
12
13
14
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
15434
15434
15434
15434
145701
135957
3006456
172034
211999
3007759
15 PAFZZ 15434 123558
16 PAFZZ 15434 3011935
SEAT, HELICAL COMPRE
HALF-COLLET
SETSCREW
NUT, CROSS HD
CROSSHEAD, VALVE INTAKE
CROSSHEAD, VALVE EXHAUST
SCREW, ASSEMBLED WAS
CROSSOVER, FUEL
PACKING, PREFORMED PART OF KIT P/N
3801330
SEAT, VALVE EXHAUST, STANDARD
SEAT, VALVE 0.005 INCH OVERSIZE
SEAT, VALVE 0.010 INCH OVERSIZE
INSERT, VALVE SEAT 0.020 INCH
OVERSIZE
SEAT, VALVE 0.030 INCH OVERSIZE
INSERT, VALVE SEAT 0.040 INCH
OVERSIZE
VALVE, POPPET, ENGINE EXHAUST
VALVE, POPPET, ENGINE
GUIDE, VALVE STEM
SEAT, HELICAL COMPRE
SPRING, HELICAL, COMP
PACKING, PREFORMED PART OF KIT P/N
3801330
PIN, STRAIGHT, HEADLE
SLEEVE, COOLING, FUEL
END OF FIGURE
9-1
24
48
12
12
6
6
8
2
8
12
12
12
12
12
12
12
12
24
24
24
6
12
6
SECTlON II
TM 5-2815-241-34&P C01
FIGURE 10. PUSHRODS AND CAM FOLLOWERS.
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
NUMBER
DESCRIPTION AND USABLE ON CODES (UOC) QTY
SECTION II
(2)
(3)
(1)
SMR
ITEM
CODE CAGEC
NO
GROUP 0105 VALVES, CAMSHAFTS, AND
TIMING SYSTEM
FIG.
1
2
3
4
5
PAFZZ
PAFZZ
PAFZZ
PAFFF
PAFFF
15434
15434
15434
15434
15434
BM47777
3027215
210650
BM37625
BH37634
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
PAFZZ
PAFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
PAFFF
PAFZZ
PAFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
PAFZZ
PFFZZ
XDFZZ
PAFZZ
PAFZZ
PAFZZ
PFFZZ
XDFZZ
XDFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
96906
96906
15434
15434
15434
15434
96906
96906
15434
68513
9260-1
118939
107738
120543
118378
3018049
68512
7348-2
118939
107738
BM-37496
118377
69736
175831
3065125
BM73976
210685
S719
MS51092-1
9237
208411
MS35338-8
MS27183-14
S223
43696
208581
139289
MS35338-45
MS90727-31
120819
36 PAFZZ 15434 9266
36 PAFZZ 15434 9266A
37 PAFZZ 15434 68586
38 PAFZZ 15434 S129
10 PUSHRODS AND CAM FOLLOWERS
PUSH ROD, EXHAUST VA
PUSH ROD, ENGINE POP
ROD, PUSH, INTAKE
HOUSING ASSY, CAM FO
. LEVER ASSEMBLY, CAM INTAKE AND
EXHAUST
. . PIN, STRAIGHT, HEADLE
.. ROLLER, VALVE CAM
.. PIN, STRAIGHT, HEADLE
.. SOCKET, CAM FOLLOWER
. . CAM FOLLOWER LEVER AND BUSHING
.. BEARING, SLEEVE
. LEVER ASSEMBLY, INJE INJECTOR
.. PIN, STRAIGHT, HEADLE
.. ROLLER, INJECTOR CAM
.. PIN, STRAIGHT, HEADLE
.. SOCKET, CAM FOLLOWER
.. CAM FOLLOWER LEVER AND BUSHING
. . BEARING, SLEEVE
. SCREW, MACHINE
. PLUG, EXPANSION
. SHAFT, STRAIGHT
. HOUSING, CAM FOLLOWER
SHAFT
PLUG, EXPANSION
WASHER, FLAT COPPER
SETSCREW SHAFT LOCK
BOLT, MACHINE CARRIAGE
WASHER, LOCK
WASHER, FLAT
NUT HEXAGON
PACKING, PREFORMED
LEVER COMPRESSION RELEASE
SPRING
WASHER, LOCK
BOLT, MACHINE
GASKET 0.026 THK PART OF KIT P/N
3018762
GASKET 0.015 THK PART OF KIT P/N
3018762
GASKET 0.007 THK PART OF KIT P/N
30l8762
BEARING, SLEEVE
SCREW, CAP, HEXAGON H
END OF FIGURE
10-1
6
6
6
3
4
1
1
1
1
1
1
2
1
1
1
1
1
1
6
2
2
1
1
1
1
1
1
19
1
1
1
1
1
1
1
1
1
1
6
18
SECTION II
TM 5-2815-241-34&P C01
FIGURE 11. ROCKER HOUSING COVER AND BREATHER.
SECTION II
(2)
(3)
(1)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0105 VALVES, CAMSHAFTS, AND
TIMING SYSTEM
F I G . 11 ROCKER HOUSING COVER AND
BREATHER
1
2
3
4
5
6
7
8
9
PAOZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
96906
96906
96906
96906
15434
15434
73165
131322
3006187
MS90728-66
MS18154-60
MS35338-8
MS27183-14
3006183
3006358
B90429
CAP, FILLER OPENING
HOUSING
COVER, ENGINE POPPET
SCREW, CAP, HEXAGON H COVER MTG
SCREW, CAP, HEXAGON H COVER MTG
WASHER, LOCK COVER MTG
WASHER, FLAT
COVER, ENGINE POPPET
COVER, ENGINE POPPET
GASKET
END OF FIGURE
11-1
1
1
9
6
15
15
1
1
3
SECTION II
TM 5-2815-241-34&P C01
FIGURE 12. ROCKER ARMS AND HOUSING.
SECTION II
(3)
(1)
(2)
ITEM
SMR
NO
CODE CAGEC
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0105 VALVES, CAMSHAFTS, AND
TIMING SYSTEM
FIG.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
XDFFF
PAFFF
PAFZZ
PAFZZ
XDFFF
PAFZZ
PAFFF
PAFZZ
XDFZZ
XDFFF
PAFZZ
PAFZZ
PAFFF
PAFZZ
PAFZZ
XDFFF
PAFZZ
XDFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
XDFZZ
XDFZZ
PAFFF
PAFZZ
PAFZZ
PAFZZ
PAFFF
PAFZZ
PAFZZ
XDFFF
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PFFZZ
15434
15434
96906
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
96906
15434
15434
15434
75078
75078
75078
15434
15434
75078
15434
15434
96906
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
89346
AR03307
BM95161
MS51968-14
168306
169704
140330
AR-02308
MS51968-14
199239
218152
140330
194037
AR51276
MS51968-14
168306
168805
140330
2514
2856
1232
199224
011573
2680
3045533
BM95162
MS51968-14
168306
140330
BM95160
MS51968-14
168306
168803
140330
199225
3000521
3007242
187589
37 PAFZZ 15434 3801433
12 ROCKER ARMS AND HOUSING
HOUSING AND ROCKER
. ROCKER ARM, ENGINE P EXHAUST
.. NUT, PLAIN, HEXAGON
. . SET SCREW
.. ARM AND BUSHING
. .. BUSHING, SLEEVE
. ROCKER, ARM, ENGINE P INJECTOR
.. NUT, PLAIN, HEXAGON
. . SCREW, INJECTOR ARM ADJUSTING
. . ARM
. .. BUSHING, SLEEVE
.. SEAT, BALL SOCKET
. ROCKER ARM, ENGINE P
.. NUT, PLAIN, HEXAGON
. . SET SCREW
.. ARM AND BUSHING
. . . BUSHlNG, SLEEVE
. WASHER, BEARlNG
. STUD
. STUD, SHOULDERED
. NUT, ROCKER
. CROSSHEAD, VALVE EXHAUST VALVE
. LOCKPLATE
. GASKET, HOUSING
. ROCKER ARM, ENGINE P
.. NUT, PLAIN, HEXAGON
.. SETSCREW
. . BUSHING, SLEEVE
. ROCKER ARM, ENGINE P
. . NUT, PLAIN, HEXAGON
.. SETSCREW
.. ARM AND BUSHING
. .. BUSHING, SLEEVE
. SCREW SHAFT LOCK
. PACKING, PREFORMED
. HOUSING, ROCKER ARM
. GASKET HOUSING TO HEAD PART OF KIT
P/N 3801330
. SHAFT, STRAIGHT
END OF FIGURE
12-1
3
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
18
10
8
18
2
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 13. OIL PAN AND DIPSTICK.
SECTION II
(3)
(1)
(2)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0106 ENGINE LUBRICATION SYSTEM
F I G . 13 OIL PAN AND DIPSTICK
1
2
3
4
5
XDFZZ
PFFZZ
XDFZZ
PAFZZ
PAFZZ
15434
15434
15434
15434
15434
112593
197230
3019400
20622
S1354
6 PAFZZ 15434 3032861
7
8
9
13
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
PFOZZ
PAOZZ
PAOZZ
PAOZZ
PFOZZ
XDFZZ
XDFZZ
PAOZZ
PAFZZ
PAFZZ
PAOZZ
PAFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
96909
96906
15434
15434
15434
15434
96906
96906
80218
15434
96906
15434
15434
15434
15434
96906
96906
96906
15434
204657
200064
MS35338-46
MS18154-58
211358
67347-1
67346
S-915-A
MS35338-8
MS90727-87
10003
70349
MS35338-47
S622
208461
185804
S626
MS35690-865
MS35338-48
MS90725-115
157551
28 PFFZZ 15434 3012527
29 PAFZZ 96906 MS35338-46
SCREW, CAP, HEXAGON HEAD
SEAL
HOSE
STRAINER ELEMENT, SE OIL PAN
SCREW, TAPPING, THREA HEAD STRAINER
MTG
GASKET OIL PAN PART OF KIT P/N
3018762
GAGE ROD, LIQUID LEV OIL
CLAMP, LOOP
WASHER, LOCK
SCREW, CAP, HEXAGON
TUBE, METALLIC OIL
BRACKET, OIL GAGE
GASKET OIL GAGE BRACKET
PLUG, PIPE
WASHER, LOCK
SCREW, CAP, HEXAGON H
PLUG, DRAIN
BOLT, MACHINE
WASHER , LOCK
WASHER, FLAT
PAN, OIL
SCREW, CAP, HEXAGON H HEAD
WASHER, FLAT
NUT, HEXAGON
WASHER, LOCK
SCREW, CAP, HEXAGON
GASKET SUCTION FLANGE PART OF KIT
P/N 3018762
ELBOW, FLANGE TO TUB OIL SUCTION
WASHER, LOCK
END OF FIGURE
13-1
2
2
1
1
4
1
1
1
1
1
1
1
1
4
2
2
1
34
38
34
1
4
4
2
2
2
1
1
2
SECTION II
TM 5-2815-241-34&P C01
FIGURE 14. ENGINE BREATHER ASSEMBLY
SECTION II
(3)
(1)
(2)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0106 ENGINE LUBRICATION SYSTEM
FIG.
1 PAFZZ 33457 2S7225S
14 ENGINE BREATHER ASSEMBLY
BREATHER ENGINE
END OF FIGURE
14-1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 15. ENGINE BREATHER HOSE.
SECTION II
(3)
(2)
(1)
ITEM
SMR
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0106 ENGINE LUBRlCATION SYSTEM
F I G . 15 ENGINE BREATHER HOSE
1
2
3
4
5
XDFZZ
XDFZZ
XDFZZ
XDFZZ
MFFZZ
15434
15434
15434
15434
19207
390782C1
274085R91
209862C1
299263091
8465575-44
6 XDFZZ 15434 364319C1
HOSE, HEATER
CLAMP, HOSE
STRAP, CABLE LOCK
CLAMP, RUBBER CUSHIO
MANUFACTURE FROM NSN 4720-00HOSE
846-5575
TUBE, HOSE
END OF FIGURE
15-1
1
3
1
1
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 16. ENGINE OIL FILTER COOLER.
SECTION II
(2)
(3)
(1)
SMR
ITEM
CODE CAGEC
No
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0106 ENGINE LUBRICATION SYSTEM
FIG.
1
2
3
4
5
6
7
XDFFF
PAFZZ
PAFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
15434
96906
96906
96906
96906
15434
15434
AR09479
MS90728-62
MS90725-67
MS35338-8
MS35782-6
213858
218245
8 XDFFF 15434 AR09478
9 PAFZZ 15434 142616
10 PAFZZ 15434 3007713
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
PAFZZ
PAFZZ
PAFZZ
PFFZZ
XDFZZ
PAFZZ
XAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
46529
15434
15434
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
A331987
S-910-B
179063
202128
201707
S911B
210832
MS90728-70
127558
68274
67946
3022961
110907
210967
211053
26 XDOOO 15434 AR-09265
27 PAOZZ 15434 173368
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
PAOZZ
XDOOO
XDOZZ
PAOZZ
PAOZZ
XDOZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
XDFZZ
PFFZZ
PAFZZ
PFFZZ
PAFZZ
15434
15434
15434
96906
15434
15434
96906
96906
96906
15434
15434
15434
15434
15434
15434
15434
158139
184387
184386
MS35782-6
8265
184388
MS27183-14
MS35338-8
MS18154-60
S145
S608
132756
210966
212161
3000907
3008017
16 ENGINE OIL FILTER COOLER
COOLER, OIL
. SCREW, CAP, HEXAGON H
. SCREW, CAP, HEXAGON H
. WASHER, LOCK
. DRAINCOCK
. COVER
. GASKET OIL COOLER COVER PART OF
KIT P/N 3018762
. COOLER, OIL
.. RETAINER, OIL COOLER
.. PACKING, PREFORMED PART OF KIT P/N
3018762
. . CORE, OIL COOLER
. . PLUG, PIPE
.. SEAT, BYPASS F I L T E R
. . . SPRING, FILLER B Y - P A
.. DISC, BY-PASS
. . PLUG, PIPE
.. HOUSING, FILTER A N D
. SCREW, CAP, HEXAGON H
. PLUNGER, OIL PUMP RE
. SPRING, HELICAL, COMP
. SPACER, RING PART OF KIT P/N 3O18762
. PLUG, MACHINE THREAD
. PLUG, MACHINE THREAD
. SUPPORT, COOLER
. GASKET OIL COOLER PART OF KIT P/N
3018762
FlLTER, OIL
. PACKING, PREFORMED FART OF KIT P/N
3018762
. FILTER ELEMENT, FLUl
. SHELL AND BOLT ASSY
.. SHELL
. . DRAINCOCK
.. WASHER, FLAT
. . BOLT, SHELL
WASHER, FLAT
WASHER, LOCK
SCREW, CAP, HEXAGON H
SCREW, CAP, HEXAGON H
WASHER, LOCK
WASHER, PLAIN
BRACKET, ANGLE
PACKING, PREFORMED
TUBE, WATER TRANSFER
GASKET COOLER SUPPORT PART OF KIT
P/N 3018762
16-1
1
1
10
12
1
1
1
1
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
8
2
1
1
1
1
2
1
1
SECTION II
(1)
(2)
(3)
ITEM
SMR
NO
CODE CAGEC
TM 5-2815-241-34&P
(4)
(5)
(6)
PARTS
NUMBER
DESCRIPTION AND USABLE ON CODES (UOC) QTY
44 PAFZZ 96906 MS90728-62
45 PAFZZ 72582 450517
46 PAFZZ 15434 5199B
SCREW, CAP, HEXAGON H
SCREW, CAP, HEXAGON H
SCREW CAP, HEXAGON H
END OF FIGURE
16-2
2
2
2
SECTION II
TM 5-2815-241-34&P C01
FIGURE 17. LUBRICATING OIL PUMP.
SECTION II
(3)
(1)
(2)
ITEM
SMR
NO
CODE CAGEC
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0106 ENGINE LUBRICATION SYSTEM
FIG.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
PAFFF
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
XDFFF
PAFZZ
PAFZZ
XDFZZ
PAFZZ
PAFFF
PAFZZ
PAFZZ
PAFZZ
15434
96906
96906
15434
15434
15434
15434
15434
15434
96906
15434
96906
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
AR-10172
MS35756-34
MS18154-59
109319
126304
134596
211939
109333
S995
MS35338-47
S-119-C
MS35338-8
MS90727-83
69519
199587
3014783
AR-03636
68365
177419
117897
S101A
AR09832
69521
204832
203145
26
27
28
29
30
31
32
XDFFF
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
96906
96906
15434
96906
15434
AR08667
69521
MS35338-45
MS90728-36
S-147-B
MS90725-34
3031434
17 LUBRICATING OIL PUMP
OIL PUMP ASSEMBLY, E
. KEY, WOODRUFF
. SCREW, CAP, HEXAGON H
. LOCK PLATE
. YOKE, CAP RETAINING
. PLUG, VENT
. SPRING, HELICAL, COMP
. PLUNGER, PRESSURE RE
. PLUG, PIPE
WASHER, LOCK
SCREW, CAP, HEXAGON H
WASHER, LOCK
SCREW, CAP, HEXAGON H
. PIN, STRAIGHT, HEADLE
. GEAR SHAFT, WORM WHEE
. GEAR, SPUR
. GEAR AND BUSHING
. . BUSHING, SLEEVE
. SHAFT, SHOULDERED
CAPSCREW
SCREW, CAP, HEXAGON H
. BODY, OIL PUMP WITH
. . BEARING, SLEEVE
. GEAR, HELICAL
. GASKET COVER PART OF KIT P/N
3018762
. HOUSING, ADAPTER
. . BEARING, SLEEVE
. WASHER, LOCK
. BOLT, MACHINE
. BOLT, MACHINE
. SCREW, CAP, HEXAGON H
GASKET PART OF KIT P/N 3018762
END Of FIGURE
17-1
1
1
1
1
1
1
1
1
2
5
1
2
1
1
1
1
1
2
1
1
2
1
2
1
1
1
1
8
1
1
6
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 18. INTAKE MANIFOLD.
SECTION II
(3)
(2)
(1)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0108 MANIFOLDS
FIG.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PAFZZ
PAFZZ
XDFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PFFZZ
PAFZZ
PAFZZ
PAFZZ
PFFZZ
63483
15434
15434
96906
96906
96906
15434
96906
15434
15434
15434
15434
15434
15434
202994-1011
238326
3022205
MS90728-64
MS35338-8
MS27183-14
3012972
MS18154-60
3019227
141761
63842
S911B
112076
202961
18 INTAKE MANIFOLD
HOSE, PREFORMED
CLAMP, HOSE
CONNECTION, AIR CROS
SCREW, CAP, HEXAGON H
WASHER, LOCK
WASHER, FLAT
GASKET PART OF KIT P/N 3801330
SCREW, CAP, HEXAGON H
GASKET
MANIFOLD, INTAKE
WASHER, FLAT
PLUG, PIPE
PLUG, FUEL OUTLET
GASKET
END OF FIGURE
18-1
1
2
1
7
17
10
1
10
1
1
3
1
3
3
SECTION II
TM 5-2815-241-34&P C01
FIGURE 19. EXHAUST MANIFOLD.
SECTION II
(3)
(1)
(2)
ITEM
SMR
NO
CODE CAGEC
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
NUMBER
DESCRIPTION AND USABLE ON CODES (UOC) QTY
GROUP 0108 MANIFOLDS
F I G . 19 EXHAUST MANIFOLD
1
2
3
4
5
6
7
8
9
10
11
12
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
3020943
151489
S155
116982
151478
112076
105199
200566
200908
114638
109594
200919
GASKET PART OF KIT P/h 3801330
MANIFOLD, EXHAUST
SCREW, CAP, HEXAGON H
LOCKING PLATE, NUT A
MANIFOLD, EXHAUST
PLUG, PIPE
DOWEL, MANIFOLD
MANIFOLD, CENTER SEC
SCREW, CAP, HEXAGON H
WASHER, KEY
REARING, SLEEVE
STRAP, RETAINING
END OF FIGURE
19-1
6
1
8
4
1
2
4
1
4
4
8
2
SECTION II
TM 5-2815-241-34&P C01
FIGURE 20. ACCESSORY DRIVE.
SECTION II
(3)
(2)
(1)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0109 ACCESSORY DRIVING
MECHANISMS
F I G . 20 ACCESSORY DRIVE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
PAFZZ
PAFZZ
XDFFF
XAFZZ
PAFZZ
PAFZZ
XDFHH
PAFZZ
PAHZZ
XDHHH
PAHZZ
XAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
XDHZZ
PAHZZ
PAFZZ
PAFZZ
PAFZZ
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
94906
15434
15434
15434
15434
96906
96906
191517
MS15795-824
AR09607
213926
190397
200809
AR08366
142689
3026556
AR08256
116391
199338
S911B
199969
MS35756-12
MS35756-18
116390
190769
191517
69550
MS35338-47
MS90728-87
NUT, SELF-LOCKING, HE
WASHER, FLAT
PULLEY FAN AND WATER PUMP DRIVE
. PULLEY
. SLEEVE, PULLEY, PUMP
GASKET
DRIVE, ACCESSORY DRI
. GEAR, HELICAL
. BEARING, WASHER, THRU
. HOUSING ASSEMBLY
. . BEARING, SLEEVE
. . HOUSING
. . PLUG, PIPE
. SHAFT, SHOULDER
. KEY , WOODRUFF
. BEARING, WASHER, THRU
. WASHER, FLAT
. COUPLING
. NUT, SELF-LOCKING, HE
KEY, WOODRUFF PART OF KIT P/N 3018762
WASHER, LOCK
SCREW, CAP, HEXAGON H
END OF FIGURE
20-1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
5
5
SECTION II
TM 5-2815-241-34&P CO1
FIGURE 21. ENGINE COMPRESSION BRAKE.
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
SECTION II
(3)
(2)
(1)
ITEM
SMR
NO
CODE CAGEC
GROUP 0112 ENGINE BRAKE
F I G . 21 ENGINE COMPRESSION BRAKE
1
2
3
4
5
6
XDFFF
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
15434
15434
15434
15434
15434
15434
2544
1484
1022
1289
1023
1492
7
8
9
10
11
12
13
14
15
16
17
18
19
23
21
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
XDFZZ
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
1030
1011
1017
2689
2390
1081
1082
1083
1026
1031
2299
1200
1012
4136
1265
BRAKE, JACOBS ASSEMBLY
. PISTON, SLAVE
. SPRING, SLAVE PISTON
. RETAINER SLAVE PISTON SPRING
. RING, RETAINING
. SCREW, CAP, HEXAGON HEAD SPRlNG
RETAINER
. WASHER, FLAT
. SPRING
MASTER PISTON
. PISTON, MASTER
. VALVE ASSEMBLY SOLENOID
. HARNESS
. SEAL, RING SOLENOID UPPER
. SEAL, RING SOLENOID CENTER
. SEAL, RING SOLENOID LOWER
. NUT, PLAIN, HEXAGON ADJUSTING SCREW
. SETSCREW
. TERMINAL BUSHING LEADOUT
. SPOOL ASSEMBLY CONTROL VALVE
. SPRING, CONTROL VALVE
. COVER, CONTROL VALVE
. SCREW, CAP, HEXAGON HEAD AIR BLEED
END OF FIGURE
21-1
1
2
2
2
2
2
2
2
2
1
1
1
1
1
2
2
1
2
2
2
2
SECTION II
TM 5-2815-241-34&P C01
FIGURE 22. FUEL INJECTOR.
SECTION II
(2)
(3)
(1)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 03 FUEL SYSTEM
GROUP 0301 CARBURETOR, FUEL INJECTOR
F I G . 22 FUEL INJECTOR
1
2
3
4
5
6
7
8
9
10
11
12
PAFZZ
PAFZZ
PAFZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
13
14
15
16
PAHZZ
PAHZZ
PAHZZ
PAHZZ
15434
15434
15434
15434
3018323
165006
3801353
191916
3054535
167157
166009
185139
174299
174298
173086
MS9241-024
193736
203426
3012537
185138
NOZZLE, FUEL INJECTI
. SCREW, CAP, HEXAGON H CLAMP MTG
. CLAMP
. PLUNGER, DETENT
. BARREL AND PLUNGER
.. BALL CHECK, FUEL INJ
. SPRING, HELICAL, COMP INJECTOR
. ADAPTER, INJECTOR
. RING, RETAINING
. STRAINER, ELEMENT, SE
. GASKET
. PACKING, PREFORMED PART OF KIT P/N
3801330
. GASKET PART OF KIT P/N 3801330
. BOLT, MACHINE
. CUP, INJECTOR
. RETAINER, CUP
END OF FIGURE
22-1
6
2
1
1
1
1
1
1
1
1
1
1
2
2
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 23. FUEL PUMP HOUSING.
SECTION II
(2)
(3)
(1)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0302 FUEL PUMPS
FIG. 23 FUEL PUMP HOUSlNG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
XDFHH
PAFZZ
PAFZZ
PAFZZ
XDHZZ
PAHHH
XDHHH
PAHHH
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHHH
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHHH
PAHZZ
XDHHH
PAHZZ
XDHZZ
PAHZZ
XDHZZ
PAHZZ
XDHZZ
PAHZZ
PAHZZ
PAFZZ
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
72962
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
3007300-2764
MS9021-116
139473
112076
138782
BM79290
BM73902
BM76665
68549
100193
163733
118227
140618
BM98430
101841
101842
101843
203350
590220940406
144302
3027633
70690
BM73718
163944
AR-00796
146437
157594
143847
144179
144178
142204
113244
MS16632-1050
175836
PUMP ASSEMBLY, FUEL
. PACKING, PREFORMED
. PLUG, MACHINE THREAD
. PLUG, FUEL OUTLET
. SPRING, TORQUE CONTR
. HOUSING, FUEL PUMP
. . HOUSING ASSEMBLY
. .. BARREL ASSEMBLY
. . . . PIN, STRAIGHT, HEADLE
. . .. BEARING, SLEEVE
. . .. CLIP, GOVERNOR BARRE
. . . . PIN, HOLLOW
. . . . HOUSING, SPRING PACK
. . PLUNGER, GOVERNOR
. .. SHlM
. .. SHIM
. . . SPACER, RING
. .. PLUNGER, GOVERNOR
. .. PIN, SPRING
. . . SPACER, FUEL PUMP
. .. BEARING, SLEEVE
. .. DRlVER, PLUNGER, GOVE
. WEIGHT AND CARRIER
. . BUSHING, SLEEVE
.. CARRIER ASSEMBLY
... WEIGHT, GOVERNOR
... WASHER, THRUST
... SPRING, HELICAL, COMP
. .. WASHER, FLAT
. .. PIN, SHOULDER, HEADLE
. .. PIN, WEIGHT PIVOT
. .. GEAR, SPUR
. .. RING, RETAINER
. VALVE, CHECK
END OF FIGURE
23-1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
4
1
1
1
2
1
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 24. MAINSHAFT COVER.
SECTION II
(2)
(3)
(1)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0302 FUEL PUMPS
F I G . 24 MAINSHAFT COVER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PAFZZ
PAFHH
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAFHH
PAHZZ
PAHZZ
PAHHH
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAFZZ
15434
15434
15434
96906
15434
15434
15434
15434
15434
96906
15434
15434
24617
15434
15434
15434
162426
BM69886
69793
MS35338-8
108330
101918
101983
BM68879
3045173
MS20066-116
AR51307
100192
903302
103036
70699
100764
17
18
19
20
21
XDFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
15434
96906
15434
15434
15434
S140
MS35338-47
S622
S274
3035053
22
23
24
25
26
27
PAFZZ
PFFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
96906
96906
88044
15434
96906
118226
MS90725-10
MS122032
AN960-416
S606
MS27183-42
. INSERT, FLEXIBLE COU
. COVER ASSEMBLY MAIN
. . BOLT, MACHINE
.. WASHER, LOCK COUPLING
.. WASHER, FLAT
.. COUPLING HALF, SHAFT
. .. GEAR, HELICAL
.. HOUSING COVER ASSEM
. .. SEAL, OIL
.. KEY, MACHINE
.. GEARSHAFT, SPUR-WORM
. .. SHAFT, SHOULDERED DRIVE
. .. BEARING, BALL, ANNULA
. .. GEAR, SPUR
. . RING, RETAINING
. GASKET COVER TO HOUSING PART OF
KIT P/N BM68356
. CAPSCREW
. WASHER, LOCK
. WASHER, FLAT
. NUT
. GASKET PUMP TO COMPRESSOR PART OF
K I T P / N 3018762
. SCREW COVER TO HOUSING
. CAPSCREW
. WASHER, LOCK
. WASHER, FLAT COVER TO HOUSING
. WASHER , LOCK
. WASHER, FLAT BODY TO COVER
END OF FIGURE
24-1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
4
4
4
4
1
1
6
6
6
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 25. GEAR PUMP
SECTION II
(3)
(2)
(1)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
NUMBER
DESCRlPTION AND USABLE ON CODES (UOC) QTY
GROUP 0302 FUEL PUMPS
F I G . 25 GEAR PUMP
1
2
3
4
PAFHH
PAHZZ
PAFHH
PAHZZ
15434
15434
15434
12204
3334233
101468
BM97497
141244
5
6
7
8
9
PAFZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
15434
15434
15434
15434
15434
68606
119363
175864
100215
110855
10
11
12
13
PAHZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
15434
15434
116936
70790
181466
210647
. PUMP, GEAR FUEL
. . BUSHING, SLEEVE
. . HOUSING ASSEMBLY, FU
. .. PIN, STRAIGHT, HEADLE COVER TO
HOUSING
. .. PLUG, MACHINE THREAD
.. GEAR, SPUR
.. SHAFT, IDLER, GEAR PU
.. SHAFT, SHOULDERED
.. GASKET COVER TO HOUSING PART OF
KIT P/N BM68356
.. ELBOW, PIPE TO TUBE
. BOLT, MACHINE
. WASHER, LOCK
. GASKET PART OF KIT P/N BM68356
END Of FIGURE
25-1
1
1
1
2
1
2
1
1
1
1
4
4
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 26. DAMPER.
SECTION II
(1)
(2)
(3)
SMR
ITEM
NO
CODE CAGEC
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0302 FUEL PUMPS
FIG. 26 DAMPER
1
2
3
4
5
6
PAFHH
PAFZZ
PAFZZ
PAFZZ
PAHZZ
PAHZZ
15434
96906
96906
88044
15434
15434
BM76340
MS90725-10
MS122032
AN960-416
153336
100099
7 PAHZZ 15434
8 PAHZZ 15434
202897
139988
PAHZZ 15434
160514
9
10
11
12
13
14
15
16
PAHZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAHZZ
PAFZZ
15434
88044
15434
15434
15434
16954
15434
153338
AN960-416
181466
70790
203849
691-10014
116936
. DAMPENER, FLUID PRES
.. SCREW, CAP, HEXAGON H
.. WASHER, LOCK
.. WASHER, FLAT
. . HOUSING, FUEL PUMP
.. PACKING, PREFORMED PART OF KIT P/N
BM68356
.. DISK, SOLID, PLAIN
. . PACKING, PREFORMED PART OF KIT P/N
BM68356
.. SPACER, RING PART OF KIT P/N
BM68356
. . COVER, ACCESS
. WASHER
. WASHER, LOCK
. BOLT, MACHINE, SDC
. ELBOW, TUBE TO BOSS
. GASKET PART OF KIT P/N DM68356
. ELBOW, CONNECTION
END OF FIGURE
26-1
1
2
2
2
1
1
1
1
1
1
2
2
2
1
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 27. SPRING PACK.
SECTION II
(2)
(3)
(1)
SMR
ITEM
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0302 FUEL PUMPS
F I G . 27 SPRING PACK
1
2
3
4
5
6
7
8
9
9
9
9
10
11
12
13
14
XDFZZ
PAFFF
PAFZZ
PAFZZ
PAFZZ
PAFZZ
XDFFF
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
88044
140925
BM-69886
144195
70715
3038220
70716
BM74747
143251
70717
70717A
70717B
189800
70713
MS16625-1100
70705
44678
AN960-416
15 PAFZZ 15434 181466
16
17
18
19
20
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
15434
15434
96906
203619
124020
124019
177999
MS90725-10
. PLUNGER, FUEL INJECT
1
1
. COVER AND GOVERNOR IDLING SPRING
1
. . SPRING, HELICAL, COMP
1
.. WASHER, FLAT
.. GUIDE, CLIP ASSEMBLY
1
1
.. SETSCREW
1
. SPRING ASSEMBLY
.. SPRING, HELICAL, COMP
1
1
. . SPACER, RING
V
. . SHIM
V
.. SHIM
1
. . SHIM GOVERNOR
1
. RING RETAINING
1
. RING, SNAP
1
. GASKET PART OF KIT P/N BM68356
1
. COVER, SPRING PACK
4
. WASHER, FLAT SPRING PACK COVER TO
HOUSING
4
. WASHER, LOCK SPRING PACK COVER TO
HOUSING
1
. SCREW SPRING PACK COVER TO HOUSING
1
. WIRE, SHAFT SEAL
2
. SEAL, FUEL PUMP REGU
1
. PLUG, PIPE
3
. SCREW, CAP, HEXAGON
END OF FIGURE
27-1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 28. ANEROID CONTROL.
SECTION II
(3)
(1)
(2)
SMR
ITEM
NO
CODE CAGEC
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0302 FUEL PUMPS
FIG. 28 ANEROID CONTROL
1 XDFHH 15434 AR-09454-00EF
2 PAHZZ 96906 MS122032
3 PAHZZ 9 6 9 0 6 MS90725-10
4
5
6
7
8
9
10
XDHZZ
PAHZZ
XDHZZ
XDHZZ
XAHZZ
XDHHH
PAHZZ
15434
15434
15434
15434
15434
15434
15434
114947
114739
114755
115033
140357
BM69381
114791
11
12
13
14
15
16
17
XDHZZ
XDHZZ
XDHZZ
XDHZZ
PAHZZ
PAHZZ
PAHZZ
15434
15434
15434
15434
15434
88044
83259
140358
115034
114940
114773
S911B
AN565F428H24
600-001 1-4
18 PAHZZ 15434 108074
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
XDHZZ
XDHZZ
PAHZZ
XDHZZ
XDHZZ
XDHZZ
XDHZZ
XDHZZ
XDHZZ
XDFZZ
PAFZZ
PAFZZ
XDFZZ
XDFZZ
PFFZZ
XDFZZ
PAFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
PAFZZ
PAFZZ
XDFZZ
15434
15434
91265
15434
15434
15434
15434
15434
15434
15434
15434
03958
15434
15434
15434
15434
96906
96906
15434
15434
96906
96906
15434
15434
114765
114764
TS33-016
114745
114795
140414
114921
124033
114754
208621
144372
MS39230-1
AS0501900SS
AS0500760SS
143950
NPN
MS51887-5
MS90728-66
S604
204851
MS27183-14
MS18154-60
63385
213713
1
CONTROL, ANEROID
3
. WASHER, LOCK
3
. SCREW, CAP, HEXAGON H COVER TO
HOUSING
1
. COVER, BELLOWS
1
. BELLOWS, ANEROID CON
1
. PISTON, BELLOWS
1
. SHAFT, BELLOWS ACTUA
1
. HOUSING, CONTROL
1
. VALVE, LEVER AND P I N
1
.. PACKING, PREFORMED PART OF KIT P/N
BM8356
1
. . VALVE
1
. . LEVER
1
. . PIN
1
. COVER, CONTROL
2
. PLUG, PIPE
1
. SETSCREW
1
.PACKING WITH RETAIN PART OF KIT P/N
BM68356
1
. NUT, SELF-LOCKING, HE ACTUATING
SHAFT
1
. PLUG, PLUNGER
1
. RETAINER, SPRING
1
SPRING
RETAINER
. GASKET
1
. SPRING, HELICAL
1
. WASHER, PRESSURIZING
1
. PLUNGER, PRESSURE
V
. SHIM, SPRING
1
. SPRING, BELLOWS
1
. WASHER BELLOWS RETAINER
1
TUBE AIR SUPPLY
1
ELBOW, TUBE TO HOSE
2
ELBOW, PIPE
1
HOSE, CONTROL
1
HOSE, CONTROL
1
ADAPTER, STRAIGHT, PI
1
ADAPTER
1
BUSHING, PIPE
2
SCREW, CAP, HEXAGON H
4
WASHER, LOCK
1
BRACKET
2
WASHER, FLAT
2
SCREW, CAP, HEXAGON H
2
SPACER
1
FILTER, AIR
END OF FIGURE
28-1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 29. TURBOCHARGER.
SECTION II
(3)
(1)
(2)
ITEM
SMR
CODE CAGEC
NO
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0305 SUPERCHARGER, BLOWER,
TURBOCHARGER OR ALTITUDE
COMPENSATOR
F I G . 29 TURBOCHARGER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
24
27
28
29
30
31
32
33
PBFZZ
XDFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
XDFZZ
PAFZZ
XDFZZ
XDFZZ
PAFZZ
PAFZZ
PAOZZ
PAOZZ
XDOZZ
PAOZZ
PAOZZ
XDOZZ
XDOZZ
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
AR12604
195469
S222A
212563
156444
211375
203294
MS122032
S118A
156416
194010
S631
167299
202457
170510
156420
216802
202376
202377
171570
3022969
AR10058
202506
107440
190849
3010915
108722
AC1600300NF
213936
183669
197733
208668
209959
TURBOCHARGER ASSEMB
. HOUSING, TURBINE
. NUT, SELF-LOCKING
. IMPELLER, TURBOCHARG
. SEAL, TURBO
. RING, SEALING
. PLATE, DIFFUSER
. WASHER, LOCK
. SCREW
. STRAP, RETAINING
. SCREW, CAP, HEXAGON H
. WASHER, FLAT
. NUT, SELF-LOCKING, HE
. PACKING, PREFORMED
. GASKET
. BEARING, SLEEVE
. SEAL, OIL, SLEEVE
. HOUSING, BEARING
. PACKING, FLAT FIBER
. SHIELD, HEAT
. SEAL
. WHEEL AND SHAFT, TUR
. CASING, TURBINE
NUT, LOCK
GASKET PART OF KIT P/N 3801330
STUD, PLAIN
CLAMP, LOOP
HOSE, NONMETALLIC
TUBE, ASSEMBLY
ADAPTER, STRAIGHT
COUPLING, PIPE
ADAPTER
HOSE, TEFLON
END OF FIGURE
29-1
1
1
1
1
1
1
1
8
8
2
2
4
2
1
1
1
1
1
1
1
1
1
1
4
1
4
2
1
1
1
1
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 30. SHUTDOWN VALVE.
SECTION II
(2)
(3)
(1)
SMR
ITEM
NO
CODE CAGEC
TM 5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0306 TANKS, LINES, FITTINGS,
HEADERS
FIG. 30 SHUTDOWN VALVE
1
2
3
4
5
6
PAFHH
PAFZZ
PAHZZ
PAFZZ
PAHZZ
PAHZZ
15434
15434
15434
15434
15434
15434
3035342
129838
129826
70295
3000266
190876
7 PAHZZ 15434 3030970
8 PAHZZ 15434 129768
9 PAHZZ 15434 129888
10
11
12
13
14
15
16
17
PAHZZ
PAHZZ
PAFZZ
PAHZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
15434
24617
15434
15434
15434
15434
91265
129839
3054611
0120217
187556
S189C
181466
67684
TS33-016
VALVE , SOLENOID
. KNOB OVERRIDE
. HOUSING, SHUT OFF VA
. PLUG, PIPE
. SHAFT, SHOULDERED
. PACKING, PREFORMED PART Of KIT P/N
8M68356
. DISK, VALUE
. WASHER, SPRING TENSI
. PACKING, PREFORMED PART OF KIT P/N
BM68356
. COVER, ACCESS
. COIL, ELECTRICAL
. WASHER, LOCK
. SCREW, MACHINE
SCREW, CAP, SOCKET HE
WASHER, LOCK
WASHER, FLAT
GASKET PART OF KIT P/N BM68356
END OF FIGURE
30-1
1
1
1
1
1
1
1
1
1
1
1
4
4
2
2
2
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 31. FUEL PUMP FILTER.
SECTION II
(2)
(3)
(1)
SMR
ITEM
CODE CAGEC
NO
TM5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0309 FUEL FILTERS
FIG. 31 FUEL PUMP FILTER
1
2
3
4
5
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
15434 157088
15434 154088
15434 70700
15434 146483
79396 33341
PLUG,MACHINE THREAD
SEAL CAP PART OF KIT F/N BM68356
SPRING,HELICAL,COMP
FILTER ELEMENT,FLUI
FILTER ELEMENT,FLUI
END OF FIGURE
31-1
1
1
1
1
1
SECTION II
TM 5-2815-241-34&P C 01
TA508274
FIGURE 32. GLOW PLUG AND PREHEATER.
SECTION II
(3)
(2)
(1)
SMR
ITEM
CODE CAGEC
NO
TM5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP
0311 ENGINE STARTING AIDS
FIG. 32 GLOW PLUG AND PREHEATER
1
2
3
4
XDOZZ
XDOZZ
XDOZZ
XDOZZ
15434
15434
15434
15434
106452R91
AC9
267627C2
236985R91
PRIMER,HAND ASSEMBL
PLUG,GLOW
HOUSING ,PREHEATER
NOZZLE,PREHEATER
END OF FIGURE
32-1
1
1
1
1
SECTION II
TM 5-2815-241-34&P C01
FIGURE 33. THROTTLE SHAFT.
SECTION IX
(3)
(1)
(2)
ITEM
SMR
CODE CAGEC
NO
TM5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0312 ACCELERATOR, THROTTLE, OR
CHOKE CONTROLS
F I G . 33 THROTTLE SHAFT
1 PAOZZ 15434 109915
2 PAOZZ 96906 MS35691-5
3 XDFFF 15434 AR 51317
4 PAFZZ 15434 100478
5
6
7
8
9
10
11
12
13
14
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
XDOZZ
PAOZZ
PAOZZ
PAOZZ
15434
15434
15434
15434
15434
15434
15434
15434
96906
88044
149030
213769
213768
149040
148977
S16206
AR03034
S159B
MS122032
AN 960-416
SETSCREW
NUT (PLAIN ,HEXAGON LEVER AND
THROTTLE ADJUSTING
THROTTLE SHAFT ASSE
PACKING,PREFORMED PART OF KIT P/N
BM68356
SHAFT, SHOULDERED
PLUG,BALL
PACKING,PREFORMED
PIN,GROOVED,HEADED
PLATE, RETAINING, SHA
RING RETAINING
LEVER,THROTTLE
SCREW ,CAP ,HEXAGON H
WASHER,LOCK
WASHER
END OF FIGURE
33-1
2
3
1
1
1
1
1
1
1
1
1
1
2
1
SECTION II
TM 5-2815-241-34&P C01
TA508276
FIGURE 34. THERMOSTAT HOUSING.
SECTION II
(2)
(3)
(1)
SMR
ITEM
CODE CAGEC
NO
TM5-2815-241-34&P
( 4 )
PART
NUMBER
(5)
(6)
DESCRIPTION AND USABLE ON CODES (UOC) QTY
GROUP 05 COOLING SYSTEM
GROUP 0503 WATER MANIFOLD, HEADERS,
THERMOSTATS, AND HOUSING GASKET
F I G . 34 THERMOSTAT HOUSING
1 XD0ZZ 15434 102231
2 PAOZZ 15434 145977
3 XDOZZ 15434 215172
HOUSING,THERMOSTAT
VALVE ,TEMPERATURE R
CONNECTION WATER OU
END OF FIGURE
34-1
1
1
1
SECTION II
TM 5-2815-241-34&P C01
13
1
TA508277
FIGURE 35. WATER MANIFOLD.
SECTION II
(3)
(1)
(2)
SMR
ITEM
CODE CAGEC
No
TM5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0503 WATER MANIFOLD, HEADERS,
THERMOSTATS, AND HOUSING GASKET
FIG. 35 WATER MANIFOLD
1 PAEZZ 96906 MS35338-8
2 XDFZZ 15434
133342
3 PAFZZ 94906 MS90728-62
4 PAFZZ
15434
70624
5
6
7
8
9
10
PAFZZ
PAOZZ
PAFZZ
PAOZZ
XDFZZ
PAFZZ
15434
15434
15434
15434
15434
15434
130394
S995
130118
S-915-A
211016
212161
11
12
13
14
PAFZZ
PAFZZ
PAFZZ
PAFZZ
15434
96906
15434
15434
S110
MS35338-45
211027
148203
WASHER,LOCK
MANIFOLD, WATER REAR
SCREW,CAP,HEXAGON
PACKING,PREFORMED PART CF KIT P/N
3801330
COUPLING,HANIFOLD
PLUG,PIPE
MlANIFOLD, FLUID COOL CENTER
PLUG,PIPE
MANIFOLD WATER FRONT
PACKING,PREFORMED PART CF KIT P/N
3801330
SCREW,CAP,HEXAGON H
WASHER,LOCK
TUBE,BENT,METALLIC
G A SKET PART of KIT P/h 3801330
END OF FIGURE
35-1
12
1
12
4
2
1
1
3
1
2
1
1
1
6
SECTION II
TM 5-2815-241-34&P C01
FIGURE 36. WATER PUMP.
TA508278
SECTION II
(3)
(2)
(1)
SMR
ITEM
CODE CAGEC
NO
TM5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0504 WATER PUWP
F I G . 36 WATER PUMP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
XDOZZ
XDOZZ
PAOZZ
PAOZZ
XDOZZ
XDOZZ
PAOZZ
XDOZZ
XDOZZ
PAOZZ
96906
96906
15434
15434
96906
15434
15434
15434
96906
15434
15434
96906
15434
15434
15434
MS90728-70
MS35338-8
S-915-A
S962
MS90728-62
210806
210805
108330
MS 90728-64
214476
208132
MS35842-13
63495-D
209600
43463-A
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
PA000
PAOZZ
PFOZZ
XD000
PAOZZ
XAOZZ
XAOZZ
PAOZZ
XDOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
XDOZZ
XD000
XDOZZ
PAOZZ
XDOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
XDOZZ
XDOZZ
PAOZZ
PAOZZ
PAOZZ
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
96906
15434
15434
15434
15434
15434
AR-045090
S911B
3033677
AR08853
AR-12732
208134
210238
3038997
208138
S16073
112302
196844
S16255
3038998
AR 08854
AR08851
210860
61623
208118
208119
S16073
S16255
145506
3038998
208120
213082
MS51967-20
MS90726-67
137797
210804
S149A
182706
130226
SCREW,CAP ,HEXAGON H
WASHER LOCK
PLUG,PIPE
PLUG,PIPE
SCREW, CAP ,HEXAGON H
CONNECTION
GASKET
WASHER,FLAT
SCREW,CAP ,HEXAGON H
BRACKET,CONNECTION
GASKET
CLAMP, HOSE
HOSE
PIPE, WATER BY-PASS..
PACKING, ,PREFORMED PART OF KIT P/N
3801330 PART OF KIT P/N BM68356
PUMP,COOLING SYSTEM
.PLUG ,PIPE
.PACKING WITH R E T A I N
.IMPELLER
. .PACKING W I T H R E T A I N
..IMPELLER,WATER P U M P
.BODY,WATER PUMP
.SEAL,PLAIN PART OF KIT P/N 3018762.
. SHAFT WATER PUMP
.BEARING BALL, ANNULA
.RING, RETAINING
. SPACER
.RING, BEARING RETAIN
.SEAL, PLAIN ENCASED
.PULLEY,WATER P U M P
IDLER, WATER PUMP
.CAPSCKEW ,BUTTON HEA
.WASHER,FLAT
.PULLEY,IDLER
. SHAFT, SHOULDERED
.BEARING,BALL,ANNULA
.RING,BEARING R E T A I N
.PACKING.PREFORMED
. SEAL ,PLAIN ENCASED
.
.SPACER,SLEEVE
.WASHER,FLAT
.NUT,PLAIN,HEXAGON
SCREW ,CAP ,HEXAGON H
CAPSCREW
CONNECTION, WATER T R A N S F E R
SCREW,CAP ,HEXAGON H
SCREW,CAP, HEXAGUN H
GASKET PART Of KIT P/N 3018762
END OF FlGURE
36-1
2
15
1
1
3
1
1
2
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
2
1
2
1
1
SECTION II
TM 5-2815-241-34&P C01
TA508279
FIGURE 37. FAN HUB.
SECTION II
(1)
(2)
(3)
ITEM
SMR
CODE CAGEC
NO
TM5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 0505 FAN ASSEMBLY
F I G . 37 FAN HUB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
XDOOO
XD0ZZ
XDOZZ
XDOZZ
PAOZZ
PAOZZ
PFOZZ
XDOZZ
PAOZZ
XDOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
XDOZZ
PAOZZ
35434
15434
15434
15434
96906
15434
60038
15434
15434
15434
96906
96906
96906
96906
15434
15434
15434
AR10142
441432
201124
210996
MS29513-142
142176
LM485548
211869
200307
AR10141
MS90727-114
MS35338-48
MS27183-17
MS90727-113
208829
X-l
166777
HUB,FAN
. SPACER
. SPACER
.RETAINER
.PACKING,PREFORMED
.NUT,HUGLOCK
.BEARING,ROLLER,TAPE
.PULLEY
. SEAL OIL
.BRACKET AND S H A F T
SCREW ,CAP ,HEXAGON H
WASHER,LOCK
WASHER,FLAT
SCREW ,CAP ,HEXAGON H
BRACKET, FAN SUPPORT
SPACER
SCREW
END OF FIGURE
37-1
1
1
1
1
1
1
A
1
1
1
;
2
2
1
1
1
SECTION II
TM 5-2815-241-34&P C01
TA508280
FIGURE 38. ENGINE DATA PLATES.
SECTION II
(3)
(1)
(2)
ITEM
SMR
No
CODE CAGEC
TM5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 22 BODY, CHASSIS, AND HULL
ACCESSORY ITEMS
GROUP 2210 DATA PLATES AND)
INSTRUCTION
HOLDERS
FIG. 38 ENGINE DATA PLATES
1 PAOZZ 15434 105375
2 PAOZZ 15434 S2286
PLATE, IDENTIFICATION
SCREW
END OF FIGURE
38-1
2
4
SECTION 11
(1)
(2)
(3)
SMR
ITEM
CODE CAGEC
No
TM5-2815-241-34&P
(4)
(5)
(6)
PART
DESCRlPTION AND USABLE ON CODES(UOC) QTY
NUMBER
GROUP 94 REPAIR KITS
GROUP 9401 REPAIR KITS
FIG. KIT
1 PAFZZ 15434 3801330
2 PAHZZ 15434 BM68356
3 PAHZZ
15434 3018762
GASKET AND SEAL SET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
PACKING,PREFORMED
PACKING,PREFORMED
PACKING,PREFORMED
PACKING,PREFORMED
PACKING ,PREFORMED
PACKING ,PREFORMED
GASKET SET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
PACKING WITH RETAIN
PACKING, PREFORMED
PACKING, PREFORMED
PACKING, PREFORMED
PACKING, PREFORMED
PACKING PREFORMED
PACKING, PREFORMED
PACKING, PREFORMED
SEAL CAP
SPACER, RING
GASKET SET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
KIT-1
1
(
(
(
(
(
(
(
(
(
(
(
(
(
1)
1)
1)
1)
2)
1)
6)
8)
6)
1)
4)
2)
2)
3-7
12-37
18-7
19-1
22-13
29-25
35-20
9- 8
9-15
22-12
35-4
35-15
35-16
1)
1)
1)
1)
1)
1)
1)
1)
1)
1)
1)
2)
1)
1)
24-27
25-11
25-17
26-11
27-12
30-16
28-21
30-6
26-6
26-8
28-14
33-9
33-8
35-15
31-2
26-9
1
(
(
(
(
(
(
(
(
(
(
(
(
(
(
1
(
(
(
(
(
(
(
(
(
(
(
(
(
(
2)
1)
1)
1)
1)
1)
1)
1)
1)
1)
1)
1)
2)
1)
2-15
2-7
4-5
5-15
8-6
10-36
10-36
10-36
13-1
13-7
16-7
16-26
16-30
16-50
SECTION II
(1)
(2)
(3)
ITEM
SMR
NO
CODE CAGEC
TM5-2815-241-34&P
(4)
(5)
(6)
PART
NUMBER
DESCRIPTION AND USABLE ON CODES(UOC) QTY
GASKET
GASKET
GASKET
GASKET
KEY,WOODRUFF
PACKING, PREFORMED
PACKING, PREFORMED
PACKING, PREFORMED
PACKING, PREFORMED
SEAL
SEAL
SEAL,PLAIN
SPACER,RING
WASHER, LOCK
(
(
(
(
(
(
(
(
(
(
(
(
(
(
END OF FIGURE
KIT-2
1)
1)
1)
1)
1)
1)
1)
2)
1)
1)
1)
1)
1)
2)
17-19
17-26
24-22
36-43
20-10
2-41
8-17
16- 10
16-28
4-7
8-4
36-19
16-22
5-16
SECTI0N II
(2)
(3)
(1)
ITEM
SHR
NO
CODE CAGEC
TM5-2815-241-34&P
(6)
(5)
(4)
PART
DESCRIPTION AND USABLE ON CODES (UOC) QTY
NUMBER
GROUP 95 GENERAL USE STANDARIZED
PARTS
GROUP 9501 BULK MATERIEL
F I G . BULK
1
PAOZZ 89346 364359C1
HOSE, NONMETALLIC
END OF FIGURE
BULK-1
v
SECTION IV
TM5-2815-241-34&P
CROSS-RFFERENCE
STOCK NUMBER
5330-00-005-0407
5305-00-005-0666
5330-00-005-0857
5330-00-005-0858
2815-00-005-7431
5330-00-006-2494
5305-00-006-8411
5360-00-009-9270
4730-00-011-3175
2815-00-011-7786
5315-30-012-0123
5315-00-014-1195
5315-00-014-1244
5315-00-014-1284
5310-00-014-5850
4730-00-018-9566
5306-00-019-4227
5330-00-026-2931
5330-90-026-2933
5315-00-041-0915
5315-00-041-0916
5306-00-041-0917
5315-00-043-1787
4730-00-044-4715
5306-00-050-1237
5340-00-050-1600
4730-00-057-5555
5330-00-058-1767
5305-00-058-6604
5305-00-062-4378
5305-00-063-5043
5330-00-064-4399
5330-00-065-5544
5305-00-068-0511
2815-00-070-2251
5305-00-071-1788
5305-00-071-2071
INDEXES
NATIONAL STOCK NUMBER INDEX
FIG.
STOCK NUMBER
ITEM
36
36
19
8
4
12
25
3
9
30
2
1
2
25
2
5
24
2
3
16
18
20
28
36
24
20
29
10
10
6
17
2
36
10
2
8
8
2
36
9
28
2
27
16
16
35
36
18
20
13
5305-00-071-2241
18
20
9
4
7
7
13
11
13
4
7
14
17
4
16
14
27
27
8
16
12
13
15
17
3
6
14
13
6
14
2
45
4
35
14
6
20
3
47
3
16
5
18
2
44
3
5
10
22
26
2940-00-073-3316
5310-00-081-6034
5360-00-081-8487
5313-00-381-8500
5330-00-081-9289
5310-00-081-9292
5333-00-081-9299
4730-00-081-9618
5360-00-082-0124
5315-00-082-0448
5355-00-082-1189
5365-00-082-1193
5310-00-082-1888
5340-00-084-7787
2815-00-085-7434
3040-00-085-7439
3120-00-090-5504
5305-00-091-4009
5330-00-106-6370
5310-00-109-7638
5305-00-115-9526
5330-00-129-9349
4820-00-130-4820
2815-00-132-0240
5360-00-132-0245
5330-00-132-0247
5330-00-132-0248
5365-00-132-0273
5330-00-132-0274
5330-00-132-0276
2910-00-132-0769
5340-00-132-3203
5340-00-134-3529
5310-00-134-4168
5310-00-134-4165
5310-00-134-4171
5306-00-136-9751
5305-00-138-9848
5310-00-141-1795
I-1
FIG.
ITEM
24
26
27
28
16
8
1C
11
16
18
28
23
4
33
20
30
2
27
23
30
28
30
30
9
33
4
5
36
5
13
3
23
9
22
22
16
6
30
22
27
19
22
5
18
6
17
30
24
26
26
23
2
20
3
28
13
29
6
34
6
39
26
2
4
17
9
15
3
28
2
41
8
10
9
5
16
12
48
11
10
6
32
9
7
11
27
13
6
13
5
12
3
3
11
11
30
13
25
4
11
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
STOCK NUMBER
5313-00-141-1795
5330-00-143-8369
5330-30-143-8376
5330-00-143-8485
3110-00-144-8499
3110-00-144-8519
5330-00-159-1464
5310-00-159-6209
3020-00-160-9092
5305-00-161-0902
5305-00-165-8157
5330-00-171-6600
5330-00-171-7267
5330-00-175-6585
5330-00-194-8385
2815-00-195-5894
2815-00-195-5897
4730-00-196-0837
5310-00-197-5304
5365-00-197-9327
4730-00-203-0549
5310-00-209-0965
5310-00-222-7240
5306-00-225-8499
5306- 0 0 - 2 2 6 - 4 8 2 9
2515-00-230-0070
5305-00-230-1939
2990-00-237-0058
5330- 0 0 - 2 3 7 - 6 2 6 6
5315-00-238-0882
5340-00-238-5435
2815-00-242-2992
5310-00-246-0221
5330-00-252-6056
5330-00-252-8888
5365-00-256-2846
5310-00-261-7340
NATIONAL STOCK NUMBER INDEX
FIG.
ITEM
STOCK NUMBER
27
33
35
13
9
24
36
36
36
5
24
26
28
29
33
20
24
16
28
2
10
29
12
12
28
2
16
2
8
13
17
20
24
6
17
17
12
29
24
27
29
2
8
22
8
16
37
26
23
2
5310-00-261-7340
14
14
14
27
8
13
25
36
15
16
24
3
2
8
13
8
22
45
17
26
36
25
13
28
35
30
21
13
2
19
10
21
18
12
31
29
35
9
2
2
5
38
8
4
14
32
5
15
31
24
5310-00-262-2986
5305-00-269-2811
5305-00-269-3217
5305-00-269-3240
5365-00-275-8276
2950-00-275-9325
2953-33-275-9344
5310-00-276-2816
5340-00-276-5847
4820-00-276-9041
5315-00-281-7613
4730-00-287-1649
4730-00-289-4770
2815-30-300-3882
2815-03-311-2521
2815-00-338-6839
5305-00-339-1415
3123-00-339-5642
5330-00-349-1219
3120-03-349-6444
5310-00-356-1447
5330-00-361-2955
2815-00-362-1780
5315-00-369-2588
4730-00-369-7824
2910-00-369-8240
3120-00-374-4342
2815-00-375-9892
3040-00-388-3126
5340-00-400-3449
5340-00-400-5178
2930-00-401-9531
I-2
FIG.
ITEM
4
8
10
11
13
16
16
17
18
24
28
35
36
30
36
16
4
29
29
29
36
2
10
16
16
2
2
28
3
17
35
9
10
13
10
2
10
4
2
4
10
23
27
24
7
10
10
29
23
20
8
12
28
5
15
4
35
12
5
4
37
1
2
16
43
3
9
6
22
4
33
39
24
5
31
2
40
30
3
9
6
5
7
4
19
35
36
14
21
5
14
9
19
8
4
22
21
27
11
5
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
STOCK NUMBER
5305-00-404-1388
5305-00-404-1390
4730-00-404-2906
4730-00-404-2909
5365-00-404-2934
2815-00-404-2940
5340-00-404-2944
2910-00-404-9999
2815-00-405-7789
5330-00-406-7789
2815-00-406-8936
53l0-00-407-9566
3130-00-408-9041
5310-00-410-6756
5305-00-411-9340
5340-00-417-5800
5365-00-420-9696
5305-00-424-3571
5310-00426-3990
5310-00432-1559
3130-00-437-0567
5310-00-442-6899
3010-00-447-9799
2910-00451-8063
5360-00-461-5738
5365-00-462-4504
5305-00-463-0428
5340-00-464-7064
5310-00-469-3998
2910-00-470-7075
5315-00-475-2574
4730-00-477-4160
2990-00-477-6159
5305-00-477-6769
5330-00-478-2962
2815-00-480-4347
5330-00-484-1718
2815-00-484-8359
2815-00-484-8360
5306-00-485-0790
5340-00-485-0945
NATIONAL STOCK NUMBER INDEX
STOCK NUMBER
FIG.
ITEM
16
36
35
2
3
12
7
23
14
29
17
10
13
17
35
2
24
29
13
36
17
9
29
16
20
20
24
23
27
27
13
27
5
31
17
18
29
9
2
5
6
25
26
27
30
2
2
25
26
10
46
46
5
25
2
12
2
6
1
19
4
34
29
28
12
19
26
11
8
26
21
4
18
9
1
19
1
24
8
9
22
17
13
5
14
2
29
6
18
15
7
12
12
15
15
19
19
11
13
20
5310-00-486-2505
5365-00-488-0799
5305-00-493-3959
2815-00-505-5116
2815-00-505-5119
5330-00-506-4866
5330-00-506-4874
5305-00-506-5722
5365-00-507-3224
5365-00-507-3225
5365-00-507-3254
5310-00-507-3259
5365-00-507-3260
5365-00-507-3261
5365-00-507-3262
5365-00-507-3271
5305-00-509-8106
5310-00-521-8595
5315-00-532-9388
5330-00-537-2382
5365-00-543-3744
5305-00-546-6698
3020-00-562-1173
5330-00-562-1173
5310-00-562-6557
5310-00-562-6558
5310-00-562-6560
3120-00-566-0480
5330-00-567-3463
3040-00-567-4338
3040-00-567-4354
3020-00-567-4356
3120-00-573-0391
5330-00-582-7484
5310-00-584-5272
5310-00-584-7796
3120-00-589-3537
2590-00-590-7378
2815-00-590-7385
I-3
FIG.
ITEM
24
36
2
33
10
10
10
24
35
27
23
23
8
27
27
27
27
31
30
10
2
2
23
2
10
24
27
8
13
24
13
29
17
25
24
25
24
2
23
5
13
37
20
12
12
12
12
12
11
10
5
8
6
12
5
9
16
16
4
6
15
15
16
4
9
9
9
1
14
30
20
11
15
23
38
14
12
3
20
19
23
12
18
9
11
6
7
36
2
4
25
12
2
6
11
17
27
32
1
2
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
STOCK
NUMBER
3120-00-593-1507
5360-00-597-4570
2930-00-603-1625
2910-00-603-2835
2815-00-603-7264
2815-00-609-7115
5315-00-616-5522
5315- 0 0 - 6 1 6 - 5 5 2 7
3120-00-627-6697
5330-00-632-6182
5340-00-632-6239
5330-00-659-3178
3120-00-659-7808
3120-00-661-6646
5360-00-664-5343
5310-00-680-6874
3120-00-682-7706
5310-00-684-3463
3120-00-695-1232
4810-00-695-3284
3040-00-695-3285
5315-00-695-3292
3020-00-701-1112
3020-00-702-3882
2815-00-705-2851
2815-00-705-2856
2851-00-705-9257
5365-00-708-3434
5305-00-709-8282
5305-00-709-8523
5305-00-709-8537
5305-00-709-8542
5365-00-716-6580
5305-00-719-5221
5305-00-719-5235
5306-00-719-5467
3120-00-719-5719
5340-00-721-5329
5365-00-721-7884
5305-00-725-2317
5330-00-729-4427
5310-00-732-0560
2930-00-732-5206
9905-00-733-7622
NATIONAL STOCK NUMBER INDEX
FIG.
ITEM
STOCK NUMBER
4
31
16
23
5
10
20
20
17
17
29
9
19
10
10
16
29
29
10
4
30
24
24
23
25
10
17
10
l6
17
13
8
8
25
37
37
13
25
3
24
18
36
2
12
12
12
12
12
34
38
2815-00-739-6098
2815-00-753-0660
5310-00-757-6367
5310-00-763-8920
5340-00-767-4012
2910-00-767-4018
5310-00-768-0318
2990-00-772-1778
2815-00-772-9434
19
3
11
8
6
4
15
16
23
27
15
12
1
11
37
20
13
16
25
21
1
6
10
30
6
12
8
1
23
13
16
7
9
5
14
11
18
2
7
15
4
9
18
3
8
14
25
29
2
1
3040-00-773-9369
5305-00-774-4246
5315-00-777-3544
5330-00-777-3545
5305-00-782-9489
5365-00-786-0102
2910-03-790-8736
3120-00-791-1440
2815-00-791-1453
3120-00-792-9834
5305-00-795-9336
5305-00-795-9353
4730-00-801-8186
4730-00-803-8353
5306-00-804-2468
5305-00-804-6318
5365-00-807-2636
5330-00-809-2667
5330-00-809-3276
5310-00-809-5997
3120-00-810-6032
2815-00-815-0355
2815-00-815-1114
5365-30-815-1137
5330-00-816-8148
5310-00-820-6653
3030-00-821-8242
2815-00-828-7013
2910-00-828-7126
2815-00-829-5227
2910-00-829-5600
2910-00-829-5603
5365-00-829-5604
I-4
FIG.
ITEM
9
6
28
36
19
28
13
23
2
8
24
33
10
10
10
11
28
33
31
10
16
20
4
5
13
35
36
25
26
2
38
27
26
26
37
23
36
36
22
22
28
1
5
37
17
26
19
30
23
23
10
10
18
42
4
5
24
20
32
10
12
1
8
15
36
3
36
10
4
18
19
11
1
9
14
8
3
10
16
22
2
11
6
8
13
10
28
37
10
9
10
4
10
18
5
1
7
3
13
18
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
STOCK NUMBER
2910-00-829-5616
5340-00-829-5617
5340-00-833-7966
5315-00-844-0140
4720-00-846-5575
5305-00-846-5703
2815-00-851-7637
2910-00-858-3522
2990-00-858-3526
5315-00-866-5015
3120-00-877-2213
5330-00-886-2509
5310-00-887-8325
5330-00-888-4988
5340-00-898-1497
3120-00-904-9595
3120-00-906-6657
5315-00-907-0711
4730-00-909-8627
2815-00-920-2073
2815-00-920-8356
5307-00-922-2626
5330-00-924-7757
2910-00-928-3505
2930-00-928-3595
5340-00-933-3009
3040-00-933-3012
5305-00-942-2196
5305-00-947-3437
5340-00-951-3536
5330-00-951-3538
5330-00-961-9470
5310-00-962-5610
2815-00-962-5623
5365-00-965-0870
5310-00-971-7989
5315-00-973-0414
5365-00-988-3668
2815-00-994-4427
2815-00-944-4429
5305-01-010-2362
NATIONAL STOCK NUNBER INDEX
FIG.
STOCK NUMBER
ITEM
26
26
17
23
BULK
16
36
12
27
33
9
8
10
19
KIT
27
23
2
23
36
19
19
29
22
9
35
9
25
8
11
16
18
28
12
12
12
12
26
28
30
31
3
9
26
33
33
23
6
6
17
5
10
6
12
1
18
1
24
13
9
15
21
31
10
2
10
22
37
17
12
5
2
26
12
7
7
1
7
11
4
36
8
40
4
15
26
30
7
21
17
2
10
10
9
2
8
3
3
4
3
5305-01-028-8869
5360-01-038-4659
2990-01-046-0171
5330-01-046-0441
5330-01-046-1991
5330-01-046-3144
2930-01-046-3493
5330-01-049-0466
5315-01-058-4551
5305-01-060-5958
5330-01-066-3908
5330-01-066-3910
2910-01-070-7979
4720-01-075-8149
2910-01-070-9710
5330-01-072-4436
5310-01-072-8821
5330-01-072-8822
5330-01-072-8829
5305-01-072-8831
5330-01-072-8983
3110-01-073-2576
3020-01-077-2229
3020-01-077-4411
2815-01-077-4463
5330-01-077-5228
4730-01-078-9859
3040-01-079-1748
3040-01-079-1799
3040-01-079-3468
3040-01-079-3469
5340-01-079-4678
5315-01-079-6506
5330-01-079-6514
3120-01-079-6527
5315-01-079-6740
3110-01-079-8190
5365-01-080-0409
5330-01-080-2992
5330-01-083-5021
2910-01-080-5570
2815-01-083-3157
3020-01-084-9640
4720-01-085-1316
2815-01-085-2573
3040-01-085-2616
2815-01-085-2618
5330-01-085-3580
I-5
FIG.
ITEM
19
17
29
8
16
16
36
2
4
22
11
17
9
18
22
9
37
37
24
27
33
37
4
4
19
16
35
26
17
12
36
17
22
22
16
19
4
33
36
36
36
36
3
23
4
17
29
17
30
9
29
3
7
1
5
7
25
16
4
18
2
9
25
16
1
6
14
6
9
9
16
7
7
11
4
8
41
10
14
15
37
35
19
16
14
43
11
22
6
40
29
39
5
16
12
16
28
1
5
11
17
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
STOCK NUMBER
2815-01-085-3733
2815-01-085-3734
3020-01-085-3779
2520-01-085-6128
4710-01-085-6130
2815-01-086-2704
5330-01-086-3991
5340-0l-086-6193
5330-01-086-6197
5365-01-086-6759
5365-01-086-7680
5365-01-086-7788
3120-01-087-3004
5305-0l-091-2498
2910-01-091-3204
5330-01-092-4143
2815-01-096-9198
2910-01-096-9200
5340-01-098-0175
2910-01-105-6457
5305-01-114-9275
2920-01-121-8859
5340-01-122-8002
2815-01-127-1060
2815-01-127-3597
2815-01-127-3598
4730-01-128-4598
5365-01-129-4324
5330-01-131-2967
5365-01-132-1984
2815-01-142-1732
5340-01-143-6048
3120-01-143-9547
3120-01-144-8882
5330- 01-145-0716
5310-01-145-0762
5330-01-145-5377
5330-01-145-7550
3120-01-145-9132
2815-01-146-1024
4120-01-146-1048
2940-01-146-1995
2815-01-146-5925
5330-01-147-0748
5365-01-147-0912
5365-01-147-0913
5307-0l-147-1316
4730-01-147-2223
5307-01-147-2821
NATIONAL STOCK NUMBER INDEX
FIG.
ITEM
STOCK NUMBER
9
17
17
12
35
6
36
3
16
2
2
8
6
37
23
KIT
12
25
37
22
35
30
5
9
9
9
2
16
18
36
11
9
4
4
8
36
2
8
4
11
30
16
4
13
8
8
12
2
2
12
5
22
24
33
13
1
38
4
10
6
6
16
9
17
14
3
2
3
15
8
11
11
1
9
9
9
33
22
7
27
7
2
13
13
17
41
44
18
13
8
7
13
6
6
16
16
19
28
31
19
5330-01-147-4071
3120-01-147-5275
5330-01-149-9715
2910-01-150-2631
5365-01-150-6257
2815-01-151-8772
2910-01-152-8531
2815-01-156-6224
4730-01-157-8923
2815-01-159-1737
5365-01-160-1832
4730-01-160-3579
5330-01-160-7460
3120-01-160-7482
5305-01-165-3300
4710-01-181-1956
5310-01-186-4361
2910-01-191-8470
5970-01-193-0895
2910-01-199-8757
5360-01-200-0323
5310-01-200-1318
5305-01-203-6444
3040-01-203-8549
5330-01-209-3583
4730-01-211-1989
3120-01-214-7779
4710-01-239-7360
5330-01-240-1630
5365-01-241-4318
4730-01-241-4639
3120-01-241-6516
5330-01-242-0722
5340-01-242-0805
6680-01-281-1226
4820-01-300-2759
I-6
FIG.
17
20
KIT
22
2
4
22
3
28
11
2
18
19
23
16
24
23
8
17
16
1
22
1
25
16
16
16
20
13
13
4
13
36
6
28
4
18
16
13
9
ITEM
32
9
1
1
29
10
15
1
29
2
12
13
6
4
12
21
19
1
11
42
7
5
15
1
14
38
37
14
2
28
17
11
23
6
33
15
9
40
7
9
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
15434
15434
88044
88044
AC1600300NF
AC9
AN565F428H24
AN960-416
15434
15434
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
46529
15434
15434
15434
15434
15434
15434
15434
15434
AR-00796
AR-02308
AR-03636
AR-045090
AR-07110
AR-08190
AR-09265
AR-09454-00EF
AR-09912
AR-10172
AR-12732
AR01176
AR03034
AR03307
AR08256
AR08366
AR08667
AR08851
AR08853
AR08854
AR09473
AR09478
AR09479
AR09607
AR09832
AR10058
AR10141
AR10142
AR12604
AR51276
AR1307
AR51317
AS0500760SS
AS0501900SS
A331987
BM-37496
BM-69886
BM27253
BM37625
BM37634
BM47777
BM52474
BM68356
PART NUMBER INDEX
STOCK NUMBER
4720-01-085-1316
5305-00-063-5043
5310-00-141-1795
2815-00-005-7431
2930-01-046-3493
2815-01-085-2573
5330-00-005-0407
2815-01-085-3734
2950-00-275-9325
2990-01-046-0171
2815-00-195-5894
3040-00-567-4338
2933-00-603-1625
2990-00-237-0058
3120-00-339-5642
2815-00-609-7115
2815-00-505-5116
2815-00-705-9257
2815-00-753-0660
5330-00-888-4988
I-7
FIG.
ITEM
29
32
28
24
26
26
27
33
23
12
17
36
4
6
16
28
2
17
36
8
33
12
20
20
17
36
36
36
8
16
16
20
17
29
37
37
29
12
24
33
28
28
16
13
27
2
10
10
10
6
KIT
28
2
16
25
4
11
14
14
23
7
17
16
13
5
26
1
1
1
20
15
11
1
10
7
26
31
19
30
19
8
1
3
22
22
10
1
1
13
11
3
32
31
11
17
2
35
4
5
1
10
2
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE
CAGEC
PART NUMBER
INDEXES
PART NUMBER INDEX
STOCK NUMBER
2910-00-369-8240
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
73165
60038
96906
BM68879
BM69381
BM69886
BM73718
BM73902
BM73976
BM74747
BM76340
BM76665
BM79290
BM95160
BM95161
BM95162
BM97497
BM98430
B90429
LM485548
MS122032
2910-00-828-7126
2910-00-603-2835
2910-00-404-9999
2815-00-195-5897
2815-01-096-9198
2815-00-851-7637
2910-01-096-9200
2910-01-091-3204
5330-01-066-3908
3110-01-073-2576
5310-00-159-6209
96906
96906
96906
96906
96906
96906
MS15795-824
MS16625-1100
MS16632-1050
MS18154-58
MS18154-59
MS18154-60
5310-00-584-7796
5365-00-807-2636
5365-00-256-2846
5305-00-115-9526
5305-01-010-2362
5305-00-942-2196
96906
96906
96906
MS20066-116
MS24665-355
MS27183-14
5315-00-695-3292
5315-00-012-0123
5310-00-080-6004
96906
96906
96906
96906
96906
MS27183-17
MS27183-42
MS29513-142
MS35206-279
MS35338-45
5310-00-809-5997
5310-00-014-5850
5330-00-252-6056
96909
96906
MS35338-46
MS35338-47
2990-00-237-0058
2815-00-375-9892
5310-00-407-9566
5310-00-209-0965
I-8
FIG.
ITEM
24
28
24
23
23
10
27
26
23
23
12
12
12
25
23
11
37
5
24
26
28
29
33
20
27
23
13
17
8
11
16
18
28
24
1
8
10
11
16
18
28
37
24
37
5
10
13
17
35
13
8
8
9
2
21
7
22
7
1
8
6
28
2
24
3
14
9
7
16
24
3
2
8
13
2
11
31
10
3
11
4
36
8
40
10
14
13
29
6
34
6
39
13
27
5
17
34
29
28
12
9
2
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
PART NUMBER INDEX
STOCK NUMBER
96906
MS35338-47
5310-00-209-0965
96906
MS35338-48
5310-00-584-5272
96906
96906
MS35338-50
MS35338-8
5310-00-820-6653
5310-00-261-7340
96906
96906
96906
96906
96906
96906
96906
MS35648-8
MS35690-805
MS35691-5
MS35756-12
MS35756-18
MS35756-34
MS35782-6
5340-00-050-1600
5310-00-768-0318
5310-00-97l-7989
5315-00-616-5522
5315-00-616-5527
5315-00-043-1787
4820-00-276-9041
96906
03958
96906
96906
96906
96906
96906
MS35842-13
MS39230-1
MS51069-41
MS51052-l
MS51887-5
MS51967-20
MS51968-14
4730-00-909-8627
4730-00-287-1649
3030-00-821-8242
5310-00-684-3463
4730-00-196-0837
5310-00-763-8920
5310-00-732-0560
96906
96906
MS9021-116
MS90725-10
5333-00-582-7484
5305-00-071-2241
96906
96906
96906
96906
96906
96906
96906
96906
96906
MS90725-115
MS90725-34
MS90725-67
MS90726-67
MS90727-113
MS90727-114
MS90727-31
MS90727-64
MS90727-83
5305-00-071-2071
5306-00-225-8499
5305-00-269-3217
5305-00-269-2811
5335-00-719-5221
5305-00-719-5235
5306-00-053-1237
5305-00-269-3240
5305-00-709-8282
I-9
FIG.
ITEM
13
17
20
24
5
13
37
1
10
11
13
16
16
17
18
24
35
36
2
13
33
20
20
17
16
16
36
28
27
10
28
36
12
12
12
12
12
23
24
26
27
28
13
17
16
36
37
37
10
4
17
19
10
21
18
4
25
12
4
28
5
15
4
35
12
5
4
1
2
14
24
2
15
16
2
5
31
12
30
18
25
35
42
3
8
14
25
29
2
23
2
20
3
26
31
3
43
14
11
35
9
13
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
PART NUMBER INDEX
STOCK NUMBER
96906
96906
96906
96906
96906
MS90727-87
MS90727-91
MS90727-94
MS9O728-36
MS90728-62
5305-00-709-8523
5305-00-709-8542
5305-00-709-8537
5306-00-226-4829
5305-00-068-0511
96906
MS90728-64
5305-00-725-2317
96906
MS90728-66
5305-00-782-9489
96906
MS90728-70
5305-00-846-5703
96906
96906
15434
89346
24617
15434
MS90728-87
MS9241-024
NPN
R9922703
S-118-A
S-119-0
5305-00-071-1788
5330-00-924-7757
15434
24617
15434
15434
S-147-B
S-600
S-605
S-908
5306-00-136-9751
4733-00-057-5555
15434
15434
15434
S-910-B
S-911-B
S-915-A
4730-01-160-3579
4733-00-018-9566
4730-00-801-8186
15434
15434
15434
15434
15434
15434
S-966E
S101A
S106
S110
S118A
S129
4730-00-203-0549
5305-00-424-3571
15434
15424
15434
15434
15434
15434
15434
S1354
S140
S145
S149A
S155
S159B
S16073
5305-01-203-6444
5305-00-404-1390
5305-01-028-8869
5305-00-493-3959
3110-00-144-8519
15434
15434
S16206
S16255
5365-00-786-0102
2815-00-815-0355
15434
15434
S189C
S199B
5305-00-509-8106
5305-00-404-1388
5305-01-165-3300
5305-01-114-9279
5305-00-230-1939
5305-00-546-6698
I-10
FIG.
ITEM
13
8
8
17
16
16
35
36
18
36
11
28
16
36
20
12
28
1
2
8
17
17
2
2
8
8
16
2
13
35
36
2
17
5
35
29
2
10
13
24
16
36
19
33
36
36
33
26
36
30
16
16
9
7
29
2
44
3
5
4
9
3
36
18
1
22
12
34
1
8
1
11
30
9
42
6
20
12
27
14
8
3
13
21
5
11
9
23
38
5
17
37
46
3
12
25
36
10
28
37
14
46
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
PART NUMBER INDEX
STOCK NUMBER
15434
15434
15434
15434
15434
15434
15434
15434
S200
S222A
S223
S2286
S274
S601
S603
S604
5310-00-134-4168
5310-00-820-6653
5310-00-261-7340
15434
15434
15434
S606
S608
S622
5310-00-410-6756
5310-01-200-1318
5310-30-562-6557
15434
15434
15434
15434
S626
S631
S658
S719
5310-00-562-6558
5310-00-562-6560
5310-00-109-7638
5340-00-276-5847
15434
S911B
4730-00-018-9566
15434
S962
4730-00-044-4715
15434
15434
S965E
S995
5365-00-404-2934
4730-00-289-4770
91265
TS33-016
5330-00-951-3533
15434
15434
24617
80218
15424
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
X-1
011573
0120217
10003
100099
100192
100193
100215
100478
100670
100764
1011
1012
101322
101468
1017
5310-00-469-3998
5310-00-521-8595
5305-00-804-6318
5330-00-809-2667
3040-00-773-9369
3120-00-810-6032
3040-00-567-4354
5330-00-081-9289
3120-00-573-0391
5330-00-506-4866
2593-00-590-7378
3120-00-719-5719
I-11
FIG.
ITEM
5
29
10
38
24
5
5
2
4
8
28
24
16
8
13
24
13
29
5
2
10
3
16
18
20
28
36
2
36
3
3
17
35
28
30
37
12
30
13
26
24
23
25
33
2
24
21
21
11
25
21
13
3
30
2
20
3
10
24
8
12
37
26
38
3
20
19
23
12
11
39
24
8
16
12
13
15
17
45
4
2
3
9
6
21
17
16
21
12
17
6
12
10
8
4
36
16
8
19
1
2
9
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
PART NUMBER INDEX
STOCK NUMBER
5365-00-507-3224
5365-00-507-3225
5365-00-543-3744
3040-00-695-3285
3020-00-567-4356
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
101841
101842
101843
101918
101983
1022
102231
1023
1026
1030
103036
1031
105199
105375
105953
106289
106452R91
107440
107738
15434
15434
15434
15434
15434
108074
1081
1082
1083
108330
5310-00-486-2505
15414
15434
15434
15434
15434
15434
15434
15434
108722
109319
109333
109594
109915
110855
110907
112076
5340-00-400-3449
2815-00-406-8936
2815-00-705-2856
3120-01-079-6527
5305-00-774-4246
5330-00-567-3463
5365-00-708-3434
5365-01-160-1832
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
112302
112593
113244
114638
114739
114745
114754
114755
114764
114765
114773
114791
114795
114921
5365-00-420-9696
3020-00-562-1173
2815-00-829-5227
9905-00-733-7622
5306-00-804-2468
5305-00-091-4009
2815-00-505-5119
5310-00-757-6367
3020-00-701-1112
5310-00-887-8325
2910-00-767-4018
5330-00-816-8148
1-12
FIG.
23
23
23
24
24
21
34
21
21
21
24
21
19
38
2
5
32
29
10
10
28
21
21
21
24
36
29
17
17
19
33
25
16
2
18
19
23
36
13
23
19
28
28
28
28
28
28
28
28
28
28
ITEM
15
15
15
6
7
3
1
5
15
7
14
16
7
1
22
12
1
24
9
16
18
12
13
14
5
8
27
4
8
11
1
9
23
12
13
6
4
26
1
30
10
5
22
27
6
20
19
14
10
23
25
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
15434
15434
15434
15434
15434
15434
15434
114940
114947
115033
115034
116390
116391
116936
15434
15434
15434
15434
15434
15434
15434
116982
117897
118226
118227
118377
118378
118939
15434
15434
15434
15434
15434
15434
75078
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15424
15434
15434
15434
15434
119363
1200
120448
120543
120819
123000
1232
123558
124019
124020
124033
126304
1265
127316
127554
127558
127935
1289
129768
129826
129838
129839
129888
130118
130226
130394
131026
132648
132756
132880
133342
134596
135957
137797
138782
PART NUMBER INDEX
STOCK NUMBER
5313-00-081-9292
3120-00-792-9834
4730-00-803-8353
5340-00-767-4012
5305-00-161-0902
5315-00-844-0140
3120-00-791-1440
3120-00-659-7808
5315-00-777-3544
3020-00-702-3882
5330-00-777-3545
5307-01-147-2821
5315-00-866-5015
5333-00-065-5544
5340-00-464-7064
2815-00-828-7013
5310-00-081-8500
5340-01-143-6048
2815-00-791-1453
4820-01-300-2759
5310-00-082-1888
2913-00-829-5600
5355-00-082-1189
5340-00-084-7787
5330-00-081-9299
2930-00-928-3595
5333-00-106-6370
4730-00-404-2906
5330-00-143-8485
4730-00-404-2909
5340-00-833-7966
2815-00-739-6098
I-13
FIG.
ITEM
28
28
28
28
20
20
25
26
19
17
24
23
10
10
10
10
25
21
5
10
10
5
12
9
27
27
28
17
21
4
9
16
9
21
30
30
30
30
30
35
36
35
9
2
16
6
35
17
9
36
23
13
4
7
12
17
11
10
16
4
20
22
12
18
11
8
15
6
18
7
10
36
8
19
15
18
17
26
5
21
2
2
19
9
4
8
3
2
10
9
7
48
5
8
25
39
2
2
6
10
44
5
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
15434
15434
15434
15434
139289
139473
139988
140330
15434
15434
15434
15434
15434
12204
24617
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
140357
140358
140414
140618
140925
141244
141284
141761
142176
142204
142616
142689
143251
143450
143847
143938
143939
143946
143947
143948
143949
143950
144178
144179
144195
144302
144372
145506
145701
145977
146437
146483
147100
147389
147670
148203
1484
148977
149030
149040
1492
150002
151478
PART NUMBER INDEX
STOCK NUMBER
5365-00-988-3668
5330-00-809-3276
3120-00-589-3537
2910-00-829-5603
5315-00-014-1244
5315-00-014-1284
2815-00-070-2251
5310-01-072-8821
2930-00-437-0567
3020-00-160-9092
5360-00-461-5738
5360-00-081-8487
5365-00-488-0799
5365-01-086-6759
5365-01-086-7680
4730-01-241-4639
5315-00-082-0448
5360-00-082-0124
5365-00-829-5604
4730-01-157-8923
5330-01-086-3991
2815-00-962-5623
2930-00-732-5206
2910-00-451-8063
2910-00-790-8736
2910-00-928-3505
5305-00-062-4378
2815-00-994-4427
5330-00-143-8369
2990-00-858-3526
3040-00-085-7439
5315-00-973-0414
2815-00-242-2992
2815-00-920-2073
I-14
FIG.
ITEM
10
23
26
12
12
12
12
12
28
28
28
23
27
25
5
18
37
23
16
20
27
7
23
2
2
2
2
2
2
28
23
23
27
23
28
36
9
34
23
31
9
9
6
35
21
33
33
33
21
8
19
33
3
8
6
11
17
27
32
8
11
24
13
1
4
14
10
6
29
9
8
8
3
26
6
6
6
6
6
6
33
28
27
3
18
29
38
10
2
24
4
7
3
3
14
2
9
5
8
6
14
5
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
PART NUMBER INDEX
STOCK NUMBER
2815-00-920-8356
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
151489
152770
153336
153338
154088
156226
156416
156420
156444
157088
157551
157594
157070
158139
160514
162426
163733
163944
165006
166009
166777
167157
167299
168306
3120-00-906-6657
2940-00-073-3316
5365-00-965-0870
3010-00-447-9799
5340-00-400-5178
3120-00-904-9595
5305-01-060-5958
5360-00-132-0245
5305-01-091-2498
2910-01-070-9710
5310-00-680-6874
5305-00-947-3437
15434
15434
15434
15434
15434
15434
15434
15434
15434
75078
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
168803
168805
169704
170296
170510
171570
172034
173086
173368
17339
174298
174299
175755
175831
175836
175864
177419
177999
179063
181466
5340-00-933-3009
5330-00-632-6182
2990-00-477-6159
5340-00-632-6239
5330-00-132-0247
5333-00-132-0248
2815-01-085-3733
2815-00-815-1114
5365-00-815-1137
5365-01-241-4318
5340-00-485-0945
4820-00-130-4820
3040-00-933-3012
3040-01-079-3469
4730-00-369-7824
2940-01-146-1995
5310-00-484-1718
15434
182706
5305-00-058-6604
2910-00-829-5616
5340-00-829-5617
5330-00-961-9470
3120-00-682-7706
5333-00-237-6266
5365-00-507-3271
5330-00-143-8376
I-15
FIG.
ITEM
19
6
26
26
31
7
29
29
29
31
13
23
2
16
26
24
23
23
22
22
37
22
29
12
12
12
12
12
12
12
9
29
29
9
22
16
9
22
22
6
10
23
25
17
27
16
25
26
27
30
36
2
13
5
10
2
6
10
16
5
1
27
25
37
28
9
1
11
22
2
7
17
6
13
4
15
26
30
31
16
5
1
15
20
12
11
27
5
10
9
6
20
32
7
19
19
13
12
12
15
15
47
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
15434
89346
15434
15434
15434
15434
15434
15434
15434
183049
183669
184386
184387
184388
185138
185139
185573
185804
187420
187556
187589
187680
187893R1
188936
189800
190397
190769
190849
190876
191517
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
191916
191970
193717
193736
193949
194010
194037
194610
195469
19581R1
196844
197230
197733
199064
15434
15434
15434
15434
15434
15434
15434
33457
15434
15434
15434
15434
15434
15434
199067
199224
199225
199239
199338
199587
199969
2S7225S
200064
200307
200566
200809
200861
200908
PART NUMBER INDEX
STOCK NUMBER
5330-00-058-1767
5340-01-079-4678
2910-01-105-6457
5365-01-086-7788
5305-00-463-0428
5365-00-132-0273
5305-00-138-9848
3120-00-593-1507
5305-00-795-9353
5365-00-462-4504
2930-00-401-9531
5330-00-194-8385
5330-00-132-0274
5310-00-442-6899
5340-00-238-5435
2815-00-480-4347
5330-00-132-9276
5330-00-129-9349
5305-00-411-9340
2815-00-404-2940
2815-00-994-4429
5365-01-132-1984
5330-01-209-3583
5330-00-478-2962
4730-01-147-2223
2520-01-085-6128
3040-01-079-1748
3040-01-203-8549
2815-00-405-1798
5340-00-417-5800
5330-01-072-8822
2815-01-077-4463
5330-00-026-2931
5310-00-134-4171
5305-00-005-0666
1-16
FIG.
2
29
16
16
16
22
22
8
13
6
30
12
4
1
5
27
20
20
29
30
20
20
22
6
5
22
3
29
12
6
29
1
36
13
29
2
5
2
12
12
12
20
17
20
14
13
37
19
20
6
19
I
T
3
30
30
29
33
16
8
16
22
13
13
36
19
8
9
9
5
18
25
6
1
19
4
7
2
13
6
11
12
4
2
13
27
2
31
18
15
28
20
33
9
12
15
14
1
8
9
8
6
11
9
E
M
SECTION I V
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
CAGEC
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
63483
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
PART NUMBER
200919
201124
201707
202128
202226
202376
202377
202457
202506
202897
202903
202961
202994-1011
203090
203131
203145
203294
203350
203426
233619
203849
204165
204657
204829
204832
204851
20622
208118
208119
208120
208132
208134
208138
208326
208411
208461
208581
208621
208668
208829
209600
209700
209862C1
209919
209959
210179
210238
210412
210647
210650
210685
PART NUMBER INDEX
STOCK NUMBER
5340-00-132-3203
5360-01-200-0323
3130-00-432-1559
5330-00-406-7789
5330-00-026-2933
5340-00-951-3536
5315-01-058-4551
4720-01-070-8149
5310-00-426-3990
5330-01-066-3910
2910-01-080-5570
5315-01-079-6506
5305-01-072-8831
4730-01-078-9859
5305-00-795-9336
6680-01-281-1226
5330-00-005-0858
3020-01-085-3779
2815-00-338-6839
3040-01-079-3468
5365-01-080-0409
4730-00-477-4160
5340-01-098-0175
5305-00-006-8411
2815-01-146-5925
5315-01-079-6740
5330-01-046-9441
5330-00-006-2494
I-17
FIG.
ITEM
19
37
16
16
2
29
29
29
29
26
4
18
18
6
9
17
29
23
22
27
26
4
13
4
17
28
13
36
36
36
36
36
36
18
10
13
10
28
29
37
36
3
15
4
29
4
36
8
25
10
10
12
3
15
14
7
18
19
14
23
7
18
14
1
8
4
25
7
16
14
16
14
1
7
7
24
38
4
34
35
40
11
21
24
2
27
21
32
28
32
15
14
11
3
6
33
22
22
5
13
3
23
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE
CAGEC
PART NUMBER
15434
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
210804
210805
210806
210832
210858
210860
210884
210895
210926
210966
210967
210996
211016
211027
211053
211358
211375
211869
211915
211918
211939
211999
212161
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
75078
15434
89346
15434
75078
15434
212563
213082
213713
213740
213768
213769
213936
214476
214950
215090
215172
215705
215965
216524
216802
218152
218245
2299
236985R91
2390
24874R1
2514
2544
25711R1
26762702
2680
2689
INDEXES
PART NUMBER INDEX
STOCK NUMBER
5365-01-150-6257
5340-01-242-0805
4710-01-085-6130
5330-01-046-3144
4710-01-239-7360
5365-00-275-8276
3020-01-077-4411
5360-01-038-4659
5360-00-009-9270
5330-01-077-5228
2950-00-275-9344
5310-00-145-0762
2815-00-011-7786
5330-01-072-8983
3110-01-079-8190
3120-01-087-3004
5330-00-064-4399
5330-01-145-0716
3020-01-077-2229
5340-01-086-6193
5333-01-085-3580
5330-01-046-1991
I-18
FIG.
ITEM
36
36
36
16
16
36
2
2
20
16
16
37
35
35
16
13
29
37
4
4
17
9
16
35
29
36
28
2
33
33
29
36
6
2
34
8
4
3
29
12
16
21
32
21
1
12
21
1
32
12
21
45
7
6
17
6
32
29
10
4
40
24
4
9
13
25
11
6
8
3
4
7
13
41
10
4
41
42
7
7
6
29
10
9
5
3
17
11
4
17
10
7
17
4
11
5
18
1
3
3
22
10
--
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
P A R T
CAGEC
15434
75078
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
PART NUMBER
274085R91
2856
29922801
299263091
3000140
3000266
3000521
3000907
3004165
3004316
3006183
3006187
3006358
3006456
3006736
3007242
3007300-2764
3007442
3007713
3007716
3007759
3007976
3008017
3008100
3008468
3008469
3008998
3009213
3010395
3010915
3011935
3012527
3012537
3012972
3014149
3014622
3014623
3014624
3014625
3014783
3017759
3018049
3018323
3018762
3019180
3011986
3319192
3019218
3319227
3019400
3020943
I N D E X
STOCK NUMBER
5307-01-147-1316
5970-01-193-0895
2815-01-083-3157
3040-01-085-2616
4710-01-181-1956
2815-01-151-8772
5330-00-005-0857
2815-01-142-0732
2815-01-159-1737
2815-01-146-1024
2815-01-085-2618
5330-01-145-7550
2815-00-230-0070
5330-01-145-5377
5330-01-086-6197
2815-01-156-6224
5330-01-072-4436
5330-01-079-6514
4730-01-147-2223
5330-01-049-0466
5310-00-356-1447
5307-00-922-2626
2910-01-070-7979
4730-01-211-1989
2910-01-152-8531
5330-01-131-2967
2815-01-086-2704
2915-00-132-0240
2815-01-127-1060
2815-01-127-3597
2815-0l-127-3598
3020-01-084-9640
2815-00-085-7434
2815-00-705-2851
2910-01-150-2631
5330-01-092-4143
3123-00-695-1232
3120-01-241-6516
3120-01-214-7779
5330-01-242-0722
5330-00-659-3178
I-19
FIG.
ITEM
15
12
1
15
4
30
12
16
4
2
19
15
4
12
5
34
42
10
4
7
2
8
11
18
35
1
44
10
1
14
43
43
9
31
34
4
21
41
26
16
28
15
7
1
9
9
9
9
8
11
11
11
9
8
12
23
2
16
3
9
2
16
3
2
2
2
2
2
29
9
13
22
18
6
9
9
9
9
17
9
10
22
KIT
4
4
4
4
18
13
19
16
9
12
1
3
21
15
20
17
9
3
1
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15424
15434
15434
15434
15434
3022205
3022961
3022969
3023177
3026556
3027215
3027633
3029852
3030970
3031434
3032861
3033677
3034233
3035053
3035342
3036065
3038220
3038997
3038998
15434
15434
15434
15434
15434
15434
79396
15434
89346
15434
15434
15434
15434
15434
15434
15414
154340
15434
89346
89346
89346
89346
15434
15434
15434
89346
15434
15434
15434
89346
15434
3045173
3045533
3047402
3054535
3054611
3065125
33341
36431901
36435901
3801261
3501262
3801263
3801330
3801353
3801433
390782C1
40662A
4136
41408501
41408901
42414002
42414102
42645
42646
42647
427820C1
43463-A
43696
441432
44188902
44383
PART NUMBER INDEX
STOCK NUMBER
5365-01-129-4324
3120-01-147-5275
2815-00-590-7385
3120-01-160-7482
3120-00-877-2213
4820-01-146-1048
5330-01-147-4371
5330-01-147-0748
5330-00-005-0407
2910-01-199-8757
5330-01-160-7460
4810-00-695-3284
2815-00-300-0882
2910-00-132-0769
5330-01-240-1630
5330-0l-080-2992
5330-01-072-6829
5333-01-080-5021
2910-01-191--8470
2920-01-121-8859
3040-00-388-3126
2910-00-470-7075
4720-00-846-5575
3120-01-143-9547
3123-01-144-8882
3123-01-145-9132
5330-01-149-9715
5340-00-134-3529
3040-01-079-1799
5330-00-361-2955
5310-01-186-4361
2815-00-484-8359
3130-00-408-9041
2815-00-484-8360
5333-00-159-1464
5333-00-886-2509
3120-00-349-6444
I-20
FIG.
18
16
29
7
20
10
23
8
30
17
13
36
25
24
30
9
27
36
36
36
24
12
3
22
30
10
31
15
BULK
4
4
4
KIT
22
12
15
4
21
1
1
1
1
2
2
2
1
36
10
37
1
4
I T E M
3
22
21
1
9
2
19
21
7
32
6
18
1
21
1
5
5
23
29
39
9
23
5
5
11
21
5
6
1
13
13
13
1
3
37
1
5
20
12
7
17
17
19
19
19
2
15
31
2
10
14
TM5-2815-241-34&P
SECTION XV
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
PART NUMBER INDEX
STOCK NUMBER
15434
89346
15434
72582
89346
89346
19207
72962
83259
15434
44387
446002R1
44678
450517
46522502
47666901
5329388
590220940406
600-001 1-4
69408
3120-00-090-5504
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
61623
63385
63495-D
63842
64482
65259-A
65259-B
65259-C
66292
67346
67347-1
67622
67684
67946
67963
68193
68274
68365
68445
5310-00-276-2816
5365-00-082-1193
15434
15434
15434
15434
15434
15434
16954
15434
15434
68512
68513
68549
68585
68586
68606
691-10014
69519
69521
15434
69550
15434
15434
15434
15434
15434
15434
15434
15434
69699
69736
69793
69901
69936
70089-1
70295
70349
2910-00-858-3522
5305-00-165-8157
5315-00-532-9388
5315-00-907-0711
5330-00-171-6600
5315-00-238-0882
5310-00-134-4169
2815-00-603-7264
5365-01-147-0912
5365-01-147-0913
5365-00-507-3254
5310-00-197-5304
4730-01-128-4598
5310-00-262-2986
5365-00-197-9327
5330-00-171-7267
5340-00-434-2944
5360-00-664-5343
3120-00-566-0480
5315-00-281-7610
5315-00-041-0915
5315-00-041-0916
5315-00-369-2588
5315-90-014-1195
3120-00-641-6646
5365-00-716-6580
5330-90-252-8888
5315-00-475-2574
3120-00-627-6697
5310-00-962-5610
5305-00-339-1415
5306-00-019-4227
4730-00-081-9618
5313-90-222-7240
5333-00-537-2382
4733-00-011-3175
5306-90-719-5467
I-21
FIG.
ITEM
4
1
27
16
1
1
2
23
28
2
8
36
28
36
18
5
8
8
8
2
13
13
2
30
16
2
7
16
17
2
2
10
10
23
2
10
25
26
17
17
17
7
20
3
10
24
2
6
2
30
13
16
11
13
45
6
9
20
17
17
38
8
33
41
13
11
6
14
16
16
30
13
12
33
16
21
26
2
20
18
2
40
13
6
9
17
37
5
15
14
23
27
5
20
10
19
3
15
12
11
4
18
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
CAGEC
PART NUMBER
PART NUMBER INDEX
STOCK NUMBER
15434
15434
15434
70459
70624
70653
5340-00-721-5329
5330-00-506-4874
2815-00-772-9434
15434
15434
15434
15424
15434
15434
15434
15434
15434
15434
15434
15434
15434
70657
70690
70699
70700
70705
70713
70715
70716
70717
70717A
70717B
70772
70790
5340-01-122-8002
2990-00-772-1778
5365-00-721-7884
5360-00-597-4570
5333-00-562-1176
5340-00-898-1497
5310-00-507-3259
5305-00-506-5722
5365-00-507-3260
5365-00-507-3261
5365-00-507-3262
5305-00-477-6769
5306-00-485-0790
15434
15434
19207
24617
15434
15434
15434
15434
15434
15434
15434
15434
89346
7348-2
8265
8465575-44
903302
9195-3
9226
9235-1
9237
9260-1
9266
9266A
9333-1
969783R1
2815-00-362-1780
5310-00-246-0221
3110-00-144-8499
5306-00-041-0917
5315-00-014-1284
3120-00-374-4342
2815-00-311-2521
5330-00-175-6585
5330-00-349-1219
5330-00-7294427
I-22
FIG.
3
35
2
8
5
23
24
31
27
27
27
27
27
27
27
9
25
26
10
16
15
24
6
2
7
10
10
10
10
2
1
I T E M
7
4
32
10
1
20
15
3
12
10
4
6
9
9
9
6
11
13
14
32
5
13
14
16
4
26
7
36
36
18
16
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
ITEM
BUCK
KIT
KIT
KIT
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
2
3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17
1
2
3
4
5
6
6
6
6
6
6
7
7
8
9
10
11
12
13
14
15
16
17
18
18
19
19
19
20
FIGURE AND ITEM NUMBER INDEX
CAGEC
STOCK NUMBER
4720-00-846-5575
5330-01-149-9715
5330-00-888-4988
5330-01-092-4143
5310-00-820-6653
5310-01-186-4361
5315-00-012-0123
5970-01-193-0895
5315-00-281-7610
5330-00-058-1767
5330-01-049-0466
5330-00-064-4399
5365-00-488-0799
5365-01-086-6759
5365-01-086-7680
2815-00-011-7786
5330-00-537-2382
5365-01-160-1832
4730-00-203-0549
5340-00-050-1600
4730-00-081-9618
5315-00-014-1284
5315-00-014-1195
5330-00-478-2962
5330-00-729-4427
2815-00-484-8359
2815-00-484-8360
3130-00-408-9041
5315-00-532-9388
I-23
89346
15434
15434
15434
89346
89346
89346
96906
89346
89346
89346
89346
89346
89346
89346
89346
89346
96906
89346
89346
89346
89346
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
24617
24617
89346
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
19207
PART NUMBER
36435901
3801330
BM68356
3018762
R9922703
42782001
25711R1
MS35338-50
24874R1
46522502
41408901
187893R1
47666901
44188902
446002R1
41408501
19581R1
MS24665-355
29922801
969783R1
42414002
42414102
AR-09912
68445
183049
3008998
215090
143938
143946
143947
143939
143948
143949
202226
213740
S-118-A
S-600
210895
70089-1
112076
S-966E
MS35648-8
69901
9226
68585
199064
9333-1
42645
42647
42646
5329388
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
ITEM
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
12
13
13
13
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
5310-00-356-1447
5306-00-804-2468
5305-00-546-6698
5310-00-261-7340
4730-00-404-2909
5330-00-171-7267
4730-00-0l8-9566
4730-01-147-2223
5365-01-150-6257
5310-00-197-5304
4730-01-147-2223
2815-00-772-9434
4730-01-128-4598
3120-00-339-5642
3120-00-573-0391
3120-00-906-6657
5315-00-238-0882
5340-00-276-5847
5315-00-281-7610
5330-01-145-5377
4730-00-044-4715
2815-01-156-6224
5365-00-404-2934
4730-00-289-4770
5340-01-086-6193
5330-01-080-5021
5330-00-129-9349
5340-00-721-5329
4730-00-018-9566
5310-00-962-5610
5305-00-006-8411
5305-00-795-9336
5310-00-081-8500
3020-01-077-4411
5330-00-361-2955
2815-01-146-5925
5330-00-005-0858
5310-00-261-7340
5305-00-269-3240
2815-01-151-8772
3020-01-077-2229
2815-01-083-3157
3120-01-143-9547
3120-01-144-8882
I-24
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
89346
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
94906
15434
15434
15434
15434
15434
15434
PART NUMBER
3009213
105953
S129
S604
132648
67963
S-911-8
199067
210884
66292
3008468
70653
67622
3008469
BM27253
100670
157870
60408
S719
68445
3010395
S-605
3007976
3007442
S962
3007716
S965E
S995
216524
3047402
193949
70459
S911B
3008100
69699
209700
204165
127316
211915
211918
40662A
209919
204829
S604
MS90727-64
3004165
215965
3000140
AR-07110
3801261
3801262
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
4
4
4
4
4
4
4
4
4
4
5
5
5
5
S
5
5
5
s
5
5
5
5
5
5
5
5
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
7
7
7
7
7
7
8
8
8
ITEM
13
14
15
16
17
18
19
20
21
22
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
13
13
14
1
2
3
4
5
6
1
2
3
FIGURE AND ITEM NUMBER INDEX
CAGEC
STOCK NUMBER
3120-01-145-9132
3120-00-349-6444
3120-01-241-6516
3120-00-090-5504
3120-01-214-7779
5315-01-058-4551
3120-00-593-1507
3120-00-695-1232
5315-01-079-6740
5340-01-122-8002
5310-00-134-4168
5310-00-584-5272
2815-00-603-7264
5305-00-795-9353
5310-00-820-6653
5310-00-109-7638
5305-00-091-4009
5310-00-469-3998
5315-00-014-1284
5330-00-478-2962
5310-00-159-6209
2815-01-086-2704
2815-00-994-4427
2815-00-994-4429
5365-01-241-4318
2815-00-480-4347
3120-01-087-3004
2815-00-753-0660
5310-00-134-4171
5310-00-222-7240
5365-00-132-0273
5306-00-041-0917
5340-00-404-2944
3120-00-374-4342
5305-01-165-3300
5310-00-209-0965
5310-00-562-6557
I-25
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
24617
15434
96906
96909
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
PART NUMBER
3801263
44383
3019186
44387
3019218
202903
187680
3019192
3019180
210179
70657
193717
S601
MS35338-48
S106
64482
120448
123000
188936
S603
S658
106289
S200
141284
199064
MS122032
MS35206-279
3014149
132880
147670
194610
AR-08190
175755
191970
203090
214950
BM52474
200861
69936
152770
187420
9195-3
3023177
68193
143450
9235-1
69550
156226
S-119-0
MS35338-47
S622
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
10
10
10
10
10
10
10
ITEM
4
5
6
7
8
9
10
11
12
13
14
15
16
16
16
16
17
18
19
20
21
1
2
3
4
5
5
6
7
8
9
9
9
9
9
9
10
10
11
12
13
14
15
16
1
2
3
4
5
6
7
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
5330-00-005-0857
5330-01-046-0441
4730-00-057-5555
5305-00-709-8537
5315-00-238-0882
5305-00-709-8542
2815-00-772-9434
5305-00-942-2196
5310-00-261-7340
5310-00-080-6004
2815-00-242-2992
5365-00-507-3254
5365-01-086-7788
5365-01-147-0912
5365-0l-147-0913
5330-01-145-0716
5330-01-145-7550
4730-00-057-5555
3120-00-877-2213
5340-00-933-3009
5340-31-143-6048
5305-00-062-4378
5310-00-426-3990
2815-00-300-0882
2815-01-085-3733
5305-00-477-6769
2910-00-928-3505
5330-00-143-8485
2815-00-085-7434
2815-00-132-0240
2815-01-127-1060
2815-01-127-3597
2815-01-127-3598
4820-01-300-2759
2815-00-739-6098
2815-00-962-5623
2815-01-085-2618
5340-00-632-6239
5360-00-009-9270
5330-01-072-4436
5315-00-866-5015
2910-0l-070-7979
2815-00-705-9257
2815-00-590-7385
2815-03-609-7115
2815-00-505-5116
5315-00-041-0916
2815-00-311-2521
I-26
15434
15434
15434
96906
15434
96906
15434
96906
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
75078
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
PART NUMBER
3004316
210412
S-908
MS90727-94
60408
MS90727-91
70653
MS18154-60
S604
MS27183-14
150002
AR01176
65259-C
185573
65259-A
65259-B
215705
3006736
AR09473
S-908
3029852
170296
127554
147385
203131
3036065
17339
70772
147100
131026
3017759
3014622
3014623
3014624
3014625
127935
135957
145701
3006456
172034
211999
3007759
123558
3011935
BM47777
3027215
210650
BM37625
BP37634
68513
9260-1
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
11
11
11
11
11
11
11
11
11
12
12
12
12
12
12
12
12
12
ITEM
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
36
36
37
38
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
5315-00-777-3544
2815-00-505-5119
3120-00-659-7808
2815-00-705-2851
5315-00-041-0915
2815-00-362-1780
5315-00-777-3544
2815-00-505-5119
3120-00-791-1440
5305-00-339-1415
5340-00-485-0945
3040-00-388-3126
2815-00-375-9892
5340-00-276-5847
5310-00-684-3463
5310-00-261-7340
5310-00-080-6004
5310-00-521-8595
5330-00-886-2509
5310-00-407-9566
5306-00-050-1237
5330-00-175-6585
5330-00-349-1219
5330-00-777-3545
3120-00661-6646
5305-00-546-6698
2590-00-590-7378
2815-01-159-1737
5305-00-782-9489
5305-00-942-2196
5310-00-261-7340
5310-00-080-6004
2815-01-142-1732
2815-01-146-1024
5330-01-066-3908
2815-0l-096-9198
5310-00-732-0560
5305-00-947-3437
3120-00-589-3537
2815-00-005-7431
5310-00-732-0560
I-27
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
96906
96906
15434
15434
15434
15434
96906
96906
15434
15434
15434
15434
15434
15434
15434
96906
96906
96906
96906
15434
15434
73165
15434
15434
96906
15434
15434
15434
15434
96906
15434
PART NUMBER
118939
107738
120543
118378
3018049
68512
7348-2
118939
107738
BP-37496
118377
69736
175831
3065125
BM73976
210685
S719
MS51092-1
9237
208411
MS35338-8
MS27183-14
S223
43696
208581
139289
MS35338-45
MS90727-31
9266
9266A
120819
68586
S129
101322
3006187
MS90728-66
MS18154-60
MS35338-8
MS27183-14
3006183
3006358
B90429
AR03307
BM95161
MS51968-14
168306
169704
140330
AR-02308
MS51968-14
199239
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
ITEM
10
11
12
13
14
15
16
17
18
19
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
FIGURE AND ITEM NUNBER INDEX
STOCK NUMBER
CAGEC
3120-09-589-3537
2815-00-404-2940
2815-00-195-5894
5310-00-732-0560
5305-00-947-3437
3120-00-589-3537
5307-01-147-1316
5307-01-147-2821
2815-00-851-7637
5310-00-732-0560
5305-00-947-3437
3120-00-589-3537
2815-00-195-5897
5310-00-732-0560
5305-00-547-3437
3120-00-589-3537
2520-01-085-6128
2815-00-230-0073
3040-01-079-1799
5330-01-209-3583
2815-00-338-6839
5330-01-147-0748
6680-01-281-1226
5340-00-417-5800
5305-00-115-9526
4710-01-239-7360
4730-00-801-8186
5310-00-261-7340
5305-00-709-8523
5306-00-719-5467
5310-06-209-0965
5310-00-562-6557
5305-00-463-0428
I-28
15434
15434
15434
15434
96906
15434
15434
15434
75078
75078
75078
15434
15434
75078
15434
15434
96906
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
89346
15434
15434
15434
15434
15434
15434
15434
15434
15434
96909
96906
15434
15434
15434
15434
96906
96906
80218
15434
96906
15434
15434
15434
PART NUMBER
218152
140330
194037
AR51276
MS51568-14
168306
168805
140330
2514
2856
1232
199224
011573
2680
3045533
BM95162
MS51968-14
168306
140330
BM95160
MS51968-14
168306
168803
140330
199225
3000521
3007242
187589
3801433
112593
197230
3019400
20622
S1354
3032861
204657
200064
MS35338-46
MS18154-58
211358
67347-1
67346
S-915-A
MS35338-8
MS90727-87
10003
70349
MS35338-47
S622
208461
185804
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
13
13
13
13
13
13
13
14
15
15
15
15
15
15
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
lb
16
16
16
16
16
16
ITEM
23
24
25
26
27
28
29
1
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
5310-00-562-6558
5310-00-768-0318
5310-00-584-5272
5305-00-07l-2071
5330-00-143-8376
4730-01-211-1989
5310-00-407-9566
2815-00-405-1798
5305-00-068-0511
5305-00-269-3217
5310-00-261-7340
4820-00-276-9041
5330-01-046-1991
2930-00-437-0567
5330-01-086-6197
2930-00-603-1625
4730-01-160-3579
2940-01-146-1995
5360-01-200-0323
4730-00-018-9566
5305-00-846-5703
2815-00-791-1453
5360-00-664-5343
5365-00-197-9327
5365-01-129-4324
5365-00-708-3434
5330-01-046-3144
5330-00-132-0248
2940-00-073-3316
4820-00-276-9041
5310-00-246-0221
5310-00-080-6004
5310-00-261-7340
5305-00-942-2196
5305-01-203-6444
I-29
15434
96906
96906
96906
15434
15434
96906
33457
15434
15434
15434
15434
19207
15434
15434
96906
96906
96906
96906
15434
15434
15434
15434
15434
46529
15434
15434
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
96906
96906
96906
15434
PART NUMBER
S626
MS35690-805
MS35338-48
MS90725-115
157551
3012527
MS35338-45
2S7225S
39078201
274085R91
2098620l
299263091
8465575-44
36431901
ARO9479
MS90728-62
MS90725-67
MS35338-8
MS35782-6
210858
218245
ARO9478
142616
3007713
A331987
S-910-B
179063
202128
201707
S911B
210832
MS90728-70
127558
68274
67946
3022961
110907
210967
211053
AR-09265
173368
158139
184387
184386
MS35782-6
8265
184388
MS27183-14
MS35338-8
MS18154-6C
S145
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
16
16
16
16
16
16
16
16
16
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
18
18
19
18
18
18
18
18
18
18
ITEM
38
39
40
41
42
43
44
45
46
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
5310-01-200-1318
5340-01-242-0805
5330-01-077-5228
4710-01-181-1956
5330-01-079-6514
5305-00-068-0511
5305-00-165-8157
5305-00-404-1388
2815-00-085-2573
5315-00-043-1787
5305-01-010-2362
2815-00-406-8936
2815-00-828-7013
5340-00-833-7966
5360-01-038-4659
2815-00-705-2856
4730-00-289-4770
5310-00-209-0965
5305-01-165-3300
5310-00-261-7340
5305-00-709-8282
5315-00-475-2574
3040-01-079-1748
3020-01-084-9640
3120-00-566-0480
3040-01-079-3469
2 0
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
5305-00-424-3571
2815-01-085-3734
3120-00-627-6697
3020-01-085-3779
5330-01-066-3910
3120-00-627-6697
5310-00-407-9566
5306-00-226-4829
5306-00-136-9751
5306-00-225-8499
5330-01-147-4071
4720-01-070-8149
4730-00-477-4160
5305-00-725-2317
5310-00-261-7340
5310-00-080-6004
5330-01-131-2967
5305-00-942-2196
5330-01-242-0722
2815-00-070-2251
I-30
15434
15434
15434
15434
15434
15434
96906
72582
15434
15434
96906
96906
15434
15434
15434
15434
15434
15434
96996
15434
96906
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
96906
15434
96906
15434
63483
15434
15434
96906
96906
96906
15434
96906
15434
15434
PART NUMBER
S608
132756
210966
212161
3000907
3008017
MS90728-62
450517
S199B
AR-10172
MS35756-34
MS18154-59
109319
126304
134596
211939
109333
S995
MS35338-47
S-119-0
MS35338-8
MS90727-83
69519
199587
3014783
AR-03636
68365
177419
117897
S101A
AR09832
69521
204832
203145
ARO8667
69521
MS35338-45
MS90728-36
S-147-B
MS90725-34
3031434
202994-1011
208326
3022205
MS90728-64
MS35338-8
MS27183-14
3012972
MS18154-60
3019227
141761
TM5-2815-241-34&P
SECTION IV
CRESS-REFERENCE INDEXES
FIG.
18
18
18
18
19
19
19
19
19
19
19
19
19
19
19
19
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
21
21
21
21
21
21
21
21
21
21
21
21
21
ITEM
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1
2
3
4
5
6
7
8
9
10
11
12
13
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
5310-00-134-4169
4730-00-018-9566
5365-01-160-1832
5330-00-659-3178
2815-00-920-8356
5305-01-028-8869
5340-00-767-4012
2815-00-920-2073
5365-01-160-1832
2815-00-829-5227
2815-01-077-4463
5305-00-005-0666
5310-00-887-8325
3120-01-079-6527
5340-00-132-3203
5310-00-442-6899
5310-00-584-7796
2930-00-401-9531
5330-00-026-2931
3020-00-160-9092
3120-31-147-5275
3120-00-792-9834
4730-00-018-9566
3040-01-203-8549
5315-00-616-5522
5315-00-616-5527
5310-00-081-9292
5310-00-442-6899
5310-00-209-0965
5305-00-071-1788
I-31
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
96904
15434
15434
15434
15434
96906
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
PART NUMBER
63842
S911B
112076
202961
3020943
151489
S155
116982
151478
112076
105199
200566
200908
114638
109594
200919
191517
MS15795-824
AR09607
210926
190397
200809
AR08366
142689
3026556
AR08256
116391
199338
S911B
199969
MS35756-12
MS35756-18
116390
190769
191517
69550
MS35338-47
MS90728-81
2544
1484
1022
1289
1023
1492
1030
1011
1017
2689
2390
1081
1082
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
21
21
21
21
21
21
21
21
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
22
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
ITEM
14
15
16
17
18
19
20
21
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
15
16
17
18
19
20
21
22
23
24
25
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
2910-01-150-2431
5305-01-060-5958
5340-00-134-3529
5340-00-238-5435
2910-01-191-8470
2910-01-070-9710
5360-00-132-0245
2910-01-105-6457
5365-00-815-1137
2815-00-815-1114
5330-00-132-0247
5330-00-924-7757
5330-00-132-0276
5315-01-079-6506
2910-01-152-8531
5340-01-079-4678
5330-00-582-7484
5365-00-988-3668
5365-01-160-1832
2910-00-404-9999
2910-00-603-2835
5315-00-369-2588
3120-00-810-6032
5340-00-400-5178
5315-00-844-0140
2910-00-829-5603
2910-01-091-3204
5365-00-507-3224
5365-00-507-3225
5365-00-543-3744
2910-01-080-5570
5315-00-907-0711
5365-00-829-5604
3120-01-160-7482
2990-00-772-1778
3120-00-904-9595
2910-00-451-8063
I-32
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
72962
15434
15434
15434
15434
15434
15434
15434
15434
PART NUMBER
1083
1026
1031
2299
1200
1012
4136
1265
3018323
165006
3801353
191916
3054535
167157
166009
185139
174299
174298
173086
MS9241-024
193736
203426
3012537
185138
3007300-2764
MS9021-116
139473
112076
138782
BM79290
BM73902
BM76665
68549
100193
163733
118227
140618
BM98430
101841
101842
101843
203350
590220940406
144302
3027633
70690
BM73718
163944
AR-00796
146437
157594
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
23
23
23
23
23
23
23
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
24
25
25
25
25
25
25
25
25
25
25
25
25
25
26
26
26
26
ITEM
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
1
2
3
4
5
6
7
8
9
10
11
12
13
1
2
3
4
FIGURE AND ITEM NUMBER INDEX
CAGEC
STOCK NUMBER
5360-00-081-8487
5315-00-082-0448
3020-00-701-1112
5365-00-256-2846
4820-00-130-4820
3010-00-447-9799
2990-00-237-0058
5306-00-019-4227
5310-00-261-7340
5310-00-486-2505
3340-06-695-3285
3020-00-567-4356
2910-00-369-8240
5330-01-072-8829
5315-00-695-3292
3040-00-567-4338
3040-00-773-9369
3110-00-144-8499
3020-00-562-1173
5365-00-721-7884
5330-00-506-4866
5310-00-209-0965
5310-00-562-6557
5330-01-160-7460
5305-00-161-0902
5305-00-071-2241
5310-00-159-6209
5310-00-141-1795
5310-00-410-6756
5310-00-014-5850
2910-01-199-8757
3120-00-719-5719
2910-01-096-9200
5315-00-014-1244
5365-00-716-6585
3020-00-702-3882
3040-00-933-3012
3040-00-567-4354
5330-00-567-3463
4730-00-803-8353
5306-00-495-0790
5310-00-484-1718
5330-00-006-2494
2910-00-828-7126
5305-00-071-2241
5310-00-159-6209
5310-00-141-1795
I-33
15434
15434
15434
15434
15434
96906
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
96906
15434
15434
24617
15434
15434
15434
15434
96906
15434
15434
15434
15434
96906
9690S
88044
15434
96906
15434
15434
15434
12204
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
96906
88044
PART NUMBER
143847
144179
144178
142204
113244
MS16632-1050
175836
161426
BM69886
69793
MS35338-8
108330
101918
101983
BM68879
3045173
MS20066-116
AR51307
100192
903302
103036
70699
100764
S140
MS35338-47
S622
S274
3035053
118226
MS90725-10
MS122032
AN960-416
S606
MS27183-42
3034233
101468
BM97497
141244
68606
119363
175864
100215
110855
116936
70790
181466
210647
BM76340
MS90725-10
MS122032
AN960-416
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
26
26
26
26
26
26
26
26
26
26
26
26
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
ITEM
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
9
9
9
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
2910-00-829-5616
5330-00-809-2667
5340-00-951-3536
5330-00-809-3276
5365-00-965-0870
5340-00-829-5617
5310-00-141-1795
5310-00-484-1718
5306-00-485-0790
4730-01-078-9859
5330-00-252-8888
4730-00-803-8353
2990-00-237-0058
5360-00-082-0124
5310-00-507-3259
2910-00-132-0769
5305-00-506-5722
5360-00-461-5738
5365-00-462-4504
5365-00-507-3260
5365-00-507-3261
5365-00-567-3262
5340-00-898-1497
5365-00-807-2636
5330-00-562-1176
2910-00-858-3522
5310-33-141-1795
5310-00-484-1718
5335-01-072-8831
5340-00-464-7064
5330-00-065-5544
4730-00-369-7824
5305-00-071-2241
5310-00-159-6209
5305-00-071-2241
2910-00-767-4018
5330-00-816-8148
4730-00-018-9566
5305-00-063-5043
I-34
15434
15434
15434
15434
15434
15434
88044
15434
15434
15434
16954
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
88044
15434
15434
15434
15434
15434
96906
15434
96906
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
88044
PART NUMBER
153336
100099
202897
139988
160514
153338
AN960-416
181466
70790
203844
691-10014
116936
140925
BM-69886
144195
70715
3038220
70716
BM74747
143251
189800
70717
70717A
70717B
70713
MS16625-1100
70705
44678
AN960-416
181466
203619
124020
124019
177999
MS90725-10
AR-09454-00EF
MS122032
MS90725-10
114947
114739
114755
115033
140357
BM69381
11A4791
140358
115034
114940
114773
S911B
AN565F428H24
SECTION IV
TM5-2815-241-34&P
CROSS-REFERENCE INDEXES
FIG.
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
28
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
29
ITEM
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
5330-00-171-6600
5310-00-757-6367
5330-00-951-3538
4730-01-157-8923
4730-00-287-1649
4730-01-241-4639
4730-00-196-0837
5305-00-782-9489
5310-00-261-7340
5310-00-080-6004
5305-00-942-2196
5365-00-082-1193
2990-01-046-0171
2950-00-275-9344
5330-00-237-6266
5365-00-275-8276
5310-00-159-6209
5305-00-230-1939
5305-00-411-9340
5310-00-562-6560
5310-00-680-6874
5330-00-026-2933
5330-00-632-6182
3120-00-682-7706
5330-01-085-3580
3130-00-432-1559
5330-00-406-7789
2990-00-477-6159
2950-00-275-9325
5330-00-194-8385
I-35
83259
15434
15434
15434
91265
15434
15434
15434
15434
15434
15434
15434
15434
03958
15434
15434
15434
15434
96906
96906
15434
15434
96906
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
PART NUMBER
600-001 1-4
108074
114765
114764
TS33-016
114745
114795
140414
114921
124033
114754
208621
144372
MS39230-1
AS0501900SS
AS0500760SS
143950
NPN
MS51887-5
MS90728-66
S604
204851
MS27183-14
MS18154-60
63385
213713
AR12604
195469
S222A
212563
156444
211375
233294
MS122032
S118A
156416
194010
S631
167299
202457
170510
156420
216802
202376
202377
171570
3022969
AR10058
202506
107440
190849
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
29
29
29
29
29
29
29
29
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
31
31
31
31
31
32
32
32
32
33
33
33
33
33
33
33
33
33
33
33
33
33
33
34
34
34
I TEN
26
27
28
29
30
31
32
33
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1
2
3
4
5
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
5307-00-922-2626
5340-00-400-3449
4720-01-085-1316
4810-00-695-3284
5355-00-082-1189
2910-00-829-5603
4730-00-011-3175
3040-00-085-2616
5330-00-132-0274
4820-01-146-1048
5310-00-082-1888
5330-00-081-9299
5340-00-084-7787
2920-01-121-8859
5305-00-138-9848
5305-00-509-8106
5310-00-484-1718
5315-00-262-2986
5330-00-951-3538
5365-00-507-3271
5330-00-961-9470
5360-00-597-4570
2910-03-790-8736
2910-00-470-7075
5304-00-774-4246
5310-00-971-7989
5330-00-081-9289
3040-00-085-7439
3110-01-079-8190
5330-01-072-8983
5315-00-973-0414
2990-00-858-3526
5365-00-786-0102
5305-00-493-3959
5310-00-159-6209
5310-00-141-1795
2930-00-732-5206
I-36
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
24617
15434
15434
15434
15434
91265
15434
15434
15434
15434
79396
15434
15434
15434
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
88044
15434
15434
15434
PART NUMBER
3010915
108722
AC1600300NF
213936
183669
197733
208668
209959
3035342
129838
129826
70295
3000266
190876
3030970
129768
129888
129839
3054611
0120217
187556
S189C
181466
67684
TS33-016
157088
154088
70700
146483
33341
106452R91
A09
267627C2
236985R91
109915
MS35691-5
AR51317
100478
149030
213769
213768
149040
148977
S16206
AR03034
S1598
MS122032
AN960-416
102231
145977
215172
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
35
35
35
35
35
35
35
35
35
35
35
35
35
35
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
36
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
FIGURE AND ITEM FIGURE INDEX
STOCK NUMBER
CAGEC
5310-00-261-7340
5305-00-068-0511
5330-00-506-4874
4730-00-404-2906
4730-00-289-4770
2930-00-928-3595
4730-00-801-8186
5330-01-077-5228
5305-01-114-9279
5310-00-407-9566
4710-01-085-6130
5330-00-143-9369
5305-00-846-5703
5310-00-261-7340
4730-00-801-8186
4730-00-044-4715
5305-00-068-0511
5310-09-4862505
5305-00-725-2317
4730-00-909-8627
5330-00-159-1464
2930-01-046-3493
4730-00-018-9566
5330-00-005-0407
5330-00-005-0407
5330-01-240-1630
3110-00-144-8519
5365-00-420-9696
5365-01-132-1984
2815-00-815-0355
5330-01-080-2992
5310-00-276-2816
3040-01-079-3468
3110-00-144-8519
2815-00-815-0355
I-37
96906
15434
96906
15434
15434
15434
15434
15434
15434
15434
15434
96906
15434
15434
96906
96906
15434
15434
96906
15434
15434
15434
96906
15434
15434
96936
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
PART NUMBER
MS35338-8
133342
MS90728-62
70624
130394
S995
130118
S-915-A
211016
212161
S110
MS35338-45
211027
148203
MS90728-70
MS35338-8
S-915-A
S962
MS90728-62
210806
210805
108330
MS90728-64
214476
208132
MS35842-13
63495-0
209600
43463-A
AR-045090
S911B
3033677
AR08853
AR-12732
208134
210238
3038997
208138
S16073
112302
196844
S16255
3038998
AP08854
AR08851
210860
61623
238118
208119
S16073
S16255
TM5-2815-241-34&P
SECTION IV
CROSS-REFERENCE INDEXES
FIG.
36
36
36
36
36
36
36
36
36
36
36
37
37
37
37
37
37
37
37
37
37
37
37
37
37
37
37
37
37
38
38
ITEM
38
39
40
41
42
43
44
45
46
47
48
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
FIGURE AND ITEM NUMBER INDEX
STOCK NUMBER
CAGEC
5330-01-086-3991
5330-01-080-2992
5365-01-080-0409
5310-01-145-0762
5310-00-763-8920
5305-09-269-2811
5305-00-404-1390
5395-00-058-6604
5330-00-106-6370
5330-00-252-6056
5310-01-072-8821
3110-01-073-2576
5330-01-072-8822
5305-00-719-5235
5310-00-584-5272
5310-00-809-5997
5305-00-719-5221
5340-01-098-0175
5305-01-091-2498
3030-00-821-8242
9905-00-733-7622
5305-00-804-6318
I-38
15434
15434
15434
15434
96906
96906
15434
15434
15434
15434
15434
15434
15434
15434
15434
96936
15434
60038
15434
15434
15434
96906
96906
96906
96906
15434
15434
15434
96906
15434
15434
PART NUMBER
145506
3038998
208120
213082
MS51967-20
MS90726-67
137797
210804
S149A
182706
130226
AR10142
441432
201124
210996
MS2513-142
142176
LM485548
211869
200307
AR10141
MS90727-114
MS35338-48
MS27183-17
MS90727-113
208829
X-1
166777
MS51069-41
105375
S2286
TM 5-2815-241-34&P
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
Support or General Support Maintenance.
All bulk materials needed to manufacture the item are listed by part number or specification number in a tabular list
on the illustration.
Section II. MANUFACTURED ITEMS ILLUSTRATIONS
DESCRIPTION:
Hose
PART NUMBER:
8465575-44
MAKE FROM:
Hose, part number 364359C1
TOOLS REQUIRED
FOR FABRICATION: Knife, Pocket Tape, Measuring 78 3/4 inch
Figure D-1. Hose
*U.S. GOVERNMENT PRINTING OFFICE: 1992 643-016/60071
Change 1
D-1/(D-2 blank)
TM 5-2815-241-34&P
APPENDIX E
TORQUE LIMITS
CAPSCREW MARKING
Current Usage
Much Used
Much Used
Used at Times
Used at Times
Quality of
Material
Indeterminate
Minimum
Commercial
Medium
Commercial
Best
Commercial
SAE Grade Number
1 or 2
5
6 OR 7
8
Capscrew Head
Markings
Manufacturer’s
marks may vary
These are all
SAE Grade 5
(3 line)
TORQUE VALUES
CAUTION
If replacement capscrews are of a higher grade than originally supplied, use torque specifications for that placement. This will prevent equipment damage due to overtorquing.
Capscrew Body Size
(Inches) - (Thread)
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
20
28
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
14
Torque
Ft Lb (N•m)
Torque
Ft Lb (N•m)
5
6
11
13
18
20
28
30
39
41
51
55
83
95
105
115
160
175
235
250
8
10
17
19
31
35
49
55
75
85
110
120
150
170
270
295
395
435
590
660
(7)
(8)
(15)
(18)
(24)
(27)
(38)
(41)
(53)
(56)
(69)
(75)
(113)
(129)
(142)
(156)
(217)
(237)
(319)
(339)
(11)
(14)
(23)
(26)
(42)
(47)
(66)
(75)
(102)
(115)
(149)
(163)
(203)
(231)
(366)
(400)
(536)
(590)
(800)
(895)
Torque
Ft Lb (N•m)
10
(14)
19
(26)
34
(46)
55
(75)
85
(115)
120
(163)
167
(226)
280
(360)
440
(597)
660
(895)
Torque
Ft Lb (N•m)
12
(16)
14
(19)
24
(33)
27
(37)
44
(60)
49
(66)
70
(95)
78 (106)
105 (142)
120 (163)
155 (210)
170 (231)
210 (285)
240 (325)
375 (508)
420 (569)
605 (820)
675 (915)
910 (1234)
990 (1342)
E-1
TM 5-2815-241-34&P
TORQUE VALUES - CONTINUED
NOTE
Always use the torque values listed above when specific torque values are not available.
Do not use above values in place of those specified in other sections of this manual;
special attention should be observed when using SAE Grade 6, 7, and 8 capscrews.
The above is based on use of clean, dry threads.
Reduce torque by 10 percent when engine oil is used as a lubricant.
Reduce torque by 20 percent if new plated capscrews are used.
Capscrews threaded into aluminum may require reductions in torque of 30 percent or
more of Grade 5 capscrews torque and must attain two capscrew diameters of thread
engagement.
E-2
TM 5-2815-241-34&P
INDEX
Page
Subject
A
Accessory drive ........................................................................................................................................
Assembly ..............................................................................................................................................
Cleaning ................................................................................................................................................
Disassembly.. .......................................................................................................................................
Inspection/Repair .................................................................................................................................
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Accessory drive, location and description .............................................................................................
Accessory drive maintenance .................................................................................................................
Accessory drive pulley .............................................................................................................................
Cleaning ................................................................................................................................................
Inspection/repair ..................................................................................................................................
Adjustments
Injector ..................................................................................................................................................
Timing, injector ....................................................................................................................................
Valve ......................................................................................................................................................
Air compressor
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Air compressor, location and description ..............................................................................................
Air intake manifold, location and description.. ......................................................................................
Aneroid control valve ...............................................................................................................................
Assembly ..............................................................................................................................................
Cleaning.. ..............................................................................................................................................
Disassembly.. .......................................................................................................................................
Inspection .............................................................................................................................................
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Aneroid control valve, location and description ....................................................................................
Army materiel, destruction of ..................................................................................................................
Assembly, general maintenance .............................................................................................................
2-276
2-279
2-277
2-276
2-277
2-84
2-43
1-7
2-276
2-280
2-281
2-281
2-106
2-74
2-106
2-86
2-41
1-7
1-6
2-398
2-402
2-400
2-399
2-400
2-132
2-25
1-6
1-1
2-8
B
Ball bearings
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body chassis and accessory items, repair parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushings
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing-type bearings
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . ..
2-4
2-5
2-6
C-99
2-5
2-7
2-5
2-7
Index 1
TM 5-2815-241-34&P
INDEX - CONTINUED
Page
Subject
C
Cam follower assembly ...........................................................................................................................
Assembly ..............................................................................................................................................
Cleaning.. ..............................................................................................................................................
Disassembly .........................................................................................................................................
Inspection .............................................................................................................................................
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Camshaft and gear assembly..................................................................................................................
Assembly ..............................................................................................................................................
Cleaning.. ..............................................................................................................................................
Disassembly .........................................................................................................................................
Inspection .............................................................................................................................................
Installation ............................................................................................................................................
Camshaft and timing system maintenance.. .........................................................................................
Capabilities, equipment ...........................................................................................................................
Castings
Cleaning ................................................................................................................................................
General maintenance ..........................................................................................................................
Inspection .............................................................................................................................................
Repair ....................................................................................................................................................
Characteristics, equipment .....................................................................................................................
Cleaning, general maintenance ..............................................................................................................
Cleaning, upon receipt.. ...........................................................................................................................
Components, major, location and description of.. ................................................................................
Compression release shaft
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Connecting rod nut tightening sequence.. .............................................................................................
Contents, table of .....................................................................................................................................
Cooling system
Maintenance .........................................................................................................................................
Repair parts list.. ..................................................................................................................................
Core hole plugs, inspection .....................................................................................................................
Crankcase access cover
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Crankcase and cylinder block maintenance.. ........................................................................................
Crankshaft assembly ...............................................................................................................................
Assembly ..............................................................................................................................................
Cleaning ................................................................................................................................................
Disassembly .........................................................................................................................................
Inspection .............................................................................................................................................
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Repair.. ..................................................................................................................................................
Crankshaft maintenance .........................................................................................................................
Crosshead
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Index 2
2-254
2-260
2-256
2-254
2-256
2-70
2-47
2-238
2-240
2-238
2-239
2-239
2-66
2-238
1-3
2-4
2-3
2-5
2-6
1-3
2-3
2-2
1-4
2-72
2-39
2-224
i
2-404
C-89
2-6
2-126
2-17
2-140
2-214
2-218
2-214
2-214
2-215
2-54
2-49
2-217
2-214
2-80
2-31
TM 5-2815-241-34&P
INDEX - CONTINUED
Page
Subject
C - CONTINUED
Cylinder block ...........................................................................................................................................
Assembly ..............................................................................................................................................
Cleaning/inspection .............................................................................................................................
Disassembly .........................................................................................................................................
Repair ....................................................................................................................................................
Cylinder head ............................................................................................................................................
Cleaning ................................................................................................................................................
Disassembly .........................................................................................................................................
Inspection. ............................................................................................................................................
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Repair/assembly ...................................................................................................................................
Cylinder head fuel line
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Cylinder head, location and description.. ...............................................................................................
Cylinder head maintenance .....................................................................................................................
Cylinder head pipe plug location ............................................................................................................
2-140
2-168
2-143
2-141
2-153
2-176
2-180
2-177
2-180
2-68
2-36
2-191
2-104
2-29
1-5
2-176
2-208
D
Data
Equipment ............................................................................................................................................
Injector spring ......................................................................................................................................
Description, equipment ...........................................................................................................................
Destruction of Army materiel to prevent enemy use.. ...........................................................................
Dipstick tube, oil .......................................................................................................................................
Disassembly and assembly, engine .......................................................................................................
1-3
2-363
1-3
1-1
2-16
2-10
E
EIR .............................................................................................................................................................
EIR MD.. .....................................................................................................................................................
Engine compression brake housing .......................................................................................................
Assembly ..............................................................................................................................................
Cleaning ................................................................................................................................................
Disassembly.. .......................................................................................................................................
Inspection .............................................................................................................................................
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Engine compression brake, location and description ...........................................................................
Engine compression brake maintenance.. .............................................................................................
Engine data.. .............................................................................................................................................
Engine disassembly and assembly ........................................................................................................
Engine lubrication system maintenance ................................................................................................
Engine oil cooler
Installation ............................................................................................................................................
Removal ................................................................................................................................................
1-2
1-2
2-282
2-286
2-284
2-282
2-284
2-116
2-28
1-4
2-282
1-9
2-10
2-264
2-127
2-20
Index 3
TM 5-2815-241-34&P
INDEX - CONTINUED
Page
Subject
E - CONTINUED
Engine, repair parts list.. ..........................................................................................................................
Engine specifications.. ............................................................................................................................
Equipment characteristics, capabilities, and features .........................................................................
Equipment data, engine.. .........................................................................................................................
Equipment description and data.. ...........................................................................................................
General.. ................................................................................................................................................
Equipment improvement recommendations, reporting ........................................................................
Equipment improvement report and maintenance digest (EIR MD). ....................................................
Equipment name and model number.. ....................................................................................................
Equipment, purpose of.. ...........................................................................................................................
Exhaust manifold .....................................................................................................................................
Assembly ..............................................................................................................................................
Cleaning/inspection.. ...........................................................................................................................
Disassembly.. .......................................................................................................................................
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Exhaust manifold, location and description.. ........................................................................................
Expendable supplies and materials list .................................................................................................
C-7
2-434
1-3
1-9
1-3
1-3
1-2
1-2
1-1
1-1
2-272
2-272
2-272
2-272
2-134
2-14
1-5
B-1
F
Fan hub
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Features, equipment.. ..............................................................................................................................
Filter screen inspection, fuel pump ........................................................................................................
Final testing, adjustments, and troubleshooting on engine test stand.. .............................................
Testing and adjustments.. ...................................................................................................................
Troubleshooting.. .................................................................................................................................
Flexible hoses, cleaning ..........................................................................................................................
Flywheel housing
Installation.. ..........................................................................................................................................
Location and description ....................................................................................................................
Removal ................................................................................................................................................
Forms and records, maintenance.. .........................................................................................................
Front cover assembly repair, fuel pump.. ...............................................................................................
Front engine mounting bracket, location and description ...................................................................
Fuel injector.. ............................................................................................................................................
Assembly.. ............................................................................................................................................
Cleaning.. ..............................................................................................................................................
Disassembly.. .......................................................................................................................................
Inspection.. ...........................................................................................................................................
Testing ..................................................................................................................................................
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Index 4
2-123
2-35
1-3
2-294
2-414
2-414
2-424
2-4
2-98
1-5
2-46
1-1
2-308
1-7
2-352
2-363
2-356
2-352
2-356
2-368
2-78
2-34
TM 5-2815-241-34&P
INDEX - CONTINUED
Page
Subject
F - CONTINUED
Fuel pump.. ...............................................................................................................................................
Assembly ..............................................................................................................................................
Cleaning ................................................................................................................................................
Disassembly .........................................................................................................................................
Filter screen inspection .......................................................................................................................
Front cover assembly repair ................................................................................................................
Fuel pump housing repair ...................................................................................................................
Gear pump repair .................................................................................................................................
Governor plunger repair .......................................................................................................................
Governor spring pack repair ................................................................................................................
Installation ............................................................................................................................................
Pulsation damper repair ......................................................................................................................
Removal ................................................................................................................................................
Shutdown valve repair .........................................................................................................................
Throttle shaft repair .............................................................................................................................
Fuel pump calibration ..............................................................................................................................
Cleaning ................................................................................................................................................
Fuel pressure testing and adjustment ...............................................................................................
Fuel pump run-in ..................................................................................................................................
Governor cutoff RPM testing ..............................................................................................................
Governor fuel pressure testing and adjusting ...................................................................................
Governor weight setting checking and adjusting .............................................................................
Idle speed testing and adjusting ........................................................................................................
Mounting pump to test stand ..............................................................................................................
Pump main pressure testing and adjusting.. .....................................................................................
Pump seal testing ................................................................................................................................
Removing pump from test stand ........................................................................................................
Throttle lever travel checking and adjusting ......................................................................................
Throttle testing and adjusting .............................................................................................................
Fuel pump location and description .......................................................................................................
Fuel system
Maintenance .........................................................................................................................................
Repair parts list ....................................................................................................................................
2-289
2-330
2-291
2-291
2-294
2-308
2-322
2-295
2-325
2-328
2-86
2-301
2-41
2-304
2-329
2-333
2-334
2-346
2-338
2-340
2-347
2-348
2-344
2-334
2-346
2-340
2-349
2-345
2-342
1-7
2-289
C-59
G
Gearcase cover .........................................................................................................................................
Assembly ..............................................................................................................................................
Cleaning/inspection .............................................................................................................................
Disassembly .........................................................................................................................................
Installation ............................................................................................................................................
Repair.. ..................................................................................................................................................
Removal ................................................................................................................................................
Gear pump repair, fuel pump ...................................................................................................................
Gears
Inspection .............................................................................................................................................
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-172
2-174
2-172
2-172
2-90
2-174
2-48
2-295
2-5
2-7
Index 5
TM 5-2815-241-34&P
INDEX - CONTINUED
Page
Subject
G - CONTINUED
General
Engine disassembly and assembly ....................................................................................................
Information ...........................................................................................................................................
Maintenance instructions ...................................................................................................................
General use standardized parts, repair parts list.. .................................................................................
Governor plunger repair, fuel pump.. ......................................................................................................
Governor spring pack repair, fuel pump .................................................................................................
2-11
1-1
2-3
C-101
2-325
2-328
H
Housing repair, fuel pump .......................................................................................................................
How to use this manual ...........................................................................................................................
2-322
iv
I
Identification plates, location and description ......................................................................................
Idler pulley.. ...............................................................................................................................................
Assembly ..............................................................................................................................................
Cleaning ................................................................................................................................................
Disassembly.. .......................................................................................................................................
Inspection.. ...........................................................................................................................................
Information, general.. ...............................................................................................................................
Injector spring data.. ................................................................................................................................
Injector
Adjustments .........................................................................................................................................
Timing adjustment.. .............................................................................................................................
Injector valve cutter specifications .........................................................................................................
Inspection
General maintenance ..........................................................................................................................
Upon receipt .........................................................................................................................................
Installation
Accessory drive.. ..................................................................................................................................
Air compressor.. ...................................................................................................................................
Aneroid control valve...........................................................................................................................
Cam follower housing.. ........................................................................................................................
Camshaft ..............................................................................................................................................
Compression release shaft .................................................................................................................
Crankcase access cover......................................................................................................................
Crankshaft ............................................................................................................................................
Crosshead .............................................................................................................................................
Cylinder head .......................................................................................................................................
Cylinder head fuel line .........................................................................................................................
Engine compression brake housing.. .................................................................................................
Engine oil cooler ..................................................................................................................................
Exhaust manifold .................................................................................................................................
Fan hub.. ...............................................................................................................................................
Flywheel housing.. ...............................................................................................................................
Fuel injector..........................................................................................................................................
Index 6
1-8
2-404
2-406
2-405
2-404
2406
1-1
2-363
2-106
2-74
2-204
2-5
2-2
2-84
2-86
2-132
2-70
2-66
2-72
2-126
2-54
2-80
2-68
2-104
2-116
2-127
2-134
2-123
2-98
2-78
TM 5-2815-24-34&P
INDEX - CONTINUED
Page
Subject
I - CONTINUED
Fuel pump.. ...........................................................................................................................................
Gearcase cover .....................................................................................................................................
Intake manifold ....................................................................................................................................
Lubricating oil pump ............................................................................................................................
Oil dipstick tube ...................................................................................................................................
Oil line ...................................................................................................................................................
Oil pan ...................................................................................................................................................
Piston assembly ...................................................................................................................................
Piston cooling nozzle ...........................................................................................................................
Push rod.. ..............................................................................................................................................
Rocker arm cover .................................................................................................................................
Rocker arm housing .............................................................................................................................
Turbocharger ........................................................................................................................................
Turbocharger crossover tube ..............................................................................................................
Water header cover ..............................................................................................................................
Water inlet housing ..............................................................................................................................
Water manifold assembly.. ..................................................................................................................
Water pump ..........................................................................................................................................
Instructions, maintenance .......................................................................................................................
Intake manifold .........................................................................................................................................
Assembly ..............................................................................................................................................
Cleaning/inspection .............................................................................................................................
Disassembly .........................................................................................................................................
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Introduction ..............................................................................................................................................
RPSTL ...................................................................................................................................................
2-86
2-90
2-119
2-88
2-133
2-136
2-96
2-60
2-120
2-73
2-118
2-82
2-136
2-138
2-125
2-124
2-130
2-121
2-1
2-274
2-275
2-274
2-274
2-119
2-26
1-1
C-1
L
Location and description of major components ...................................................................................
Location, cylinder head pipe plug.. .........................................................................................................
Lubricating oil filter ..................................................................................................................................
Lubricating oil pump.. ..............................................................................................................................
Assembly ..............................................................................................................................................
Cleaning ................................................................................................................................................
Disassembly.. .......................................................................................................................................
Inspection/repair ..................................................................................................................................
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Lubricating oil pump, location and description .....................................................................................
1-4
2-208
2-264
2-264
2-270
2-266
2-265
2-267
2-88
2-40
1-6
M
Maintenance
Accessory drive ....................................................................................................................................
Camshaft and timing system.. ............................................................................................................
Cooling system ....................................................................................................................................
2-276
2-238
2-404
Index 7
TM 5-2815-241-34&P
INDEX - CONTINUED
Page
Subject
M - CONTINUED
Maintenance - Continued
Crankcase and cylinder block.. ...........................................................................................................
Crankshaft ............................................................................................................................................
Cylinder head .......................................................................................................................................
Engine compression brake.. ................................................................................................................
Engine lubrication system.. .................................................................................................................
Fuel system ..........................................................................................................................................
Manifold.. ..............................................................................................................................................
Piston and connecting rod ..................................................................................................................
Maintenance forms and records .............................................................................................................
Maintenance instructions.. ......................................................................................................................
General.. ................................................................................................................................................
Major components, location and description of.. ..................................................................................
Manifold maintenance.. ...........................................................................................................................
Manual
How to use.. ..........................................................................................................................................
Type of ..................................................................................................................................................
Model number, equipment.. .....................................................................................................................
Mounting bracket, front engine, location and description ...................................................................
2-140
2-214
2-176
2-282
2-264
2-289
2-272
2-220
1-1
2-1
2-3
1-4
2-272
iv
1-1
1-1
1-7
N
Name, equipment.. ...................................................................................................................................
National stock number and part number index.. ...................................................................................
1-1
C-103
O
Oil cooler and filter, location and description .......................................................................................
Oil dipstick tube
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Oil line
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Oil pan .......................................................................................................................................................
Cleaning/inspection.. ...........................................................................................................................
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Oil passages, cleaning .............................................................................................................................
Oil seals
Cleaning.. ..............................................................................................................................................
Inspection.. ...........................................................................................................................................
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . ..
Index 8
1-5
2-133
2-16
2-136
2-12
2-174
2-175
2-96
2-44
2-4
2-4
2-6
2-7
TM 5-2815-241-34&P
INDEX - CONTINUED
Page
Subject
P
Pipe plug, cylinder head, location.. .........................................................................................................
Piston and connecting rod ......................................................................................................................
Assembly ..............................................................................................................................................
Cleaning/inspection.. ...........................................................................................................................
Disassembly .........................................................................................................................................
Repair ....................................................................................................................................................
Piston assembly
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Piston cooling nozzle
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Preliminary starting procedures ..............................................................................................................
Preparation for storage and shipment ....................................................................................................
Pulsation damper repair, fuel pump .......................................................................................................
Purpose of equipment ..............................................................................................................................
Push rod
Installation ............................................................................................................................................
Removal ................................................................................................................................................
2-208
2-220
2-235
2-222
2-220
2-231
2-60
2-52
2-120
2-24
2-9
1-1
2-301
1-1
2-73
2-33
R
Receipt, service upon ...............................................................................................................................
References ................................................................................................................................................
Removal
Accessory drive ....................................................................................................................................
Air compressor .....................................................................................................................................
Aneroid control valve.. .........................................................................................................................
Cam follower housing ..........................................................................................................................
Compression release shaft .................................................................................................................
Crankcase access cover ......................................................................................................................
Crankshaft ............................................................................................................................................
Crosshead .............................................................................................................................................
Cylinder head .......................................................................................................................................
Cylinder head fuel line.. .......................................................................................................................
Engine compression brake housing.. .................................................................................................
Engine oil cooler.. ................................................................................................................................
Exhaust manifold.. ...............................................................................................................................
Fan hub.. ...............................................................................................................................................
Flywheel housing.. ...............................................................................................................................
Fuel injector..........................................................................................................................................
Fuel pump.. ...........................................................................................................................................
Gearcase cover .....................................................................................................................................
Intake manifold ....................................................................................................................................
Lubricating oil pump ............................................................................................................................
Oil dipstick tube.. .................................................................................................................................
Oil line ...................................................................................................................................................
Oil pan ...................................................................................................................................................
2-1
A-1
2-43
2-41
2-25
2-47
2-39
2-17
2-49
2-31
2-36
2-29
2-28
2-20
2-14
2-35
2-46
2-34
2-41
2-48
2-26
2-40
2-16
2-12
2-44
Index 9
TM 5-2815-241-34&P
INDEX - CONTINUED
Page
Subject
R - CONTINUED
Removal - Continued
Piston assembly ...................................................................................................................................
Piston cooling nozzle.. .........................................................................................................................
Push rod.. ..............................................................................................................................................
Rocker arm cover.. ...............................................................................................................................
Rocker arm housing.. ...........................................................................................................................
Turbocharger and oil line ....................................................................................................................
Water header cover.. ............................................................................................................................
Water inlet housing.. ............................................................................................................................
Water manifold assembly.. ..................................................................................................................
Water pump ..........................................................................................................................................
Repair, general maintenance ..................................................................................................................
Repair parts and special tools list (RPSTL). ...........................................................................................
Repair parts list
Body chassis and accessory items.. ..................................................................................................
Cooling system ....................................................................................................................................
Engine.. .................................................................................................................................................
Fuel system ..........................................................................................................................................
General use standardized parts.. ........................................................................................................
Reporting equipment improvement recommendations (EIR) ...............................................................
Reporting errors and recommending improvements.. ...........................................................................
Rocker arm cover
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Rocker arm housing and push rod.. ........................................................................................................
Assembly ..............................................................................................................................................
Cleaning ................................................................................................................................................
Disassembly.. .......................................................................................................................................
Inspection .............................................................................................................................................
Rocker arm housing
Installation.. ..........................................................................................................................................
Location and description ....................................................................................................................
Removal ................................................................................................................................................
Rocker housing cover, location and description.. .................................................................................
2-52
2-24
2-33
2-27
2-30
2-12
2-23
2-22
2-18
2-37
2-6
C-1
C-99
C-89
C-7
C-59
C-101
1-2
i
2-118
2-27
2-242
2-251
2-244
2-242
2-245
2-82
1-5
2-30
1-4
S
Scope
General information.. ...........................................................................................................................
General maintenance ..........................................................................................................................
Service upon receipt.. ...............................................................................................................................
Shipment, preparation for.. ......................................................................................................................
Shutdown valve repair, fuel pump.. .........................................................................................................
Specifications
Engine.. .................................................................................................................................................
Injector valve cutter .............................................................................................................................
Valve.. ....................................................................................................................................................
Valve seat insert.. .................................................................................................................................
Starting procedures, preliminary ............................................................................................................
Index 10
1-1
2-3
2-1
1-1
2-304
2-434
2-204
2-206
2-195
2-9
TM 5-2815-241-34&P
INDEX - CONTINUED
Page
Subject
S - CONTINUED
Storage, preparation for ...........................................................................................................................
Studs
Inspection .............................................................................................................................................
Repair ....................................................................................................................................................
Supersedure ..............................................................................................................................................
1-1
2-5
2-7
i
T
Table of contents ......................................................................................................................................
Tagging parts, general maintenance ......................................................................................................
Taping threads, general maintenance.. ..................................................................................................
Testing, upon receipt ...............................................................................................................................
Throttle shaft repair, fuel pump ..............................................................................................................
Tightening sequence, connecting rod nut .............................................................................................
Timing adjustment, injector ....................................................................................................................
Torque limits .............................................................................................................................................
Troubleshooting .......................................................................................................................................
Troubleshooting on engine test stand ....................................................................................................
Turbocharger ............................................................................................................................................
Assembly ..............................................................................................................................................
Cleaning ................................................................................................................................................
Disassembly .........................................................................................................................................
Final inspection ...................................................................................................................................
Inspection.. ...........................................................................................................................................
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Turbocharger crossover tube installation ..............................................................................................
Turbocharger, location and description .................................................................................................
Type of manual .........................................................................................................................................
i
2-8
2-8
2-2
2-329
2-224
2-74
E-1
2-2
2-424
2-384
2-393
2-388
2-385
2-397
2-389
2-136
2-12
2-138
1-5
1-1
U
Unpacking, upon receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
2-2
V
Valve
Adjustments .........................................................................................................................................
Specifications ......................................................................................................................................
Vibration damper.. ....................................................................................................................................
Cleaning/inspection .............................................................................................................................
Valve seat insert specifications ..............................................................................................................
2-106
2-206
2-219
2-219
2-195
Index 11
TM 5-2815-241-34&P
INDEX - CONTINUED
Page
Subject
W
Warnings ...................................................................................................................................................
Water header cover
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Water inlet housing
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Water manifold assembly
Installation.. ..........................................................................................................................................
Removal ................................................................................................................................................
Water manifold, location and description.. ............................................................................................
Water pump ...............................................................................................................................................
Assembly ..............................................................................................................................................
Cleaning.. ..............................................................................................................................................
Disassembly.. .......................................................................................................................................
Inspection .............................................................................................................................................
Installation ............................................................................................................................................
Removal ................................................................................................................................................
Water pump, location and description ...................................................................................................
Index 12
a
2-125
2-23
2-124
2-22
2-130
2-18
1-4
2-408
2-410
2-409
2-408
2-409
2-121
2-37
1-7
By Order of the Secretary of the Army:
JOHN A. WICKHAM, JR.
General, United States Army
Chief of Staff
Official:
R.L. DILWORTH
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-25A (Block 1971) Direct and General Support for
Engine, Diesel NTC 290 for Truck, Dump 20 Ton, 6 x 4, F-5070 (CCE).
*U.S. GOVERNMENT PRINTING OFFICE: 1987 743-822/60127
PIN: 061227-000
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