TM-9-2815-213-34
TM 9-2815-213-34
TECHNICAL MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
(INCLUDING DIRECT SUPPORT, AND GENERAL SUPPORT
REPAIR PARTS LIST AND DEPOT MAINTENANCE ALLOWANCES)
FOR
ENGINE, DIESEL, WITH ACCESSORIES
CUMMINS MODEL V8-300
(2815-910-8217)
This copy is a reprint which includes current pages from Changes 1 and 2.
HEADQUARTERS, DEPARTMENT OF THE ARMY
FEBRUARY 1972
TM 9-2815-213-34
C2
CHANGE
No. 2
}
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, DC, 26 November 1976
Direct Support and General Support Maintenance
Manual (Including Direct Support, and General
Support Repair Parts and Special Tools List
For
ENGINE, DIESEL, WITH ACCESSORIES
CUMMINS MODEL V8-300
(2815-00-910-8217)
Current as of 6 April 1976
TM 9-2815-213-34, 2 February 1972, is changed as follows:
1. Remove old pages and insert new pages as indicated below. New or changed material is indicated by a vertical bar in
the margin of the page. Added or revised illustrations are indicated by a vertical bar next to the identification number.
Remove pages
3-9and3-10
3-31 and 3-32
3-35 and 3-36
3-61 and 3-62
3-67 and 3-68
B-7 through B-18
B-21 through B-24
B-43 and B-44
B-61 and B-62
B-67 through B-87
Insert pages
3-9 and 3-10
3-31 and 3-32
3-35 and 3-36
3-61 and 3-62
3-67 and 3-68
B-7 through B-18
B-21 through B-24
B-43 and B-44
B-61 and B-62
B-77 through B-87
2. File this change sheet in front of the publication for reference purposes.
TM 9-2815-213-34
By Order of the Secretary of the Army:
Official:
BERNARD W. ROGERS
General, United States Army
Chief of Staff
PAUL T. SMITH
Major General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-38, Direct/General Support TM requirements for 10-ton truck tractor,
M123, M123AlC, M123C, M123E2 and Cargo Truck, M125.
TM 9-2815-213-34
C1
CHANGE
No. 1
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, DC, 23 July 1975
}
Direct Support and General Support Maintenance Manual
(Including Direct Support, and General Support
Repair Parts and Special Tools List)
For
ENGINE, DIESEL, WITH ACCESSORIES
CUMMINS MODEL V8-300
(2815-00-910-8217)
Current as of 7 April 1975
TM 9-2815-213-34, 2 February 1972, is changed as follows:
1. Remove old pages and insert new pages as indicated below. New or changed material in the maintenance portion is
indicated by a vertical bar in the margin of the page. Added or revised illustrations are indicated by a vertical bar next to the
identification number.
Remove pages
3-57 and 3-58
3-61 and 3-62
B-1 thru B-38
B-59 and B-60
None
B-77 thru B-89
Insert pages
3-57 and 3-58
3-61 and 3-62
B-1 thru B-27
B-59 and B-60
B-62.1
B-77 thru B-87
2. File this change sheet in front of the publication for reference purposes.
By Order of the Secretary of the Army:
Official:
VERNE L. BOWERS
Major General, United States Army,
The Adjutant General.
FRED C. WEYAND
General, United States Army,
Chief of Staff.
Distribution:
To be distributed in accordance with DA Form 12-38, (qty rqr block No. 92). Direct and General Support maintenance
requirements for Truck, Tractor, 10-Ton, 6x6 M123A/C and M123E2.
TM 9-2815-213-34
TECHNICAL MANUAL
No. 9-2815-21334
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington D.C., 2 February 1972
}
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE MANUAL
(INCLUDING DIRECT SUPPORT AND GENERAL SUPPORT
REPAIR PARTS LIST AND
DEPOT MAINTENANCE ALLOWANCES)
FOR
ENGINE, DIESEL, WITH ACCESSORIES
CUMMINS MODEL V8-300
(2815-910-8217)
Paragraph
CHAPTER
Section
CHAPTER
Section
CHAPTER
Section
1.
I.
II.
2.
I.
II.
III.
3.
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.
XI.
XII.
XIII.
XIV.
XV.
XVI.
XVII.
XVIII.
XIX.
XX.
XXI.
XXII.
XXIII.
XXIV.
XXV.
XXVI.
XXVII.
XXVIII.
INTRODUCTION
General....................................................................................
Description and Data...............................................................
MAINTENANCE INSTRUCTIONS
Repair Parts, Special Tools and Equipment ...........................
General Maintenance ..............................................................
Removal of Engine Components ............................................
REPAIR INSTRUCTIONS
General....................................................................................
Repair of Cylinder Block..........................................................
Repair of Crankshaft ...............................................................
Repair of Connecting Rod and Piston Assembly ....................
Repair of Front Cover..............................................................
Repair of Oil Pump Assembly .................................................
Repair of Camshaft .................................................................
Repair of Crankshaft Adapter..................................................
Repair of Flywheel Housing and Spacer Plate........................
Repair of Oil Pan .....................................................................
Repair of Flywheel...................................................................
Repair of Valve and Injector Tappets......................................
Repair of Cylinder Head ..........................................................
Repair of Fuel Injectors ...........................................................
Repair of Rocker Arm Assembly and Push Rods ...................
Repair of Push Rod Cavity Covers..........................................
Repair of Cylinder Head Covers..............................................
Repair of Air Compressor and Drive Assembly.......................
Repair of Fuel Pump and Fuel Lines.......................................
Repair of Water Crossover Pipe and Lifting Eyes...................
Repair of Air Intake, Preheater Assembly and Intake Manifolds
Repair of Water Pump Assembly ............................................
Repair of Fan Drive Pulley, Vibration Damper and Water Pump
Pulley Assembly
Repair of Thermostat Assembly ..............................................
Repair of Fan, Fan Hub, and Bracket Assembly.....................
Repair of Hydraulic Pump and Mounting Brackets .................
Repair of Alternator Assembly and Mounting Bracket ............
Repair of Starter Assembly .....................................................
*This manual supersedes TM 9-2015-213-34, 13 April 1966 including all changes.
i
Page
1-1
1-4
1-1
1-1
2-1
2-4
2-8
2-1
2-1
2-3
3-1
3-2
3-7
3-13
3-19
3-24
3-30
3-36
3-40
3-46
3-52
3-58
3-64
3-71
3-80
3-86
3-91
3-96
3-102
3-110
3-114
3-120
3-125
3-1
3-1
3-3
3-5
3-8
3-9
3-11
3-12
3-12
1-3
3-13
3-14
3-16
3-23
3-33
3-35
3-35
3-36
3-6
3-52
3-52
3-53
3-2
3-131
3-137
3-143
3-149
3-155
3-54
3-56
3-56
3-56
3-56
*TM 9-2815-213-34
Paragraph
CHAPTER
APPENDIX
Section
Group
Group
Group
Group
Group
Group
Group
Group
Section
Group
Section
3.
XXIX.
XXX.
XXXI.
XXXII.
XXXIII.
A.
B.
I.
II.
01
0100
0101
0102
0103
0104
0105
0106
0108
03
0301
0302
0304
0311
05
0503
0504
0505
06
0601
12
1209
14
1410
33
3301
47
4701
III.
26
2604
2606
IV.
REPAIR INSTRUCTIONS--Continued
Repair of Oil Cooler..............................................................................
3-157
Repair of Exhaust Manifolds ................................................................
3-162
Engine Removal from Engine Rebuild Stand.......................................
3-162
Engine Test and Adjustment ................................................................
3-167
Repair and Rebuild Standards .............................................................
3-174
REFERENCES
REPAIR PARTS AND SPECIAL TOOLS LIST
Introduction........................................................................................... .....................
Repair Parts List................................................................................... .....................
-ENGINE
Engine Assembly.................................................................................. .....................
Block and Cylinder Head...................................................................... .....................
Crankshaft ............................................................................................ .....................
Flywheel Assembly............................................................................... .....................
Piston and Connecting Rod.................................................................. .....................
Valves and Camshaft ........................................................................... .....................
Engine Lubrication System................................................................... .....................
Manifolds .............................................................................................. .....................
-FUEL SYSTEM
Fuel Injector.......................................................................................... .....................
Fuel Pump ............................................................................................ .....................
Air Cleaner ........................................................................................... .....................
Starting Aids ......................................................................................... .....................
-COOLING SYSTEM
Thermostat ........................................................................................... .....................
Water Pump ......................................................................................... .....................
Fan Assembly....................................................................................... .....................
-ELECTRICAL SYSTEM
Generator ............................................................................................. .....................
-BRAKES
Air Compressor and Drive Mechanism ................................................ .....................
-STEERING
Hydraulic Pump Assembly ................................................................... .....................
-SPECIAL PURPOSE KITS
Reusable Shipping Containers............................................................. .....................
-GAGES
Tachometer .......................................................................................... .....................
Special Tools List
-TOOLS AND TEST EQUIPMENT
Special Tools........................................................................................ .....................
Test Equipment .................................................................................... .....................
Index-Federal Stock Number and Reference Number Cross-Reference to Figure
and Item Number ................................................................................. .....................
ii
Page
3-56
3-57
3-57
3-57
3-62
B-1
B-4
B-4
B-5
B-7
B-7
B-8
B-8
B-10
B-13
B-14
B-15
B-20
B-20
B-21
B-22
B-22
B-22
B-23
B-23
B-24
B-24
B-25
B-27
Index-1
*TM 9-2815-213-34
LIST OF ILLUSTRATIONS
Number
Title
Page
Number
Title
Page
1-1.
Model V8-300 ...... Engine Assembly 3/4 Left
3-12.
Piston Ring Gap Check ..................................... 3-7
Front View .................................................
1-2
3-13.
Rod Side Clearance Check ............................... 3-8
1-2.
Model V8-300 Engine Assembly 3/4 Right ...
3-14.
Crankshaft Oil Seal-Removal/Installation .......... 3-9
Rear View ................................................
1-3
3-15.
Front Cover Bore Alinement Check .................. 3-9
1-3.
Engine Assembly Rear Sectional View .........
1-6
3-16.
Front Cover to Block Alinement Check ............. 3-9
2-1.
Exhaust Manifold-Removal/Installation .........
2-4
3-17.
Drive Gear Backlash Check ............................. 3-10
2-2.
Oil Cooler-Removal Installation .....................
2-5
3-18.
Camshaft End Play Check ............................... 3-11
2-3.
Engine Rebuild Stand-Removal/ ...................
3-19.
Crankshaft Gear Backlash Check ..................... 3-11
Installation..................................................
2-5
3-20.
Crankshaft Adapter Tightening Sequence ........ 3-12
2-4.
Fan Hub and Bracket Assembly- ...................
3-21.
Flywheel Housing Concentricity Check ........... 3-13
Removal/Installation .................................
2-5
3-22.
Flywheel Tightening Sequence ......................... 3-14
2-5.
Thermostat Assembly-Removal/ ...................
3-23.
Flywheel Bearing Bore and Wobble Limits
3-14
Installation .................................................
2-6
3-24.
Tappet Assembly Test ...................................... 3-15
2-6.
Drive Pulleys and Vibration Damper- ............
3-25.
Cylinder Head in Holding Fixture ..................... 3-16
Removal/Installation ..................................
2-6
3-26.
Valve Assemblies-Removal/Installation ............ 3-16
2-7.
Water Pump Assembly-Removal ..................
3-27.
Injector Sleeves-Removal/Installation .............. 3-16
Installation .................................................
2-6
3-28.
Crosshead Guide-Removal/Installation ............. 3-16
2-8.
Air Intake Crossover and Preheater ..............
3-29.
Valve Seat Removal Sectional View ................. 3-17
Assembly-Removal/Installation ..................
2-7
3-30.
Injector Sleeve Holder Installation .................... 3-17
2-9.
Intake Manifold, Fuel Pump and Fuel ............
3-31.
Injector Tip Protrusion Measurement ................ 3-17
Lines-Removal/Installation ........................
2-7
3-32.
Valve Head and Collet Check ........................... 3-18
2-10.
Water Crossover Pipe and Lifting Eye ..........
3-33.
Crosshead Guide Check ................................. 3-18
Removal/Installation .................................
2-8
3-34.
Valve Guide Check ........................................... 3-18
2-11.
Oil Dipstick Tube Assembly-Removal/ ..........
3-35.
Valve Spring Test ............................................ 3-18
Installation .................................................
2-8
3-46.
Valve and Injector Counterbore Measure.
2-12.
Cylinder Head Covers-Removal/ ...................
ments ................................................................ 3-19
Installation..................................................
2-9
3-37.
Cylinder Head Regrooving ................................ 3-19
2-13.
Crankcase Breather Tube Removal/ .............
3-38.
Valve Guide Installation .................................... 3-20
Installation..................................................
2-9
3-39.
Crosshead Guide Installation- ........................... 3-20
2-14.
Push Rod Cavity Covers-Removal/ ...............
3-40.
Injector Sleeve Installation ............................... 3-20
Installation..................................................
2-9
3-41.
Injector Sleeve Rolling-Upper Portion ............... 3-21
2-15.
Rocker Arms and Push Rods-Removal/ ........
3-42.
Injector Sleeve Rolling-Lower Portion ............... 3-21
Installation..................................................
2-10
3-43.
Injector Sleeve Seat Cutting.............................. 3-21
2-16.
Injector Clamps Removal/Installation ............
2-10
3-44.
Valve Seat Insert Counterbore ......................... 3-21
2-17.
Fuel Injector and Hold-Down Clamp..............
2-10
3-45.
Intake Valve Port Swirl Plate Installation ........... 3-22
2-18.
Valve Crossheads-Removal/Installation ........
2-11
3-46.
Valve Seat Insert Peering ................................. 3-22
2-19.
Cylinder Head-Removal/,Installation .............
2-11
3-47.
Valve Seat Test.3 .............................................. 3-22
2-20.
Valve and Injector Tappets-Removal/ ...........
3-48.
Cylinder Head Tightening Sequence ................ 3-23
Installation..................................................
2-11
3-49.
Fuel Injector PT (Type C) .................................. 3-24
2-21.
Flywheel-Removal/Installation .......................
2-12
3-50.
Injector Cup-Removal/Installation ..................... 3-24
2-22.
Crankshaft Adapter-Removal/Installation
2-12
3-51.
Injector Link-Removal/Installation ..................... 3-24
2-23.
Flywheel Housing-Removal/Installation .........
2-13
3-52.
Plunger Seat Pattern ........................................ 3-24
2-24.
Camshaft Gear, and Spacer Plate- ...............
3-53.
Fuel Injector-Exploded View.............................. 3-26
Removal/Installation ..................................
2-13
3-54.
Injector Check Ball Seating ............................... 3-26
2-25.
Oil Pan-Removal/Installation .........................
2-13
3-55.
Injector Body 0-Ring Installation ....................... 3-26
2-26.
Oil Pump Assembly-Removal/Installation
2-13
3-56.
Injector Body and Plunger Markings ................. 3-27
2-27.
Front Cover-Removal/Installation ..................
2-14
3-57.
Injector Cup Markings ...................................... 3-27
2-28.
Connecting Rod and Piston Assembly- .........
3-58.
Injector Plunger Seat Test................................. 3-27
Removal/Installation ..................................
2-14
3-59.
Injector Test Stand- ........................................... 3-29
2-29.
Crankshaft and Main Bearings-Removal/ ......
3-60.
Alining Timing Wheel and Pointer ..................... 3-29
Installation..................................................
2-14
3-61.
Hydraulic and Air Valves ................................... 3-29
3-1.
Camshaft Bushing Removal .........................
3-1
3-62.
Air Pressure Adjustment ................................... 3-30
3-2.
Cylinder Sleeve Removal .............................
3-1
3-63.
Master Injector Installation- ............................... 3-30
3-3.
Main Bearing Bore Alinement Check.............
3-2
3-64.
Fuel Inlet Installation ......................................... 3-30
3-4.
Cylinder Sleeve Seals Installation .................
3-2
3-65.
Injector Mounted in Test Stand ......................... 3-30
3-5.
Crankshaft Dimensions .................................
3-4
3-66.
Test Stand Air Pressure Connection ................. 3-31
3-6.
Crankshaft End Clearance Check .................
3-5
3-67.
Load Cell Test ................................................... 3-31
3-7.
Bearing Cap to Block Clearance Check ........
3-5
3-68.
Ball Seat Resurfacing........................................ 3-32
3-8.
Side Bolt Tightening Sequence .....................
3-5
3-69.
Orifice Hole Burnishing Tool Installation ........... 3-33
3-9.
Piston and Ring Assembly ............................
3-6
3-70.
Orifice Plug Burnishing ..................................... 3-33
3-10.
Connecting Rod Check .................................
3-6
3-72.
Injector Push Rod Timing ................................. 3-33
3-11.
Ring Groove Wear Check .............................
3-7
3-72.
Air Compressor Drive Gear Timing Mark .......... 3-37
iii
*TM 9-2815-213-34
LIST OF ILLUSTRATIONS-Continued
Number
Title
3-73. Fuel Pump PT (Type G) .........................
3-74. Mounting Plate and Ball Joint Vise..........
Installation ............................................
3-75. Governor Weights Assembly-Removal/ ..
Installation ............................................
3-76. Governor Shaft Oil Seals-Removal/ ........
Installation ...........................................
3-77. Tachometer Drive Assembly-Removal/...
Installation ............................................
3-78. Plunger Assembly-Removal/Assembly ...
3-79. Fuel Pump Test Stand Equipment ..........
3-80. Fuel Pump Test Stand ............................
3-81. Mounting Pump on Test Stand ...............
3-82. Engaging Stand Drive Shaft ...................
3-83. Pump Preparation for Test and Calibration
3-84. Fuel Pump Nameplate.............................
3-85. Scribing Governor Barrel.........................
3-86. Reaming Mainshaft Bushing ...................
3-87. Throttle Shaft 0-ring Installation .............
3-88. Throttle Assembly Installation ................
3-89. Thrust Washer-Drive Plunger Governor..
Clearance ............................................
3-90. Main Throttle Shaft Shim Check ............
3-91. Weep Hole Leakage................................
3-92. Governor Spring Shimming ....................
3-93. Throttle Stop Screw Adjust......................
3-94. Idle Speed Setting ..................................
3-95. Valve Timing Marks.................................
3-96. Engine Firing Order .................................
3-97. Crosshead Adjustments ..........................
3-98. Engine Blow-By Check ...........................
3-99. Manifold Fuel Pressure Check ...............
3-100. Fuel Flow Rate Check ............................
3-101. Performance Curve .................................
3-102. Cylinder Block-Points of Measurement ...
3-103. Crankshaft and Bearings Points of..........
Measurement ......................................
3-104. Connecting Rod-Points of Measurement
3-105. Piston-Points of Measurement ...............
3-106. Cylinder Sleeve-Points of Measurement .
3-107. Camshaft and Bearings-Points of ...........
Measurement ......................................
Page
3-38
Number
Title
Page
3-108. Gear Train-Points of Measurement ..........
3-109. Oil Pressure Regulator and Oil PumpPoint of Measurement ...............................
3-110. Cylinder Head-Points of Measurement .....
3-111. Tappets and Push Rod/Points of
Measurement .............................................
3-112. Rocker Arms and Shaft-Points of
Measurement ............................................
3-113. Water Pump-Points of Measurement ........
3-114. Assembly Data-Points of Measurement.....
B-1.
Engine and Container Assembly................
B-2.
Cylinder Block and Head Assembly ..........
B-3.
Crankshaft Main Bearing and Drive Pulley
B-4.
Flywheel Assembly.....................................
B-5.
Connecting Rod, Piston and Rings ...........
B-6.
Cylinder Head, Valves, Rocker Arms and
Covers........................................................
B-7.
Front Cover and Camshaft.........................
B-8.
Engine Lubrication System (crankcase
breather).....................................................
B-9.
Engine Lubrication System (oil pan) ..........
B-10. Engine Lubrication System (pump) ...........
B-11. Engine Lubrication System (oil cooler) ......
B-12. Manifold intake and Exhaust......................
B-13. Fuel Injector ...............................................
B-14. Fuel Pump Assembly .................................
B-15. Fuel Pump Housing (exploded) .................
B-16. Fuel Pump Gear and Damper Assembly ...
B-17. Fuel Shut-off and Solenoid Valve and
Governor Spring Pack Assembly ..............
B-18. Governor Assembly (main shaft cover) .....
B-19. Air Intake Components .............................
B-20. Glow Plug and Heater Accessories ...........
B-21. Thermostat and Crossover Tube ...............
B-22. Water Pump ..............................................
B-23. Fan, Hub, and Bracket ...............................
B-24. Generator ...................................................
B-25. Air Compressor and Drive Mechanism ......
B-26. Power Steering Pump ................................
B-27. Tachometer Drive ......................................
B-28. Special Tools...................................... B-66
B-29. Test Equipment.................................. B-75
3-39
3-39
3-39
3-39
3-40
3-42
3-43
3-44
3-45
3-46
3-46
3-47
3-47
3-47
3-47
3-48
3-49
3-49
3-50
3-50
3-51
3-58
3-59
3-59
3-63
3-63
3-63
3-64
3-65
3-65
3-66
3-66
3-67
3-67
3-67
3-39
3-69
3-69
3-70
3-71
3-72
B-39
B-40
B-41
B-42
B-43
B-44
B-45
B-46
B-47
B-48
B-49
B-50
B-51
B-52
B-53
B-54
B-55
B-56
B-57
B-58
B-59
B-60
B-61
B-62
B-63
B-64
B-65
B-74
B-76
LIST OF CHARTS
Number
Title
Page
3-1.
Injection Timing ......................................... 3-33
Number
Title
Page
3-2.
Fuel Pump Troubleshooting................... 3-51
iv
*TM 9-2815-213-34
CHAPTER 1
INTRODUCTION
Section I. General
1-1. Scope
1-2.
Forms and Records
a. This technical manual contains instruction for
Maintenance forms, records, and reports which are to be
used by maintenance personnel at all maintenance
direct and general support maintenance of the Cummins
levels are listed in and prescribed by TM 38-750.
Diesel Engine, Model V8-300, (fig. 1-1 and 1-2). It
contains descriptions of, and procedures for,
1-3.
Reporting of Equipment Publication
disassembly, inspection, repair, rebuild, and assembly of
Improvement
the engine.
The
reporting
of
errors,
omissions,
and
b. Appendix A contains a list of current refer ences,
recommendations for improving this publication by the
including supply manuals, forms, technical manuals, and
individual user is encouraged. Reports should be
other available publications applicable to the engine.
submitted on DA Form 2028, Recommended Changes to
c. Appendix B lists repair parts, special tools, and
Publications, and forwarded direct to the Commanding
test equipment required for the performance of direct
General, U.S. Army Tank-Automotive Command
and general support maintenance of the engine.
Attention: ASMTA-4, Warren, MI 48090.
Section II. Description and Data
gases from the cylinders. Proper engine operation
1-4. Description
depends upon the high compression of the intake air and
a. General.
the timed injection of the correct measure of diesel fuel
(1) In this manual the following terms will be used to
into the cylinder.
identify the location for engine parts and assemblies:
b. Engine Assembly. The model V8-300 engine
(a) Front-fan end of engine.
(fig. 1-1 and 1-2) is a diesel eight cylinder V-type, valve in
(b) Rear-flywheel end of engine.
head, water cooled, compression ignition engine. The
(c) Right and Left-are identified as viewed from
engine is rated 300 horsepower at 3000 rpm and will
the rear.
operate on diesel fuel.
(2) The model V8-300 diesel engine is as eight
c. Engine Systems.
cylinder,
V-type,
Valve-in-head,
water
cooled,
(1) Fuel System. The system consists of a filter, fuel
compression-ignition engine, using the four stroke cycle
pump with governor, fuel passages, and injectors (one
principle of operation. The four strokes consist of intake,
for each cylinder). The system is designed so that the
compression, power and exhaust. Intake and exhaust
volume of liquid flow is proportionate to the fluid
valves, and fuel injectors, are operated from a single
pressure, the time allowed to flow, and the size of the
camshaft. The intake stroke of the cycle brings filtered,
orifice fuel flows through. The pump draws fuel from the
heated air to the cylinders. The compression stroke
vehicle supply tank and delivers it to each injector. A
compresses the air (17:1 compression ratio) to 500-600
governor controls the flow of fuel from the gear pump, as
p.s.i, and raises the cylinder temperature to
well as the idle and maximum engine speed.
approximately 1000 degrees Fahrenheit. During the top
(2) Lubrication System. All working parts of the
of the compression stroke and start of the power stroke,
engine are pressure lubricated. Oil is supplied by a duala metered charge of diesel fuel is injected into the
type gear driven lubricating pump located below the
cylinders. The high temperature within the cylinders
crankshaft and driven by the crankshaft gear. On
ignites the diesel fuel resulting in the power stroke. The
completion of the lubrication cycle, oil is accumulated in
fourth stroke of the cycle exhausts the burned
the oil pan sump by gravity and is drawn from this sump
by the oil
1-1
*TM 9-2815-213-34
Figure 1-1. Model V8-300 engine assembly--3/4 left front view.
pump. Oil is delivered to all working parts of the engine
through drillings in the block, cylinder head, crankshaft,
and rocker levers. Lubricating oil is forced through the
crankshaft to lubricate the main and connecting rod
bearings. Lubricating oil pressure is controlled by a
regulator which is an integral part of the oil pump
assembly. The air compressor receives pressure
lubrication from the engine oil supply. The oil flow cycle
is as follows.
(a) Oil is drawn to oil pump through suction tube, in
oil pan. It is then pumped through a passage in rear of
block through right bank water header cover to front of
the block.
(b) The oil flow crosses in front of block to left bank
through oil filter and into cooler. From cooler, oil flows to
left bank oil drilling at rear of engine. The oil pump bypass dumps oil directly into pan.
(c) From left bank oil drilling, at rear of engine, oil
flows to no. 4 cam bushing and no. 4 main bearing which
in turn supplies no. 3 and 7 connecting rods.
(d) Right bank rocker arms are oiled intermittently
through no. 5 cam bushing.
(e) From left bank oil drilling, oil flows to left bank
tappets, to no. 2 and 3 cam bushings, and no. 2 and 3
main bearings. No. 3 main bear-
1-2
*TM 9-2815-213-34
Figure 1-2. Model V8-300 engine assembly--3/4 right rear view.
ing supplies oil to no. 2 and 6 connecting rods.
(f) Oil flows through a crossover at front of
block to supply no. 1 cam bushing and no. 1 main
bearing. No. 1 main bearing supplies oil to no. 1 and no.
5 connecting rods.
(g) The left bank rocker arms are oiled
intermittently through no. 1 cam bushing.
(h) Right bank tappets are oiled from drilling at
rear of engine.
(i) Oil flows through a drilling in the air
compressor gear case to the rear of the case, through a
drilling in the compressor support
cover up to the bushing in support cover.
(3) Cooling System. The coolant is circulated by a
centrifugal type water pump mounted on the front of the
engine and is belt driven by the crankshaft pulley. The
water circulates around the cylinder sleeves, through the
cylinder heads, and around the injector sleeves. The
injectors are seated in copper injector sleeves for quick
dissipation of heat. Outlet castings at the front of the
heads are connected to the thermostat housing. The
thermostat maintains engine operating temperature
between 173 degrees and 186
1-3
*TM 9-2815-213-34
degrees. Coolant flows from the thermostat housing to
the expansion tank in the radiator.
(4) Air Intake System. The V8-300 diesel engine is a
naturally aspirated engine. The air flows from the air
cleaner through connections into the air intake manifold
and is drawn into the combustion chamber.
(5) Ventilation System. Ventilation for the removal of
water and fuel vapor from the engine is accomplished by
the crankcase breather system. The combination
breather and pressurizing valve is located on the left
hand valve cover. During normal operation with valve in
the open position, crankcase ventilation is atmospheric.
For the deep water fording operation, valve is closed
manually to pressurize the engine crankcase.
d. Engine External Components.
(1) Oil filler assembly and oil level gage. The oil filler
cap is mounted on top of the left hand cylinder head
cover. The oil level gage is mounted on the front left of
the engine oil pan.
(2) Sending units. A sending unit mounted on the
engine oil cooler transmits engine oil pressure to the oil
pressure gage on the vehicle instrument panel. A
sending unit mounted to the thermostat housing
transmits the coolant temperature to the water
temperature gage on the vehicle instrument panel.
(3) Water pump with pulley assembly. The impeller
type water pump with pulley assembly, mounted on the
front of the cylinder head, is driven from the crankshaft
pulley assembly by one fan belt. The pump circulates
water from the bottom of the radiator through the engine
cooling system. The coolant fan is of the pull-type and
mounted to the idler pulley which is driven by the
crankshaft pulley.
(4) Water temperature thermostat. The water
thermostat is installed in a housing on the front of the
right cylinder head. Water leaving this housing goes to
the radiator expansion tank. The thermostat operates
from 173 degrees to 186 degrees Fahrenheit. A
thermostat by-pass line allows a limited circulation of
coolant when the thermostat is closed.
(5) Exhaust manifolds. The exhaust manifolds
installed on the right and left side of the engine, collect
exhaust gases from the eight cylinders and route it to two
exhaust pipe and muffler combinations located on each
side of the vehicle.
(6) Intake Manifold Heater. To aid in starting the
engine when the ambient temperature is 10 degrees
Fahrenheit or below, an intake air preheater is used. The
preheater equipment con-
sists of a hand-priming pump which pumps fuel into the
intake manifold, a glow plug which is electrically heated
by the battery, and a switch to turn on the glow plug while
fuel is pumped into the intake manifold. The fuel burns in
the intake manifold and heats the air.
NOTE
Refer to the, appropriate technical
manuals listed in Appendix A for a detailed description of the engine starter
and alternator.
e. Engine Internal Components (fig. 13).
(1) Cylinder block with bearing cap assemblies. The
cylinder block with bearing cap assemblies which serve
as a crankcase, is a cast iron alloy. Wet-type cylinder
sleeves are installed in the cylinder block. Lubricating oil
passage ways extend the full length of the block and
supply oil to cylinder heads, crankshaft, and rocker
levels.
(2) Oil pan. The engine oil pan is cast aluminum and
contains a deep sump for 60% angularity operation. A
scavenge intake oil line attached to the double acting oil
pump (located at the flywheel end of the oil pan) extends
into the front sump, providing an intake for supplying the
necessary oil for lubrication.
(3) Crankshaft. The crankshaft, is a steel forging
with four integrally forged counterweights, five main
bearing journals, and four connecting rod bearing
journals. The crank throws are forged in two planes 180
degrees apart, with two throws in each plane. Cylinder
block oil drain passages provide lubrication to the
crankcase main bearing. Holes drilled diagonally through
the crankshaft and connecting rod bearing journals
provide direct passages for pressure lubrication of
connecting rod bearings. The crankshaft is statically and
dynamically balanced.
(4) Crankshaft bearings and crankshaft thrust
bearings. The five bearings supporting the crankshaft
are steel-backed, copper-lead, insert type, split on the
diameter so that each bearing half is interchangeable. A
small tang at the joint positions the bearings in the
cylinder block and bearing caps. Holes in the bearings
are alined with the oil passages in the cylinder block.
Grooves in the bearing surfaces aline with the drilled
holes in the crankshaft bearing journals to provide a
route for oil flow to connecting rod journals. Four
crankshaft thrust half-rings (bearings) are mounted on
both sides of the rear main
1-4
*TM 9-2815-213-34
bearing cap to absorb crankshaft thrust loads. Dowel
pins are used to position each dowel pin half-ring.
(5) Crankshaft gear. A crankshaft gear is keyed to
the rear end of the crankshaft driving the gear train for
the camshaft and air compressor.
(6) Vibration damper. A vibration damper is
mounted to the forward end of the crankshaft to dampen
crankshaft vibrations. The unit consists of a rubber
damper hub and inertia member, both of which have
alinement marks and are matched when assembled. The
unit is further matched with alinement marks when
installed on the crankshaft to aid in dynamic balance.
(7) Connecting rod with piston pin bushing. The
connecting rod assemblies are two piece, I-beam, steelforgings split at the crankshaft end. Two piston pin
bushings are press fit into the rod at the piston end for
the floating-type piston pin. The pin is held in the piston
by two retaining rings.
rod bearings. Connecting rod
(8) Connecting
bearings are steel backed, copper-lead, insert type, split
on the diameter. They are interchangeable and are
installed without reaming, scraping, or use of shims.
(9) Pistons. Aluminum alloy pistons are "barrel
ground", which provides a greater diameter at the thrust
surface than at the piston pin bosses. Pistons have three
piston rings (two compression and one oil). Compression
rings are located in the bottom groove. All rings are
located above the piston pin boss.
(10)Camshaft. A single camshaft positioned in the Vsection of the cylinder block directly above the
crankshaft, controls all valve and injector operations for
both banks. It is supported by five camshaft bushings
installed in the cylinder block. A camshaft thrust bearing
is installed at the gear (rear) end of the camshaft to
absorb thrust loads. Drilled oil passages in the cylinder
block lubricate the five camshaft bearings. The camshaft
gear is pressed and keyed to the rear of the camshaft
and is meshed (marked "O") with the crankshaft gear.
The camshaft is driven at one-half crankshaft speed.
The camshaft gear is meshed with the fuel pump and air
compressor drive gear at the upper rear portion of the
engine. The camshaft has twenty-four cams, eight
operate exhaust valves, eight operate intake valves, and
eight operate fuel injectors.
(11)Cylinder head. Two cylinder heads (one each
bank) are attached to the cylinder
block with 16 hold-down capscrews. Injectors and valves
are mounted in the cylinder head. Rocker levers and
bearing assemblies are located on top of each head on
pedestals.
(12)Valves, valve springs, valve rocker levers,
bearings, and fuel injectors.
(a) There are dual intake and exhaust valves
for each cylinder. Sixteen valve rocker levers with
bearing assemblies are mounted on the rocker lever
shafts. A cross-head moves two valves in unison from
pressure excited by the rocker lever. Right and left
movement comes from a push tube connected to the
cam followers. The cam followers ride on the lobe of the
camshaft. The valves and their companion crossheads
operate in replaceable guides. Valve springs are secured
to valve stems by valve spring retainers and locks.
Rocker lever shafts are supported by four rocker lever
brackets mounted on the cylinder heads.
(b) Eight injector rocker levers and bearing
assemblies are mounted on the rocker arm shaft along
with the valve rocker assemblies. The injector is actuated
by the same method used to actuate the valve.
(13)Flywheel with Ring Gear Assembly. The flywheel
with ring gear assembly consists of a cast iron flywheel
with a replaceable steel ring gear. The flywheel is
attached to the rear of the crankshaft by means of a
crankshaft adapter using eight capscrews. The ring gear
meshes with the starter gear during the cranking
operation.
(14)Oil Pump Assembly. The oil pump installed
within the oil pan is of the positive placement gear type in
mesh with a gear train. Oil is drawn from the oil pan
sump through the oil pump inlet pipes (both suction and
scavenger lines) to the pump inlet ports. Oil is pumped
from the pressure pump under pressure through the
discharge port into various drillings in the block, cylinder
head, crankshaft, and rocker levers lubricating the
engine. The scavenger evacuates oil from the rear of the
oil pan and returns it to the main sump when the vehicle
is operating on steep grades. Oil pressure is maintained
by a regulator installed in the oil pressure pump.
1-5.
Tabulated Data
Refer to TM 9-2320-206-20 for tabulated data pertaining
to general characteristics and performance of the engine
assembly.
a. General.
Manufacturer Cummins Engine Company, Inc.
1-5
*TM 9-2815-213-34
Figure 1-3. Engine assembly--rear sectional view.
Model................................
Ordinance number............
Type..................................
..........................................
..........................................
Weight (dry) ......................
Number of cylinders .........
Type of cylinders ..............
..........................................
Bore and stroke (inches) ..
Displacement....................
Maximum gross brake
horsepower.......................
Compression ratio ............
Number of pistons ............
V8300
10946107
Four cycle diesel valvein-head V-type compression ignition
2,250 lb
8
Wet type replaceable
sleeve
5 1/2X4 1/8
785 cu in
Number of rings per piston3 (2 compression, 1 oil)
Crankshaft type ....................... counterweight
Number of counterweight ........ 4
Firing order.............................. 1-5-4-8-6-3-7-2
Normal oil pressure ................. 30 to 45 psi
Normal oil temperature:
(degrees Fahrenheit)............... 180 to 250
Normal water temperature:
(degrees Fahrenheit)............... 165 to 195
b. Valves.
Number of valves:
Intake ...................................... 16
Exhaust ................................... 16
Type of valves ......................... Poppet
300 at 3000 rpm
17:1
8
1-6
*TM 9-2815-213-34
Type of Guides ...................
Timing:
Injector (discharge).............
Intake valve (closed) ..........
Exhaust valve (closed) .......
the engine block
Valve lash adjustment (hot):
Intake..................................
Exhaust...............................
c. Oil Pump Assembly.
Manufacturer ......................
pany, Inc.
Type....................................
tion
Driven by ............................
Capacity..............................
(approx.)
d. Water Pump with Pulley Assembly.
Manufacturer ...................... Cummins Engine Company, Inc.
Type ................................... centrifugal w/split pulley
Driven by ............................ single belt
Capacity ............................. 80 gpm at 3000 rpm
(approx.)
e. Crankcase Breather and Oil Filler
Assemblies.
Manufacturer ...................... Cummins Engine Company, Inc.
f. Oil Filter Assembly (Full Flow).
Manufacturer ...................... Cummins Engine Company, Inc.
Type ................................... Replaceable element
Removable
No. 1 V-S on vibration
damper timing mark
matched to arrow on
0.014 inch
0.027 inch
Cummins Engine Comgear-type double lubricacrankshaft
25 gpm at 3000 rpm
1-7
*TM 9-2815-213-34
CHAPTER 2
MAINTENANCE INSTRUCTIONS
Section I. Repair Parts, Special Tools, and Equipment
functions described in Chapter 3 are listed in Appendix
2-1. Tools and Equipment
B.
Tools, equipment, and repair parts authorized for the
Cummins Model V8-300 diesel engine are listed in
2-3. Maintenance Repair Parts
Appendix B.
Repair parts are listed in the repair parts and special
2-2. Special Tools and Equipment
tools listed in Appendix B.
Special tools and equipment required to perform
Section II. General Maintenance
(2) Wash passages by flushing with dry-cleaning
2-4. Scope
solvent or mineral spirits paint thinner.
This section contains general maintenance instructions
(3) Dry passages by blowing them out with dry,
for cleaning, inspection, repair, and assembly of the
compressed air.
engine. Instructions which apply only to specific
d. Oil Seals, Electric Cables, and Flexible Hoses.
subassemblies or components are provided in the
Clean seals, cables, and flexible hoses with soap and
subsequent sections in which those items are covered
water.
individually.
CAUTION
2-5. Cleaning
Do not allow dry-cleaning solvent or
a. General. The following procedures shall be
mineral spirits paint thinner to be in
applied in all maintenance work:
contact with seals, cables, and flexible
(1) Clean all parts before inspection, after repair,
hoses. These cleaners cause leather,
and before assembly.
rubber, and synthetic materials to dry
(2) After cleaning, cover all parts or wrap them in a
out, rot, and lose pliability, making them
suitable covering as protection against dust and dirt.
unserviceable.
b. Castings
e. Ball Bearings. Refer to TM 9-214 for information
(1) Clean the inner and outer surfaces of castings
on care and maintenance of bearings.
and all areas subject to oil and grease with a dry2-6. Inspection
cleaning solvent or mineral spirits paint thinner.
a. Castings.
(2) Remove sludge and gum deposits from castings
using stiff brush.
(1) Inspect all ferrous (cast iron, steel, etc.) castings
for cracks with magna-flux equipment. Inspect all nonWARNING
ferrous (aluminum) castings for cracks using a
Particles blown by compressed air
magnifying glass and a strong light. Carefully check
arehazardous. Make certain the air
areas adjacent to studs, pipe plugs and threaded inserts,
stream is directed away from the user
also check sharp corners and fillets.
and any other persons in the area.
(2) Inspect machined surfaces of castings for nicks,
(3) Blow out all tapped holes with compressed air
burrs, or raised metal, and mark damaged areas for
and dry castings, after cleaning with compressed air.
repair.
c. Oil passages. All oil passages must be clean
(3) Check all mating flanges on housings and
and free of obstructions.
supports with straight edge or surface plate for warpage.
(1) Clean passages with wire or probes to break up
Inspect mating flanges for discoloration which may
any sludge or gum deposits.
indicate persistent oil leakage.
(4) Inspect all pipe plug and cap screw tapped
openings for damaged or stripped threads.
2-1
*TM 9-2815-213-34
(2) Replace all castings which do not conform to
tolerances specific, repair and rebuild standards in
paragraph 3-174
(3) Repair minor damage to machined surfaces with
a fine mill file or crocus cloth dipped in dry-cleaning
solvent or mineral spirits paint thinner. Replace all
castings on which machined surfaces are burred or
nicked to the point of impairing subsequent assembly or
operation.
(4) Repair minor warpage of mounting flanges and
gasket surfaces by working surface across a sheet of
crocus cloth held tightly on a surface plate or similar flat
surface. Replace castings having flanges which are
warped to the point of impairing assembly or operation.
(5) Repair damaged pipe or cap screw threads in
tapped holes with a tap, or repair threaded opening by
installing a threaded insert.
NOTE
Pipe plug threads in castings must be in
good condition to prevent oil and water
leakage.
b. Ball Bearings.
(1) Replace all galled, pitted, or damaged ball bearings.
(2) Replace all ball bearings which do not conform to
tolerances specified in the repair and rebuild standards
in paragraph 3-174.
c. Studs. Replace all bent or loose studs, or studs
showing evidence of stretching. Repair minor thread
damage with a thread chaser. Replace all studs having
stripped or several damaged threads. Remove and
replace studs as outlined in (1) and (2) below.
CAUTION
Avoid damage to casting while using
welding equipment. Refer to TM 9-237
for welding instructions.
(1) Removal. Using stud extractor, back studs out slowly
to avoid heating and possible seizure. When studs are
broken off too short to use stud extractor, drill stud and
extract with a suitable remover. Short studs may also be
removed by welding a piece of bar stock or a nut to stud
and removing it with a wrench.
(2) Replacement. Only standard studs are supplied for
replacement in steel or iron castings. Unless threads in
castings are damaged beyond repair, use standard
studs. If threaded openings are damaged and retapping
will not clean up the threads, drill the tap opening in
castings and install a suitable threaded insert.
(5) Check all castings for conformance to applicable
repair and rebuild standards in paragraph 3-174.
b. Ball Bearings. Refer to TM 9-214 for inspection
of ball bearings. Check all bearings for conformance to
the applicable repair and rebuild standards in paragraph
3-174.
c. Studs. Inspect all studs for stripped or damaged
threads, bent or loose condition and for evidence of
stretching.
d. Gears.
NOTE
There are no established wear limits on
gear teeth. Good judgement is required
to determine need for replacement.
(1) Inspect gears for cracks using magnaflux
equipment. When magnaflux equipment is not available,
use magnifying glass and strong light.
(2) Inspect all gear teeth for wear, sharp fins, burrs,
and galled or pitted surfaces.
(3) Check all gears for conformance to applicable
repair and rebuild standards.
e. Bushings and Bushing-type Bearings.
(1) Check all bushings and bushing-type bearings
for secure fit in their respective casting or mating part
and for evidence of heating which may be indicated by
discoloration of bushing or bearing surface.
(2) Inspect bushings and bushing-type bearings for
wear, burrs, nicks, or out-of-round condition.
(3) Check for dirt in lubricating holes or grooves of
bushings or bushing-type bearings. Holes and grooves
must be clean and free from damage to insure proper
lubrication.
(4) Check all bushings and bushing-type bearings
for conformance to applicable repair and rebuild
standards in paragraph 3-174.
f. Oil Seals. Metal encased oil seals should be
replaced unless inspection indicates the seal is not
damaged.
(1) Inspect feather edge of oil seal for damage.
(2) Check seal for loss of pliability and resiliency.
g. Core Hole Expansion Plugs. Inspect core hole
expansion plugs for evidence of leakage. Replace plugs
if there is evidence of leaking or damage.
2-7.
Repair
a. Castings.
(1) Replace all cracked castings.
2-2
*TM 9-2815-213-34
NOTE
Special application studs have a nylok
insert for sealing the threaded opening.
The nylok insert end of the stud is inserted in the casting.
(3) Oversize studs. Only 0.003-inch oversize studs
are furnished for field replacement of studs in aluminum
castings. If a standard stud requires replacement, install
a 0.003-inch oversize stud. For identification purposes,
0.003-inch oversize studs are dipped in red dye.
NOTE
Studs may have a coarse thread on one
end and a fine thread on the other end.
The coarse thread end must enter the
aluminum casting. Studs having coarse
threads on both ends are used in
particular applications and normally the
short threaded end is in the casting.
Special application studs have a nylok
insert for sealing threads of studs. The
nylok insert end of stud is inserted in
casting. Marking on coarse thread end
of stud determines when stud is
standard or oversize. All replacement
studs have a special coating and must
have a small amount of mica-base antiseize compound applied on threads
before the stud is installed in casting.
Install replacement stud into opening
slowly to prevent overheating.
d. Gears.
(1) Replace all cracked gears.
(2) Replace all gears which do not conform to
tolerances specified in repair and rebuilt standards,
paragraph 3-174.
(3) Replace gears having worn, pitted, or galled
teeth. Remove sharp fins and burs from
gear teeth with a crocus cloth dipped in dry. cleaning
solvent or mineral spirits paint thinner.
e. Bushings and Bushing-type Bearings. When
bushings and bushing-type bearings are damaged or
worn beyond the limits specified in paragraph 3-174,
generally the mating parts with which they are used must
also be replaced. Reference to (1) and (2) below will be
made in the rebuild section for the particular part when
replacement of bushings and bushing-type bearings is
required.
(1) Removal. Remove bushings or bushing-type
bearings by pressing out part with suitable arbor press or
with the special tools provided.
(2) Installation. Clean repaired parts thoroughly
before assembly or installation. Aline bushing or bushingtype bearing in casting or retaining cage and press into
place with a suitable arbor press or with the special tools
provided.
(3) Reaming. The bushing-type bearings in oil pump
must be finish reamed after installation to size specified
in repair and rebuild standards. All other bushing-type
bearings are machined for proper clearance and do not
need reaming.
f. Oil Seals. Oil seals must be replaced when thin
feather edge is damaged or when seal material has
become hard or brittle.
(1) Removal. Press or pry damaged oil seal from
casting or housing, being careful not to damage bore in
casting or housing.
(2) Repair. When oil seal bore in casting is burred or
damaged to a point where an oil-tight seal is impossible,
replace casting. Remove slight nicks, burs, and
scratches from bore in casting with crocus cloth dipped
in dry-cleaning solvent or mineral spirits paint thinner.
(3) Installation. Install new oil seal in bore of casting
or adapter, using a suitable oil seal replacer tool.
Section III. Removal of Engine Components
tems, (i.e., cooling, fuel, electrical, drive, intake, exhaust,
hydraulic, and air, that are externally attached to the
engine).
c. Internal Components. Internal components are
defined as the units and assemblies within the engine
block and oil pan, the cylinder heads and associated
parts, and block.
2-9.
Engine Preparation
NOTE
Check to insure that coolant and lube oil
has been completely removed from
engine.
2-8. General
a. Removal and Installation. The instructions for
removal and installation of engine components have
been arranged in the most logical order of removal for
complete engine disassembly. Installation in general,
shall be the reverse order of the removal instructions. To
facilitate the removal, and later disassembly, assembly
and installation procedures, the components are
separated into categories, (i.e., external components,
and internal components).
b. External Components. External components are
defined as the basic units of the engine sys2-3
*TM 9-2815-213-34
b. Remove eight capscrews, spacers, and four
lockplates, securing left bank exhaust manifold to head.
c. Remove manifold and four manifold to block
gaskets (fig. 21).
a. Using a suitable hoisting device, (i.e., over-head
chain fall, A frame hoist, or gooseneck hoist), attach
lifting hooks to engine front and rear lifting eyes, (figs. 11 and 1-2) and raise engine.
Figure 2-1. Exhaust mainifold--removal/installation.
d. Remove 13 capscrews and lockwashers
securing oil cooler to engine (fig. 2-2).
e. Remove oil cooler and four gaskets.
f. Remove 12 capscrews, lockwashers, and one
gasket, securing cover plate to block and remove plate.
g. Install engine rebuild stand and adapter (26 and
27, fig. B-28) to engine block as shown in figure 2-3.
h. Remove hoisting equipment.
(3) Remove two capscrews, and lockwashers
securing alternator to mounting bracket and remove
alternator.
(4) Remove four capscrews, lockwashers, and flat
washers securing mounting bracket to intake manifold.
(5) Remove capscrew and lockwasher securing fan
assembly mounting bracket to alternator mounting
bracket.
(6) Remove capscrew, lockwasher and flat washer
securing tension adjusting arm to block. Remove arm.
d. Hydraulic Pump Assembly.
NOTE
If engine is received for repair without
the power steering pump (hydraulic
pump), bracket, pulley and drive belt, do
not requisition these items for installation
on the repaired engine. The rebuilt
engine will be shipped to the using unit
without the pump assembly.
2-10. External Components
a. Starter Assembly. Remove three capscrews and
lockwashers securing starter to flywheel housing, and
remove starter.
b. Exhaust Ma_tifold-Right Bank. Remove eight
capscrews, spacers, four lockplates and four gaskets
securing manifold to head.
c. Alternator Assembly.
(1) Disconnect electrical connector.
(2) Remove belt tension adjusting arm bolt.
2-4
*TM 9-2815-213-34
curing fan assembly mounting bracket to pump mounting
bracket.
(5) Remove pump assembly mounting bracket.
e. Fan, Fan Hub, and Bracket Assembly (fig.
2-4).
(1) Loosen fan hub shaft and back-off adjusting
screw to relieve belt tension.
(2) Remove belts from crankshaft pulley.
(3) Remove shaft locknut and washer.
(4) Pull fan and hub assembly forward to remove
from bracket. Remove washer from shaft.
(5) Remove six capscrews and lockwashers
securing bracket to engine block.
(6) Remove two capscrews and lockwashers
securing bracket to alternator and hydraulic pump
brackets and remove bracket.
Figure 2-2. Oil cooler and cover plate-removal/installation.
Figure 2-4. Fan hub and bracket assembly-removal/installation.
f.
Thermostat Assembly (fig. 2-5).
(1) Loosen clamp securing water pump hose to
thermostat housing.
(2) Remove four capscrews and lockwashers
securing assembly to cylinder head.
(3) Remove thermostat assembly and assembly to
cylinder head gasket.
g. Fan Drive Pulley, Vibration Damper, and WaterPump Drive Pulley (fig. 2-6).
(1) Remove seven capscrews and lockwashers
securing drive pulley and vibration damper to crankshaft.
(2) Remove pulleys and vibration damper.
h. Water Pump Assembly (fig. 2-7).
(1) Remove five capscrews and lockwashers
securing water pump assembly to block.
(2) Remove pump assembly by pulling straight
forward so impeller clears block. Remove and discard
gasket.
i. Air Intake and Preheater- Assembly (fig. 2-8).
Figure 2-3. Eligible rebuild stand--removal/installation.
(1) Remove capscrew and lockwasher securing belt
tension adjusting arm to pump bracket.
(2) Remove two mounting bolts securing hydraulic
pump and bracket assembly to main mounting bracket,
and remove assembly.
(3) Remove three capscrews, lockwashers, and flat
washers securing bracket to engine block.
(4) Remove capscrew and lockwasher se2-5
*TM 9-2815-213-34
Figure 2-5. Thermostat assembly--removal/installation.
and flat washers securing each manifold to each cylinder
head.
(2) Remove manifolds and gaskets.
k. Water Crossover Pipe and Lifting Eyes (fig. 210).
(1) Remove eight capscrews and lockwashers
securing crossover and lifting eyes to cylinder heads.
(2) Remove crossover, lifting eyes, and two gaskets.
Figure 2-6. Drive pulleys and vibration damperremoval/installation.
(1) Loosen hose clamps on crossover to air
compressor flexible hose connection.
(2) Remove eight capscrews, lockwashers, and flat
washers securing crossover and preheater assembly to
intake manifolds.
(3) Disconnect flexible hose at air compressor and
remove crossover and preheater assembly from
manifolds. Remove and discard two gaskets.
j. Intake Manifolds (fig. 2-9).
(1) Remove eight capscrews, lockwashers,
Figure 2 7. Water pump assembly--removal/installation.
2-6
*TM 9-2815-213-34
Figure 2-8.
Air intake crossover and preheater assembly--removal/installation.
Figure 2-9. Intake manifolds fuel pump and fuel lines--removal/installation.
l. Fuel Pump and Fuel Lines (fig. 2 9).
(1) Disconnect flexible fuel drain return line at fuel
pump.
(2) Disconnect two fuel supply lines at shutdown valve.
(3) Disconnect fuel supply lines from cylinder heads
(front end).
(4) Loosen fuel supply line clips securing lines to push
rod cavity covers, and remove lines.
(5) Disconnect fuel drain crossover line at
2-7
*TM 9-2815-213-34
drive gear from camshaft gear, and remove compressor.
n. Oil Dipstick Tube Assembly (fig. 2-11).
(1) Remove capscrew and lockwasher securing
tube clip to engine block.
(2) Disconnect tube at oil pan fitting and remove
tube.
Figure 2-10. Water crossover pipe and engine lifting
eyes--removal/installation.
rear end of each cylinder head and remove cross-over
with flexible metallic drain return line at tached.
(6) Loosen two capscrews, securing fuel pump
support bracket (32, fig. B-18), to engine block.
(7) Remove four capscrews, lockwashers, and flat
washers, securing fuel pump to air compressor housing
and support bracket.
(8) Slide support bracket towards front, pull pump
towards front and remove from compressor. Remove
gasket.
(9) Remove two capscrews, lockwashers, and flat
washers securing bracket to block and remove bracket.
NOTE
The fuel pump is driven through a
freefloating coupling between the pump
and compressor. Insure that coupling
and plate are removed with pump.
m. Air Compressor and Drive Assembly (fig. 1-2).
(1) Disconnect coolant input and output lines at
compressor.
(2) Disconnect air discharge line at compressor.
(3) Remove six capscrews (10, fig. B-25) and
lockwashers (9, fig. B-25) securing rear support (8, fig.
B-25) to flywheel housing.
(4) Remove support and gasket.
(5) Pull compressor and drive assembly toward front
of engine, to disengage compressor
Figure 2-11. Oil dipstick tube assemblyremoval/installation.
2-11. Internal Components
a. Cylinder Head Covers (fig. 2-12).
(1) Right Head Cover.
(a) Remove ten capscrews, lockwashers, and plain
washers securing cover to head.
(b) Remove cover and gasket.
(2) Left Head Cover.
(a) Loosen hose clamp securing breather tube to
crankcase breather and pressurizing unit (fig. 2-13).
(b) Remove breather tube from unit.
2-8
*TM 9-2815-213-34
Figure 2-14. Push rod cavity coversremoval/installation.
Figure 2-12. Cylinder head covers-removal/installation.
(5) Remove 24 push rods (16 valve and 8 injector)
from tappets.
d. Fuel Injectors (fig. 2-16).
(1) Remove eight capscrews and flat washers and
nylon inserts securing injector clamps to cylinder head.
(2) Remove clamps.
(3) Pull injectors from cylinder head (fig. 2-17).
e. Valve Crossheads (fig. 2-18). Remove sixteen
crossheads by lifting each straight up from guides.
f. Cylinder Heads (fig. 2-19).
(1) Attach cylinder head lifting plate (45, fig. B-28).
(2) Attach lifting hook of chain fall, or other suitable
lifting device, to lifting plate. Take-up slack in chain or
cable.
(3) Remove 16 capscrews and flat washers (fig. 218) securing heads to block (eight cap screws per head).
(4) Using lifting device remove each cylinder head.
Remove gaskets.
g. Valve and Injector Tappets (fig. 2-20).
(1) Remove 16 capscrews and lockwashers (eight
per cylinder head) securing eight tappet guide plates to
heads (four per head).
(2) Remove guide plates.
(3) Lift tappet assembly from block.
h. Flywheel (fig. 2-21).
(1) Cut lockwire on six capscrews securing flywheel
to crankshaft adapter.
(2) Remove two opposing capscrews.
(3) Insert two 5/8 x 6-inch headless studs in
Figure 2-13. Crankcase breather tuberemoval/installation.
(c) Remove ten capscrews, lockwashers, and flat
washers securing cover to cylinder head.
(d) Remove cover, breather and pressurizing unit,
and gasket.
b. Push Rod Cavity Covers (fig. 2-14).
(1) Remove 26 capscrews, lockwashers, and flat
washers securing each cover to cylinder heads.
(2) Remove covers and gaskets.
c. Rocker Arms and Push Rods (fig. 2-15)
(1) Loosen all push rod adjusting screw locknuts
and back-off adjusting screws.
(2) Secure rocker arms with rubber bands.
(3) Remove ten capscrews and flat washers
securing each irocker arm to respective cylinder head.
(4) Remove rocker arms and brackets.
2-9
*TM 9-2815-213-34
Figure 2-15. Rocker arms and push rods--removal/installation.
screws to pull flywheel from adapter onto the six-inch
studs.
(7) Remove the flywheel by sliding over studs.
Remove studs.
i. Crankshaft Adapter (fig. 2-22).
(1) Remove grease retainer cup from adapter base.
Figure 2-16. Injector clamps--removal/installation.
the holes and secure into the adapter. These shall serve
as a support for removal of the flywheel.
(4) Remove two of the slotted head screws and
install 1/2-13 x 2 1/2, inch capscrews.
(5) Remove the four remaining flywheel to adapter
securing capscrews.
(6) Alternately turn-in the 1/2-inch cap
Figure 2-17. Fuel Injector and hold-down clamp.
2-10
*TM 9-2815-213-34
(3) Remove adapter.
J Flywheel Housing (fig. 2-23).
(1) Remove eight cap screws, lockwashers,
and flat washers securing oil pan to flywheel housing.
(2) Remove
seven
cap
screws
and
lockwashers securing flywheel housing to engine block.
(3) Using a rubber mallet, or brass head
driver, free housing from block and remove housing and
gasket.
k. Camshaft, Gear, and Spacer Plate (fig. 2-24).
(1) Straighten lockplate fingers on two cap
screws securing camshaft thrust plate to engine block.
(2) Remove
cap
screws
and
discard
lockplates.
(3) Remove camshaft and gear from block.
Rotate camshaft gear slightly while pulling.
(4) Remove spacer plate and two plate to block
gaskets.
l. Oil Pan (fig. 2-25).
(1) Remove six cap screws and lockwashers,
on right side of pan, securing pan inspection plate (6,
fig. B-9).
(2) Remove inspection plate and gasket.
(3) Reach inside oil pan and remove two cap
screws and lockplates securing the oil pump by-pass
tube (13, fig. B-9) and oil suction tube (20, fig. B-9),
respectively, to the oil pan.
(4) Remove 12 cap screws, lockwashers, and
flat washers securing oil pan to block.
(5) Remove pan and gasket.
m. Oil Pump Assembly (fig. 2-26).
(1) Remove cap screw, nut, lockplate, and
clamps securing oil suction tube to block.
(2) Remove cap screw and lockplate securing
oil by-pass tube to block.
(3) Remove four cap screws and lockplates
securing oil pump to block.
(4) Remove pump and tubes from block.
n. Front Cover (fig. 2-27).
(1) Remove 12 cap screws and lockwashers
securing cover to engine block.
(2) Remove cover and gasket. Pull straight out
to avoid damaging the dowels.
o. Connecting Rod and Piston Assembly (fig. 2-28).
Figure 2-18. Valve crossheads - removal/installation.
Figure 2-19. Cylinder heads - removal/installation.
NOTE
The following instructions cover the
removal of one connecting rod and
piston assembly from engine block.
Remove remaining seven rods and
pistons in the same manner.
Figure 2-20. Valve and injector tappets removal/installation.
(2) Cut and remove lockwire on adapter to
crankshaft securing screws and remove cap screws.
2-11
*TM 9-2815-213-34
Figure 2-21. Flywheel-removal/installation.
(1) Remove carbon and wear ridges at of
cylinder to facilitate piston removal.
(2) Straighten tangs of lockplates on two bolts
and nuts securing rod to crankshaft.
(3) Remove nuts and lockplates.
Discard
lockplates.
(4) Using a rubber mallet or brass driver, tap
rod bearing cap to free cap from crankshaft
Figure 2-22. Crankshaft adapter-removal/installation.
2-12
(5)
*TM 9-2815-213-34
Tape bearing half shell to cap as re.
moved.
(6) Using a wooden stick, or hammer handle.
push piston up out cf cylinder.
(7) Tape upper bearing half shell to rod.
(8) Assemble cap on rod and tag to identify
assembly with cylinder.
p. Crankshaft and Main Bearings (fig. 2-29).
(1) Remove 19 main bearing side locking bolts
and plain washers.
(2) Remove 10 main bearing cap screws and,
plain washers securing caps to block.
(3) Using a small pry bar, loosen and remove
the bearing cap and bearing half shell. Mark half shells
to identify with mating cap.
(4) Remove rear bearing thrust half rings.
Figure 2-23. Flywheel housing - removal/installation.
CAUTION
Insure that lifter hooks are rubber
covered or otherwise prepared to
prevent metal-to-metal contact with shaft
throws.
(5) Using an overhead chain fall, or other
suitable lifting device, attach a double hook lifter to two
shaft throws and remove crankshaft from block.
(6) Remove upper bearing half shells and tag
on removal with mating bearing cap identification.
(7) Remove rear bearing upper thrust halfrings.
Figure 2-24. Camshaft, gear and spacer plateremoval/installation.
Figure 2-25. Oil pan-removal/installation.
and remove cap and
shaft.
Figure 2-26. Oil pump assembly-removal/installation.
bearing half from crank
2-13
*TM 9-2815-213-34
Figure 2-28. Connecting rod and piston assemblyremoval/installation.
Figure 2-27. Front cover-removal/installation.
Figure 2-29. Crankshaft and main bearings-removal/installation.
2-14
*TM 9-2815-213-34
CHAPTER 3
REPAIR INSTRUCTIONS
Section I. General
order of engine reassembly.
c. The
instructions
covering
cleaning,
inspection, and repair are in addition to the general
maintenance requirements of Chapter 2.
d. Standard parts kits used in repair are
described in Appendix B.
3-1. Procedures
a. The repair instructions contained in chapter
cover the disassembly, cleaning, inspection, repair,
test, adjustment, and assembly components and
component assemblies.
b. The procedures also provide for the
installation of repaired components that permits a logical
Section II. Repair of Cylinder Block
3-2. Disassembly
a. Pipe Plugs. Remove all pipe plugs from and
water passages.
b. Camshaft Bushings (fig. 3-1).
Figure 3-2. Cylinder sleeve removal
Using cylinder sleeve puller and plate (10 and 11, fig. B28) remove and discard sleeve(s).
3-3. Cleaning
Clean block in accordance with paragraph 2-5. Clean all
water and oil passages with compressed air.
3-4. Inspection
a. Camshaft Bushings.
(1) Visually inspect the five bushings in
accordance with paragraph 2-6.
(2) Check the ID of the bushings against limits
specified in repair and rebuild standards (para. 3-180).
Replace any bushing worn beyond specified limits.
Refer to paragraph 3-2.b. for bushing removal.
b. Cylinder Sleeves.
(1) Visually inspect each sleeve for cracks and
scratches. Replace sleeve if cracks or heavy scratches
are present.
Figure 3-1. Camshaft bushing removal.
NOTE
Remove camshaft bushings only if
inspection (para. 3-4) indicates need for
replacement. Using camshaft driver and
mandrel (7 and fig. B-28), remove and
discard bushing(s).
Using camshaft driver and mandrel (7 and 8,
fig.B-28), remove and discard bushing.
c. Cylinder Sleeves (fig. 3-2).
NOTE
Remove cylinder sleeves only if
inspection (para. 3-4) indicates need of
replacement.
3-1
*TM 9-2815-213-34
e. Block Mating Surfaces. Check top machined
surfaces of block with straight edge and feeler gage. If
warped, distorted or uneven replace block.
f. Expansion Plugs. Inspect all expansion plugs
for evidence of coolant leakage. Replace all plugs that
are defective.
g. Miscellaneous Parts. Inspect main bearing cap
screws, washers, and all pipe plugs. Check for
damaged threads, nicks, burs, and other unserviceable
conditions. Replace all unserviceable parts.
3-5. Repair
Repair of the cylinder block is limited to general
procedures as outlined in paragraph 2-7. Any defect, or
measurement outside the tolerances listed in paragraph
3-175, is cause for replacement of block.
36. Assembly
a. Camshaft Bushings. Refer to paragraph 3
2.b., and reverse the order of removal.
b. Pipe Plugs. Install all pipe plugs. Refer to
paragraph 3-186, for plug torque specifications. Use
sealing tape or lead solder to prevent leakage.
c. Cylinder Sleeves.
(2) Check ID of the sleeve against limits
specified in repair and rebuild standards (para 3-179).
Measurements shall be made at middle, and skirt of
sleeve. Replace any s worn beyond specified limits.
NOTE
Refer to paragraph 3-2.c. for sleeve
removal. If any sleeve requires removal
perform steps 3 and 4 below.
(3)
Discard preformed packings and crevice
seals.
(4) Using block gage (24, fig. B28) cylinder
counterbore and bore against limits specified in repair
and rebuild standards (13-175).
Replace block if
measurements are beyond specified limits.
c. Main Bearing Bore (fig. 33).
(1) Install and tighten bearing caps. Refer to
paragraph 3-186, for cap screw torque specifications.
(2) Check
bearing
bores
horizontally,
vertically, and diagonally against limits specific repair
and rebuild standards (para. 3-175).
(3) Check alignment of bore using bearing bore
alignment checking bar (19, fig. B-28)
NOTE
NOTE
Inspect bar for run-out and OD prior to
use. Bar must be 3.7510-3.7506-inch
OD and straight within 0.0005 in full
length. Bar must pass through all bores
and turn freely. Replace any cap that
prevents free passage and turning.
Before installing sleeves insure that
each sleeve protrusion is 0.004 to 0.006inch.
(1) Install crevice seal ring on machined
surface above packing ring grooves, as shown in figure
3-4, with green stripe color code showing.
(2) Lubricate packing rings with light coating of
OE-10 lubricant.
(3) Roll each ring into grooves (fig. 3-4) and
straighten using ring mold mark as a guide.
d. Tappet Bores. Check valve and injector pet
bores against limits specified in repair rebuild standards
(para. 3-175).
Figure 3-3. Main bearing bore alignment check
Figure 3-4. Cylinder sleeve sells installation
3-2
*TM 9-2815-213-34
(4) Lubricate machined packing ring bore of
twisted seal rings, cocked crevice seal or sleeve to block
block with light coat of OE-10 lubricant.
contact which could cause distortion of sleeve. If no
(5) Start sleeve into bore by hand.
apparent cause is evident replace sleeve.
(6) Use a sleeve driver (31, fig. B-28) place
sleeve in block.
(8) Install sleeve and check sleeve protrusion
(7) Using a dial bore gage check sleeve
using gage block (24, fig. B-28) to determine if
against limits specified in repair and rebuild standards
protrusion is uniform.
(para. 3-174). If specified limits are exceeded remove
sleeve and check for possible
Section III.
3-7. Disassembly
a. Attach a gear puller to shaft gear.
b. Using a heating torch head gear hub 300 - 400
degrees Fahrenheit.
c. Apply 75 to 100 foot pounds torque on puller
screw and remove gear and key.
d. Remove all pipe plugs.
3-8. Cleaning
Clean crankshaft and gear in accordance with paragraph
2-5.
3-9. Inspection
a. Visually inspect shaft journals for the lowing
defects. Replace shaft if all or any defect is present:
(1) Deep nicks, grooves, scratches, evidence
of galling or scuffing.
(2) Burned areas, if color is a very do blue.
(3) Heavy discoloration throughout shaft from
over-all heating.
b. Measure all bearing surfaces with a micrometer
(fig. 3-5). Check against wear limits specified in repair
and rebuild standards (para 3-174).
c. Check shaft for out-of-round condition. Shaft
must be reground or replaced if main beings or journals
are worn out-of-round more than 0.002.inch.
d. Visually inspect thrust flange at rear main
bearing. If surface is scored or scratched, flange must
be reground.
e. Measure flange wear (P, fig. 3-5).
NOTE
Undersize grinding shall be to a limit of
0.010-inch. If one bearing or journal
requires grinding,
all bearings or
journals shall be ground to the same
undersize dimension.
b. Regrinding Rear Main Bearing Thrust Flange.
Flange shall be reground to restore flatness to accept
either standard or oversize thrust rings.
NOTE
If total wear and regrinding does not
exceed 0.005-inch,
standard thrust
rings may be used. Maximum regrinding
for oversize rings shall not exceed
0.005-inch undersize.
c. Minor Defects. Minor defects on journal and
bearing surfaces may be repaired by polishing with a
crocus cloth dipped in dry-cleaning solvent or mineral
spirits paint thinner.
d. Repair Inspection. Shaft must be inspected by
the electro magna-flux method for fractures after
refinishing. If any evidence of cracks are noted, replace
shaft.
3-11. Assembly
a. Install all pipe plugs using sealing tape or lead
sealer to prevent leakage. Refer to para-graph 3-186,
for pipe plug torque specifications.
b. Install key in shaft keyway.
c. Oil shaft with OE-10 lubricant.
NOTE
If flange wear does not exceed 0.003inch at any one point, flange condition is
acceptable. If wear is 0.003-inch or
more,
flange must be reground to
restore flatness.
CAUTION
3-1 0. Repair
a. Regrinding Main Bearing and Rod Journal If outof-round or worn beyond repair and rebuild standards
specified limits, (para. 3-175) main bearing and rod
journals may be ground undersize.
When using heating torch keep flame
away from direct contact with gear teeth.
d. Heat gear in oven, or with heating torch, to
approximately 400 degrees Fahrenheit.
e. Using rubber mallet, or brass head driver, drive
gear on shaft.
3-3
*TM 9-2815-213-34
Figure 3-5. Crankshaft dimensions.
(2) Alternately torque both bolts in each cap to
340-350 ft. lbs.
(3) Fully loosen all bolts to relieve tension.
(4) Alternately torque both bolts in each cap to
80-90 ft. lbs.
(5) Alternately torque both bolts in each cap to
170-180 ft lbs.
(6) Scribe each cap in line with a corner hex of
each bolt head.
(7) Advance each bolt 60 degrees alternately
on each cap in 30 degree increments.
k. Check shaft clearance against limits specified in
repair and rebuild standards (para. 3-176) as follows:
(1) Using a suitable holder attach a dial
indicator to rear of block (fig. 3-6) with gage plunger
resting against flange face.
(2) Using a pry bar move shaft to front of block.
(3) Set gage to zero.
(4) Move shaft to front of block and observe
gage reading.
3-12. Installation
a. Lay upper main bearing shells in block engaging
shell tang in recess. Refer to paragraph 2-ll.p. (6) and
(7).
b. Coat shells with GAA.
c. Install shaft in block. Refer to paragraph 2-11.p.
(5) for installation instructions.
d. Install upper thrust half-rings in rear main
bearing with grooved side next to shaft flange.
e. Coat lower bearing shells with GAA and snap
into position in bearing caps.
f, Install lower main bearing thrust half-rings over
dowels in bearing cap.
g. Install bearing caps over shaft.
NOTE
Main
bearing
caps
are
not
interchangeable, insure that numbers
stamped on caps correspond with
numbers stamped on block.
NOTE
If clearance, with a new shaft and thrust
rings, is less than 0.005-inch loosen all
bearing cap bolts and move shaft to
front of block then to rear of block.
Refer to paragraph 3-12.j., and
h. Lubricate threads of the bearing cap bolts with
OE-10 lubricant.
i. Install bolts and plain washers in each cap and
engage threads by hand.
j. Tighten bolts as follows:
(1) Alternately torque both bolts in each cap to
150-160 ft. lbs.
3-4
*TM 9-2815-213-34
tighten cap bolts. Recheck end clearance. If the original
shaft and thrust rings are installed and end clearance
exceeds the wear limits the thrust rings must be
replaced.
l. Check clearance between main bearing caps
and block at side bolt contact area on each of cap;
clearance must be 0.002-0.005-inch fig. 3-7).
m. Coat threads of bearing cap side bolts v
OE-10 lubricant.
n install bolts and flat washers engage threads by
hand.
o. Refer to figure 3-8 for bolt tightening sequence.
Torque each bolt to 70-75 foot-pounds 35-40 footpounds increments.
Figure 3-7. Bearing cap to block clearance check.
Figure 3-6. Crankshaft end clearance check.
Figure 3-8. Side bolt tightening sequence.
Section IV. Repair of Connecting Rod and Piston Assembly
3-13. Disassembly
a. Remove piston pin snap rings.
b. Heat pistons in hot water for several minutes to
facilitate pin removal. Push pin from piston with thumb
pressure.
c. Using a suitable ring expander remove piston
rings (fig. 3-9).
NOTE
Maintain each rod and piston assembly
as a group. Do not mix with other
assemblies.
3-14. Cleaning
Refer to paragraph 25 for cleaning instructions.
3-15. Inspection
a. Inspect rod visually for nicks, notches gashes
; depressions with a 1/16-inch radius or less are not
acceptable on the edge of the I beam section or on the
periphery of the forging. Nicks, notches, or gashes
1/32-inch or less in depth may be removed by grinding
and blending to the original contour within a minimum
distance of ½ inch on either side of the defect.
b. Assemble cap to rod and tighten down bolt nuts
to proper torque (para. 3-186).
c. Check crankpin bore with inside micrometers.
The bore must be within limits shown in paragraph 3177. Out-of-round limits should not exceed 0.00075
inch.
d. Using a dial bore gage, check crankpin bore for
out-of-round condition. Out-of-round limits must not
exceed 0.00075 inch.
e. Using inside micrometers, check piston pin
bushing diameter. Piston pin bushing bore must
3-5
*TM 9-2815-213-34
Figure 3-9. Piston and ring assembly.
.
Figure 3-10. Connecting rod check.
not exceed wear limits shown in repair an build
standards in paragraph 3-178. f. Check connecting rod
piston pin and bearing bore alignment, rod twist, and
rod centerline (fig. 3-10) in rod checking fixture (40, fig.
B-28). Calibrate fixture, before checking rod, as foil (1)
Select a new rod that has been checked for correct
absolute length. (Production rods vary from 8.192/8.194
inches in length.)
(2) Assemble cap to rod and tighten nuts to
proper torque (para. 3-186).
(3) Insert mandrel (22, fig. B-28) without
bushing or (21, fig. B-28) used bushing into piston pin
bushing bore.
(4) Insert mandrel (20, fig. B-28) crankpin
bushing bore. Tighten mandrel in to snug fit.
(5) Position rod with mandrels installed into
fixture (40, fig. B-28).
(6) Move dial holders so dial pins seat on
piston pin bore mandrel. Turn dial indicator gages back
to zero indication.
(7) Remove rod with mandrels installed from
fixture, rotate rod 180 degrees and reinstall in fixture
with connecting rod mandrel at top.
(8) Turn dial indicator adjusting screws until
dial pins seat on connecting rod mandrels. Note reading
of dial indicators. Divide reading in half and adjust each
dial indicator gage accordingly.
(9) Remove mandrels from connecting bores.
g. Check rod alignment as follows:
B28) into connecting rod bore. Tighten mandrel to snug
fit.
(2) Install mandrel (22, fig. B-28) used without
bushing or (21, fig. B-28) used with bushing into piston
pin bushing bore.
(3) Install rod with mandrels in fixture Note
reading, rotate rod 180 degrees, and note reading
again. Total cumulative readings of each dial on fixture
must not exceed 0.004 inch with piston pin bushing
installed or 0.008 inch with-out piston pin bushing
installed.
h. Check rod twist with a feeler gage between
piston pin mandrel and dial holding plate. Twist must not
exceed 0.010-inch with bushing installed or 0.020-inch
without bushing.
i. Check rod centerline as follows:
(1) Attach dial indicator gage to fixture (fig. 310) so that it will contact the milled surface of piston pin
end of rod.
(2) Slide crankpin end of rod sideways to
contact checking fixture on same side that dial indicator
is mounted.
(3) Adjust indicator gage to zero reading. Turn
Rod 180 degrees and repeat step (2) above. Dial
indicator reading must not exceed 0.015 inch.
j. Check connecting rod bolts, bolt holes, and bolt
pads as follows:
(1) Bolt head must rest squarely on milled
surfaces of rod.
(2) With rod bolt in connecting rod and cap,
measure bolt length without torque applied,
then
measure bolt length with it torqued to 105/115 ft lbs. If
bolt length increases over 0.015 inch it must be
discarded.
(3) Discard all bolts and nuts that have
distorted threads.
(4) Check bolt hole diameter, if it exceeds
0.5643 inch, discard rod.
NOTE
Measurements taken directly from dial
indicator indicate comparative length
and misalignment of bores.
(1)
Install connecting rod mandrel (20,fig
3-6
*TM 9-2815-213-34
(5) Check bolt pad corner radius (0.25 0.2700
inch). If radius does not check to tolerance, machine to
proper dimensions.
k. Inspect connecting rod bearing caps using ball
point micrometer, dial indicator thickness gage, or
Comparator. Refer to paragraph 3-177, for shell
thickness and allowable wear.
l. Inspect pistons for scoring,
burning,
or
damaged ring grooves and cracks inside piston struts. A
badly scored piston must be replaced; a slightly scored
piston may be cleaned and reused.
m. Inspect top of piston for burned spots indications
of over-heating such as carbon formation on underside
of the piston. Replace burned pistons.
n. Using ring groove wear gage (52, fig. 28) check
groove wear as follows: (fig. 3-11)
(1) Insert ring groove wear gage (52, fig. B28) into each of the top and second ring grooves.
(2) If shoulders of gage touch ring grooves
lands, piston must be discarded.
Figure 3-12. Piston ring gap check.
NOTE
Measurement should be
ambient air temperature
degrees Fahrenheit.
taken at
of 70/90
q. Using inside micrometer, measure piston pin
bore; discard piston if bore exceeds 2.005-inch.
3-16. Repair
Repair of the connecting rod and piston assembly is
limited to general procedures as outlined in paragraph 27. Any defect, or measurement outside the tolerances
listed in repair and rebuild standards (paras. 3-177, and
3-178) is cause for replacement. If piston pin bushings
must be replaced use bushing driver (46, fig. B-28) for
bushing removal and replacement. Check with plug
gage (50, fig. B-28).
3-17. Assembly
Assemble rod to piston in reverse order of paragraph 313.
NOTE
Figure 3-11. Ring groove wear check.
o. Check ring gap as follows:
(1) Insert each compression ring into worn
portion of cylinder liner, seating it squarely using a piston
head (fig. 3-12).
(2) Measure ring gap with feeler gage. The
allowable ring gap is 0.013/0.0230: Rings exceeding this
limit should be discarded.
(3) If necessary, file ring ends to obtain gap of
0.0130/0.0230 inch.
p. Measure piston skirt diameter with micrometer at
right angle to piston pin bore. Refer to paragraph 3-178,
for wear limits. If piston wear exceeds 0.004-inch
discard piston.
When installing rings insure the word
"Top" inscribed on the ring, is to the top
of the piston.
3-18. Installation
a. Lubricate rod and piston assembly with OE- 10
lubricant.
b. Compress piston rings with suitable cylindrical
ring compressor.
c. Remove connecting rod cap from bolts and
make certain bolt heads are seated squarely on rod
shoulder. These parts are not interchangeable (fig. 326).
3-7
*TM 9-2815-213-34
NOTE
If new rods are used, be sure caps and
rods have number stamped on them
before caps are removed. Caps are not
interchangeable.
(3)
Loosen both nuts completely to remove all
(4)
Tighten both nuts to 30 to 32 foot- pounds
(5)
Tighten both nuts to 60 to 65 foot-pounds
tension.
torque.
torque.
d. Rotate engine to a vertical position on the engine
stand. Rotate crankshaft to position crank throw for
cylinder being assembled at bottom center.
(6) Advance both nuts to 60 degrees in 30
degrees increments.
m. Follow steps a through I above, install piston
and rod assembly opposite one just installed. Secure
rod to same crankshaft journal.
CAUTION
Ring breakage will result from improper
use of ring compressor. If band type
compressor is used, make certain inner
band does not slip down and bend
piston.
NOTE
Chamfered side of rod faces respective
crankshaft cheeks and square sides
face each other.
e. With ring compressor in place, insert piston
and rod assembly in the cylinder. Position numbered
side of rod toward outside of block.
n. Check rod for freedom of movement and
clearance.
(1) Use hand pressure to move rod side-ways.
Tap lightly with soft hammer if necessary.
(2) If rod is not free, loosen cap and check for
dirt or burs. Secure cap as described above.
(3) Push rods apart. Check for 0.008 to 0.016 inch
clearance between rods with feeler gage (fig. 3-13).
o. Bend tangs on lockplates (fig.
3-13),
to
locknuts.
CAUTION
Pistons are marked to indicate which
side is to be assembled to "Out" exhaust
side.
f. Push piston assembly through ring compressor
until rings seat in cylinder sleeve.
g. Moving to bottom of block, grasp piston and rod
assembly by rod bolts and pull down to rod journal.
Leave piston assembly a short distance from actual
seating.
h. Coat rod bearing shell with GAA next to the
crankshaft.
i. Roll rod bearing shell into rod. Shell locking tang
must fit in milled recess.
j. Coat lower shell crankshaft bore with hit
pressure grease, and seat in rod cap.
k. Position rod cap over bolts that numbered side
of cap mates with numbered side of rod.
l. Lubricate bolt and nut threads and lock plates
with clean OE-10 lubricating oil. Install lockplate and
nuts to bolts, tighten nuts as outlined below.
(1) Tighten both nuts 55 to 66 foot-pounds
torque.
Figure 3-13. Rod side clearance check.
(2) Tighten both nuts 105 to 115 foot pounds
torque.
Section V. Repair of Front Cover
3-19. Disassembly
Using the front crankshaft oil seal driver (38, fig. B-28)
and suitable arbor press remove oil seal as shown in
figure 3-14.
3-20. Cleaning
Refer to paragraph 2-5 for cleaning instruction.
3-21. Inspection
Refer to paragraph 2-6 for inspection procedures.
NOTE
Dowel replacement is not authorized.
If dowels are bent or damaged replace
the cover.
3-8
TM 9-2815-213-34
3-22. Repair
No repair procedures beyond those specified paragraph
2-7 are authorized.
3-23. Installation
a. Position front cover with new gasket to block
Secure snugly with lockwashers and capscrews.
b. Place dial indicator gage on crankshaft with dial
pointer inside front cover bore. Rotate crankshaft and
check total indicator reading. Run-out must not exceed
0.0025 inch (fig. 3-15).
e. Install cover and secure with lockwashers and
capscrews. Tighten capscrews to 30 to 35 foot-pounds
torque.
Figure 3-15. Front cover bore alinement check
Figure 3-14. Crankshaft oil seal-removal/installation.
c. Check that the bottom of the front cover and
cylinder block are level with a straight edge. There must
be no variation (fig. 3-16).
d. Remove front cover and press in new oil seal (314).
(1) Position seal with open lip to inside.
(2) Use oil seal driver (38, fig. B-28) and arbox
press for pressing operation.
Figure 3-16. Front cover to block alinement check.
Section VI. Repair of Oil Pump Assembly
dowels in pump body. Discard gasket (3).
f. Remove six capscrews and lockplates (32 and
33, fig. B-10) securing scavenger pump body (2) to oil
pump body. Tap scavenger pump body to remove from
dowels in oil pump body.
NOTE
Gears and shafts will be removed
from the pumps only in inspection
warrants.
3-24. Disassembly
a. Remove two capscrews and lockplates (11 and
fig. B-9) securing suction tube to pump.
b. Remove four capscrews and lockplates (11 19,
fig. B-9) securing scavenger tube to pump Discard
gasket (17).
c. Remove three capscrews and lockplates (11 and
12, fig. B-9) securing suction tube to pump. Discard
gasket (21).
d. Remove four capscrews. (15, fig. B-10) securing
cover plate (16) to pump cover (20). Remove plate
e. Remove four capscrews and lockplates (18 and
19, fig. B-10) securing pump cover to oil pump body (9).
Tap cover with soft head hammer to remove from
g. Remove idler gear (31, fig. B-10) from shaft (30)
in scavenger pump body.
h. Using a suitable puller; pull drive gear (17, fig.B10) from cover.
3-9
C2, TM 9-2815-213-34
0.185/0.215 inch through drive gear.
g. With new gasket (3) over dowels in pump body,
position scavenger body to lubricating oil pump body,
engaging pump gears. Secure with lockplates and
capscrews (32 and 33), lock capscrews in plate with lock
tangs.
h. With new gasket (13) over dowels, position
pump cover (20) to lubricating oil pump body, engaging
pump gears; secure with lockplates and capscrews (18
and 19). Lock capscrews in place with lock tangs.
i. With dial indicator, check for 0.0035/0.0075 inch
clearance of pump drive shaft.
j. Position cover plate (16) on cover body secure
with socket head capscrews (15). Center punch around
screw heads to lock in cover.
k. Position pressure regulator plunger, shim and
spring (25, 26 and 29) in pump body, secure with cap
and lockplate (27 and 28).
l. Lubricate pump body freely with lubricating oil,
OE-10, drain oil, and cover openings with tape to prevent
entry of foreign material.
m. Install tube assemblies (suction and aerator) on
lubricating oil pump to permit installation of complete unit
during engine assembly. Reverse steps a., b., and c.,
paragraph 3-24.
i. Remove pressure regulator cap (28, fig. B-10
lockplate (27), spring (26), plunger (29) and shim (25)
from bore.
3-25. Cleaning
Clean all components in accordance with instructions
contained in paragraph 2-5
3-26. Inspection
a. Refer to general inspection procedures
paragraph 2-6.
b. Inspect pump drive gear. Replace pump if teeth
are chipped, cracked, scored or worn smaller than 2.397
inches outside diameter.
c. Inspect drive shaft, replace pump if shafts scored
or worn smaller than 0.8740 inch outs diameter.
d. Inspect idler shafts, replace pump if shafts are
scored or worn smaller than 0.8750 inch outside
diameter.
e. Inspect all bushings for distortion and wear
replace pump if bushings are worn larger than .8750’ inch
inside diameter.
f. Check gear pockets. If finished surfaces are
damaged or pocket inside diameter is worn larger than
2.4105 inches or if depth is worn deeper than 1.252
inches, replace pump.
g. Inspect pressure regulator valve, replace if
damaged. Check for burs or scratches on slide plunger.
3-27. Repair
No repair procedures beyond
paragraph 2-7 are authorized.
those
specified
3-29. installation
a. Refer to paragraph 2-llm, and reverse removal
procedures to install pump.
b. Check pump drive gear backlash as follows:
(1) Attach dial indicator to block, place indicator
arm on gear teeth as shown in figure 3-19.
(2) Rotate gear by hand to advance position and
set indicator at zero. Back gear to retard position and
note indicator reading. Check indicator reading against
specified limits in repair and rebuild standards (para. 3181). If reading is outside limits specified pump gear train
must be replaced.
in
3-28. Assembly
(fig. B-10)
a. Press idler shaft (30) into scavenger body (2)
until shaft protrudes 1.935/1.965 inches from bottom
surface to pocket.
b. Position idler gear (31) on scavenger idler shaft
c. Press lubricating oil pump driven gear (6) with
drill oil hole on main shaft (7) until shaft protrudes
0.590/0.620 inch through gear. Insert shaft through pump
body (9).
d. Press scavenger pump driven gear (6) on main
shaft and maintain 0.002/0.004 inch clearance between
gear and body.
e. Press lubricating oil pump drive gear (6) on drive
shaft until drive end of shaft protrudes through gear
1.455/1.485 inches. Insert long end of shaft.
f. With convex (numbered) side of pump drive gear
(17) up, press gear onto shaft until shaft protrudes
Figure 3-17. Drive gear backlash check.
3-10
•TM 9-2815-213-34
Section VII. Repair of Camshaft
e. Check camshaft and clearance as follows:
(1) With a suitable holder attach a dial indicator
NOTE
to the block, as shown in figure 3-18, with indicator arm
Remove camshaft gear only if thrust
resting on face of gear teeth.
plate or gear is chipped, cracked or
(2) Push and pull on shaft several times.
visibly worn. If necessary to facilitate
(3) Push shaft in until shaft bottoms and set
removal, heat gear to 400 degrees F.
indicator to zero.
(4) Pull out oil shaft and note reading on
a. Place shaft in a suitable press between blocks and
indicator.
press off gear.
(5) Check reading against specified limits in
b. Remove key and thrust plate. Discard key.
repair and rebuild standards (para. 3-180). If end
3-31. Cleaning
clearance is not within limits specified remove camshaft
Clean camshaft and components in accordance with
and replace thrust plate.
instructions contained in paragraph 2-5
f. Attach dial indicator as shown in figure 3-19 and
3-32. Inspection
measure gear backlash against limits specified in repair
a. Check shaft journals and injector lobes against
and rebuild standards (para. 3-180). If backlash is not
specified limits in repair and rebuild standards paragraph
within specified limits replace camshaft gear.
3-180. Replace shaft if any measurement is outside limits
specified.
b. Check thrust plate against specified limits in
repair and rebuild standards, replace plate if limits are
exceeded.
c. Visibly inspect gear in accordance with general
inspection procedures, paragraph 2-6
d. Check gear diameter against specified limits in
repair and rebuild standards paragraph 3-180 Replace
gear if limits specified are exceeded
3-33. Assembly
a. Install key in place, red tip to rear of camshaft.
b. Coat camshaft thrust bearing with lubricating oil
OE10 and place thrust bearing on camshaft.
c. Coat gear hub area on camshaft with lubricating
oil OE-10.
d. Heat gear to 400 degrees Fahrenheit in oven or with
heating torch and press gear onto shaft
Figure 3-18. Camshaft end play check.
3-30. Disassembly
CAUTION
When using heating torch, heat gear
hub only. Do not direct flame at gear
teeth.
3-34. Repair
Repair of camshaft and gear is limited to general
procedures outlined in paragraph 2-7.
3-35. Installation
a. Lubricate lobes and journals with high pressure
grease.
b. Install camshaft in the block (fig. 2-24).
c. Index "0" mark on camshaft gear with “O” mark
on crankshaft gear to insure correct timing.
d. Secure camshaft thrust plate to block with
lockplates and capscrews.
Figure 3-19. Crankshaft gear backlash check.
3-11
•TM 9-2815-213-34
Section VIII. Repair of Crankshaft Adapter
3-36. Cleaning
Refer to paragraph 2-5 for cleaning instruction
3-37. Inspection
Inspect adapter in accordance with instruction in
paragraph 2-6.
3-38. Repair
No repair procedures beyond those
paragraph 2-7 are authorized for this part.
specified
in
3-39. Installation
a. Refer to paragraph 2-1ll.i., and reverse procedures to install adapter.
b. Tighten capscrews in the sequence as shown in
figure 3-20.
Figure 3-20. Crankshaft adapter tightening sequence
Section IX. Repair of Flywheel Housing and Spacer Plate
3-40. Disassembly
(fig. B4)
a. Using suitable arbor press remove oil seal (8).
b. Remove pipe plugs (6 and 17).
NOTE
If a replacement housing is to be
installed replace dowels only if the
housing will not line up within bore
tolerance.
3-41. Cleaning
Clean housing and spacer plate in accordance with
instructions contained in paragraph 2-6
d. Install dial gage and holder (34, fig. B-28) as shown
in figure 321, and check crankshaft flange concentricity
as follows:
(1) Place chalk marks at position A, A’, B, and B’
as shown in (fig. 3-21).
(2) Check reading at B and B’. Total runout is not
to exceed 0.010 inch.
(3) Check reading at A and A’. Total runout is not
to exceed 0.010 inch.
(4) If flywheel housing bore is not within limits,
move as necessary to correct measurements.
CAUTION
Oil seal bore run-out must also
remain within limit of 0.005-inch.
3-42. Inspection
Inspect housing and spacer plate in accordance with
instructions in paragraph 2-6.
3-43. Repair
No repair procedures beyond those specified
paragraph 2-7 are authorized for these units.
in
3-44. Assembly
a. Using a suitable arbor press, and with housing
properly supported to prevent distortion install oil seal.
b. Install pipe plugs.
e. If both bores cannot be brought within limits, the
flywheel housing must be replaced.
f. After measurements are brought within limits,
tighten capscrews alternately and evenly; make final
check after tightening. Tighten capscrews to 35 ft. lbs.
torque.
g. Check flywheel housing face as follows.
(1) Move dial gage-(fig. 3-21) and attachment to
housing face.
(2) Using a pinch bar wedged between a main
bearing cap and crankshaft throw, take up crankshaft
end clearance.
3-45. Installation
(fig. B-4).
a. Install gasket (3) on block.
b. Install spacer plate (2) and gasket (1).
c. Install housing. Refer to paragraph 2-11 and
snug tighten capscrews.
3-12
•TM 9-2815-213-34
(3) Turn crankshaft and check at points A, A’, B,
and B’ housing face (fig. 3-21).
NOTE
Take up crankshaft end clearance in
the same direction each time a
measurement is taken.
(4) Total flywheel housing face run-out must not exceed
0.008 inch.
(5) If necessary, to correct housing face run-out,
after the bore has been alined, remove housing and
recheck mating surfaces. Then install housing on
housing dowels and install capscrews. Tighten
capscrews to 35 foot-pounds torque.
Figure 3-21. Flywheel housing concentricity check.
Section X. Repair of Oil Pan
3-46. Disassembly
3-51. Installation
(fig. B-9).
a. Shellac new single-piece gasket (9) to pan.
b. Aline pan to block and install 12 capscrews,
lockwashers, and flat washers (25, 3, and 24), finger
tighten capscrews.
c. Reach inside inspection opening on right side of
pan and install two capscrews and lockwashers (10 and
11) securing suction and scavenger tubes (13 and 20) to
sump.
d. Shellac new single-piece gasket (7) to inspection
plate (6).
e. Install plate with six capscrews and lockwashers
(5 and 3).
f. Aline oil pan to flywheel housing and install two
capscrews (12), lockwashers (3) and flat washers (24),
finger tighten. Install six capscrews, lockwashers, and flat
washers (16, 10, and
9. fig. B-4). Tighten all oil pan securing capscrews.
Remove drain and pipe plugs.
3-47. Cleaning
Clean oil pan in accordance with instructions contained in
paragraph 2-5.
3-48. Inspection
Inspect pan and plugs in accordance with instructions
contained in paragraph 2-6.
3-49. Repair
a. Repair damaged threaded holes by tapping.
Refer to paragraph 2-7 for instructions.
b. Repair small cracks by welding. Refer to
paragraph 2-7 for welding instructions.
CAUTION
Do not weld finished surfaces.
3-50. Assembly
Install all pipe plugs and drain plugs.
Section XI. Repair of Flywheel
3-52. Disassembly
3-54. Inspection
Using blunt chisel and mallet drive the ring gear from the
Inspect flywheel and ring gear in accordance with
flywheel. Apply pressure, during removal, at various
instructions contained in paragraph 2-6.
positions around ring gear to prevent distortion.
3-53. Cleaning
3-55. Repair
Clean flywheel and ring gear in accordance with
No repair procedures beyond those specified in
instructions contained in paragraph 2-5.
paragraph 2-7 are authorized for flywheel or ring gear.
3-13
•TM 9-2815-213-34
3-56. Assembly
Assemble flywheel and ring gear as follows: a. If an oven
with a heat control is not available, heat gear with heating
torch, (not a cutting torch) from inside diameter so heat
travels outward towards the teeth.
b. Use a Tempilstick crayon or equivalent to
determine amount of heat applied. Stroke gear with 600
degrees Fahrenheit crayon. At 600 degrees Fahrenheit
the crayon will leave a liquid smear.
NOTE
Crankshaft end clearance must be
kept to rear limit while the above check
is made.
(7) Tighten flywheel capscrews to a final 200 to 205 footpounds torque in 50 foot-pound increments in sequence
shown in figure 3-22. Secure flywheel capscrews with
locking wire.
CAUTION
Overheating
gear
to
temperatures above 600 degrees
Fahrenheit will soften gear metal.
c. Place the ring gear on flywheel and quickly drive onto
flywheel until gear is firmly seated.
3-57. Installation
a. Install two 5/8-18x6 inches long, guide headless
studs in crankshaft flange.
b. Position flywheel over guide studs.
c. Insert eight flywheel capscrews, and tighten
alternately to 50 to 60 foot-pounds torque in sequence
shown in figure 3-22. Tighten flywheel capscrews to final
torque of 200/205 foot-pounds.
d. Check flywheel bore and clutch face as follows:
(1) Attach indicator and check pilot bearing bore
and drive ring pilot bore. Total run-out must not exceed
0.004 inch.
(2) Shift gage to indicate clutch mounting face.
(3) Chalk four marks equidistant on flywheel
circumference (fig. 3-23).
(4) Turn crankshaft, taking up crankshaft end
clearance as chalk marks aline with indicator Run-out
must not exceed 0.005 inch.
(5) If run-out exceeds 0.005 inch, remove
flywheel and clean flywheel and crankshaft mating
surfaces.
(6) Again install flywheel and recheck bore and
face.
NOTE: USE LOCKWIRE
AS REQUIRED
AT 40263
Figure 3-22. Flywheel tightening sequence.
A-BORE .004 INCH (RUN OUT)
B-CLUTCH MOUNTING FACE .005 INCH (WOBBLE)
Section XII. Repair of Valve and Injector Tapplets
(26 and 32) that is not secured by lockwire to remove pin.
c. Discard pin and lockwire.
d. Press bearing sleeve (27) or injector roller (29)
from injector tappet.
a. Remove and discard spring clips (31 and 35)
from tappet body (25 and 33).
3-59. Cleaning
b. Place 0.006 inch shim between body side of
roller (27 and 29) to prevent sprit back when removing
Clean tappets in accordance with instructions contained
roller. Press on end of pin
in paragraph 2-5.
3-58. Disassembly
(fig. B-6).
3-14
•TM 9-2815-213-34
e. Using dial indicator gage (calibrated in tenths of
a thousandth inch) check concentricity of rotating roller.
CAUTION
Injector and valve tappet dimensions are
not alike. Use correct dimensions when
checking wear.
3-60. Inspection
a. Perform inspection in accordance with the
instructions contained in paragraph 26.
b. Check for scored, flaked, or chipped rollers on
bearing sleeves. Discard damaged parts.
NOTE
If any of the above conditions exist,
camshaft should be inspected very
closely for damage.
NOTE
Roller eccentricity of the injector tappet
cannot exceed 0.005 inch, the valve
tapped cannot exceed 0.001 inch. Move
indicator to a new location and recheck.
c. Measure tappet body outside diameter for wear.
Measure roller and bearing sleeves od and id for wear.
Discard if worn beyond limits contained in repair and
rebuild standards paragraph 3-183.
d. Check tappet sockets by "bluing" corresponding new
push rod on ball end and rotating in tappet. A full seat
should be indicated.
e. Check body pin holes and inspect hole for burrs
before reassembly.
f. Using same indicator check squareness of roller
by sweeping indicator across diameter or end of roller,
then sweeping the other end. Rotate tappet roller 180
degrees and check again at roller ends by sweeping
across the diameter. Roller squareness must not exceed
0.001 inch in either injector or valve tappet assemblies. It
is recommended to extend some downward pressure
against the roller when gaging to assure firm contact.
NOTE
Assemblies that do not pass the
inspections
above
must
be
disassembled,
(perform
inspection
during disassembly to determine the
cause for rejection) reassembled, and
reinspected.
3-61. Repair
No repair procedures beyond those
paragraph 2-7 are authorized for tappets.
specified
in
3-62. Assembly
a. Press new injector roller on bearing sleeve in tappet
until securely seated.
CAUTION
Lubricating oil passage in pin must be
alined for proper lubrication.
b. Insert 0.006 inch shim between side of roller or
sleeve and tappet fork. Press pin through body and roller
with lockwire in pin.
362. Testing
NOTE
Tests of either the injector or valve
tappet assemblies require a surface
plate, small V block with clamp (to hold
tappet in position), and dial indicator
calibrated in tenths of a thousandth inch
attached to a surface plate (fig. 3-24).
a. With a small wire, check indexing of pins and
body lubricating oil passages.
b. Check freeness of roller by rotating two or three
turns. If "drag" is felt, the plating on the pin has probably
picked up burrs during assembly or pin is not being held
securely during assembly.
c. Stand small V block on surface plate.
d. Stand tappet assembly on surfacing plate with
roller up. Secure tappet in V block with clamp.
Figure 3-24. Tappet assembly test.
3-63. Installation
a. Install new retainer spring on each tappet (31
and 35, fig. B-6).
b. Install tappets in tappet bores of block, refer to
paragraph 2-ll.g. Injector tappets are larger
3-15
•TM 9-2815-213-34
and are placed between valve tappets. Aline tappet and
must be 0.010 inch clearance between tappet and plate
lock in position with retainer plate. There
when capscrew is tightened down.
Section XIII. Repair of Cylinder Heads
3-64. Disassembly
a. Install head in holding fixture (25, fig. B-28 as
shown in figure 3-25.
b. Using valve spring compressor (44, fig. B-28)
remove valve assemblies as shown in figure 3-26.
c. Using injector sleeve puller (19, fig. B-28)
remove injector sleeves as shown in figure 3-27.
d. Using cross head guide puller (43, fig. B-28)
remove crosshead guides as shown in figure 3-28.
e. Remove all pipe plugs.
3-45. Cleaning
Clean cylinder heads and valve assemblies in
accordance with instructions in paragraph 2
Figure 3-27. Injection sleeves-removal/installation.
Figure 3-25. Cylinder head in fixture.
Figure 3-28. Crosshead guide-removal/installation.
3-66. Inspection
Refer to paragraph 2-6 for general inspection
procedures.
a. Cylinder Head Fuse Plugs (fig. B-6). Cylinder
heads are equipped with fuse plugs containing a metal
alloy center that melts if the engine overheats. Examine
all fuse plugs for evidence of overheating. Replace all
defective plugs.
b. Valtve Seats (fig. 3-29). Inspect for loose valve
seats by tapping lightly on the cylinder head near the
inserts. If valve seat is loose enough to bounce, or
cannot be reground, mark for replacement, If valve seat
area exceeds 0.125 inch at any point, replace head
assembly.
c. Injector Sleeves.
(1) Perform a water test as follows.
Figure 3-26. Valve assemblies-removal/installation.
3-16
•TM 9-2815-213-34
NOTE
If nylok capscrew breakaway torque is
less than 15 inch pounds, replace
capscrews.
Figure 3-29. Valve seat-sectional view.
(a) Install injector sleeve holder (15, fig. B-28) on a
scrap injector and cup assembly into each injector
sleeve. Tighten sleeve holders to 10/12 foot-pounds
torque or injector capscrews to 30/35 foot-pounds torque
as shown in figure 3-30.
(b) Using water heated to 175/200 degrees
Fahrenheit, test cylinder head for leaks at 35/85 pounds
pressure.
(c) Check carefully around injector for any evidence
of water leaks. Mark sleeves for replacement that
evidence leakage. If cylinder head shows leakage,
replace head.
(d) Open water outlet valve to check for free water
circulation through cylinder head.
(2) Inspect injector sleeves for scratches on cup
seat area and for continuous contact by using Prussian
Blue. Mark sleeve that is scratched on does not show
continuous seat contact, of at least 0.060 inch wide, for
replacement.
(3) Check injector tip protrusion by installing
injector assembly and torquing to 30/35 footpounds. If
injector protrusion exceeds 0.125 inch mark sleeve for
replacement (fig. 3-31).
Figure 3-31. Injector tip protrusion measurement.
d.
Valves.
(1) Inspect valve heads for pitted, cupped,
cracked, or excessively worn condition. Check valve
head rim thickness (fig. 3-32) and replace valve if less
than 1/16 inch.
(2) Inspect valve stems for scored, cracked or
excessively worn condition. If stems are worn beyond
0.4490 inch replace valve.
(3) Inspect collet recesses (fig. 3-32) for
serviceability.
f. Crosshead Giudes (fig. 3-33).
(1) Check crosshead guides with a square. They
must be perpendicular at four right angles with the
cylinder head.
(2) Measure outside diameter of crosshead
guides using a micrometer. Guides must measure
0.4322 inch minimum. Discard if worn beyond that limit.
(3) Measure crosshead protrusion above block to
2.090/2.110 inches. Discard guides not within these
tolerances.
g. Valve Guides (fig. 3-34).
(1) Adjust a small bore gage with a micrometer
at 0.0002 inch above worn limit, and use as "No-Go"
gage.
(2) Mieasure the hole at several points crosswise
and endwise of the head.
(3) Mark valve guide for replacement if worn
larger than 0.4545 inch inside diameter.
(4) Inspect sharp edge of guides for chips,
cracks and burrs. If damaged, mark for replacement.
Figure 3-30. Injector sleeve holder installation.
3-17
•TM 9-2815-213-34
NOTE
A 1/32 inch spacer may be used under
valve spring when insert and valve have
been refaced.
(2) Replace springs if load is less than indicated
under "wear limits" at required compressed length.
Figure 3-32. Valve head and collet check.
Figure 3-34. Valve guide check
Figure 3-33. Crosshead guide cheek.
(5) Check valve guide protrusion to limit of
0.695/0.710 inch.
h. Valve Springs (fig. 3-35).
NOTE
Weak valve springs may cause flutter
which results in excessive wear on both
valve and seat. Valve flutter interferes
with valve timing and may cause valve to
strike the piston head. Weak springs
may also cause valve warping, cracking
and breaking.
Figure 3-35. Valve spring test.
3-67. Repair
a. Resurface Cylinder Head. Resurface head only
if it has been scratched, etched, or worn unevenly at
point of contact with gasket sealing areas.
(1) Remove a maximum of 0.006 inch of
material.
NOTE
The gasket surface should not deviate
from a true plane b, mote than 0.004inch.
(1) Using a spring tester capable of very
accurate measurements of spring lengths and applied
load, check springs against limits speciflied in repair and
rebuild standards, paragraph 3-183.
3-18
•TM 9-2815-213-34
(2) Measure head height using micrometer or
vernier calipers; dimensions must not exceed
4.4890/4.4990 inches.
(3) Restore counterbore and pocket depth at
valves and shallow counterbore area around injector port
(fig. 3-36) by grinding with a stone dressed to the
indicated contours.
b. Regroove Cylinder Head. If cylinder head has
been resurfaced, regroove with grooving tool (33, fig. B28), as shown in figure 3-37.
(1) Select scrapped injector, preferably one with
class "0" plunger bore and injector cup. Cut off cup to
expose plunger bore, to keep cup seal area intact.
(2) Install injector in cylinder head and tighten
30/35 foot-pounds torque.
(3) Select correct tool spacer block, 0.940 inch
thick. Assemble the regrooving tool, positioning largest
pilot pin so it protrudes downward
in same direction as cutter; tighten assembly in place.
(4) Rotate cylinder head and install regrooving
cutter in injector bore (fig. 347).
(5) Check position of stop in tool holder to make
certain it will not contact water hole during regrooving
operation.
(6) Adjust regrooving cutter so it protrudes
0.006/0.008 inch below stop. Rotate tool clockwise to cut
grooves. Do not rotate counterclockwise.
CAUTION
Do not attempt to cut deeper than cutter
groove depth or grooves will not form in
head. Groove lands should be
0.010/0.015 inch wide and must not
extended above head surface
Figure 3-36. Valve and injector counterbore dimensions.
Grind Valves.
(1) Wet grind valve from horizontal to exactly 30
degree angle.
(2) Inspect rim thickness after grinding as shown
in figure 332; if rim is less than 1/16 inch, valve is not
suitable for use and must be replaced.
(3) Check valve in reamed guide and against
newly ground valve seat face. Pencil mark valve face and
drop into position and rotate 10 degrees. A good seat will
be indicated if all pencil marks are broken. If pencil
marks are not broken either valve seat or valve refacing
tools have not been properly adjusted; final check should
be made with vacuum tester.
3-68. Assembly
a. Valve Guide.
c.
Figure 3-37. Cylinder head regrooving.
3-19
•TM 9-2815-213-34
(2) Ream crosshead guide bore to 15/82 inch if
necessary after installation.
c. Injector Sleeves.
(1) Install injector sleeves using sleeve driver
(14, fig. B-28) as shown in figure 3-40.
(2) Remove injector sleeve driver and install
injector sleeve holder (fig. 3-30).
(3) Using sleeve expander (13, fig. B-28), roll
upper portion of injector sleeve to 1.145/1.155 inches
inside diameter as shown in figure 3-41.
NOTE
Set drill press at 250 rpm and 600
pounds pressure for 30 seconds; apply
OE-10 oil during operation.
(4) Remove injector sleeve holder.
(5) Using sleeve roller (16, fig. B-28), roll lower
portion of injector sleeve as shown in figure 3-48.
(6) Cut injector sleeve seat with sleeve cutter
(17, fig. B-28) as shown in figure 343, to provide
maximum allowable sleeve protrusion of 0.125 inch,
0.100/0.115 inch nominal.
CAUTION
Insure that the 1/16 inch hole in valve
guide is turned toward exhaust manifold
and that the hole remains open after
assembly.
(1) Install valve guides as shown in figure 338.
Press in valve guide to 0.695/0.710 inch above head
surface with valve guide driver (49, fig. B-28).
(2) Ream valve guide from bottom side of
cylinder head using reamer, drill press and floating tool
holder. Valve guide must have inside diameter of
0.4525/0.4532 inch after reaming.
Figure 3-38. Valve guide installation
b. Crosshead Guides.
(1) Install crosshead guides as shown in figure 3-39.
Press in crosshead guide to 2.090/
2.110 inches above head surface with guide spacer (47,
fig. B-28).
Figure 3-40. Injector sleeve installation.
d. Valve Seat Inserts.
(1) Recondition valve seat counterbore using tool
kit, cutter, and valve guide (48, 51 and 41, fig. B-28) to
proper size (A, fig. 3-36), as shown in figure 3-44.
(2) Install swirl plate in intake valve ports only as
shown in figure 3-45.
(3) Install valve seat insert using valve seat insert
tool kit and peen insert in cylinder head as shown in
figure 3-46.
e. Grind Valve Seats.
(1) Select a suitable valve grinding machine
Figure 3-39. Crosshead guide installation.
3-20
**TM 9-2815-213-34
Figure 3-41. Injector sleeve rolling-upper portion.
Figure 3-43. Injector sleeve seat cutting.
Figure 3-42. Injector sleeve rolling-lower portion
Figure 3-44. Valve seat insert counterbore.
and proper size mandrels to fit reamed valve guides.
Dress grinding stone to 30 degrees from horizontal.
(2) Grind valve seats, holding motor as
nearly vertical as possible.
(3) Check valve seat width which should
be 1/16 to ¼/ inch.
(a) If ground seat is wider than 1/8
inch maximum stock can be removed from points "A"
and "B" (fig. 3-29) with specially dressed valve seat
grinder stones.
(b) Narrowing should not extend beyond
chamfer on seat insert. Chamfer provides for peen
metal.
(4) Dress wheel for final finish and finish
grind with light touches of stone against valve seat
face.
(5) Check valve seat concentricity with valve
seat indicator.
(a) Use valve guide as a center. Gage
must be a perfect fit on pilot mandrel.
(b) Run out should not exceed 0.002 inch total
indicator reading.
f.
Valve Assemblies. Reassemble valve assemblies
in reverse order of disassembly (para. 3-64).
3-69. Tests
a. Valve Seating (fig. 3-47). Test valve seating for
leaks with cylinder head gage (2, fig. B-29) as follows:
CAUTION
Never vacuum test cylinder head with injector
installed.
Installation of injectors could cause
misalignment of valves in valve seat area and result
in leakage during test.
(1) Select a vacuum cup of proper size for
valve to be tested.
3-21
*TM 9-2815-213-34
is less than "10" seconds valve seat is unsatis- factory. (7)
If valve seat seal is unsatisfactory:
(a) Check for leaking connections on tester.
(b) Operate tester with suction cup against
clean glass plate.
(c) Check for dirt on valve and seat.
(8) If necessary regrind valve seat (para. 368.e.).
NOTE
It is possible to mistake leakage around the
valve seat insert for valve seat leakage. If
this is suspected, apply grease to the
outside edge of the insert to make a grease
seal.
Perform vacuum test and insert grease
seal for a "break" indicating air leakage
between wall of counterbore and valve seat
insert. If leak around insert is detected,
correction is required before continuing with
test
Figure 3-45. Intake valve port swirl plate-installation
b. Head Assembly. Perform a water test on the
rebuilt head assembly (para. 366.c.).
Figure 3-46. Valve seat insert peening.
(2) Valve and seats must be dry and clean.
Place suction cup over valve head. O-Ring on cup
should seat on flat surface of head surrounding
valve. Grease area lightly with GAA for a better seal.
(3) Turn hand shut-off valve to open
position. Hold push button down to operate vacuum
pump.
(4) Operate vacuum pump until hand on
vacuum gage stops climbing at 15/25 inches of
mercury on the dial.
(5) Close shut-off valve; release push button
to stop pump.
(6) Time vacuum pressure decrease on
gage
to test valve seat.
(a) "Start" timing as soon as hand
reaches "15" inches of mercury on dial.
(b) "Stop" timing when hand reaches
"12" inches of mercury on dial, if elapsed time
Figure 3-47. Valve seat test.
3-70. Installation
a. Make certain pipe plugs are installed and
secure.
b. Clean mating surfaces of cylinder block and
cylinder heads. Make certain cylinder walls are
clean and well lubricated with OE-10 engine oil.
c. Place grommet retainers in water passages
in block, small end up.
d. Lay gasket on flat surface. Press grommets
in place by hand.
e. Install head gaskets over ring dowels so that
3-22
word "TOP" on gasket is visible. Be careful not to
dislodge grommets as gasket is lowered over
grommet retainers.
f. Using cylinder head lifting plate (45, fig.
B-28) as shown in figure 2-19, capscrews, lift head
with suitable hoist and lower into place over
dowels.
g. Blow all liquid and dirt from cylinder head
capscrew holes with compressed air.
rust preventive lubricant and install.
sequence shown in figure 3-48.
*TM 9-2815-213-34
Tighten each in
CAUTION
Keep rust preventative oil from internal
engine parts to prevent corrosive damage.
h. Coat short cylinder head capscrews with
Section XIV. Repair of Fuel Injectors
3-71. General
This section covers the disassembly, inspection,
repair, assembly and testing of injectors (fig. 3-49).
The injector is a simple mechanical unit which
receives fuel from the fuel pump, under pressure,
and injects it through fine injector cup spray holes
into the combustion chamber. The description "PT
Injectors" is only used to in the cate that the injector
is used with the PT fuel systems. The PT injectors
are mounted in the cylinder head and are cylindrical
in shape. ’The V8-300 engine uses of PT type C
injector. It consists of two major assemblies: injector
body and plunger; and the injector cup. The orifice
descriptions below are given for functional maintenance purposes.
a. Adjustable Orifice Plug. The orifice plug
used in the inlet drilling of the cylindrical injec- tor
adjusts delivery of fuel. Fuel delivery is ad- justed by
changing the orifice plug or by burnish- ing the plug in
operating position. Some ori plugs have a flange and
require a gasket bene the flange.
b. Drain Orifice. The drilled orifice in cup E
of the injector is the drain drilling. This orifice is fixed
in size and must not be altered in any way.
c. Metering Orifice. The orifice in cup end
of the injector allows fuel to enter plunger bore and
cup; do not alter in any manner.
3-72. Disassembly
(fig. 3-49).
a. Lift out injector plunger and spring. Tag
mating parts.
NOTE
Injector bodies and plungers are class fits, do not
interchange.
b. Remove and discard O-Rings
from injector
body.
c. Disassemble clamp securing screen to injector
body.
NOTE
Do not remove adjustable orifice plug from inlet
groove.
d. Place injector in injector cup wrench (30,
fig. B-28) and install in injector holding fixture
(29, fig. B-28) as shown in figure 3-50.
e. Remove injector cup; note size markings on
injector body for future reference.
f. Remove ball retainer, ball, and gasket from
top of injector body, discard gasket.
g. Place injector plunger in suitable holding
device with spring retainer upward.
h. Pull link and retainer as an assembly.
i. Using a collet type hand tap holder, pull
injector links (fig. 3-51).
3-73. Cleaning
Clean injector components in accordance with paragraph 25.
3-74. Inspection
Perform general inspection of components in accordance
with wear limits in repair and rebuild standards (para. 3-183).
Detailed inspection of injector components follow.
3-23
*TM 9-2815-213-34
sulphur content in fuel or overload operating conditions.
(3) Enlarged or distorted spray holes, caused by
cleaning with drills, wires, or other instruments.
(4) Plunger seat pattern covers less than 40 %
continuous area around cup, cone or plunger bore (fig. 352).
Figure 3-51. Injector Link-removal/installation.
Figure 3-49. Fuel injector PT (type C)
Figure 3-52. Plunger seat pattern.
Figure 3-50. Injector cup-removal/installation.
CAUTION
Never alter size of injector spray holes.
a. Injector Cup. Inspect injector cup spray
holes and tip with magnifying glass and compare
with new cup. Discard cup if any of following
conditions exist:
(1) Interior/or exterior abrasive wear.
(2) Corrosion damage and effect of excessive heat, usually resulting from high acid or
b. Injector Body.
(1) Inspect injector body plunger bore for
scoring, if scores are too deep, injector body
should be replaced.
(2) Use strong magnifying glass to check
for burs, carbon, and distorted radii in orifices.
When injector orifices are damaged, the injector
will not function properly.
c. Injector Plunger.
(1) Check closely for metal seizure caused
by scuffing or scoring.
(2) Spots or surface disruption at top of
plunger or at mid-point, usually are normal results of rocker lever thrust action. Unless metal is
displaced or wear is measureable at these points,
3-24
plunger may be reused. If worn excessively, place
body and plunger.
(3) Narrow streaks running the length
plunger usually are the result of varying thick- ness of
penetrate treatment used to prevent rust ing.
Plunger is satisfactory for reuse unless surface
distortion is evident.
d. Injector Spring.
(1) Check spring for excessive wear breaks.
(2) Test spring tension on spring tester that
is capable of very accurate measurements of spring
lengths and applied load by means of standards and
dial indicator gage.
(3) If injector springs compress to dimensions at less than loads given in repair and re- build
standards, springs must be replaced.
3-75. Repair Repair of the injector assembly is
limited to re- placement of spare parts and general
repair pro- cedures in accordance with paragraph 27.
3-76. Assembly
(fig. 3-53).
a. Drop check ball into bore in top of injector
body.
b. Using check ball seating tool (5, fig. B28)
screw down against ball and tighten to 30-40 inlb torque as shown in figure 3-54.
c. Install retainer plug, with a new gasket,
and
tighten to 30-40 inch pounds.
d. Lubricate new injector body O-ring with
OE-30 oil.
e. Using O-ring tool (39, fig. B-28), slide Oring onto injector body as shown in figure 3-55.
*TM 9-2815-213-34
h. Place new retaining ring on new plunger link and
press link into place. Press retainer flush to 0.010 inch below
bore surface.
i. Select cup of proper size (fig. 3-57) and in- stall
finger tight on injector body. Apply tension to aline plunger in
body, back off % turn, tighten with cup wrench (30, fig. B-28)
to 55 foot- pounds as shown in figure 3-50.
NOTE
Spring tension in tool is controlled by spacers
marked by the engine model which alines plunger
and cup when per- forming above operation.
CAUTION
If cup is replaced, always use identical
replacement cup.
j. Check injector assembly plunger seating on test
stand as described in paragraph 3-77.a.
k. Remove injector plunger from body. Lubricate plunger with test oil. Install injector spring
and plunger in body. Check to see that it does
not bind as it seats in cup.
l. Check cup spray pattern as described in test
section. If spray pattern tools are not available,
fill injector body two-thirds full of clean fuel.
Insert plunger forcing fuel out cup spray holes to
see that they are open and clean.
3-77. Test and Calibration
a. Injector Plunger Seat Test.
(1) Install injector assembly on test stand
as shown in figure 3-58.
NOTE
Figure 3-56 illustrates the injector checking fixture
currently in use in the Army supply system and is
available through normal supply channels.
NOTE
If sealing surface of PT (type C) cup is
slightly damaged, use lapping blocks and
mixture of 600 grit lapping compound and
OE-30 lubricant to smooth cup. Oscillate
cup on block, applying light pressure.
Clean thoroughly before in- stalling.
f. Select plunger and body with same size
markings (fig. 356), immerse injector plunger
in clean injector test oil.
g. Install plunger in injector body from which
it was removed and place injector in fixture (fig.
3-50).
NOTE
(2) Attach 80/90 p.s.i. air supply to test stand air
coupling.
(3) Remove spring and plunger from the assembled
injector and re-install plunger only in the injector body.
(4) Place injector in test set-up with cup seated in the
counterbore below the air valve.
(5) Install cylindrical injectors with drain and outlet
holes up.
(6) Position injector plunger with size mark centered
between the injector inlet and drain openings. Fill opening
with fuel oil and operate plunger several times to purge any
air trapped in injector.
(7) Seat handle against injector plunger
Oil injector cup and retainer with OE30 oil before assembly.
3-25
*TM 9-2815-213-34
CAUTION
Before deciding the injector is leaking,
be sure any air trapped in the fuel passage has been purged,
(9) If leakage exists, check for dirt or other
foreign material, changing or reassembly of the
cup will often correct leakage.
Figure 3-54. Injector check ball seating.
link and let weight control force against plunger Do
not apply any additional force to handle during test.
(8) Turn on air pressure. Injector is
acceptable if the duration of time before the first air
bubble appears is more than ten seconds, and time
between the observed air bubbles is not less than
five seconds.
3-26
*TM 9-2815-213-34
Figure 3-56. Injector body and plunger markings.
Figure 3-57. Injector cup marking.
10) If the cup seat is damaged in any way and
injector does not pass cup-to-plunger seat test,
plunger may be lapped into cup to obtain good
seating. Use no greater than 300 grade lap- ping
compound mixed with OE30 lubricating oil. Applying
light pressure, oscillate plunger in cup back and forth
for approximately one minute.
CAUTION
Figure 3-58. Injector plunger seat test.
tors.
It flow tests the complete injector assembly by
measuring fuel delivery. The injector is actuated under
controlled conditions closely simulating actual operating
conditions. The test stand counts injection strokes, supplying
fuel at specified pressure, and measures the delivery in a
glass graduate.
The following preliminary steps and
procedures are required prior to test stand operation.
CAUTION
Before operating the test stand make sure that the
cam box is filled to the level of the sight glass with
OES-30 oil.
After lapping, both the cup and plunger must
be thoroughly cleaned. Lapping compound
will damage fuel system unless removed.
The most effective cleaning process is the
use of an ultrasonic cleaner, if available, and
an after rinse in fuel oil.
(11) If injector is satisfactory, remove
plunger. Re-install spring and plunger.
b. Calibrating Injector Test Stand (fig. 3-9).
The injector test stand is used to test all injec.
NOTE
The test stand must be located near hot and cold
water connections. Water temperature, controlled by
a mixing valve, is used to maintain test fuel at an
80/100 degree Fahrenheit temperature
range.
3-27
*TM 9-2815-213-34
(1) Install factory calibrated master injector gage (36, fig. B-28), in test stand to adjusting
other injectors for fuel delivery.
CAUTION
The master injector must never be tampered with.
(2) Fill hydraulic fluid reservoir.
(3) Test oil tank on stand must be kept at
least ye full of diesel fuel.
(4) Aline timing mark (fig. 3-60) and close
hydraulic valve and open the air valve (fig. 3-61).
Place load cell tester (1, fig. B-29) in test stand
and clamp in place by opening hydraulic valve
(fig. 3-61).
CAUTION
Never operate test stand with load cell
in position.
(5) Adjust air pressure by turning knurled
button on air regulator until the load cell indi
cates within marked band on load cell gage (0
3-62). Lock knurled button in place with locknut. Note air gage pressure (gage at top
hydraulic reservoir).
(6) Remove load test gage by opening ]
draulic valve and returning air valve knob center
position. With cylinder rod in down posi- tion, check
to make sure hydraulic fluid shows hydraulic oil lever
sight bulb.
(7) Open air valve. While cylinder rod is at
the top of its travel, check to make sure there no air
in hydraulic fluid sight glass.
(8) Make sure injector seat contains 0.0
inch restrictor orifice when calibrating test stand.
(9) Place injector adapter (fig. 3-63) o~
master injector and engage locators in inject
mounting holes. Make sure seat is retracted a timing
marks are alined at timing wheel.
(10) Position test stand link (marked NV NH,
H) over injector plunger link and place adapter and
injector assembly in injector se tip back until link is
below machine push rod. necessary adjust bracket
so link is alined but r rubbing.
NOTE
Turn injector plunger so that class size
marking on top of spring retainer is midway
between inlet and drain connec- tions.
(11) Open air valve (fig. 3-61) and as
jector goes in clamped position make sure plunk
link is properly alined and engaged in link gui
(12) Check air gage pressure at top of ]
draulic reservoir as originally established with load test cell.
Close hydraulic valve (fig. 3-61) to lock injector in clamped
position. Connect inlet and drain connectors (fig. 3-64) to
injector.
(13) Start test stand motor and allow to run until fuel
temperature reaches a minimum of 80 degrees.
(14) Adjust fuel pressure by turning pressure
regulator knob until fuel pressure gage
shows 120 psi. If this pressure can not be achieved, the
trouble probably is due to a sticking air regulator, or to a worn
gear pump. Pres. sure of 120 psi must be maintained at all
times during calibration and testing.
(15) All counter wheels (fig. 3-60) must be set at
zero (0) as a starting point.
(a) Shift silver-colored counter wheels to right, rotate as
necessary then release them to indicate 1020 strokes.
Rotate empty vial into position by turning vial knob.
(b) Clear counter by rotating with thumb screw until all white
counter wheels show zero.
(16) Engage counter and
divert fuel to vial for measurement by pressing and releasing
red flow start switch.
(17) Stir fuel with a rod to settle out foam. Check
amount collected in vial at end of 1020 counter strokes.
(18) Look directly into vial at fuel level to avoid
parallax. If this reading shows 129 cc which is 3 cc below
correct injector master de livery specifications (132 cc @ 120
psi.), or an- other value, repeat test.
(19) Dump fuel from vial and repeat test at least
twice to insure consistent results.
(20) If 3 cc low, it will be necessary to set counter up
to approximately 1043 strokes or
about 71/2 strokes for each cc. Roll counter back,
all white counter wheels must show zero (0).
(21) Repeat
tests and adjust counter as necessary to obtain 132 cc
delivery at 120 psi. with fuel temperature at 80 degrees to
100 degrees Fahrenheit while master injector is in test stand.
Check readings for three cycles to insure repeatability, at this
point test stand is correctly
calibrated.
(22) Remove master injector from test
stand.
c. Injector Spray Pattern Check.
(1) Locate injector spray angle tester (6, fig. B-29)
on or near injector test stand (fig. 3- 59) or other source of
50 p.s.i. constant fuel pressure, so that injector inlet
connection of test stand will reach injector to be checked.
Use injector test oil or diesel fuel to perform test.
3-28
*TM 9-2815-213-34
Figure 3-59. Injector test stand
(6) Remove plunger assembly and spring from
injector.
(7) Select correct size plunger bore plug and rubber
seal and install in injector plunger bore
(8) Install the solid knurled plug (fig.
65) in the injector drain opening.
(9) Place injector in spray angle tester seat (fig. 365) and adjust hold-down bracket to position required, then
tighten thumb screw.
(2) Attach drain hose to tester base and place loose
end in test stand drain pan.
(3) Assemble 2 degree cup seat and space
to seat bracket bore.
(4) Check cup markings as shown in figure
3-57, for number of spray holes and place 6 and 9
hole target ring in base.
(5) Insert injector in injector adapter (2’ fig.
B-28) as shown in (fig. 3-65).
Figure 3-61. Hydraulic and air valves.
3-29
*TM 9-2815-213-34
Figure 3-62. Air pressure adjustment.
test stand or other pressure source to injector inlet or
adapter.
(12) Start test stand or other source of fuel and set
pressure at 50 psi.
(13) Shift target ring in base of tool so one spray
stream hits center of No. 1 or index window. This is tallest
window and is next to target
slide handle.
(14) Each spray stream must hit a window in the
target.
(15) If a stream hits above, below, left, or right of a
small window, shift the target ring so No. 1 window is at that
stream. If stream is still outside No. 1 window, cup is
defective or spray hole is dirty. Clean spray holes with
compressed air and recheck cup. If spray pattern is still defective, discard cup or check to make sure proper target ring
is being used.
NOTE
For a cup to be acceptable or more than one stream
must require the increased tolerance of the No. 1
window.
Figure 3-63. Master injector installation.
Figure 3-65. Injector mounted in test stand
Figure 3-64. Fuel inlet installation
(16) After testing, assemble plunger with spring in
body and store in clean place until ready for flow test.
d. Injector Flow Check.
(1) The injector test stand must be located near hot
and cold water connections. Water tem- perature, controlled
by a mixing valve, is used to maintain test fuel at an 80/100
degree Fahren- heit temperature range.
(2) Fill test fuel tank a/4 full of test fuel and maintain
this level or higher during test. Test fuel capacity is
approximately five gallons.
(3) Fill hydraulic fluid reservoir to half
(10) Tighten knurled knob to seal plunger
bore.
(11) Attach fuel inlet line from injector
3-30
*TM 9-2815-213-34
level in sight bulb with clean type A auto transmission
fluid. Be careful not to allow oil to standpipe in center
of reservoir, figure 3-59.
(4) Fill cam box with 3 inches of OE
lubricating oil. Refill with oil level drops to glass.
(5) Plug electrical connection into recel
carrying necessary voltage to operate test stand
(6) Before clamping on injector in test stand
must be timed by rotating timing wheel so
mark and pointer are alined as shown in figure
(7) Shop air pressure regulated by al
regulator is used to apply balanced force on hydl
system, (fig. 3-66). Air gage at top of hydraulic I voir
is used as a reference indicating that pre has not
changed after being set using a load tei during test
stand calibration.
(8) When air valve is opened, air travels ul in
center of tube type hydraulic reservoir and 4
downward pressure against column of hydraulic (fig.
3-67), activating load cell tester.
(9) When both air valve and hydraulic valve361) are opened, hydraulic fluid is admitted piston in
cylinder and lifts injector into clamped tion. Any leak
in hydraulic clamping system directly affect injector
loading and must not be per-mitted.
(10) In clamped position and with appropriate
link in place, tension on injector is same as it
operating engine. Use of improper link will clamp
load and upset delivery valves.
(11) Fuel is delivered to injector through
connector. Fuel pressure here is controlled a point
by connecting line and pressure reg (3-64).
(12) The second connection with clear plastic
line
is injector outlet connection (fig. 3-64) which c drain
fuel from injector back to tank.
(13) During test stand operation, operator a
test cycle which diverts fuel to vial graduate so
amount of fuel being injected can be measure
(14) Fuel is delivered to vial during a mea
number of strokes as recorded by counter (fig. 3
e. Ball Valve Seating Check.
(1) Attach test stand inlet pressure line to
connection injector adapter (23, fig. B-28) as s
in (fig. 3-64).
(2) Hold injector plunger down against its
seat in
injector cup with injector in vertical position (fig.
Figure 3-66. Test stand air pressure connection.
Figure 3-67. Load cell tester.
3-63), assembly may be hand held. Do not place in
test stand holding device.
(3) Turn on test stand, and adjust pressure to 150
psi.
(4) Check orifice plug inlet opening of injector
adapter (23, fig. B-28)ras shown in figure 3-62, for
leakage past ball valve.
NOTE
Insure plunger is seated in cup.
(5) If leakage is observed, the ball must be
reseated.
f Seating the Ball Valve (fig. 3-68).
(1) Remove retainer plug at top of injector body.
Leave ball in place, but discard retainer gasket.
(2) Screw check ball seating tool (5, fig. B-28) as
shown in figure 3-54, down against ball and tighten to 50
inch-pounds torque.
3-31
(3) Remove seating tool and install retainer
with new gasket. Tighten retainer to 30-40 i
pounds torque.
(4) Recheck injector for ball valve leakage (e
above).
(5) If ball has not seated satisfactorily, it will
be
necessary to resurface ball seat using seating
surface
cutter (6, fig. B-28). Great care must be exercised
in
removing only enough material to reface a new seating surface and remove all metal cuttings.
(6) Re-install ball, new gasket, and retaining
plug
fl2) and fA3), above.
(7) Perform ball seating check (e above).
*TM 9-2815-213-34
(4) Lock cap on injector and injector adapter (23,
fig. B-28) with two socket head capscrews.
(5) Install spring and plunger in injector.
NOTE
Turn injector plunger so class size marking
on top of spring retainer is midway
between inlet and drain ports of injector.
(6) Assembly retainer plate over injector and injector adapter.
NOTE
The side of the retainer plate with two
small pins locates against the injector
adapter as it is installed in the test stand.
All tests on the test stand are performed
without a screen on the injector.
(7) PT injector delivery is adjusted during test by
burnishing inlet orifice plug with orifice hole bur- nishing tool
(9, fig. B-28). Install tool as shown in figure 3-69.
(8) Retract burnishing tool needle by pulling out small
knob. With the needle retracted, tool may be
left in connector during all test operations.
(9) Run injector through a test cycle (d above), check
cc delivery. If delivery is lower than
specifications, turn knob with indicator point until it
1A
is spaced inch from large knob (fig. 3-70).
Figure 3-68. Ball seat resurfacing
g. Calibrating PT (Type C) Injectors.
(1) Remove injectors spring and plunk
Lubricate injector adapter (23, fig. B-28) with h
pressure lubricant so injector O-Rings will slide i
adapter without damage to O-Rings.
(2) Install cap and rotate into its notched
(fig. 3-63).
NOTE
The cap of the adapter contains a movable
dowel screw so the fuel inlet can easily be
centered in the sleeve hole after installing the
cap.
(3) Seat injector in adapter so injector inlet
alines
with adapater inlet after injector body is rotated into
adapter. Cap pin must seat in slot in adapter.
Check to be sure injector inlet is centered in sleeve
inlet hole.
(10) Slowly push small knob in until you feel nee- dle
enters orifice plug inside diameter, then turn knob
counterclockwise to lock needle shaft to larger knob with
indicator. Turn indicator knob in until you feel needle contact
plug. Index indicator with mark for each two cc increased
delivery (fig. 3-70).
(11) Back off adjusting screw and retract needle.
Retest injector (para. d, above). If delivery is more than 116117 cc. a new injector body must be install- |
ed.
(12) Recheck injector delivery for specified 116-|
117 cc with new injector body.
3-78. Installation
a. Inspect injector, it must be clean and the screen
around inlet groove must have no gaps or holes.
b. Check that copper sleeves in cylinder heads are
clean, free of chips, and carbon particles.
3-32
*TM 9-2815-213-34
ward position. Refer to Paragraph 3-43.
a. Install injector push rod in no. 1 cylinder. Only
no. 1 need be checked.
b. Install injector timing fixture (12, fig. B-28) in
injector bore as shown in figure 3-71. Indi- cator extension
must rest in socket of injector push rod. Tighten tool in place
with injector mounting capscrews.
Figure 3-71. Injector push rod timing.
Figure 3-69. Orifice hole burnishing tool installation
c. Rotate engine counterclockwise to top center
firing position. At point of maximum piston rise, set dial
indicator above piston to zero.
d. Rotate engine to 60 degrees ATDC; at this point,
60 degree mark on the moving plunger should be in line with
groove on retainer.
e. Set dial indicator for push rod travel to
zero.
f. Rotate engine in clockwise direction to approximately 60 degrees BTC of retainer. This is the same
index mark indicated in d, above.
g. Rotate engine in counterclockwise direction until
dial indicator reading shows piston has traveled to location
indicated at first check point under "Piston Travel" in chart 31 below. Read push rod travel on dial indicator and check
read- ing against limits.
Figure 3-70. Orifice plug burnishing
Chart 3 -1. Injection Timing
c. Lubricate O-Rings with GAA lubricant.
d. Start injectors into bores with inlet toward
camshaft. Guide them by hand until injectors are
alined in bores and not binding in any manner.
e. A hard push on injector bodies with butt
end of a hammer handle will seat injectors. A snap
should be heard and felt as cups seat in copper
sleeves.
f. Install hold-down clamps, flatwashers, and
capscrews. Tighten capscrews, 30 to 35 footpounds torque.
Crank angle
Piston travel
degrees
inches
normal
Push tube travel
fast
slow
22.5 BTC
15.5 BTC
6.0 ETC
0.0575
0.0307
0.0115
0.2032
0.0816
0.0143
0.0610
0.0330
0.0135
0.0645
0.0357
0.0155
h. Check push rod travel against piston travel
3-79. Injector Timing
NOTE
Woodruff key used to key camshaft gear to
the camshaft provides one degree advanced
timing and may be identified by a yellow-tip
which is placed in a for3-33
*TM 9-2815-213-34
at each of remaining positions shown above (16 and
6.0 BTC). If push rod travel is greater or le than
limits shown, timing is slow or fast respectively. A
new camshaft key must be installed bring push rod
travel within limits. Refer to paragraph 212.k. for
removal of shaft, and pal graph 3-30 for disassembly.
NOTE
Before installing new key, make sure
guide spring on tappet body is not holding tappet off camshaft lobe.
i. Recheck limits as outlined in Chart 3-1.
j. Remove timing fixture and injector push rod.
Section XV. Repair of Rocker Arm Assembly and Push Rods
3-80. Disassembly
(fig. B-6)
a. Remove locating socket head stew (44)
from mounting bracket (8). The rocker shaft locating
socket head screws are located on rear left bank and
front of right bank assemblies.
b. Slide rocker arm shaft brackets and rock
arms (47, 50, and 52) from the shaft (46).
c. Remove rocker arm shaft plugs (45) from
each end of each shaft.
d. Remove adjusting screws (55) and
locknut
(54) from rocker arms.
gage or by observation of small protrusion at the
bottom of socket.
(6) Check that all lubricating oil passages
are open.
(7) Inspect thread condition on all screws and rocker
arms. Check closely for thread dam- age at assembled
position of locknut. Ensure
that screws operate freely through rocker arms.
(8) Check rocker arm shaft for scoring, galling, outof-round and wear. If worn smaller than 1.1845 inches,
install new shaft.
NOTE
New rocker arm shaft measures 1.1856/
1.1865 inches with a wear limit to 1.1845
inches,
3.81. Cleaning
Clean all parts in accordance with paragraph 2
3-82. Inspection
a. Rocker Arm Assembly
(1) Perform general inspection of rocker arm
assembly in accordance with paragraph 2-8
(2) Gage rocker lever bushings with tele
scope gage and micrometer.
(a) Set telescopic gage 0.0002 inch above
worn limit of 1.1905 inches for use as a plug gage.
NOTE
The inside diameter of a new rocker arm
bushing is 1.1875/1.1895 inches and may
wear to 1.1905 inches maximum.
(b) Replace bushings worn beyond limits
(para. d, below).
(3) Check intake and exhaust rocker arm
crosshead contact surface. If worn or damaged,
replace with new rocker arm.
(4) The ball end of rocker arm adjusting
screws must be true spheres. Test with 1/4 inch
radius gage and replace worn adjusting screw
(5) Worn injector rocker arm sockets must
be replaced. Wear is easily detected with fillet
(9) Examine rocker arm shaft brackets for cracks,
breaks and stripped threads. Replace as necessary.
(10) Visually inspect arm side surfaces which mate
with adjacent arms. If galled, grind surfaces to original
smoothness.
b. Push Rods.
(1) Check ball end of all push rods for worn radii. A
new allowance of 0.3150 inch. Check in- jector and valve
push rod ball ends with 5/16 inch radius gage.
(2) Test sockets of push rods with ball end of a new
rocker lever adjusting screw or with 1/4 inch fillet gage.
(3) Replace defective push rods. Extreme wear on
either end of push rod will result in loss of lubricating oil
pressure and may interfere with proper injector and valve
adjustment.
3-83. Repair
Repair of the rocker arm assembly and push rods is limited
to replacement of defective parts. Re- place rocker arm
bushing as follows:
a. Press out worn bushing with mandrel and
block set (4, fig. B-28).
3-34
*TM 9-2815-213-34
b. Blow out lubricating oil passages with
compressed air.
c. Install new bushings using mandrel and
block
set.
3-84. Assembly
a. Dip rocker arm shaft plugs in lubricating
oil,
OE-10, to prevent galling. Insert plugs in shaft with
an appropriate mandrel. Refer to paragraph 3-’80.
NOTE
Shafts are plugged at both ends. Do not install plug in shaft without a mandrel.
b. Install rocker arm adjusting screws and
NOTE
For ease of handling tie rocker arm assembly
together with heavy rubber bands or cord (fig. 2-15).
Keep that end of assembly which is opposite the
locating screw up, to prevent parts from sliding off.
3-85. Installation
a. Install push rods in tappets.
NOTE
Injector push rod is the largest and fits between the
exhaust and intake push rods. If new rod is used,
make sure it has same part number as the one
removed.
b. Position rocker arm assembly to cylinder head
and engage push rod adjusting screws in push rod
sockets.
nuts.
c. Install sockets in injector rocker arms.
d. Coat rocker arm shaft with OE-10
lubricating
oil.
e. Position rocker arm shaft bracket with
locating
screw hole on rocker shaft. Aline shaft and bracket
locating holes and secure with allen head locating
screw.
f Slide valve rocker arm, injector arm, and
valve
rocker arm onto rocker arm shaft.
g. Slide rocker arm shaft bracket onto shaft
and
repeat Step 6 until all arms are in place.
h. Slide the last bracket into position.
CAUTION
Rocker arm adjusting screws must be loose to
permit tightening the cylinder head hold down
capscrews.
c. Repeat procedures in paragraph 3-70g and h, for
capscrews through rocker arm brackets.
d. With feeler gage, check for clearance between all
rocker arms and rocker arm brackets.
Section XVI. Repair of Push Rod Cavity Covers
3-86. Disassembly
There are no disassembly procedures required.
3-87. Cleaning
Clean covers in accordance with the requirement
paragraph 2-5.
3-88. inspection
Inspect in accordance with paragraph 2-6.
3-89. Repair
Repair is limited to replacement of defective parts
and general repair procedures in accordance with
paragraph 2-7.
3-90. Installation
a Check for installation of pipe plugs in the block.
b. Position cover with new gasket to block (fig.
2-14). Secure with flatwasthers and capscrews.
Section XVII. Repair of Cylinder Head Covers
3-91. Disassembly
There are no disassembly procedures required.
3-92. Cleaning
Clean covers in accordance with paragraph 2-5.
3-93. inspection
Inspect cover in accordance with paragraph 2-6.
3-94. Repair
Repair is limited to replacement of defective covers
and general repair procedures in accordance with
paragraph 2-7. Refer to TM 9-2320-206-20 for
repair of breather tube assembly.
3-95. Installation
Refer to paragraph 2-11a, and reverse procedures.
3-35
*TM 9-2815-213-34
Section XVIII. Repair of Air Compressor and Drive Assembly
3-96. Disassembly
a. Remove drive gear and woodruff from shaft
b. If inspection indicates need, remove sleeve
bushing from air compressor rear support.
CAUTION
Be sure that oil ports in sleeve bushing are alined with
corresponding oil ports in rear
support.
3-97. Cleaning
Clean air compressor and drive assembly in accordance with paragraph 2-5.
3-101. Installation
a. Slide air compressor and drive assembly with new gasket,
into engagement of drive gear with camshaft gear.
3-98. Inspection
a. Inspect oil flow passage in air compressor rear
support to insure unrestricted passage.
b. Inspect air compressor rear support sleeve
bushing for wear, restricted oil groove, and alinement
of oil ports in support. Replace bushing if excessive
wear is evident.
c. Inspect drive gear against specified limits in
repair and rebuild standards paragraph 3-136.
Replace gear if outside limits specified.
d Inspect air compressor in accordance with
paragraph 2-6.
3-99. Repair
Repair of air compressor and drive assembly is
limited to replacement of spared parts or units
3-100. Assembly
a. Install drive gear on drive shaft.
b. Press sleeve bushing into air compress rear
support.
CAUTION
Be sure that "O" index mark on drive gear tooth (fig.
3-72) is alined between the two punched-marked
teeth on camshaft gear.
b. Secure assembly snug tight only with three capscrews as
shown in figure 8-78.
c. Attach a dial indicator to flywheel housing as shown in
figure 3-70.
d. Advance drive gear as far as possible and set dial
indicator to zero.
e. Retard drive gear and note indicator reading.
NOTE
Indicator reading should be within 0.006-0.009
inch. If reading is outside these limits, gear train
must be replaced.
f. Remove capscrews and lockwashers (step b.).
g. Install rear support on drive shaft and position to housing
securing support with five capscrews and lockwashers.
Section XIX. Repair of Fuel Pump and fuel Lines
3-102. Disassembly
NOTE
Perform the requirements of paragraph
3-104 a through d before disassembling the
pump. If the pump operation is in accordance with the specified requirement of
these paragraphs, proceed to paragraph 3107 (fuel pump test and calibration
Disassembly of the pump will not be
necessary.
a. Disassembly Into Sub-assemblies. Mount
fuel
pump (fig. 3-73) to fuel pump mounting plate and
ball joint vise (1 and 2, fig. 28) as shown in figure
3-74.
(1) Fuel shut-off solenoid valve assembly
B-17).
(a) Remove two capscrews, lockwashers, and
flat washers (3, 4, and 5) securing valve to pump.
(b) Remove valve (1). Discard O-Ring (17).
(c) Remove four screws and lockwashers (14
and 15) securing coil assembly (13) to pump housing
(6).
(d) Remove shield (12), O-Rings (8 and 11), spring (10), and valve (9).
(e) Remove knob (18) on manual override shaft
(7) and remove shaft.
(f) Remove outlet connection (2) and pipe plug
(16).
(2) Fuel pump damper assembly (fig. B-16).
(a) Remove two capscrews, lockwashers, and
flat washer (23, 24, and 25) securing damper assembly
to pump gear assembly.
3-36
*TM 9-2815-213-34
Figure 3-72. Air compressor drive gear timing mark.
(b) Remove plate (16), packing (17), nylon washer
(18), diaphram (19), O-ring (20), body (21), and seal ring
(22).
(3) Mainshaft Cover and Governor Assembly (fig. B18).
(a) Remove six capscrews, lockwashers, and plain
washers (33, 34, and 35) securing main shaft cover and
governor assembly to pump housing.
(b) Using fuel pump governor weights puller (28, fig.
B-28), remove governor weights assembly (19) from
cover as shown in figure 3-75.
(c) Remove retaining ring (30) from governor weight
carrier shaft (27).
(d) Remove sleeve bushing (29) and drive shaft
gear (28).
(e) Remove weight pivot pins (24) and hollow pin
shafts (25), supporting governor weights (26), and thrust
washers (20).
(f) Remove weights, washers, compression spring
(21), flat shimming washers (22), and weight assist
plunger (23).
(g) Remove capscrew (7), lockwasher (8), flat
washer (9), and hub (10) securing drive assembly to
cover.
NOTE
The hub is keyed to the shaft by key (18).
(h) Remove tachometer drive gear (16),
3-37
*TM 9-2815-213-34
Figure 3-73. Fuel Pump PT (type G).
pump drive gear (15), bearing ring (14), and drive shaft
ball bearing (13), from drive shaft
(i) Using oil seal tool (35, fig. B-28), re(12).
move two oil seals (11) from cover as shown in figure 376.
(4) Fuel Pump Gear Assembly (fig. B-16).
(a) Remove four capscrews (10, 13, and
3-38
*TM 9-2815-213-34
(14) and lockwashers (9) securing gear assembly
(1) to pump housing. Remove gasket (2).
(b) Separate cover (15) and housing
from two dowels (4) to release two shafts (6 and
7) two gears (5). Discard gasket (8).
(c) Remove ring dowels (3) from housing.
(d) Remove inlet adapter (12) and ball
check valve elbow (11) from cover.
(5) Governor Spring Pack Assembly (fig.
B-17).
(a) Cut seal wire (33) and remove capscrew seal (34).
(b) Remove two capscrews (32), two capscrews (36), four lockwashers (31) and four flat
washers (30) securing assembly to pump housing. Discard gasket (28).
(c) Remove spring pack assembly from
housing barrel.
(d) Remove snap ring (27) from guide
and clip assembly (22).
(e) Remove spring retainer (26), high
speed spring shims (25), and high speed spring
(24).
(f) Remove idle adjusting screw (23),
adjusting screw washer (21), idle speed spring
(20), and plunger (19).
(g) Remove pipe plug (35) from cover.
(6) Tachometer Drive Assembly (fig. B-27).
(a) Remove two slotted-head screws (3)
securing tachometer cable drive adapter (1) and
cap (2) to pump housing.
(b) Remove adapter, cap, gasket (2), and
shaft seal (5). Discard gasket.
(c) Using a brass drift, as shown in figure
3-77, drive the assembled shaft (6), bearing
Figure 3-74. Mounting plate and ball joint vise
installation.
Figure 3-75. Governor weight assembly removal/
installation.
Figure 3-77. Tachometer drive assemblyremoval/installation.
Figure 3-76. Governor shaft oil sealsremoval/installation
3-39
*TM 9-2815-213-34
sleeve (7), and gear (8) from housing.
(d) Press the gear from shaft and remove bearing
sleeve.
b. Fuel Pump Housing Assembly (fig. B-15).
(1) Filter Assembly.
(a) Remove filter cap (3), sealing ring (2), filter
spring (4), and filter element (5).
(b) Discard sealing ring.
(2) Governor Plunger Assembly.
(a) Remove plunger assembly from housing as
shown in figure 3-78.
(b) Remove spring pack housing (31).
(c) Remove pin (36) securing drive governor
plunger (16) tc plunger spacer (37) and shaft (35).
(d) Remove compression spring (33), shims (34),
and thrust washer (38).
3-103. Cleaning
Clean all fuel pump components in accordance with
paragraph 2-5.
3-104. Inspection
a. Visual. Visually inspect the assembled pump in
accordance with paragraph 2-6.
b. Housing Porosity and Leakage Check.
(1) Fill fuel pump with clean diesel fuel.
(2) Remove suction fitting at fuel pump gear
assembly and install suitable air fitting to facilitate
attaching 20 psi. air pressure hose.
(3) Apply 20 psi maximum air pressure to fitting.
(4) Pour fuel oil over pump and examine for leaks
indicated by air bubbles.
(5) Wipe pump dry and check for seepage of fuel oil
from inside pump.
(6) If either type of leak is evident, fuel pump
housing must be replaced.
(7) Remove air hose and fitting.
(8) Replace suction fitting on fuel pump gear
assembly.
c. Mounting Pump On Test Stand.
(1) Mount adapter ring assembly (2, fig. 3-79) to
adapter bracket (1, fig. 3-79) and secure with four
capscrews and plain washers.
NOTE
"TOP" or part number on adapter ring
must be at top.
(2) Place ring and adapter assembly on stand mounting
rails and secure to rails with clamp bar (fig. 3-80). Finger
tighten clamp bar only.
(3) Mount pump on adapter ring and bracket
assembly and secure with four capscrews and flat
washers (fig. 3-81).
(4) Place coupling insert (3, fig. 3-79) into coupling
in stand drive shaft (fig. 3-81).
(5) Loosen bar clamp and slide pump and bracket
assembly to engage stand drive shaft. Allow 1.16-inch
end clearance between pump drive and stand drive.
Tighten bar clamp screw securely (fig. 3-82).
(6) Install pump inlet adapter assembly (5, fig. 3-79)
in pump inlet port as shown in figure 3-82.
(7) Connect 1/2-inch ID flexible hose (11, fig. 3-79)
from stand suction control valve (fig. 3-82) to flare
connector of inlet adapter assembly on pump.
(8) Connect 1/4-inch clear flexible hose (7, fig. 3-79)
from stand supercharger inlet con-
Figure 3-78. Plunger assembly-removal/installation.
(3) Throttle Assembly.
(a) Remove two throttle adjusting jam nuts (6) and
two adjusting screws (7).
(b) Remove throttle snap ring (17).
(c) Cut seal wire (24) and remove throttle cover seal
(23).
(d) Pull throttle assembly from housing
(e) Remove nut (22), lockwasher (21), flat washer
(20), and capscrew (19) securing throttle lever (18) to
shaft.
(f) Remove shaft cover (16), spacer (15), and stop
pin (14) from shaft (13).
(g) Remove setscrew (8), lockwasher (9), plunger
(10), shim (11), and O-Ring (12) from shaft.
(4) Remove pipe plug (27), clip (28), fuel body plug
(43), O-Ring (42), and pipe plug (1) from pump housing.
3-40
*TM 9-2815-213-34
nector (fig. 3-83), to 1/4-inch flare connector on pump
inlet adapter assembly.
NOTE
If during operation of the stand oil is sucked
into vacuum gage no. 1 (fig. 3-80) it will be
necessary to use a supplementary vacuum
gage (vacuum gage no. 2, fig. 3-80).
Disconnect hose from stand supercharger inlet
connector (fig. 3-83) to pump inlet adapter.
Connect flexible hose from supplementary
vacuum gage no. 2 to pump inlet adapter (5,
fig. 3-79).
(7) Turn range crank to "LOW RANGE" (fig. 3-80).
(8) Start stand and pump operation by depressing
start switch. Depress and release switch until pump
operation is between 400-450 rpm as observed on stand
"TACHOMETER" (fig. 3-80).
NOTE
Check rotameter for presence of air in fuel
flow. If air bubbles are present, work pump
throttle from full open to idle, several times, to
relieve any entrapped air in pump.
(9) Turn on "AUX MOTOR" switch for one minute, to
eliminate any air entrapped in test stand (fig. 3-80).
(10)Adjust "FUEL REGULATOR" to a maximum of
20 psi as observed on "FUEL PRESSURE" gage (fig. 380).
(11)Shut-off "AUX MOTOR" switch.
(9) Install pump discharge fitting assembly (4, fig. 3-79)
in pump fuel shutoff solenoid valve (fig. 3-83).
(10)Install flexible hose (10, fig. 3-79) from stand
"PRESSURE GAGE" outlet to pump discharge fitting (fig.
383).
(11)Install flexible hose (9, fig. 3-79) from stand
"FUEL INPUT" connection to pump discharge fitting (fig.
3-83)
(12)Install /2-inch ID flexible hose (8, fig. 379) from
stand "FUEL OUTLET" connector to stand "FUEL
RETURN" connector (fig. 3-83).
(13)Install flexible hose (6, fig. 3-79) to no. 1
accumulator can (fig. 338), from stand "LEAK TEST"
connector.
(14)Turn on fuel heat switch (fig. 3-80), observe that
temperature on "FUEL TEMPERATURE" gage is
between 80 to 100 degrees for testing.
d. Gear Pump Test.
NOTE
If air bubbling persists check all lines for
leakage. If no leaks are uncovered, or, if fuel
pump fails to pick-up fluid the pump must be
disassembled and repaired or replaced.
Proceed with the following steps only if pump
is operating satisfactorily.
(12)Increase pump speed to 2100 rpm.
(13)Set pump throttle to wide open position.
(14)Set "SUCTION VALVE," "BYPASS VALVE" and
"FLOW CONTROL" to fully open position.
CAUTION
Never operate fuel pump until check valve has
been checked for restrictions.
NOTE
Indicated flow on the rotameter should be not
less than 850 pounds per hour (pph).
(1) Set stand motor switch (fig. 3-80) to "FORWARD."
This corresponds to code designation on pump name
plate. "L" for left-hand (fig. 3-84), as viewed from rear of
pump.
(2) Open stand "BYPASS VALVE," "SUCTION
VALVE" and "FLOW CONTROL VALVE." Back seat all
other valves to prevent leakage (fig. 3-80).
(3) Open pump solenoid manual overide knob (fig.
3-73) by turning fully clockwise.
(4) Install throttle spring (fig. 3-82) to hold throttle in
wide open position.
(5) Set stand 4-way valve to "ROTAMETER"
position (fig. 3-80).
(6) Set stand power switch to "ON" position.
e. Inspection of Sub-Assemblies.
(1) Fuel Shut-Off Solenoid Valve Assembly.
(a) Visually inspect shut-off valve and valve seat for
wear and corrosion. Valve seat must be 0.015 inch
minimum width.
(b) Check oil assembly with ohm-meter. Replace
coil if resistance is below 30 +3 ohms.
(2) Fuel Pump Damper Assembly. Inspect body,
plate, and diaphragm for excessive wear.
(3) Mainshaft Cover and Governor Assembly.
(a) Perform general inspection in accordance with
paragraph 2-6.
(b) Place one leg of depth gage base of pedestal
across the carrier walls and measure down to the front
cover gasket surface (no
3-41
*TM 9-2815-213-34
1 Adapter bracket (11020392)
2 Adapter ring assembly (11020532)
3 Coupling insert (110200539)
4 Discharge fitting assembly (11020540)
5 Leakage accumulator hose (11020361-10)
6 Leakage accumulator hose (11020361-10)
7 Fuel manifold hose (11020361-10)
8 Fuel suction hose (110203613)
9 Fuel input hose (11020361-11)
10 Fuel pressure hose (11020361-14)
11 Fuel return hose (11020361-12)
Figure 3-79. Fuel pump test stand equipment.
Gasket). Move depth gage to opposite side of carrier and
down to plunger.
(b) Subtract second measurement from average
again measure to front cover gasket surface directly
across cover from previous measurement (do not turn
determined under (b) above. The result is the weight
carrier or cover). Average these two measurements. This
assist protrusion. If weight assist protrusion is below
procedure is necessary to determine uneven carrier wall
specifications, (0.840/0.860), add shims on reassembly.
heights.
If weight assist protrusion is above specifications,
(c) Position depth gage across carrier directly over
remove shims or grind exposed end of weight assist
weight assist plunger. Measure
plunger.
(4) Pump Gear Assembly.
3-42
*TM 9-2815-213-34
Figure 3-80. Fuel pump test stand.
(a) Perform general inspection in accordance with
inch I.D. Replace pump if parts are defective.
paragraph 2-6.
NOTE
(b) Check pump shafts for wear or scoring. Discard
If shaft bore is scored 1/3 of circumference or
shaft if damaged. Replace shaft if worn smaller than
more in cover or body, replace shaft. If scored
0.4998/0.5001 inch.
less than 1/3 clean shaft.
(c) Check gear width. New gears are 0.7483/0.7486
(5) Governor Spring Pack Assembly. Perform
inch wide. If gears are scored or worn, gear must be
general inspection in accordance with paragraph 2-6.
replaced.
(6) Tachometer Drive Assembly. Perform general
(d) Check gear body and cover for scoring or wear.
inspection in accordance with paragraph 2-8.
Replace parts if required. New gear pocket depth should
be 0.7479/0.7483 inch. Shaft bore in cover and body
should be 0.5013/0.5016
3-43
*TM 9-2815-213-34
Figure 3-81. Pump mounted on test stand.
(7) Fuel Pump Housing.
of defective spared parts (appendix B).
c. Mainshaft Cover and Governor Assembly. Repair of
(a) Perforn general inspection of housing and
the assembly is limited to general main. tenance repair
components in accordance with paragraph 2-6.
procedures (para. 2-7), and replacement of spared parts
(b) Check front main shaft bushing for evidence of
(appendix B).
seizure or burns.
d. Pump Gear Assembly. Repair of the gear assembly
(c) Using an inside micrometer measure inside
is limited to general maintenance repair procedures
diameter of bushing. If worn beyond 0.7525-inch replace
(para. 2-7), and replacement of spared parts (appendix
bushing.
B).
3-105. Repair
e. Governor Spring Pack Assembly.
a. Fuel Shut-Off Solenoid Valve Assembly. Repair
(1) Replace governor if worn beyond limits specified in
of the valve assembly is limited to general maintenance
serviceability standards. Replace with plunger and lap to
repair procedures, paragraph 2-7, and replacement of
fit with No. 80 fine grit lapping compound. Remove all
defective spared parts (appendix B).
lapping compound from parts.
b. Fuel Pump Damper Assembly. Repair of the
damper assembly is limited to general maintenance
NOTE
procedures (para. 2-7), and replacement
PTG Governor Plungers are color coded. Red
represents size 0 (standard) and
3-44
*TM 9-2815-213-34
Figure 3-82. Pump to stand drive shaft engagement.
Blue represents size 1 (oversize). Standard size
can be used. Minimum 0.001 inch interference fit is
diameter is 0.37460-0.37468 and oversize diameter is
required.
0.37470-0.37478.
(4) To locate a new governor barrel in the housing,
(2) If governor barrel is worn too large for the
scribe a center line on barrel and housing, lining up the
oversize plunger, replace barrel by heating housing in
fuel passages to prevent fuel flow restriction (fig. 3-85).
boiling water 112 to 2 minutes, and press out worn
(5) Heat housing in oven to 300 degrees Fahrenheit.
governor barrel.
(6) Cool barrel in dry ice or by another suitable
method.
CAUTION
(7) Coat new governor barrel with high pressure
Remove spring dowel which secures barrel in
lubricant.
fuel pump, before attempting to remove
(8) Place governor barrel in housing bore lining up
governor barrel. To pull spring dowel, insert
scribe marks, then press barrel into housing with arbor
wire hook into hole provided in dowel and
press.
remove.
(9) Select new governor plunger and fit it in barrel. If
(3) Check barrel bore in housing to determine
plunger enters try larger size plunger. If the larger size
whether standard size barrel (fig. B-17)
plunger fits loosely in bore, replace barrel and plunger.
3-45
*TM 9-2815-213-34
Figure 3-83. Pump preparation for test and calibration.
(11)If lapping is necessary, see paragraph e(1),
above.
(12)Install spring dowel into bottom of barrel, with
slot of pin to front of housing.
f. Tachometer Drive Assembly. Repair of
tachometer drive assembly is limited to general
maintenance repair procedures (para. 2-7) and
replacement of spared parts (appendix B).
g. Fuel Pump Housing.
(1) Perform general maintenance repair procedures
(para. 2-7) and replace defective spared parts (appendix
B).
NOTE
If replacement of front main shaft bushing (fig.
B-18) is necessary perform steps (2) through
(5).
(10)Brush plunger lightly with crocus cloth to remove
(2) Drive out worn bushing using a gouge chisel and
any lubricant.
mallet.
3-46
*TM 9-2815-213-34
governor plunger. Assembled in reverse order of
(para. 3-102.b. (2)).
(5) Insure clearance between thrust washer
and drive plunger governor as shown in figure
3-89.
(6) Install governor plunger assembly as
shown in figure 3-78.
(7) Install new filter assembly. Assemble in
reverse order of disassembly (para. 3102,
b. (1)).
b. Tachometer Drive Assembly. Assemble in re.
verse order of disassembly (para. 3-102.a. (7)).
c. Governor Spring Pack Assembly. Assemble
in reverse order of disassembly (para. 3-102.a.
(6)).
d. Fuel Pump Gear. Assemble in reverse order
of disassembly (para. 3-102.a. (5)) insuring that
notches in housing and cover correspond.
e. Mainshaft Cover and Governor Assembly.
(3) Apply thin coat of high pressure lubricant and press bushing flush into housing bore
using arbor press.
(4) Attach fuel pump fixture (42, fig. B-28)
as shown in figure 3-86.
(5) Line ream bushing to 0.7495/0.7505
inch.
3-106. Assembly of Sub-Assemblies and
pump
a. Pump Housing.
(1) Install all pipe plugs, dowels, and clips
using new O-Rings as required.
(2) Assemble throttle assembly in reverse
order of disassembly (para. 3-102.b. (3)), installing new 0 Ring with O-Ring assembly tool (37,
fig. B-28) as shown in figure 3-87.
(3) Install throttle assembly as shown in
figure 3-88.
(4) Install compression spring and assemble
Figure 3-85. Scribing governor barrel.
Figure 3-87. Throttle shaft O-ring installation.
Figure 3-86. Reaming mainshaft bushing.
Figure 3-88. Throttle assembly installation.
3-47
*TM 9-2815-213-34
Governor-cutoff rpm ....................... 3020 3040
Set-p.s.i. @ max rpm ..................... 40 @ 3250
Throttle leakage--cc ....................... 35
Idle speed-p.s.i. @ rpm................... 22 @ 600
Manifold pressure p.s.i. @ rpm ....... 227 @ 3000
Check point 1 p.s.i. @ rpm.............. 165/173 @ 200
Check point 2 p.s.i. @ rpm.............. 117/125 @ 2000
Weight assist p.s.i. @ rpm .............. 46/54
800
Weight assist setting ...................... 890/910
Gear pump size............................... 3/4
Idle plunger code No ......................
40
Torque spring-part No ..................... 142698
Torque spring-color code ................ WHITE-BROWN
Torque spring--hims ....................... NONE
Governor spring-part No ................. 147292
Governor spring--color code ........... BROWN
Governor weight-part No................. 107261
Injector-part No ............................... BM97421
Injector-flow code ........................... 117
Piston-part No ................................ 172580
Camshaft-part No ........................... 155500
c. Test Fuel. Fill fuel pump test stand with
authorized fuel.
d. Precalibration Tests. The precalibration tests
(para. 3104.b., 3-104.d.) are to be performed to check
porosity of fuel pump housing, excessive leakage, or low
gear pump output, prior to calibration on the fuel pump
test stand.
e. Mounting Pump For Calibration. Refer to
paragraph 3-104.c., for procedures.
f. Fuel Pump Run-.In.
(1) Completely open the fuel pump manual override
knob (fig. 3-73).
(2) Open throttle to maximum position and secure
with spring (fig. 3-82).
(3) Start test stand motor and run pump at 500 rpm.
(4) If pump is newly rebuilt or has been
disassembled and reassembled, run at slightly overrated
speed of 3000 rpm for 5 minutes to flush, allow bearings
and seals to seat, and to purge air from system.
(5) Check pump fuel flow in the flow meter for air. If
air is present, correct the leak before continuing. Refer to
paragraph 3-104.d. (8) and (9).
(6) Check main throttle shaft for proper shimming
(fig. 3-90) to insure main throttle port is completely open.
(7) Periodically check the fuel to insure that it is 80
to 100 degrees Fahrenheit and clean of all foreign
matter.
NOTE
If visual inspection or run-in check indicate
internal problems perform inspection of the
disassembled pump.
Figure 3-89. Thrust washer-drive plunger governor
clearance.
CAUTION
When installing governor weight assembly, do not press
against weights. Press against center of weights carrier
shaft.
(1) Using oil seal assembly tool (35, fig. B-28) and
suitable press, install first oil seal into cover with lip
toward inside of cover. Then, install second oil seal into
reverse side of cover with lip toward inside of cover (fig.
3-76).
(2) Assemble remaining components in reverse
order of disassembly (para. 3-102.a. (3)).
NOTE
When weight assist plunger is installed in
weight carrier assembly it must protrude
0.840/0.860 inch.
f. Fuel Pump Damper Assembly. Assemble
damper assembly in reverse order of disassembly (para
3-102.a. (2)).
g. Fuel Shut-Off Solenoid Valve Assembly.
Assemble solenoid valve in reverse order of disassembly
(para. 3-102.a. (1)). Use new preformed packing, ORing, and gaskets for assembly.
3-107. Fuel Pump Test and Calibration
a. General. PT type G fuel pump is tested and
calibrated on the fuel pump test stand (fig. 3-80).
b. Fuel Pump Test and Calibration Data.
Engine model .................................. V8 300
Pump code ...................................... 50CR3000
HP C rpm (sea level) ....................... 300 @ 3000
Fuel rate-lb hr min/max ................... 119/124
Engine fuel pressure min/max......... 215 235
Flow meter-lb hr @ rpm................... 560 @ 3000
3-48
*TM 9-2815-213-34
line connections between tank and
pump for tightness. Check for proper
mating of gear pump to pump housing.
Insure that fuel supply tank is full.
(2) Adjust Vacuum.
(a) Open test stand flow control valve
completely.
(b) Increase pump speed to 100 rpm below
engine rated speed of 3000 rpm.
(c) Adjust control valve in fuel pump suction
line to obtain 8 on vacuum gage (fig. 3-80).
(3) Set Pump Flow.
(a) Set pump speed to 3000 rpm.
(b) Close flow control valve (fig. 3-80) until
flow meter registers 540 p.p.h.
(c) There must be no air bubbles visible in
the flow meter.
Figure 3-90. Main throttle shaft shim check.
NOTE
Disregard change in vacuum meter
readings.
g. Calibration Procedure (Flow Meter Method:
CAUTION
Test stand motor switch is marked "REVERSE" and "FORWARD." For all
testing of this pump the stand switch
must be set to the "FORWARD"
position.
This corresponds to the
rotation requirements of "L" on the pump
name- plate (fig.
3-84).
Refer to
paragraph 3-104.d. (1).
(4) Set Ground Speed.
(a) With throttle wide open, increase pump
speed to point where fuel pressure just begins to
decrease (peak point). This should occur at speed of
3020 to 3040 rpm. Check speed twice as fuel pump
tachometer drive is turning at /2 engine speed.
(b) If peak point speed is lower than
specified, add shims (fig. 3-92) between governor
spring and retainer. To reduce speed, remove shims.
Each 0.001 inch shim thickness will change speed
approximately 2 rpm.
(5) Set Throttle Leakage.
(a) Insure that flow-meter reading is 540
(1) Check Pump Seals.
(a) With test stand operating at 5C rpm
(throttle wide open) close control valve in fuel pump
suction line till vacuum gage reads 1 inches vacuum.
The fuel flow control or need valve should be open
during this check.
(b) Put a small amount of Lubriplate ( light
cup grease over the vent or "weep" hole main shaft seal
bore of fuel pump front cover (fig. 3-91).
(c) If the lubricant is sucked into the ho at
the 15-inch vacuum setting, it is an indicate that the seal
will not permit proper fuel pun performance and should
be replaced.
(d) Perform the above check on the throttle
shaft to check the shaft O-Ring. App lubricant at the
throttle.
(e) Remove tachometer cap and fill the
tachometer seal bore with test fuel from the stand. If the
fuel is drawn into the pump, r place the seal.
Figure 3-91. Weep hole leakage.
NOTE
During the above checks observe the
flow meter for the presence of air
bubbles. Air bubbles are an indication of
air leakage into the system. Check the
3-49
*TM 9-2815-213-34
setting.
(6) Set Idle Speed.
(a) Set throttle shaft to idle position.
(b) Set 4-way valve to "IDLE" position.
(c) Set speed to 600 rpm.
NOTE
Reading on pressure gage should be 22
p.s.i. If pressure is low, adjust idle
adjusting screw using idle adjusting tool
(32, fig. B-28) as shown in figure 3-94.
(Remove pipe plug to insert tool). To
lower pressure, back-out screw. If
pressure is low, and screw bottoms on
guide, washers will have to be added to
the spring end of the screw.
Each time pipe plug is removed to
(d
adjust idle screw, run pump until purged of air.
(7) Check Point Flow Tests.
(a) Set 4-way valve to "ROTAMETER"
position.
(b) Set throttle to full open position.
(c) Operate pump at 2500 rpm and adjust
flow to 445 p.p.h. Pressure gage should read 165-173
p.s.i.
(d) Reduce speed to 2000 rpm and adjust
flow to 335 p.p.h. Pressure gage should read 117-125
p.s.i.
(e) Reduce speed to 800 rpm and adjust
Figure 3-92. Governor spring shimming.
p.p.h. with throttle fully open (3000 RPM).
(b) Reduce speed to 500 rpm.
(c
Set 4-way valve to "LEAKA TEST"
position.
(d) Turn count selector switch to 1000 pulse
position (fig. 3-80).
NOTE
Fuel delivery should be 35cc-plus or
minus 5-cc for a one minute period. The
test stand has a maximum count of 1000
strokes, therefore, at 3000 RPM each
cycle will be of one-third minute duration,
and the fuel delivery will also be onethird the above cc valves. (e) Pull out
fuel dumping lever ( 3-80).
(f) Remove throttle spring and manually
operate throttle.
(g) Depress pulse counter button to No. 1
burette (fig. 3-80) and push in fuel dumping lever.
NOTE
Burette will overflow before cycle is
completed, therefore, it is important to
push-in fuel dumping lever and return
throttle to idle position when burette is
filled.
(h) Increase speed to 3000 rpm and h
(i) Pull out fuel dumping lever and press
counter button to start count.
NOTE
At completion of count cycle the fuel delivery in No. 1 burette should be 10 to
13.5 cc. If not to specification adjust
throttle stop screw (fig. 3-93) until fuel
delivery is to specification and lock
Figure 3-93. Throttle stop screw adjust.
3-50
*TM 9-2815-213-34
properly seat ’or that correct spring is installed.
(g) If pressure is low add shims below the
governor weight assist plunger (fig. 3-92) in the governor
weight carrier.
(h) If pressure is high, remove shims.
NOTE
If shims are added or removed recheck
pump calibration.
(i) Reduce Speed to 500 rpm and press
"STOP" button.
(j) Close pump solenoid valve by turning
manual override knob fully counterclockwise.
3-108. Fuel Pump Troubleshooting with Test Stand
Chart 3-2 lists the malfunctions, probable causes, and
corrective actions applicable to the PT (type G) fuel
pump that can be determined and corrected with the use
of the fuel pump test stand (fig. 3-80).
Figure 3-94. Idle speed setting.
flow to 140 p.p.h.
p.s.i.
Pressure gage should read 46-45
3-1 09. Installation
Refer to paragraph 210.1., and reverse procedures for
the installation of the fuel pump and
fuel lines.
NOTE
If check point tests are out of tolerance
perform the following steps.
(f) Check torque spring to insure that spring is
Chart 3-2. Troubleshooting Fuel Pump
Malfunction
Probable cause
FUEL PUMP ASSEMBLY
Corrective action
1. Pump gear will not pick up
necessary.
fuel at 450 rpm.
a. Openings not sealed correctly.
a.
b. Suction connection is not tight or
is damaged-
b. Tighten suction connection or reis damaged
c. Idle plunger dirty.
c. Check the face of the idler plunger.
2. Air bubbles and fuel are
a. Front seat leakage.
passing through the. flowmetercover
NOTE
This can be located by covering
the "weep hole" in front cover with high
pressure grease which stops air leak.
3. Governor cannot be adjusted
NOTE
"Governor cutoff rpm" on the
V8300 engine fuel pump is3020 to 3040 rpm--
Seal all openings and use new gaskets where
a. Install new seals in the cover after first removing the
pump from the stand and then remove the front
b. Suction connection is not tight or
the fitting is damaged.
b. Tighten suction connection and
replace damaged parts.
c. Shutoff valve leaking air. Leakage
is either past shut-off override
shaft O-Ring or past main housing O-Rings
c. Replace O-Rings to resume
satisfactory operation.
a. Governor spring incorrect due
correctly at breaking point.
a. Replace worn spring.
either to wear or incorrect spring.
b. Incorrect selection of shims positioned
between governor spring and retainer
b. If speed is lower than specified
add shims, Conversely to reduce
speed remove shins.
NOTE
Each 0.001 inch shim will change speed 2 rpm.
3-51
*TM 9-2815-213-34
Chart 4.-Troublsshooting Fuel Pump Continued
Malfunction
Probable cause
4. The 40 p.s.i. checkpoint cannot be
obtained within specified maxi
mum speed limits
NOTE
"Governor setting 3020 to 3040
rpm" is 40 psi manifold pressure
is specified.
Corrective action
FUEL PUMP ASSEMBLY
a. Governor plunger has wrong chamfer
or has a worn chamfer.
b. Governor barrel and plunger in
correct Aft.
c. Governor torque spring incorrect.
d. Governor weight incorrect or weight
assist setting incorrect.
5. Throttle leakage is above specified. a. Throttle shaft scored or incorrect
NOTE
fit in throttle sleeve.
The permissible throttle leak
b. Governor plunger incorrect fit in
age Is 3ce.
governor barrel.
6. Incorrect fuel manifold pressure.
a. Incorrect idle plunger (button) or
NOTE
surface finish is rough.
Fuel manifold pressure should
b. Gear pump fails to pump 850 pounds
be 227 psi 6 3000 rpm.
of fuel per hour at 2100 rpm.
c. Wrong throttle restriction.
7. Incorrect check point pressure.
a. Idle plunger rough or has void &
NOTE
Checkpoint pressure should be
b. 800 rpm checkpoint.
165 to 170 p.s.i at 2500 rpm.
c. Incorrect torque or governor spring.
8. 800 rpm checkpoint out of
specification.
NOTE
The desired checkpoint pressure at 800 rpm is 46 to p54.
a. Checkpoint pressure is too low.
b. Checkpoint pressure is too high.
a. Replace plunger with correct chafer
b. Refit governor barrel to accept a
plunger two classes larger.
c. Install correct spring.
d. Install correct weights Make weight
assist setting 0.890/0.910-inch and
46 to 54 psi e 800 rpm for V8-300 engine pump.
a. Install new throttle shaft (standard
or oversize) and lap to fit.
b. Install new governor plunger (standard
or oversize) and lap to fit.
a Install new idle plunger.
b. Install new gear pump.
c. Set throttle restriction at correct value
a. Polish surface with oilstone or replace with like or serviceable part.
b. Check 800 rpm checkpoint under
malfunction No. 8 to be sure it is
within specifications before proceeding.
c. Remove front cover and check for
proper torque or governor spring.
a. If weight assist protrusion is within
specification (0.890 to 0.910 inch)
one or more shims may be added
to the assembly to obtain the
desired pressure.
b. Remove weight assist shims required to
decrease pressure.
Section XX. Repair of Water Crossover Pipe and Lifting Eyes
connection and new gaskets to right bank cylinder head
(fig. 210). Secure with lockwashers and cap screws.
b. Position water connection with new gasket to left
bank cylinder head. Secure with lockwashers and cap
screws.
c. Install new water hose and clamps on water
crossover pipe.
d. Position crossover pipe to connections. Place
hose in position and secure with hose clamps.
.
3-110. Cleaning
Clean components in accordance with paragraph
2-5.
3-111. Inspection
Refer to paragraph 26 for inspection procedure
3-112. Repair
Refer to paragraph 2-7 for general repair procedures.
3-113. Installation
a. Position (rear) engine lifting eye, water
Section XXI. Repair of Air Intake Preheater Assembly and Intake Manifolds
c. Remove nozzle (6) and key washer (5) from
3-114. Disassembly
adapter.
(fig. B-20).
d. Remove glow plug from air cleaner assembly
connection.
a. Remove hoses from assembly.
b. Remove preheater adapter (2) from cleaner
assembly connection.
3-52
*TM 9-2815-213-34
3-115. Cleaning
Refer to paragraph 2-5 for general cleaning procedures.
Clean adapter and nozzle with carburetor cleaner or
equivalent. Insure that nozzle screen and spray holes
are open.
3-116. Inspection
Refer to paragraph 2-6 for general inspect procedures.
Check glow plug operation with a vdc source of power.
3-117. Repair
Refer to paragraph 27 for general repair procedures.
Replace all defective parts.
3-118. Assembly
Refer to paragraph 3114 and reverse procedures.
3-119. Installation
Refer to paragraph 2-10.i.,
removal procedures.
and 2-lO.j.,
and reverse
Section XXII. Repair of Water Pump Assembly
g. Inspect ceramic seal seat that is bonded to the
impeller counterbore (vane side) for damage and
excessive wear. Replace if seal is damaged.
3-120. Disassembly
(fig. B-22).
a. Remove large snap ring from pump housing by
reaching through the access ports in the drive pulley,
with a pair of snap ring pliers.
b. Using a suitable puller, pull the impeller (18)
from the drive shaft.
c. Press on impeller end of shaft to remove
assembly from pump body. Press out bear (11).
d. Remove carbon face seal (15) from pump body.
e. Press shaft through drive pulley (3) and large
bearing (8). Lift off spacer (9).
f. Remove snap ring (10) from groove shaft.
3-123. Assembly
a. Lubricate shaft outside diameter and bearings
inside diameter with multipurpose industrial grease.
CAUTION
Do not use lead base sealer.
b. Pack bearings with GAA.
3-121.Cleaning
Clean all components in accordance with instructions
contained in paragraph 2-7.
NOTE
One piece sealed bearing must be installed on the shaft and pressed in the
body with BLACK shield to the pulley
end of the shaft.
3-122. Inspection
Perform general inspection of all component accordance
with instructions contained in pa graph 2-7. Specific
inspection procedures follow.
a. Inspect water pump bearings. Replace those
with rough or worn races.
b. Inspect water pump impeller. Replace impeller
assembly if cracked or corroded to extent that it will
interfere with circulation.
c. Replace impeller assembly if the minimum 0.001
inch press-fit between shaft and impeller exceeded.
Measure impeller bore and shaft side diameter to project
this minimum allowance
d. Inspect water pump mounting parts damage.
Replace as necessary.
e. Examine carbon seal carefully to make sure it is
not cracked or chipped. Replace if necessary
f. Inspect silicone oil seal. Replace if damaged
c. Install snap ring in groove of shaft. Press inner
bearing on shaft with shielded side out to ward impeller
end of shaft until inner race seats against snap ring.
d. Position shaft and bearing in bore of pump body.
Slide spacer over shaft seating on shoulder of shaft.
e. Fill cavity of bore 1 to % full of GAA.
f. Place large bearing over shaft and into bore of
housing with shielded side out. Press bearing into its
seat in the housing bore.
g. Install large snap ring in bore of pump body to
secure bearings in place.
h. Support shaft on impeller end and press on
pulley fixed sheave until sheave hub is tight against
bearing inner race.
Attach adjustable sheave to
complete the pulley installation.
i. Turn water pump body assembly over and press
in a new carbon face seal using a suitable mandrel and
pressing arbor.
3-53
*TM 9-2815-213-34
clearance between impeller vanes and pump body.
3-1 24. Installation
Position water pump and new gasket to cylinder block
and secure with five cap screws and lock. washers.
NOTE
Driving flange of seal case must seat
properly on edge of bore in pump body.
j. Support pump on pulley end of shaft.
Pr on impeller and maintain 0.010/0.020
inch
Section XXIII. Repair of Fan Drive Pulley, Vibration Damper,
and Water Pump Pulley Assembly
3-125. Disassembly
Using a soft hammer or brass driver, remove vibration
damper from water pump drive pulley hub.
3-130. Installation
a. Loosen adjustable sheave on water pump and
set crankshaft-to-pump drive belt in pulley.
b. Set water pump drive belt on drive pulley. c.
Position pulley and damper assembly on crankshaft
flange.
d. Position three sheave fan drive pulley to vibration
damper and secure to crankshaft with seven cap screws
and lockwashers.
e. Tighten water pump pulley adjustable sheave to
obtain required belt tension.
3-126. Cleaning
Refer to paragraph 2-5 for cleaning procedure
3-127. Inspection
Refer to paragraph 26 for inspection procedure
3-128. Repair
Repair of the assembly is limited to the procedures of
paragraph 27.
3-129. Assembly
Press vibration damper onto water pump pulley hub.
Insure that cap screw holes are aligned.
Section XXIV. Repair of Thermostat Assembly
3-131. Disassembly
(fig. B-21).
a. Remove two cap screws (16) lockwasher and
flat washer (15) securing thermostat cover (14) to
housing (7).
b. Remove thermostat (12) and gasket (13) c.
Remove pipe plugs (10) and temperature transmitter
(11).
d. Loosen hose clamp and remove hose.
(3) Compare
thermostat
operation
with
temperature indicated on thermometer.
c. The high range thermostats installed on the V8300 engine start to open at 173 degrees Fahrenheit and
are fully open at 186 degrees Fahrenheit.
d. Discard thermostats not operating in correct
range. Replace with same range thermostat.
e. Inspect thermostat for physical damage. If
damaged, replace thermostat.
3-132. Cleaning
Refer to paragraph 2-5 for cleaning procedure:
3-134. Repair
Refer to paragraph 2-7 for general repair procedures.
3-133. Inspection
a. Perform general inspection in accordance with
paragraph 26.
b. Check thermostat as follows:
(1) Immerse thermostat and thermometer in
water.
3-135. Assembly
Refer to paragraph 3-131 and reverse procedures.
3-136. Installation
a. Position thermostat housing with new gasket to
cylinder head and secure with four cap- screws and
lockwashers.
b. Position hose on water pump and tighten hose
clamps.
NOTE
Season
thermostat
by
operating
thermostat for a period of 45 minutes at
200 degrees Fahrenheit.
(2) Cool water to the initial operating
temperature,
173
degrees
Fahrenheit
of the
thermostat.
3-54
*TM 9-2815-213-34
Section XXV. Repair of Fan, Fan Hub, and Bracket Assembly
3-137. Disassembly
(fig. B23).
c. Install pipe plugs in housing. Seal plugs with
sealing tape or sealer to prevent leaks.
d. Install rear bearing inner race with largest inside
diameter into rear of fan hub and press new oil seal into
housing flush with bore.
e. Install shaft through oil seal and bearing inner
race. Seat with light tapping of a soft hammer or press.
f. Fill cavity between bearings ½ to % full of GAA.
g. Install front bearing,
clamp washer,
and
retaining nut.
h. Slowly rotate housing around spindle and at the
same time tighten retaining nut until a small "drag" is felt
during rotation of housing.
a. Remove six cap screws (1) and lockwashers (2)
securing fan (3) fan spacer (4) pilot spacer (6) to seven
sheave pulley (11).
b. Pull cotter pin and remove nut (7) washer (8)
from shaft (13).
c. Press shaft from pulley.
d. Remove bearings (9) and oil seal (12).
e. Using suitable puller remove bearing outer races
(10).
3-138. Cleaning
Clean all components in accordance with procedures in
paragraph 2-5.
CAUTION
Hub must be rotated while nut is being
tightened. Failure to rotate hub will
result in excessive end play.
3-139. Inspection
a. Inspect bearing cone and rollers, and tape roller
bearing cup (rear). Replace if damaged, rough or worn.
b. Inspect threads for stripped or crossed threads.
Replace all damaged parts.
c. Inspect fan hub nut, idler seal, and idler fan hub
shaft for damage or wear. Replace if damaged or worn.
d perform general inspection in accords with
paragraph 2-6.
i. Tap fan hub assembly lightly with a soft hammer
to relieve clearances. Check shaft end clearance. It
must be 0.001/0.007 inch and the hub must rotate freely.
Loosen or tighten nut and repeat step h above, if
required. Lock retaining nut with cotter pin.
j. Apply GAA to outer bearing. Assemble new
gasket, spacer, and fan to pulley assembly with
lockwashers and cap screws.
3-140. Repair
Repair of the assembly is limited to the instructions in
paragraph 2-7.
3-141. Assembly
3-142. Installation
a. Install fan assembly bracket on block (fig. 24)
and secure with six cap screws and lock- washers.
b. Position flatwasher on shaft and insert shaft in
bracket. Secure with flatwasher and lock nut.
c. Install adjusting bolt in bracket and through
shaft.
d. Set hydraulic pump drive belt on inner sheave,
and two alternator drive belts on next two sheaves.
e. Install three drive belts from crankshaft drive
pulley to three outer sheaves of fan drive pulley.
CAUTION
Aline shaft in bearing before pressing.
Use only enough pressure to slide
bearing over the shaft.
a. Using suitable arbor press install o races of
tapered bearings into fan hub hour with cupped area up.
Outer races must against shoulders provided in housing.
b. Pack bearing cones of both bearings ’with GAA.
Section XXVI. Repair of Hydraulic Pump and Mounting Bracket
to the using unit without the pump assembly.
NOTE
If engine is received for repair without
the power steering pump (hydraulic
pump), bracket, pulley and drive belt,
do not requisition these items for installation on the repaired engine. The repaired or rebuilt engine will be shipped
3-143. Disassembly
(fig. B-26).
a. Remove swivel elbow (7) and nipple (6).
b. Remove adapter (10) bushing (9) and elbow (8).
3-55
*TM 9-2815-213-34
c. Remove locknut (2) securing pulley to shaft and
remove pulley and woodruff key (3).
d. Remove two cap screws (14) lockwasher (12)
and flat spacer washers (15) securing pump (5) to
mounting bracket (4).
Insure that flat spacer washers are
placed between pump body and
mounting bracket.
3-148. Installation
a. Install pump and bracket assembly mounting
bracket on block and secure with three cap screws,
lockwashers and plain washers.
b. Install pump and bracket assembly on engine
mounting bracket and secure with two cap screws,
lockwashers, and plain washers.
c. Install pump drive belt on pulley.
d. Install tension adjusting strap on engine block
with cap screw, lockwasher and plain washer. Finger
tighten.
e. Secure tension adjusting strap to pump
mounting bracket with cap screw, lockwasher, and plain
washer.
f. Adjust pump to obtain proper belt tension and
tighten tension strap to block securing cap-screw.
3-144. Cleaning
Clean all components in accordance with procedures in
paragraph 2-5.
3-145. Inspection
Perform general inspection
paragraph 2-6.
in
accordance
with
3-146. Repair
Repair of the pump and brackets is limited to the
instructions contained in paragraph 2-7.
3-147. Assembly
Refer to paragraph 3-143 and reverse procedures to
assembly the pump.
NOTE
Section XXVII. Repair of Alternator Assembly and Mounting Bracket.
3-149. Disassembly
3-152. Repair
(fig. B-24)
Repair of the alternator and bracket is limited to the
a. Remove locknut from shaft and remove two
instructions of paragraph 2-7. The alternator shall be
replaced if noisy or voltage cannot be maintained
sheave pulley and key.
between 27-29 volts.
b. Remove cap screw and lockwasher securing
adjusting arm to alternator end plate.
3-153. Assembly
Refer to paragraph 3-149 and reverse disassembly
3-150. Cleaning
procedures.
Clean all components in accordance with procedures in
paragraph 2-5.
3-154. Installation
3-151. Inspection
Refer to paragraph 2-lO.c.,
and reverse removal
Perform general inspection in accordance with the
procedures.
requirements of paragraph 2-6.
Section XXVIII. Repair of Starter Assembly
3-155. Inspection and Repair
3-156. Installation
Refer to TM 9-2920-242-34 for inspection and repair
Refer to paragraph 2-10.a.,
and reverse removal
procedures, and repair parts listing.
procedures.
Section XXIX. Repair of Oil Cooler
(14) and filter element (15).
3-157. Disassembly
(fig. B-1l)
3-158. Cleaning
a. Remove transmitter (16) and bushing (17) from
a. Oil Side.
pipe tee (18).
b. Remove pipe plug (5) and (10).
c. Remove five cap screws (23) and lockwasher (7)
CAUTION
securing cover (12) to housing (22).
Perform the following operation in a well
d. Remove gasket (13) O-Rings (24) retainer
ventilated area to avoid toxic effect of
chemicals being used.
3-56
*TM 9-2815-213-34
paragraph 2-6.
(1) Immerse the filter element in carbon
tetrachloride to trichloethylene,
or other approved
cleaning solvent.
(2) Using a rubber suction cup force solvent
around and through the tubes until clean.
b. Assembly oil cooler. Plug oil outlet and attach
70/100 p.s.i. air line to oil inlet.
c. Immerse unit in water and apply air pressure.
The slightest leak will be indicated by the appearance of
air bubbles.
d. Assemble front and rear heads to cooler.
e. Plug either inlet or outlet connection and check
for leaks as described in steps (1) and (2) above.
3-160. Repair
a. Header leaks may occur where tubes protrude
through header plate or where header is soldered. The
header may become cracked in service due to excessive
pressure. Resolder tubes to header as necessary.
CAUTION
Do not burn tubes or header material with torch flame.
b. Perform general repairs in accordance with
paragraph 2-7.
3-161. Assembly
Assemble cooler in reverse order of disassembly (para
3-157), and perform a leak test.
NOTE
If all passages are badly clogged,
circulate an oakite or alkaline solution
through the tubes.
(3) After cleaning flush thoroughly with hot
water.
b. Water Side.
(1) Plug oil inlet and outlet.
(2) Immerse oil cooler in solution of one part
muriatic acid, nine parts water, one pound oxalic acid,
and 0.01 gallon of pyridene to each five gallons of acid.
(3) Remove core when foaming and bubbling
stops. This usually takes 30 to 60 seconds.
(4) Immerse unit in a 5 percent solution sodium
carbonate. Remove when bubbling stops and pressure
flush with clean warm water.
CAUTION
(5) Clean’ inside of case thoroughly will steam
Insure element is assembled so "O"
or solvent.
marks are aligned on case and element.
3-159. Inspection
a. Perform general inspection in accordant with
Section XXX. REPAIR OF EXHAUST MANIFOLDS
paragraph 2-6.
3-164. Installation (right bank)
Secure manifold to head with eight cap screws, spacers,
four lockplates, and four gaskets.
3-162. Cleaning
Clean manifolds in accordance with instructions in
paragraph 2-5.
3-163. Inspection
Inspect manifolds in accordance with instructions in
Section XXXI. ENGINE REMOVAL FROM REBUILD STAND
with 12 cap screws and lockwashers.
d. Install oil cooler and four gaskets securing with
13 cap screws and lockwashers to block and cover plate.
e. Install left bank manifold and four gaskets to
cylinder head securing with eight cap screws, spacers,
and four lockplates.
3-165. General
Attach lifting hooks to hoist to front and rear engine lifting
eyes (fig. 1-1 and 1-2), and takes slack in chain.
3-166. Rebuild Stand Removal
a. Remove cap screws and lockwasher securing
engine stand and adapter plate to engine block.
b. Remove stand and adapter from engine. c.
Install gasket and left side cover plate to block securing
Section XXXII. ENGINE TEST AND ADJUSTMENT
reaching operating temperature.
(2) Always adjust injectors before crossheads and
valves.
3-167. Adjustment
a. Injectors, Crossheads, and Valves.
(1) Injector plungers, crossheads and valve
must be adjusted before starting engine first time at cold
setting and-again during engine test after
3-57
C 1, TM 9-2815-213-34
(3) Valve timing marks are located on the
vibration damper at the front of the engine (95).
(4) Advance adjusting screw slightly, then
loosen. Retighten adjusting screw until valve contact is
made.
(5) Tighten 7/16 inch high locknut 60 to 70 footpounds torque.
(6) Check clearance between crosshead and
valve spring retainer with a wire gage. There must be a
minimum of 0.025 inch clearance at this point.
d. Value Clearance.
CAUTION
Check that index marks on outer ring an
hub of vibration damper aline. If no
replace vibration damper.
(4) To aline the timing marks rotate engine
manually in a counterclockwise rotation (left-hand as
viewed from flywheel low towards the fan) until one of the
47
is in line with the "A" arrow head on the
sets of marks
vs.
In this position, both intake exhaust
front cover.
valves will be closed for one of the cylinders indicated.
Make adjustments or cylinder.
(5) Adjust injector plunger, then cross] and
valves of each cylinder as explains succeeding
paragraphs. Turn crankshaft wise to the next VS mark
corresponding to order of the engine which is 1-5-4-8-63-7-2 figure 3-96 for complete sequence of adjusts
(6) After injectors,
crossheads and v are
adjusted for this cylinder, rotate crankshaft in direction of
rotation (right-hand the next VS mark corresponding to
the order of the engine and repeat the adjust
procedures.
NOTE
Two complete revolutions (720 degrees)
the crankshaft are needed to set all
injector plungers,
crossheads and
valve: Injectors, crossheads and valves
can E adjusted for only one cylinder at
any or VS setting.
b. Injector Plungers.
(1) Turn adjusting screw down until plunger just
contacts cup, then advance an addition degrees to
squeeze oil from cup.
(2) Loosen adjusting screw one turn.
(3) With a torque wrench calibrated in pounds
and a screwdriver adapter, tighter adjusting screw for a
cold setting (70 de Fahrenheit) at 50 inch-pounds torque.
setting 140 degrees Fahrenheit 50 inch-pounds.
c. Valve Crossheads.
(1) Loosen valve crosshead adjusting locknut
and back off screw one turn.
(2) Use light finger pressure at "A" to
crosshead in contact with valve stem at point “B” (fig 397).
(3) Turn adjusting screw down until contacts its
mating valve stem at point "C' (fig. 3-97).
NOTE
The same engine position used in
setting the injectors is used for setting
the intake and exhaust valves.
(1) Loosen the locknut and back-off the
adjusting screw. Insert feeler gage between rocker lever
and top of crosshead; turn screw down until lever just
touches the gage. Lock adjusting screw in position with
locknut.
(2) Always make final valve adjustment after
injectors and crossheads are adjusted and with the
engine at operating temperature (140 degrees
Fahrenheit). Valve clearances are as follows: Intake
Valves: 0.016 inch at 70 degrees Fahrenheit, 0.014 inch
at 140 degrees Fahrenheit. Exhaust Valves: 0.029 inch
at 70 degrees Fahrenheit, 0.027 inch at 140 degrees
Fahrenheit.
(3) Position valve covers to heads with new
gaskets. Secure with flatwashers, lockwashers, and
cap screws.
3-168. Starting and Testing
Engine break-in and testing are accomplished together.
Break-in on a new or rebuilt engine is
Figure 3-95. Valve timing marks.
3-58
*TM 9-2815-213-34
engine horsepower (288 H.P.) ] capacity is insufficient,
testing procedure must b modified to prevent damage to
the dynamometer
a. Using proper lifting device, place engine on
dynamometer test stand.
b. Position engine on the front engine support and
preselected risers for the rear engine supports; secure
engine mounting pads to engine support risers with bolts,
lockwashers and nuts. Remove lifting device.
c. Position dynamometer driveshaft flange to
engine flywheel. Use proper flywheel adapter flange to
match flywheel cap screw holes.
d. Check for proper alignment.
(1) If direct or flexible drive coupled, place a
dial gage holding fixture on face of flywheel housing and
dial gage on adapter flange hub; bar engine over to
obtain measurement. Relocate flange hub on flywheel
as needed and retighten cap screws. Flywheel adapter
flange must be con- centric to flywheel and flywheel
housing within 0.005 inch total run-out. When using a
direct coupled dynamometer, a reading must be taken
from face of flywheel housing to outer edge of
dynamometer drive flange. It must not exceed 0.005
inch total run-out when barring dynamometer one
complete revolution.
(2) If universal drive coupled, flywheel and
dynamometer drive flanges must be concentric within
0.005 inch run-out; reading to be taken as above. Install
engine so that centerline of engine crankshaft and
centerline of dynamometer drive shaft are, by design,
out of plane either horizontally or vertically from 1/4 inch
minimum to 1/2 inch maximum. True alignment will
cause universal bearing failure. Secure flywheel to drive
flange with lockwashers and cap screws.
e. Connect water supply and return hose to the
water cooling arrangement.
f. Attach fuel pump return line, if used.
g. Attach fuel supply line to fuel pump suction
connection.
h. Connect electrical connections to starting motor
if motor is used for starting. If another means of starting
is used make necessary connections.
i. Connect throttle linkage and all instruments
which are included on the control panel of the particular
dynamometer being used.
j. Connect exhaust piping to engine exhaust
manifold.
k. Connect air intake piping to air intake manifold.
Use a standard air cleaner approved for the V8300
engine.
l. Connect a full flow lubricating oil filter to remove
any entrapped dirt or grit.
m. Install a Blow-By Checking Tool (3, fig. B-28) to
the crankcase breather with adapter.
Figure 3-96. Engine firing order.
Figure 3-97. Crosshead adjustment.
essential because it provides an operating period during
which coving parts acquire their finish and mating
surfaces reach a full seat. Engine testing helps detect
possible assembly errors an the need for adjustments as
engine "breaks-in as well as establishing a period for
final adjustments for best engine performance.
A
dynamometer provides the simplest and most accurate
tool for testing and breaking in an engine. (Follow the
instructions in sequence below for pr starting checks,
dynameter mounting,
engine starting,
testing,
adjustments and break-in.
3-169. Dynamometer Test
Check the capacity of the dynamometer. The stand
must be capable of testing at 96 percent c maximum
3-59
*TM 9-2815-213-34
Also, connect a manometer to the Blow-By Tool
measure the amount of blow-by gases escaping past the
piston rings.
NOTE
This is essential to indicate seating of
rings and to ascertain if and when
additional run-in time is necessary.
3-171. Starting Engine
a. Position the throttle at idle speed.
b. Disengage the drive unit.
c. Electrical shut-down valve operates (opens)
automatically.
NOTE
A manual override knob provided on the
forward end of the electric shut-down
valve allows the valve to be opened in
case of electric power failure.
To
operate "open" by turning fully clockwise.
d. Press starter button or turn switch-key to "start"
position.
e. Warm-up engine.
f. Check all tubing, hoses, lines, fittings and
plugs for leaks. Correct as necessary.
g. Open cooling water supply valves to heat
exchanger. Introduce water to absorption unit per
manufacturers instructions.
3-170. Preparation For Starting
As an assist in priming the fuel and lubricating oil s3stems it is recommended that all filter: removed and
serviced with their respective
a. Prime fuel pump before starting engine the first
time. Remove plug next to tachometer drive and fill with
clean diesel fuel.
b. Check Fuel Tanks. There must be an adequate
supply of good grade, clean diesel fuel the tanks.
c. Close all drain cocks and open vent cocks, on
air compressor and vent (pipe plugs) water crossover
tubes to insure circulation.
d. Fill engine with required coolants until it flows
from vent cocks and vents; close all vents and fill the
system.
e. Fill oil pan to "L" (low) mark on dipstick.
f. Connect a hand or motor driven priming pump
line from a source of clean OES-20 It lubricating oil to Oil
Cooler (Left Bank) "INL OUTLET" connections, fill oil
pan to "H" position of the dipstick.
g. Prime until a 30 psi minimum pressure obtained.
h. Crank engine for at least 15 seconds while
maintaining external oil pressure at a minimum of 15 psi.
i. Allow engine to fire and operate 5 to seconds.
j. Remove external oil supply and replace full flow
oil filter system as used on the vehicle.
k. Fill crankcase with oil to "H" (high) n on dipstick.
Grades used, OES-10, OES-2( OES-30, will depend on
ambient temperature. special oil is required for break-in
period. change in oil viscosity or type is needed for or
newly rebuilt engines.
3-172. Test Procedure
NOTE
Dynamometer manufacturers provide a
figure known as a "brake constant" with
each dynamometer.
This simplifies
computing brake horsepower,
since
only engine rpm and the scale reading in
pounds need be found.
a. Horsepower Ratings.
(1) The maximum horsepower rating 300 at
3000 rpm is established for engines on number 1 curve
in figure 101 in automotive or intermit- tent-duty
applications at sea level, 60 degrees Fahrenheit intake
air temperature and 29.92 inches Hg.
(Mercury
barometric pressure).
(2) Where necessary an engine may be derated because of high altitude-operation or for the sake
of fuel economy, the derating may be done by reducing
governed rpm or maximum fuel rate in the proportion
desired.
(3) Naturally-aspirated engines must be
derated 3 percent for each 1000 feet altitude above sea
level, and 1 percent for each 10 degrees Fahrenheit
ambient temperature rise above 60 degrees Fahrenheit.
(4) New or rebuilt engines during dynamometer test are not required to deliver more than 96
percent of maximum horsepower at power checks. The
additional 4 percent will be achieved after a few hours
operation.
b. Break-In-Run.
Start engine and idle at
approximately 800 rpm no-load for 5 to 10 minutes.
CAUTION
Service engine oil after a few minutes of
operation to compensate for oil
absorbed into filter- elements and
leakage.
l. Check Oil Level. Add oil if necessary to reach
the "H" level on the dipstick. Never operate engine
below "L" mark or above "H” mark.
3-60
C2, TM 9-2815-213-34
generally no reason for concern. As the rings and
cylinder liner combination wear in, the blow should come
down below 5 inches of water. If blow-by does not
decrease after 30 minutes, continue to operate for up to
50 hours. If blow-by is not below 5 inches of water within
50 hours of operation, the engine must be considered
unacceptable.
d. Power Check.
(1) Run engine ar rated speed for 5 minutes. It
should indicate 96 percent of rated power at standard
fuel rate (120 pounds per hour). Check crankcase blowby.
(2) If crankcase blow-by exceeds value shown
(5 inches of water), reduce engine speed and load to
preceding level. Run engine 30 to 45 minutes.
(3) Repeat procedures described above until
engine develops 96 percent power (288 horsepower) at
standard fuel rate (120 pounds per hour) within
permissible crankcase blow-by limit (5 inches of water).
Check oil pressure and water circulation: look leaks.
(1) Apply dynamometer load to develop
horsepower at speed (rpm) indicated below.
Maximum Rated HP @ [email protected] 3000
Maximum Fuel Rate lbs./hr.-120
Maximum Crankcase Pressue-5
Valve and Injector Settings (130 degrees/150
degrees Fahrenheit)
Injector, Inch-Pounds-50
Valves: Intake-14, Exhaust-27
First ½h Hour [email protected] RPM-75 @ 2000
Second % Hour HP @ RPM-125 @ 2500
Third % Hour HP @ RPM-150 @ 2700
Fourth ½ Hour HP @ RPM--250 @ 3000
Fifth ½'i Hour HP @ RPM-275 @ 3000
Power check 5 min. maximum 96 percent Rated
Power-288 @ 3000
(2) Check crankcase blow-by (paragraph
below). If not excessive, reduce run-in time by one-half.
(3) If blow-by is too high, run engine for time
period shown under item (1) above.
(4) At first period only: Run the engine until
temperature reaches 140 degrees Fahrenheit. Add to
bring level up to "H" mark on dipstick.
(5) At second period only: Reset valves and
injectors. Set engine governed speed and fuel rate.
(6) At third and thereafter: if blow-by is
excessive, reduce load to preceding phase and run 30
minutes; then return to original sequence and continue
planned program.
c. Blow-By Check.
(1) Install right bank rocker housing. Install
sealed type oil dipstick.
(2) Install right bank rocker housing. Install
sealed type oil dipstick.
(3) Attach a manometer to the hose coupling
the checking too (fig 3-98), and fill the tube w water to
the "0" mark at the middle of scale.
(4) Manometer readings must be taken
frequently during the break-in test to note any blow-by
crease. If there is any increase, engine speed must
decreased for a few minutes and then brought back
original setting.
(5) During each 5 minute power check, keep a
constant check on the manometer. If the press rises,
more run-in is required. Maximum press limits for engine
running, at governed speed a operating at 96 percent to
100 percent of rated horsepower are listed in paragraph
b (1), above.
(6) Observe variation in rate of blow-by during
initial engine run. If the crankcase pressure, or blow- by
is greater at the end of the testing period than maximum
values listed, the engine should operated at 96-100
percent rated load and rpm for minutes. If the blow-by is
not is' not increasing, although it may be above 5 inches
of water (maximum crankcase pressure), there is
CAUTION
Do not exceed 5 minute power check
limitation.
(4)
as follows:
During power check, check lubricating oil
(a) Oil pressure at idle speed, 10 to 30
p.s.i. @ 225 degrees Fahrenheit, at maximum speed,
60 p.s.i., maximum. Lubricating oil pressure should
remain at or near a constant figure at constant engine
speed and load, after normal operating temperatures
have reached.
NOTE
Abnormally high oil pressures may
indicate restricted lubricating oil lines.
Low pressures indicate an insufficient oil
sup- ply or increased oil clearance which
may be due to bearing wear.
(b) Under full load conditions, oil pressure
may drop to 30 p.s.i. and oil temperature may reach 250
degrees Fahrenheit to 265 degrees Fahrenheit to 265
degrees Fahrenheit for a short period. This is not cause
for alarm.
CAUTION
Any sudden increase in oil temperature
which is not caused by loading increases
in a warning of possible mechanical
failure and should be investigated at
once.
(c) After the first 5 to 10 minutes operation the
engine should be shut down and engine oil added to
compensate for engine oil absorbed by filters.
3-61
C2, TM 9-2815-213-34
Thereafter, check oil level of the engine, with the
dipstick every two (2) hours during run-in test. Maintain
oil level at "H" mark on the dipstick.
(5) Check engine coolant as follows:
(a) After engine is started, add coolant as
required to completely fill cooling system and replace
entrapped air.
(b) The ideal water temperature is 175
degrees Fahrenheit for best engine performance. It
should ] exceed 190 degrees Fahrenheit during
operation.
(c) Do not turn off engine immediately after
load operation. Heat stored in the iron masses will boil
cooling water in the jackets if air and water circulation
cease while engine is still hot. Allow engine to idle for a
few minutes before shutting down.
(6) Check fuel pressures as follows.
(a) Check fuel manifold pressure with f
system pressure gage (4, fig. B-29) as shown figure 399.
Accelerate from idle to full throttle a record
maximum pressure recorded on gage; it should be 202
to 218 pounds.
(b) Check fuel rate with fuel flow rate check
gage (2, fig. B-24) as shown in figure 3-100.1 gage’s
flow tank is placed between the engine and t fuel supply
tank. Fuel return line(s) and the f pump suction line are
then attached to the circulating tank.
culating tank from the fuel supply tank.
This make-up fuel passes through the
flowmeter and is the fuel rate of the
engine registered in pounds per hour.
Fuel rate is 120 pounds per hour.
(c) Accelerate engine from idle to full
throttle and check manifold pressure with Pressure
Gage. It should be 202 to 218 pounds.
(d) Refer to Section XIX Fuel Pump for fuel
pump governor adjustments.
(e) Inspect all fuel lines and connections for
leaks and security of mounting.
(f) Inspect lubricating oil connections for
leaks. Check oil cooler for security of mounting and inlet/outlet connections for leaks.
(g) After run-in has been completed, load
applications should be minimal for the first 50 hours of
operation. This gives new parts a chance to "wear- in"
without undue stress and strain.
3-173. Performance Curve
Figure 3-101 is an engine performance curve. Solid
lines represent maximum ratings at 500 feet altitude
29.38 inches mercury and 85 degrees Fahrenheit
ambient air temperature. The dotted lines indicate
standard sea level conditions. These curves indicate
engine performance with fuel system, water pump,
lubricating oil pump and air cleaner. It does not include
battery charging generator,
compressor,
fan and
optional equipment.
NOTE
As the engine burns fuel, the float valve
allows make-up fuel to flow into the cir-
Section XXXIII. REPAIR AND REBUILD STANDARDS
proved for further service. An asterisk in the "Wear
3-174. General
Limits" column indicates that the part or parts should be
The repair and rebuild standards give maximum
replaced when worn beyond the limits given in the "New
minimum, and key clearances of new or rebuilt pa Wear
Dimensions" column. All dimensions are given in inches.
limits are given, which indicate the point which a part or
parts may be worn, in order to receive maximum service
before replacement. Normally, parts which have not
3-175. Cylinder Block
been worn beyond the dimensions shown in "Wear
(para 3-4)
Limits" column will be
3-62
*TM 9-2815-213-34
Figure 3-98. Engine blow-by check.
Figure 3-100. Fuel flow rate check.
Figure 3-99. Manifold fuel pressure check.
3-63
*TM 9-2815-213-34
Figure 3-101. Performance curve.
Fig.
No.
Ref.
Letter
a. Height
3-102.
a
b
Point of Measurement
New Dimensions
(inches)
Distance surface of checking bar to top of cylinder block ........ 1.2710/11.2765
Center of main bearing bore to top of cylinder block ............... 3.1480/13.1540
Maximum amount removed in resurfacing...............................
b. Liner Counterbore.
3-102
c
Inside diameter.........................................................................
d
Depth 0.....................................................................................
Depth after repair .....................................................................
c. Camshaft Bushing.
3-102.
e
Inside diameter.........................................................................
Bore inside diameter ................................................................
11.2655
13.1420
.006
.4990 to 6.5010
.3500 to 0.3520
6.6016
*
.4130
.4990 to 2.5005
.6245 to 2.6255
2.5020
d. Main Bearing Bore.
3-102.
f
Inside diameter......................................................................... .7520 to 3.7530
Alignment-Check with checking bar 5120-981-3115
3-64
Wear Limits
(inches)
3.75.5
*TM 9-2815-213-34
Fig.
Ref.
Point of Measurement
New Dimensions Wear Limits
No.
Letter
(inches)
(inches)
e. Tappet Bore Inside Diameter
g
Valve ................................................................................................ 1.1000 to 1.1010
1.1025
g
Injector ............................................................................................. 1.4000 to 1.4010
1.4025
Out-of-round .....................................................................................
0.0015
3-176. Crankshaft
(para. 3-9)
a. Crankshaft Journals.
3-103.
a
Diameter of main bearing journals ...........................................
b
Rod journal diameter................................................................
c
Rear main (thrust) width...........................................................
b. Crankshaft End Clearance.
3-6
Flywheel end of assembled crankshaft....................................
c. Crankshaft Bearings.
3-103.
d
Main bearing shell thickness ....................................................
e. Thrust bearing thickness ..........................................................
f
Crankshaft adapter outside diameter.......................................
3.4990 to 3.5000
3.1240 to 3.1253
1.9400 to 1.9420
3A.4965
3.1215
1.9440
0.005 to 0.015
0.0220
0.1245to 0.12525
0.1510 to 0.1530
4.749 to 4.751
0.1230
0.1490
4.717
3-177. Connecting Rod
(para. 8-19)
a. Measurements.
3-104.
a
Length center to center ............................................................ 8.1920 to 8.1940
b
Inside diameter of connecting rod bore.................................... 3.3160 to 3.3165
3-104
c
Inside diameter of connecting rod bore (piston pin end-in rod)1.9995 to 2.0005
d
Inside diameter of piston pin bushing ...................................... 1.7510 to 1.7515
b. Bearing Shell.
3-104.
e
Shell thickness ......................................................................... 0.0942 to 0.0947
Journal clearance..................................................................... 0.0015 to 0.0045
0.0929
0.0070
c. Bore Misalignment. Check on Fixture (Refer to fig. 3-10).
Bend with bushing installed......................................................
Twist with bushing installed......................................................
0.0040
0.0100
3-178. Piston
(para. 3-15)
a. Measurements.
3-105.
a
Outside diameter of piston skirt (at 70sF.) ............................... 5.4870 to .4880
b
Piston pin bore inside diameter................................................ 1.7485 to 1.7489
c
Piston pin outside diameter...................................................... 1.7488 to 1.7490
5.4830
1.7500
1.7478
Figure 3-102. Cylinder block-points of measurement.
1.7525
Figure 3-103. Crankshaft and bearings-points of
measurement.
3-65
*TM 9-2815-213-34
Figure 3-104. Connecting rod-points of measurement
Figure 3-105. Piston-points of measurement.
Fig.
Ref.
Point of Measurement
New Dimensions Wear Limits
No.
Letter
(inches)
(inches)
b. Ring
3-105
d
Piston ring-to-groove clearance (use gage 1600043)
new ring flush with piston wall ........................................... 0.002
0.006
e
Piston ring gap clearance (In new liners).................................
Top compression ring. Part Number (15434-129260) .................... 0.017 to 0.027
Level compression ring. Part Number (15434168680) ................... 0.013 to 0.023
Oil ring. Part Number (15434-172550)............................................ 0.015 to 0.027
3-179. Cylinder Sleeve
(para. 3-2.b.)
3-106.
a
Cylinder sleeve inside diameter ...............................................
a
Cylinder sleeve out-of-round:
Packing ring area ..............................................................
Above piston pin area........................................................
b
Cylinder sleeve outside diameter:
Packing ring hands ............................................................
Top flange (press fit area) .................................................
c
Cylinder sleeve flange:
Thickness ..........................................................................
Protrusion above block ......................................................
Cylinder sleeve to block packing ring bore clearance..............
3-180. Camshaft and Bearings
(para 832)
a. Camshaft.
3-107.
a
Outside diameter of journals ....................................................
b
Injector(s) lobe total lift .............................................................
b. Camshaft Bearings.
3-107.
c
Inside diameter of camshaft bushing .......................................
d
End play of camshaft................................................................
e
Engine camshaft thrust plate (thickness) .................................
* Replace thrust plate when end play exceeds 0.0150.
3-181. Gear Train
a Crankshaft Gear (para. 3-9).
3-108.
a
Inside diameter of gear ............................................................
b
Outside diameter of crankshaft ................................................
ab Gear-to-crankshaft clearance ..................................................
3-66
5.4995 to 5010
5.5050
0.0015
0.003
5.9930 to 5.9970
6.5015 to 6.5035
5.9900
6.5015
0.3550 to 0.3560
0.0040 to 0.0060
0.0020 to 0.0080
0.355
0.0040
2.4960 to 2.4970
0.1680to0.1720
2.4940
0.1670
2.4990 to 2.5005
0.0070 to 0.0110
0.124 to 0.126
2.5020
0.0150
*
4.040 to 4.041
4.045 to 4.046
PRESS FIT
*
*
*TM 9-2815-213-34
Figure 3-106. Cylinder sleeve-points of measurement. Figure 3-107. Camshaft and bearings points of measurement.
3-108.
3-108.
c
d
d
e
Inside diameter of gear ............................................................
Outside diameter of driveshaft .................................................
Gear to shaft clearance............................................................
Figure..................................................
3-108. Gear train-points of
Oil pump drive gear backlash
measurement.
3-67
0.8730 to 0.8735
0.8745 to 0.8750
PRESS FIT
0.010 to 0.015
*
*
0.015
C2, TM 9-2815-213-34
Fig.
Ref.
Point of Measurement
New Dimensions Wear Limits
No.
Letter
(inches)
(inches)
c. Camshaft Gear (para 3-32).
3-108.
f
Inside diameter of gear ............................................................ 1.7980 to 1.7985
*
g
Outside diameter of shaft ......................................................... 1.7985 to 1.7990
g
Gear to shaft clearance............................................................ PRESS FIT
h
Camshaft to crankshaft backlash............................................. 0.006 to 0.009
0.009
j
Camshaft and clearance .......................................................... 0.007 to 0 001
0.011
d. Air Compressor Drive Gear (para 3-9),
3-108.
k
Inside diameter of gear ............................................................ 12885 to 1.2890
*
I
Outside diameter of shaft ......................................................... 12890 to 12895
Gear to shaft clearance............................................................ PRESS FIT
m Gear to camshaft gear backlash .............................................. 0.006 to 0.009
0.009
Figure 3-109. Oil pressure regulator and oil pump-points of measurement.
a Valve Spring Measurements.
3-109.
a
Free spring length (approx.)...........................................................
3.410
a
Compressed length (at valve opening) (Force 45 Ibs.)..................
2.125
a
Compressed length (at max. valve opening) (Force of 35 Ibs.) ....
71.438
b. Oil Pump
3-109
b
c
d
e
Pump gear(s) outside diameter......................................................
Shifts (3) outside diameter .............................................................
Bushings (4) inside diameter .........................................................
Gear pockets (2) inside diameter...................................................
Gear pockets (2) inside depth ........................................................
3-183. cylinder Head
(para 3-66)
a. Valves, Guides and Valve Seats.
3-110.
a
Outside diameter of valve stem ..................................................
b
Inside diameter of valve guide ....................................................
c
Valve guide protrusion ................................................................
d
Intake valve seat insert thickness ...............................................
e
Exhaust valve seat insert thickness............................................
3-110.
f
Swirl plate thickness (intake) ......................................................
c
Head counterbore inside diameter 0 (std) ..................................
ad/ae Angle of seating face-valve and insert seat ................................
c
Valve seat width..........................................................................
g
Valve springs.(5340-082-0126) ..................................................
Free length..................................................................................
Load Length: Valve open-1.317..................................................
Number of coils ...........................................................................
3-68
*
2.399 to 2.400
0.8745 to 0.8750
0.8770 to 0.8775
2.4070 to 2.4090
12490 to 12510
2397
0.8740
0.8785
2.4105
1.252
0.4500 to 0.4512
0.4525 to 0.4532
695 to 0.710
02580 to 0.2200
0.02180 to 0.820
0.0200 to 0.0210
1.995 to 2.0005
30 Degrees
0.4490
0.4545
*
*
*
*
*
*
0.1250
0.0780
2.090
155 Ibs.
161 to 179 Ibs.
6’/..
*TM 9-2815-213-34
Figure 3-110. Cylinder Head-Points of measurement.
Figure 3-111. Tappets and push rods-points of measurement.
3-69
*TM 9-2815-213-34
b. Tappets and Push Rods.
(1) Injector tappet.
3-111.
h
Body outside diameter ................................................................
J
Guide spring outside diameter....................................................
k
Roller outside diameter...............................................................
k
Roller inside diameter .................................................................
l
Roller pin outside diameter ........................................................
(2) Valve tappet.
3-111.
m
Body outside diameter ................................................................
n
Guide spring outside diameter....................................................
3-111.
p
Roller outside diameter...............................................................
p
Roller inside diameter .................................................................
q
Roller pin outside diameter .........................................................
(3) Injector Push Rod.
3-111.
r
Ball end radius ............................................................................
r
Socket end radius .......................................................................
(4) Valve Push Rod.
3-111.
s
Ball end radius ............................................................................
s
Socket end radius .......................................................................
c. Rocker Lever and Shaft (para. 3-82).
3-112.
t
Lever bushing-inside diameter....................................................
u
Shaft-outside diameter................................................................
Adjusting screw ball end radius:
v
Injector ........................................................................................
w
Valve ...........................................................................................
x
Rocker lever(s) and rocker lever brackets ..................................
d. Cylinder Head (para. 3-66).
3-110
c
Cylinder head height...................................................................
y
Injector tip protrusion ..................................................................
1.3980 to 1.3900 1.3965
1.456
1.1690 to 1.1710 1.1670
0.6280 to 0.6290 0.6300
0.6246 to 0.6250 0.6235
1.0980to 1.0990
1.148
0.9290 to 0.9310
0.5030 to 0.5040
0.4995 to 0.5000
0.9270
0.5050
0.4985
0.3110 to 0.3125
0.2188 to 0.2203
0.3200
0.2165
0.3110 to 0.3125
0.1875 to 0.1890
0.3150
0.1850
1.875 to 1.1895
1.1855 to 1.1865
1.1905
1.1845
0.4350 to 0.4370
0.3725 to 0.3745
Clearance
*
*
*
4.4950 to 4.5050
0.1000 to 0.1150
*
0.1250
Figure 3-112. Rocker arms and shaft-points of measurement.
3-70
1.0965
*TM 9-2815-213-34
Fig.
No.
Ref.
Letter
Point of Measurement
New Dimensions
(inches)
c
Injector sleeve-upper inside diameter.........................................
c
Guide-outside diameter ..............................................................
y
Protrusion above the head..........................................................
c
Inside diameter ...........................................................................
e. Injector Plunger Spring Data (para. 3-74).
3-110.
z
Free length..................................................................................
Load at:
2.139 inches................................................................................
1.975 inches................................................................................
z
Injector cup torque-ft. Ibs. ..........................................................
z
Orifice plug torque-ft. Ibs. ..........................................................
3-110.
Wear Limits
(inches)
1.140 to 1.150
0.4332 to 0.4335
2.0900 to 2.1100
0.4340 to 0.4360
*
0.4322
*
0.4400
2.4500 to 2.4900
*
87.6 to 95.6 lbs.
13 to 147 Ibs.
50 to 55
6to 8
*
*
0.0100 to 1.0200
*
Figure 3-113. Water pump-points of measurement.
3-113.
a
Impeller to body clearance..........................................................
3-185. Assembly Data
3-114.
a
Front cover
Crankshaft to seal bore ........................................................
3-114.
b
Flywheel and Housing
Housing bore run-out............................................................
b
Housing face run-out ..................................................................
3-114.
Flywheel pilot bearing .................................................................
c
Bore run-out ................................................................................
c
Clutch face run-out .....................................................................
0.0050
0.010
0.008
*
*
*
*
*
004
005
3-186. Torque Specifications
CAUTION
Bolts threaded into aluminum may require
reduction in torque of 30 percent or more,
unless inserts are used.
Fig.
Item
. Cylinder Block Group.
2-29
*Main bearing stude nuts or cap screws ................................
3-8
Main bearing side bolts ..........................................................
2-28
*Connecting rod nuts..............................................................
2-6
Vibration damper mounting cap screws .................................
Crankshaft pipe plugs ............................................................
Engine block-pipe plugs .........................................................
Engine block-pipe plugs .........................................................
3-71
Nut or bolt size
3/4x 5.8in.
5/8x31/4in.
9/16x4.4in.
5/5x3y4 in.
1/8 in.
1/8 in.
½ in.
Lb-ft. torque
170 to 180 +
70 to 75
60 to 65+
190 to 200
5
5 to 10
45to 55
*TM 9-2815-213-34
Figure 3-114. Assembly data-points of measurement (run-out).
Fig.
Item
2-27
Front cover-cap screws..........................................................
+ equals template method of tightening cap screws.
Cylinder Head Group.
3-46
Cylinder head cap screws ......................................................
2-15
Cylinder head cap screws ......................................................
2-16
Cylinder head cap screws ......................................................
2-18
Valve crosshead nuts .............................................................
2-9
Fuel fittings ............................................................................
c. Rock Lever. Cam Follower and Tappet Group.
Nut or bolt size
2/8x1 to1 1/2 in.
2-12
Cylinder head cover cap screw ..............................................
2-15
Valve injector adjusting screw jam nut ...................................
d. PT Fuel Pump Group
B-18
Front cover cap screws ..........................................................
B-17
Spring pack cap screw ...........................................................
B-16
Gear pump cap screws ..........................................................
Gear pump cap screws ..............................................................................
B16 Gear pump eaprew .............................................................................
W16 Fuel pump damper cap screws ...........................................................
W17 Electric shut-down valve capscrewa ...................................................
'These cap screws or nuts are tightened by template method.
**Inch-pounds.
e. Injector and Connections Group.
3-49
Cups .......................................................................................
3-48
Orifice plug .............................................................................
2-15
Mounting cap screws (9/64 nylon insert)................................
f. Lubrication System Group.
2-25
Oil pan cap screw (108707) ...................................................
2-2
Oil cooler plate cap screw ......................................................
3/8x1 1/2in.
5/16x 3/4 in.
30 to 35
18 to 20
3/8x3 ½ in.
1/4x1.28 in,
1/4x1.78 in.
1/4x2.5 in.
1/4x3.5 in.
1/4x1 1/4 in.
.#10-24
**90 to 96
**90 to 96
7 to 9
7 to 9
7 to 9
7 to 9
**15 to 20
3-72
5/8x6 1/4 in.
5/8x7in.
5/8x10 1/8 in.
7/16 n.
Lb-ft. torque
30 to 35
175 to 185
175 to 186
175 to 18
60 to 70
11 to 18
3/8x2.in,
55
*8 to 10
30 to 35
3/8X1./2
3/8x1 in.
28 to35
29 to 31
*TM 9-2815-213-34
Fig.
Item
B-9
Oil pan drain plug ...................................................................
B-10
Oil pump cover cap screws ....................................................
g. Cooling System Group.
2-4
Fan hub marsden nut ...........................................................
2-7
Water pump pulley adjustable cap screws.............................
2-10
Water header cover plates .....................................................
h. Intake and Exhaust System Group.
2-1
Exhaust manifold....................................................................
2-8
Intake manifold.......................................................................
B-12
Preheater nozzle ....................................................................
B-19
Air inlet adapter cap screws ...................................................
i. Air Compressor Group.
2-10
Air compressor support cap screws.......................................
Air compressor mounting cap screws ....................................
j. Engine Mounting and Adaption Group.
3-22
Flywheel cap screws (140567)...............................................
2-22
Crankshaft adapter (140566) .................................................
2-28
Flywheel/gear housing cap screws ........................................
Nut or bolt size
1 in. dia.
3/8x7/8in.
1 ¼ in. dia.
1/4x1 ¼ in.
3/8x1 in.
3/8x1 1/4 in.
3/8x 1 1/4 in.
Lb-ft. torque
60 to 70
29 to 31
400 to 500
8 to 10
29 to 31
5/16x1 ¾ in.
29 to 31
29 to 31
15 to 20
17
3/8x1 ¼ in.
3/8x3¼. in.
29 to 31
29 to 31
5/8x1.5 in.
5/8x 27/64 in.
3/8x2 1/2 in.
NOTE
Always use the specific specifications of the manufacturer listed
above when assembling the engine and its components. The
torque values given are based on the use of clean, dry threads.
Reduce torque 10 percent when threads are lubricated with
engine oil. Reduce by 20 percent if new plated bolts are used.
200 to 205
200 to 205
28 to 86
*TM 9-2815-213-34
APPENDIX A
REFERENCES
1. Publication Indexes
Index of Army Motion Pictures, and related audio-visual aids..................................................................
DA Pam 10.-1
Military Publications:
Index of Administrative Publications.............................................................................................
DA Pam 310-1
Index of Blank Forms ...................................................................................................................
DA Pam .10-2
Military Publications: Index of Supply Catalogs and Supply Manuals
(excluding Types 7, 8 and 9) ...............................................................................................
DA Pam 310-6
Military Publications Index of Technical Manuals, Technical Bulletins,
Supply Manuals Types 7, 8 and 9, Supply Bulletins and Lubrication Orders .....................
DA Pam 3104
Index of Doctrinal Training and Organizational Publications ........................................................
DA Pam 31.3
Military Publications U.S. Army Equipment Index of Modification
Work Orders.........................................................................................................................
DA Pam 310-7
2. Supply Catalogs
The following Department of the Army Supply Catalogs pertain to this materiel:
Tool Kit, Auto Fuel and Electrical System Repair (4910-24-0655) ........................................................... SC 491-9-CL-A50
Tool Kit, Automotive Maintenance:
Organizational (2nd Echelon), Set 2, Common (5180-754-0650) ..............................................SC 4910-95-CLA72
Tool Kit, Automotive Maintenance:
Organizational (2nd Echelon), Set 2, Supplemental (4940-754-0743).......................................SC 4940-9.-CIA08
Tool Kit, Organizational Maintenance, Set No. 1, Common (5180-754-0654) ......................................SC 4910-95-CLA74
3. Forms
a. Refer to DA Pamphlet 310-2 for listing of blank forms required for support of this materiel.
b. TM 38-750 contains instructions on use of applicable forms.
4. Other Publications
a. Vehicle (Operation, Maintenance and Overhaul).
Truck Tractor 10-ton, 6 x 6, M123, M123C and M123A1C and Truck, Cargo M125 . TM 9-2320-206-10
Truck Tractor 10-ton, 6 x 6, M123, M123C and M123A1C and Truck, Cargo M125 TM 9-2320-206-20
Organizational Maintenance Repair Parts and Special Tools for Truck,
Tractor, 10-ton, 6 x 6, M123, M123C and M123A1C and Truck, Cargo M125 .. TM 9-2320-206-20P
Direct Support and General Support Maintenance (including repair parts)
for Truck Tractor, 10-ton, 6 x 6, M123, M123C, and M123A1C and
Truck, Cargo M125......................................................................................................................TM 9-2320-206-34
b. Accessory Maintenance.
Direct Support, General Support and Depot Maintenance Manuals
(including repair parts.) Generator Assembly (2920-737-4750)
(Electric Autolight Model GHA-4802UT) ......................................................................................TM 9-2920-209-35
Engine Electrical Generator:
Delco-Remy (2920-735-5736)...................................................................................................... TM 9-2920-2145
Engine Electrical Alternator:
Leece-Neville................................................................................................................................TM 9-2920-22535P
Engine Electrical Starter:
Leece-Neville (2920-267-9987) .................................................................................................... M 9-2920-24335
c. Miscellaneous (Maintenance and Overhaul).
Authorized Abbreviations and Brevity Symbols .........................................................................................
AR 310-50
Maintenance Assistance and Instruction Team Program..........................................................................
AR 750-51
Dictionary of United States Army Terms ...................................................................................................
AR 310-25
Inspection, Care, and Maintenance of Antifriction Bearings....................................................................
TM 9-214
Military Symbols ........................................................................................................................................
FM 21-30
Ordnance Corps Equipment Data Sheets .................................................................................................
TM 9500
A-1
TM 9-2815-213-34
Ordnance Engines:
Run-in and Test Procedures ...........................................................................................................
Organization, Policies, and Responsibilities for Maintenance Operations ..........................................
Preservation, Packaging, and Packing of Military Supplies and Equipment .......................................
Preservation, Packaging, Packing and Marking of Item of Supply......................................................
Principles of Automotive Vehicles .........................................................................................................
Protection of Ordnance General Supplies in Open Storage..................................................................
Publications for Packaging Army General Supplies ..............................................................................
Report of Packaging and Handling Deficiencies ...................................................................................
The Army Maintenance Management System ......................................................................................
Use and Care of Handtools and Measuring Tools ................................................................................
Welding; Theory and Application...........................................................................................................
A-2
TB 9-2800-20050
AR 750
TM 38-230-1
AR 700-15
TM 9-8000
TB ORD 379
SB 764
AR 7008
TM 38750
TM 9-24
TM 9-287
C 1, TM 9-2815-213-34
APPENDIX B
REPAIR PARTS AND SPECIAL TOOLS LIST
Section I.
B-1. Scope
This appendix lists the repair parts and specific tools
required for the performance of dire support and general
support maintenance of the V8-300 diesel engine.
B-2. General.
This Repair Parts and Special Tools List divided into the
following sections:
a. Section II. Repair Parts List. A list of repair parts
authorized for use in the performance maintenance. The
list also includes parts which must be removed for
replacement of the authorized parts. Parts lists are
composed functional groups in ascending numeric,
sequence, with the parts in each group listed figure and
item number sequence. Bulk material are listed in NSN
sequence.
b. Section III. Special Tools, Test and Support
Equipment. A list of special tools, test at support
equipment authorized for the performance of
maintenance at the direct support and general support
levels.
c. Section IV. National Stock Number and Part
Number Index. A list, in ascending numerical sequence,
of all National stock numbers appearing in the listings,
followed by a list in alphameric sequence, of all part
number appearing in the listings. National stock numb,
and part numbers are cross-referenced to each
illustration figure and item number appearance This
index is followed by a cross-reference list reference
designations to figure and item number: when applicable.
B-3. Explanation of Columns.
The following provides an explanation of columns found
in the tabular listings: a. Illustration. This column is
divided follows:
(1) Figure Number. Indicates the figure number
of the illustration in which the item shown.
(2) Item Number. The number used identify
each item called out in the illustration
b. Source, Maintenance, and Recoverability Codes
(SMR ).
(1) Source Code. Source codes are assigned to support
items to indicate the manner of acquiring support items
for maintenance, repair, or overhaul of end items.
Source codes are entered in the first and second
positions of the Uniform SMR Code format as follows:
Code
Definition
PA ..... Item procured and stocked for anticipated or
known usage.
PB ..... Item procured and stocked for insurance
purpose because essentially dictates that a minimum
quantity be available in the supply systems.
PC ..... Item procured and stocked and which otherwise
would be coded PA except that it is deteriorate in nature.
PD ..... Support item, excluding support equipment,
procured for initial issue or outfitting and stocked only for
subsequent or additional initial issues or outfittings. Not
subject to automatic replenishment.
PE ..... Support equipment procured and stocked for
initial issue or outfitting to specified maintenance repair
activities.
PF...... Support equipment which will not be stocked but
which will be centrally procured on demand.
PG ..... Item procured and stocked to provide for
sustained support for the life of the equipment. It is
applied to item peculiar to the equipment which,
because of probable discontinuance or shutdown of
production facilities,
would prove uneconomical to
reproduce at a later time.
KD ..... An item of a depot overhaul/repair kit and not
purchased separately. Depot kit defined as a kit that
provides items required at the time of overhaul or repair.
KF...... An item of a maintenance kit and not purchased
separately.
Maintenance kit defined as a kit that
provides an item that can be replaced at organizational
or intermediate levels of maintenance.
KB ..... Item included in both a depot overhaul/repair kit
and a maintenance kit.
MO .... Item
to be manufactured or fabricated at
organizational level.
MF ..... Item to be manufactured or fabricated at the
direct support maintenance level.
MH..... Item to be manufactured or fabricated at the
general support maintenance level.
MD..... Item to be manufactured or fabricated at the
depot maintenance level.
AOItem to be assembled at organizational level.
AF...... Item to be assembled at direct support
maintenance level.
AH ..... Item to be assembled at general support
maintenance level.
B-1
C 1, TM 9-2815-213-34
support level.
D....... The lowest maintenance level capable of
complete repair of the support item is the depot level,
performed by depot, mobile depot or specialized repair
activity.
L ....... Repair restricted to designated specialized repair
activity.
Z ....... Nonreparable. No repair is authorized.
B....... No repair is authorized. The item may be
reconditioned by adjusting, lubricating, etc., at the user
level. No parts or special tools are procured for the
maintenance of this item.
(3) Recoverability Code. Recoverability codes
are assigned to support items to indicate the disposition
action on unserviceable items. The recoverability code is
entered in the fifth position of the Uniform SMR Code
format as follows:
Recoverability
Codes
Definition
Z ....... Nonreparable item.
When unserviceable,
condemn and dispose at the level indicate in position 3.
O ...... Reparable item.
When uneconomically
reparable, condemn and dispose at organizational level.
F ....... Reparable
item.
When uneconomically
reparable, condemn and dispose at the direct support
level.
H....... Reparable item.
When uneconomically
reparable, condemn and dispose at the general support
level.
D....... Reparable item. When beyond lower level repair
capability, return to depot. Condemnation and disposal
not authorized below depot level.
L ....... Reparable item. Repair, condemnation, and
disposal not authorized below depot/specialized repair
activity level.
A....... Item requires special handling or condemnation
procedures because of specific reasons (i.e., precious
metal content, high dollar value, critical material or
hazardous
material).
Refer
to
appropriate
manuals/directives for specific instructions.
c. National Stock Number. Indicates the National
stock number assigned to the item and will be used for
requisitioning purposes.
d. Part Number. 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.
NOTE
When a stock numbered item is requisitioned,
the repair part received may have a different
part number than the part being replaced.
e. Federal Supply Code for Manufacturer
(FSCM). The FSCM is a 5-digit numeric code
CodeDefinition
AD.... Item to be assembled at depot maintenance level
XA.... Item is not procured or stocked because
requirements for the item will result in replacement of the
next higher assembly.
XB.... Item is not procured or stocked. If not available
through salvage, requisition.
XD.... A support item that is not stocked. required,
item will be procured through normal supply channels.
NOTE
Cannibalization or salvage may be used as a
source of supply for any items source coded
above except those coded XA, XD, and
aircraft support items as restricted by AR
700-42.
(2) Maintenance Code. Maintenance cc are
assigned to indicate the levels of maintenance
authorized to USE and REPAIR support items The
maintenance codes are entered in the t and fourth
positions of the Uniform SMR C format as follows:
(a) The maintenance code entered in third position
will indicate the lowest maintenance level authorized to
remove,
replace,
use the support item.
The
maintenance c entered in the third position will indicate
on the following levels of maintenance:
Code
Application/Explanation
C ...... Crew or operator maintenance performed within
organizational maintenance.
0....... Support item is removed, replaced, used a
organizational level.
I........ Support item is removed, replaced, used by the
direct support element of integrated support
maintenance.
F ...... Support item is removed, replaced, used a direct
support level.
H ...... Support item is removed, replaced, used a
general support level.
D ...... Support items that are removed, replaced, us
depot, mobile depot, specialized repair activity only.
NOTE
Codes "I" and "F" will be considered the same
by direct support units.
(b) The maintenance code entered in fourth
position indicates whether the item is t repaired and
identifies the lowest maintenance level with the capability
to perform comp repair (i.e., all authorized maintenance
functions). This position will contain one of following
maintenance codes:
Code
Application/Explanation
0....... The lowest maintenance level capable of
complete repair of the support item is the organizational
level.
F ...... The lowest maintenance level capable of con
repair of the support item is the direct support level.
CodeApplication/Explanation
H ...... The lowest maintenance level capable of
complete repair of the support item is the general
B-2
C 1, TM 9-2815-213-34
listed in SB 708-42 which is used to identify the
manufacturer, distributor, or Government agency, etc.
f. Description. Indicates the Federal item name and,
if required, a minimum description to identify the item.
Items that are included in kits and sets are listed below
the name of the kit or set with the quantity of each item in
the kit or set indicated in the quantity incorporated in unit
column. When the part to be used differs between serial
numbers of the same model,
the effective serial
numbers are shown as the last line of the description. In
the Special Tools List, the initial basis of issue (BOI)
appears as the last line in the entry for each special tool,
TMDE, and support equipment. When density of
equipments supported exceeds density spread indicated
in the basis of issue, the total authorization is increase
accordingly.
g. Unit of Measure (U/M). Indicates the standard of
the basic quantity of the listed item as used in performing
the actual maintenance function. This measure is
expressed by a two character alphabetical abbreviation
(e.g., ea., in pr, etc.). When the unit of measure differs
from the unit of issue, the lowest unit of issue that will
satisfy the required units of measure will be
requisitioned.
h. Quantity Incorporated in Unit. Indicate the
quantity of the item used in the breakout shown on the
illustration figure, which prepared for a functional group,
subfunctions group, or an assembly. A "V" appearing in
this column in lieu of a quantity indicates that no specific
quantity is applicable, (e.g., shims spacers, etc.).
B-4. Special Information
a. Repair parts kits and gasket sets appear a the
last entries in the repair parts listing for the figure in
which its parts are listed as repair parts
b.
The following publications pertain to the
M123A1C and M123E2 10-ton trucks which us the V8300 diesel engine:
Publication and short title
LO 9-2320-206-12, Truck, Tractor, 10-Ton, 6x6
TM 9-2320-206-ESC, Truck, Tractor, 10-Ton, 6x6
TM 9-2320-206-20, Truck, Tractor, 10-Ton, 6x6
TM 9-2320-206-20P, Truck, Tractor, 10-Ton, 6x6
B-5. How To Locate Repair Parts
a. When National Stock Number or Part Number is
Unknown:
(1) First. Using the table of contents, determine
the functional subgroup within which the repair part
belongs.
This is necessary since illustrations are
prepared for functional subgroups and listings are
divided into the same groups.
(2) Second. Find the illustration covering the
functional subgroups to which the repair part belongs.
Identify the repair part on the
(3) Third.
illustration and note the illustration figure and item
number of the repair part.
(4) Fourth. Using the Repair Parts Listing, find
the figure and item number noted on the illustration.
b. When National Stock Number or Part Number is
Known.
(1) First. Using the Index of National Stock
Numbers and Part Numbers, find the pertinent National
stock number or part number. This index is in ascending
NSN sequence followed by a list of part numbers in
ascending alphameric sequence, cross-referenced to
the illustration figure number and item number.
(2) Second. After finding the figure and item
number, locate the figure and item number in the repair
parts list.
B-6. Reporting of Errors.
You can improve this manual by recommending
improvements using DA Form 2028 (Recommended
Changes to Publications and Blank Forms) and mailing
the form direct to Commander,
US Army TankAutomotive Command, ATTN: AMSTA-MTP, Warren,
MI 48090. A reply will be furnished direct to you.
B-3
SECTION II
(1)
TMC 1, TM 9-2815-213-34
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
(6)
DESCRIPTION
FSCM
USABLE ON CODE
(7) (8)
QTY
INC
U/M IN
UNIT
GROUP 01-ENGINE
0100-ENGINE ASSEMBLY
B-1
1 PAFDL
2815-00-910-8218
5703466
19207
B-1
2 PAFDL
2815-00-910-8217
10946107-1
19207
B-1
B-l
3 PAOZZ
4 XBOXX
2815-00-226-8089
154643
154528
15434
15434
B-1
5 PAOZZ
5310-00-637-9541
MS35338-46
96906
B-1
6 PAOZZ
5305-00-269-3214
MS90725-64
96906
B-1
- PAFZZ
2815-00-910-8219
BM 95886
15434
B-2
B-4
B-4
B-4
B-7
B-9
B-9
B-9
B-9
B-10
B-10
B-10
B-11
B-11
B- 11
B-11
B-11
B-11
B-11
B- 11
B-20
B-21
B-22
B-22
B-23
B-23
B-25
B-25
B-24.1
B-25B-25B-25B-25B-2
B-2
B-2
B-2
B-2
B-6
B-8
B-12
19
1
3
8
18
7
9
7
21
3
13
27
1
2
13
24
25
26
27
28
7
7
5
23
6
12
2
7
- PAFZZ
7
8
9
28
7
3
9
5330-00-918-0606
BM 96854
15434
B-4
ENGINE, DIESEL, WITH .......................................
CONTAINER: Truck Tractor
NOTE
See group 3301 for engine container repair parts
ENGINE, DIESEL: Cummins Model ........................
V8-300
BRACKET, LIFTING: engine rear ...........................
BRACKET, LIFTING: front, left .............................
bank
WASHER, LOCK: engine lifting ............................
lifting bracket
SCREW, CAP, HEXAGON HEAD:.........................
engine lifting bracket
PARTS KIT, ENGINE OVER- ...............................
HAUL: V8-300 diesel engine
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
SEAL .......................................................................
SEAL .......................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
PACKING ................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
SPACER..................................................................
GASKET ..................................................................
SEAL .......................................................................
GASKET ..................................................................
GASKET ..................................................................
SEAL .......................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
PACKING ................................................................
PACKING ................................................................
GASKET ..................................................................
PACKING ................................................................
GASKET SET: cylinder head ...................................
GROMMET ..............................................................
GASKET ..................................................................
RETAINER...............................................................
PACKING, PREFORMED .......................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
EA
1
EA
1
EA
EA
2
1
EA
8
EA
8
EA
1
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
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
2
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
17
2
17
4
2
1
2
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
FSCM
(6)
DESCRIPTION
USABLE ON CODE
(7) (8)
QTY
INC
U/M IN
UNIT
B-12
B-12
B-12
B-12
B-13
B-19
B-20
B-21
0100-ENGINE ASSEMBLY-Cont
GASKET ..................................................................
GASKET ..................................................................
LOCKPLATE............................................................
GASKET ..................................................................
PACKING, PREFORMED ........................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
10
12
17
19
13
11
6
15
B-2
1 PAFHH
2815-00-913-1743
BM 176119
15434
B-2
2 PAFZZ
5310-00-081-8500
127316
15434
B-2
3 PAFZZ
5306-00-082-0660
151348
15434
B-2
4 PAFZZ
5306-00-970-8923
151350
15434
B-2
5 PAFZZ
5306-00-082-0661
151349
15434
B-2
B-2
6 PAHZZ
7 PAFZZ
2815-00-085-7442
5330-00-866-5079
147056
132705
15434
15434
B-2
8 PAFZZ
2815-00-972-5388
149973
15434
B-2
9 PAFZZ
2815-00-712-8496
131168
15434
B-2
10 XAHZZ
161991
15434
B-2
11 XBHZZ
S 136
15434
B-2
B-2
12 XAHZZ
13 PAHZZ
5306-00-062-3995
161992
148001
15434
15434
B-2
B-2
B-2
14 PAHZZ
15 PAHZZ
16 PAHZZ
5310-00-595-6612
2815-00-454-7806
5305-00-269-3211
MS20002-12
167825
MS90725-60
96906
15434
96906
B-2
17 PAHZZ
5310-00-637-9641
MS35338-46
96906
B-2
B-2
18 PAHZZ
19 PAHZZ
5310-00-562-6563
2815-00-084-7784
S 602
151781
15434
15434
B-2
B-2
20 PAFZZ
21 PAHDL
4730-00-018-9566
2815-00-454-5058
189566
BM 94173
21450
15434
B-2
B-2
22 PAFZZ
23 PAHZZ
4730-00-801-8186
5330-00-913-3949
S 915A
168035
15434
15434
B-2
24 PAHZZ
5330-00-082-0454
122929
15434
B-2
25 PAHZZ
2815-00-994-4418
155172
15434
B-2
26 PAHZZ
2815-00-903-6633
158630
15434
B-2
B-2
27 PAFZZ
28 PAFZZ
5365-00-086-8293
5330-00-582-7484
100973
MS90121-116
15434
96906
B-5
0101-BLOCK AND
CYLINDER HEAD
CYLINDER HEAD, DIESEL .....................................
ENGINE: includes guides, springs
and inserts
WASHER: cylinder head (36), side ..........................
locking cap screw (10)
SCREW, CAP, HEXAGON HEAD:...........................
cylinder head
SCREW, CAP, HEXAGON HEAD:...........................
cylinder head
BOLT, EXTERNALLY RELIEVED:...........................
cylinder head
SLEEVE, INJECTOR: cylinder head ........................
GROMMET: cylinder head gasket............................
part of kit P/N BM 96854
GASKET: cylinder head part of kit............................
part of kit P/N BM 96854
RETAINER: cylinder head grommet.........................
part of kit P/N BM 96854
CAP, MAIN BEARING: inter- ...................................
mediate
SCREW, CAP: main bearing side ............................
locking
CAP, MAIN BEARING: front ....................................
BOLT, SHOULDER: main bearing ...........................
caps
WASHER, FLAT: main bearing caps .......................
COVER: water header: cylinder block ......................
SCREW, CAP, HEXAGON HEAD:...........................
water header cover
WASHER, LOCK: water header...............................
cover
WASHER: water header cover.................................
GASKET: water head, cylinder block .......................
part of kit P/N BM 95886
PLUG, PIPE: cylinder block .....................................
BLOCK, CYLINDER: diesel engine, .........................
V8-300
PLUG, PIPE: cylinder block .....................................
PACKING, CYLINDER LINER: ................................
bottom
PACKING, CYLINDER LINER: ................................
center
PACKING, CYLINDER LINER: ................................
upper
CYLINDER SLEEVE: cast iron, ...............................
6.175 in. O.D., 5.520 in. bore dia.,
8.250 in. overall length
DOWEL: cylinder head to block ...............................
PACKING, PREFORMED: cylinder ..........................
head to block part of kit P/N BM 96854
EA
EA
EA
EA
EA
EA
EA
EA
2
2
8
8
32
1
1
1
EA
2
EA
46
EA
16
EA
10
EA
10
EA
EA
8
17
EA
2
EA
17
EA
3
EA
10
EA
EA
1
10
EA 10
EA
1
EA
4
EA
4
EA
EA
4
1
EA
EA
1
1
EA
EA
2
8
EA
8
EA
8
EA
8
EA
EA
1
4
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
FSCM
B-2
B-2
B-2
29 XAHZZ
30 PAHZZ
31 PAHZZ
5315-00-632-9388
5315-00-082-1901
148000
5329388
128765
15434
19207
15434
B-2
32 PAHZZ
5315-00-081-8509
128766
15434
B-3
1 PAOZZ
5305-00-905-0831
64487J
15434
B-3
2 PAOZZ
5310-00-820-6653
MS35338-50
96906
B-3
B-3
B-3
B-3
B-3
3
4
5
6
7
3020-00-905-4427
2815-00-909-5956
2815-00-924-4491
2815-00-907-9013
3120-00-994-4419
164349
BM 92141
163821
158370
146590
15434
15434
15434
15434
15434
B-3
7 KFHZZ
146591
15434
B-3
8 PAHZZ
146690
15434
B-3
8 KFHZZ
140091
15434
B-3
9 PAHZZ
2815-00-085-7470
150100
15434
B-3
B-3
10 PAHZZ
11 PAHZZ
5315-00-081-8509
3120-00-994-4423
128766
146610
15434
15434
B-3
11 KFHZZ
140141
15434
B-3
B-3
B-3
B-3
12
13
14
15
PAHZZ
PAHZZ
PAHZZ
PAHZZ
4730-00-018-9566
5315-00-062-4395
2815-00-453-9077
5306-00-081-8507
189566
144131
161701
140566
21450
15434
15434
15434
B-3
B-3
16 PAHZZ
17 PAHZZ
2815-00-297-0068
5315-00-082-1901
158759
128765
15434
15434
B-3
B-3
B-3
B-3
18
19
20
21
2815-00-085-7457
2815-00-842-5330
3020-00-082-1899
3120-00-994-4424
154166
154167
150138
140100
15434
15434
15434
15434
B-3
21 KFHZZ
14661
15434
B-3
22 PAHZZ
140090
15434
B-3
22 KFHZZ
146601
15434
PAOZZ
PAOZZ
PAOZZ
PAHHH
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
3120-00-994-4421
3120-00-994-4422
B-6
(6)
DESCRIPTION
USABLE ON CODE
0101-BLOCK AND CYLINDER
HEAD-Cont
CAP, MAIN BEARING: rear .....................................
DOWEL: main bearing cap, front .............................
DOWEL: main bearing cap, .....................................
intermediate
DOWEL: main bearing cap, rear ..............................
0102-CRANKSHAFT
SCREW, CAP, HEXAGON HEAD:...........................
vibration damper
WASHER, LOCK: vibration damper .........................
mounting
PULLEY, GROOVE: fan drive ..................................
DAMPER, VIBRATION ............................................
PULLEY: water pump drive......................................
CRANKSHAFT, ENGINE .........................................
BEARING, FRONT, UPPER: ...................................
HALF: crankshaft (standard) Part of set P/N BM 71630
BEARING, FRONT, UPPER ....................................
HALF: crankshaft (undersize) Part of
set P/N BM 72531
BEARING, INTERMEDIATE, ...................................
UPPER HALF: crankshaft
(standard) Part of set P/N BM 71630
BEARING, INTERMEDIATE, ...................................
UPPER HALF: crankshaft
(undersize) Part of set P/N BM 71531
RING, THRUST: crankshaft Part of..........................
sets P/N BM 71630 and P/N BM
71531
DOWEL: upper half, crankshaft ...............................
BEARING, REAR, UPPER HALF:............................
Crankshaft (standard) Part of set
P/N BM 71630
BEARING, REAR, UPPER HALF:............................
crankshaft (undersize) Part of set
P/N BM 71531
PLUG, PIPE: crankshaft ..........................................
KEY, WOODRUFF: crankshaft gear ........................
CUP: crankshaft grease retaining ............................
BOLT, EXTERNALLY RELIEVED:...........................
flywheel adapter to crankshaft
ADAPTER: flywheel .................................................
DOWEL: lower half crankshaft thrust .......................
ring
SHIELD, OIL: gear housing......................................
SLINGER, OIL: crankshaft .......................................
GEAR, CRANKSHAFT: engine ................................
BEARING, REAR, LOWER HALF:...........................
crankshaft (standard) Part of set P/N
P/N BM 71630
BEARING, REAR, LOWER HALF:...........................
crankshaft (undersize) Part of set
P/N BM 71531
BEARING, INTERMEDIATE, ...................................
LOWER HALF: crankshaft
(standard) Part of set P/N BM 17630
BEARING, INTERMEDIATE, ...................................
LOWER HALF: crankshaft
(undersize) Part of set-P/N BM 71531
(7) (8)
QTY
INC
U/M IN
UNIT
EA
EA
EA
1
1
3
EA
1
EA
7
EA
7
EA
EA
EA
EA
EA
1
1
1
1
1
EA
1
EA
3
EA
3
EA
4
EA
EA
4
1
EA
1
EA
EA
EA
EA
1
1
1
7
EA
EA
1
4
EA
EA
EA
EA
1
1
1
1
EA
1
EA
3
EA
3
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-3
23 PAHZZ
B-3
23 KFHZZ
B-3
- PAHZZ
B-3
B-3
B-3
B-3
B-3
B-3
B-3
B-3
7
8
9
11
21
22
23
- PAHZZ
B-3
B-3
B-3
B-3
B-3
B-3
B-3
7
8
9
11
21
22
23
3120-00-994-4420
2815-00-085-7444
2815-00-903-1334
FSCM
140080
15434
140081
15434
BM71630
15434
BM 71531
15434
B-4
1 PAFZZ
2815-00-084-7783
151780
15434
B-4
2 PAFZZ
2815-00-297-0619
151035
15434
B-4
3 PAFZZ
5330-00-980-9604
151100
15434
B-4
4 PAFZZ
2815-00-104-3637
69562
15434
B-4
5 PAFZZ
2815-00-815-0530
102957
15434
B-4
B-4
B-4
6 PAOZZ
7 XBFZZ
8 KFFZZ
4730-00-018-9566
189566
174437
186908
21450
15434
15434
B-4
9 PAFZZ
5310-00-562-6553
S 602
15434
B-4
10 PAFZZ
5310-00-637-9541
MS35338-46
96906
B-4
11 PAFZZ
5305-00-177-5552
S 126
15434
B-4
12 PAFZZ
2815-00-907-8979
BM 78683
15434
B-4
B-4
B-4
13 PAFZZ
14 PAFZZ
15 PAFZZ
3020-00-528-5053
5306-00-335-4755
5305-00-269-3220
4797
8333620
MS90725-70
15434
19207
96906
B-4
16 PAFZZ
5305-00-269-3215
MS90725-65
96906
B-4
B-4
17 PAOZZ
18 PAFZZ
4730-00-289-4770
5305-00-269-3210
S 995
MS90725-59
15434
96906
B-4
19 PAFZZ
2815-00-353-9395
68908
15434
B-7
(6)
DESCRIPTION
USABLE ON CODE
0102-CRANKSHAFT-Continued
BEARING, FRONT, LOWER HALF: ........................
crankshaft (standard) part of set
P/N BM 17630
BEARING, FRONT, LOWER HALF: ........................
crankshaft (undersize part of set P/N
BM 71531
BEARING SET, CRANKSHAFT:..............................
standard
BEARING HALF ......................................................
BEARING HALF ......................................................
RING, THRUST .......................................................
BEARING HALF ......................................................
BEARING HALF ......................................................
BEARING HALF ......................................................
BEARING HALF ......................................................
BEARING SET, CRANKSHAFT:..............................
0.010 undersize
BEARING HALF ......................................................
BEARING HALF ......................................................
RING, THRUST .......................................................
BEARING HALF ......................................................
BEARING HALF ......................................................
BEARING HALF ......................................................
BEARING HALF ......................................................
0103-FLYWHEEL ASSEMBLY
GASKET: cylinder block part of kit ...........................
P/N BM 95886
PLATE, SPACER: block to flywheel .........................
housing
GASKET: flywheel housing to plate .........................
part of kit P/N BM 95886
DOWEL, MASTER: flywheel housing.......................
to block
TOWEL, DIAMOND: flywheel hous-.........................
ing to block
LUG, PIPE: top flywheel housing .............................
HOUSING: flywheel .................................................
SEAL, OIL: crankshaft to flywheel............................
part of kit P/N BM 95886
WASHER, FLAT: flywheel housing to ......................
block
WASHER, LOCK: flywheel housing to .....................
block
SCREW, CAP, HEXAGON HEAD:...........................
flywheel housing to block
FLYWHEEL ASSEMBLY WITH ...............................
RING GEAR
GEAR, RING,: flywheel ............................................
BOLT: flywheel to crankshaft ...................................
SCREW, CAP, HEXAGON HEAD............................
flywheel housing to block
SCREW, CAP, HEXAGON HEAD:...........................
flywheel housing
LUG, PIPE: flywheel housing drain ..........................
SCREW, CAP, HEXAGON HEAD:..........................
plate to block
LOCKPLATE: plate to block.....................................
(7) (8)
QTY
INC
U/M IN
UNIT
EA
1
EA
1
EA
1
EA
EA
EA
EA
EA
EA
EA
EA
1
3
4
1
1
3
1
1
EA
EA
EA
EA
EA
EA
EA
1
3
4
1
1
3
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
EA
EA
1
1
1
EA
18
EA
18
EA
9
EA
1
EA
EA
EA
1
6
3
EA
6
EA
EA
2
8
EA
8
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-5
1 KFHZZ
129260
B-5
2 KFHZZ
168680
B-5
3 KFHZZ
12550
B-5
B-5
B-5
B-5
B-5
B-5
B-5
4
5
6
7
8
6
10
B-5
B-5
B-5
PAHZZ
KFHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
5305-00-062-4373
2815-00-082-0462
3120-00-994-4432
2815-00-909-2491
2815-00-907-8950
BM 93100
172580
155267
140120
126600
156304
BM 79166
10 XDHZZ
11 PAHZZ
12 PAHZZ
2815-00-062-9566
5310-00-062-6632
BM 97339
139950
139438
B-5
13 PAHZZ
3120-00-913-9746
156310
B-5
13 KFHZZ
B-5
B-5
B-5
B-5
B-5
- PAHZZ
1
2
3
- PAHZZ
B-5
B-5
13
- PAHZZ
B-5
13
B-6
B-6
B-6
1 PAFZZ
2 PAFZZ
3 PAFZZ
B-6
2815-00-907-8952
156311
2815-00-911-7612
BM 92350
3120-00-908-7320
BM 96100
3120-00-910-8220
BM 97590
5310-00-562-6553
5310-00-637-9541
5305-00-269-3214
FSCM
(6)
DESCRIPTION
USABLE ON CODE
0104-PISTON AND
CONNECTING ROD
15434 RING, PISTON: upper part of set.............................
P/N BM 92350
15434 RING, PISTON: lower Part of set .............................
P/N BM 92350
15434 RING AND SPACER, PISTON: Part ........................
set of P/N BM 92350
154341 PISTON SET: with pin and snap rings .....................
15434 PISTON: diesel engine ............................................
15434 RING, RETAINING: piston pin .................................
15434 PIN, PISTON ...........................................................
15434 BEARING: piston pin ...............................................
15434 BOLT connecting rod ...............................................
15434 CONNECTING ROD, PISTON: with- .......................
out bearing
15434 CONNECTING ROD:...............................................
15434 LOCKPLATE: connecting rod bolt............................
15434 NUT, HEXAGON: connecting rod.............................
bolt
15434 BEARING: connecting rod Part of set ......................
P/N BM 96100
15434 BEARING: connecting rod Part of set ......................
P/N BM 97590
15434 RING SET, PISTON: standard .................................
RING, PISTON ........................................................
RING, PISTON ........................................................
RING AND SPACE, PISTON ...................................
15434 BEARING SET, CONNECTING ROD ......................
standard
BEARING ................................................................
15434 BEARING SET, CONNECTING ROD ......................
0.010 in. undersize
BEARING ................................................................
S 602
MS35338-46
MS90725-64
15434
96906
96906
4 XBFZZ
156144
15434
B-6
5 XBFZZ
BM 97370
15434
B-6
B-6
6 PAOZZ
7 PAFZZ
2815-00-362-1548
5330-00-994-4409
S 2902
151299
15434
15434
B-6
B-6
8 PAFZZ
9 PAFZZ
2815-00-085-3952
2815-00-994-4434
138935
127554
15434
15434
B-6
10 PAFZZ
2815-00-085-7469
139896
15434
B-6
11 PAFZZ
5360-00-082-0126
128235
15434
B-6
12 PAFZZ
2815-00-905-4453
163361
15434
B-6
13 PAFZZ
5330-00-994-4435
156641
15434
B-8
0105-VALVES AND CAMSHAFT
WASHER, FLAT: cylinder head cover......................
WASHER LOCK: cylinder head cover......................
SCREW, CAP, HEXAGON HEAD:...........................
cylinder head cover
COVER, CYLINDER HEAD: right ............................
bank
COVER, CYLINDER HEAD: left...............................
bank
CAP, FIILER: cylinder head cover............................
GASKET: cylinder head cover Part of ......................
set P/N BM 96854
BRACKET: rocker lever shaft...................................
LOCK, VALVE SPRING RETAINING:......................
half-collet, intake and exhaust valve
GUIDE, VALVE SPRING: exhaust ...........................
and intake valve
SPRING, HELICAL, COMPRESSION:.....................
intake and exhaust valve
RETAINER, VALVE COMPRESSION......................
SPRING: intake and exhaust valve
SEAL: intake valve...................................................
(7) (8)
QTY
INC
U/M IN
UNIT
EA
8
EA
8
EA
8
EA
8
EA
8
EA 16
EA
8
EA 16
EA 16
EA
8
EA
EA
EA
8
16
16
EA
16
EA
16
EA
EA
EA
EA
EA
1
8
8
8
1
EA
EA
16
1
EA
16
EA 20
EA 20
EA 20
EA
1
EA
1
EA
EA
1
2
EA
8
EA 64
EA
32
EA
32
EA
32
EA
16
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
FSCM
B-6
14 PAFZZ
2815-00-981-3160
138937
15434
B-6
B-6
B-6
B-6
B-6
B-6
B-6
B-6
B-6
B-6
15
16
17
18
19
20
21
22
23
24
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
5315-00-907-0712
4730-00-018-9566
5340-00-721-5329
4730-00-289-4770
2815-00-085-7441
2815-00-085-7452
2815-00-994-4438
2815-00-939-8084
5310-00-407-9566
5306-00-225-8497
161837
189566
70459
S 995
146064
146120
138886
171085
MS35338-45
MS90725-32
15434
21450
15434
15434
15434
15434
15434
15434
96906
96906
B-6
25 PAFZZ
2815-00-939-8924
BM 94150
15434
B-6
26 PAFZZ
2815-00-783-9751
108187
15434
B-6
B-6
27 PAFZZ
28 PAFZZ
3120-00-984-1851
2815-00-909-2485
152082
168327
15434
15434
B-6
B-6
B-6
B-6
29
30
31
32
PAFZZ
PAFZZ
PAFZZ
PAFZZ
3120-00-973-2972
2815-00-045-9875
2815-00-045-9877
5315-00-783-9730
154571
114223
156438
108186
15434
15434
15434
15434
B-6
B-6
B-6
B-6
B-6
B-6
B-6
B-6
B-6
B-6
33
34
35
36
37
38
39
39
40
41
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
PAFZZ
2815-00-907-8954
2815-00-505-5119
2815-00-045-9876
2815-00-944-4437
2815-00-085-7434
2815-00-085-7450
2815-00-085-7451
2815-00-085-7438
5305-00-062-4378
5310-00-275-3435
BM 94151
107738
156439
138887
127930
138948
144896
144897
147389
S 273
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
B-6
B-6
B-6
42 PAFZZ
42 PAFZZ
43 PAFZZ
2990-00-970-8930
2815-00-148-7469
2815-00-994-4444
153615
169352
153614
15434
15434
15434
B-6
43 PAFZZ
2815-00-159-8678
169351
15434
B-6
B-6
B-6
44 PAFZZ
45 PAFZZ
46 PAFZZ
5305-00-297-4022
5340-00-470-6173
2815-00-916-1879
168319
161825
BM 71425
15434
15434
15434
B-6
B-6
47 PAFZZ
48 PAFZZ
2815-00-912-4609
3120-00-082-0240
BM 96832
141875
15434
15434
B-6
B-6
B-6
49 PAFZZ
50 PAFZZ
51 PAFZZ
2815-00-085-3944
2815-00-912-4611
3120-00-082-0241
152173
BM 96828
146975
15434
15434
15434
B-6
B-6
52 XBFZZ
53 PAFZZ
2815-00-085-3954
BM 96830
143021
15434
15434
B-9
(6)
DESCRIPTION
USABLE ON CODE
0105-VALVES AND CAMSHAFT
-Continued
GUIDE, VALVE STEM: intake and...........................
exhaust valve
PIN, SPRING DOWEL, SPLIT .................................
PLUG, PIPE: cylinder head......................................
PLUG, FUSE: cylinder head ....................................
PLUG, PIPE: cylinder head......................................
PLATE, SWIRL: intake valve ...................................
SEAT, VALVE: intake ..............................................
VALVE, POPPET: engine intake..............................
PLATE, GUIDE: tappets ..........................................
WASHER, LOCK: tappet guide ................................
SCREW, CAP, HEXAGON HEAD:...........................
tappet guide plate
TAPPET, POPPET VALVE: intake ..........................
and exhaust
PIN, STRAIGHT, HEADLESS: intake ......................
and exhaust tappet
BEARING, SLEEVE: intake and exhaust6 ...............
PIN, ROLLER, CAM FOLLOWER:...........................
intake and exhaust tappet
BEARING SLEEVE: injector tappet..........................
PIN, INJECTOR: tappet roller ..................................
CLIP, SPRING: intake and exhaust tappet...............
PIN, STRAIGHT, HEADLESS: .................................
injector tappet
TAPPET, INJECTOR ...............................................
SOCKET, CAM FOLLOWER: injector tappet ...........
CLIP, SPRING: injector tappet .................................
VALVE, POPPET: engine exhaust...........................
SEAT, VALVE: exhaust ...........................................
GUIDE, CROSSHEAD: exhaust...............................
CROSSHEAD, VALVE: intake .................................
CROSSHEAD, VALVE: exhaust ..............................
SETSCREW: crosshead adjusting ...........................
NUT, PLAIN, HEXAGON: crosshead .......................
adjusting setscrew
ROD, PUSH: injector tappet (early)..........................
ROD, PUSH: injector tappet (late)............................
ROD, PUSH: intake and exhaust valve ....................
(early)
ROD, PUSH: intake and exhaust .............................
valve (late)
SETSCREW: rocker shaft locating...........................
PLUG, PIPE: rocker shaft ........................................
SHAFT, ROCKER ARM: left and .............................
right bank
ROCKER ARM: exhaust valve .................................
BUSHING, SLEEVE, ROCKER ARM:......................
intake and exhaust valve
SOCKET, INJECTOR: rocker arm ...........................
ROCKER ARM: injector tappet ................................
BUSHING, SLEEVE: injector rocker ........................
arm
ROCKER ARM: intake poppet valve ........................
BRACKET, END: rocker lever shaft .........................
(7) (8)
QTY
INC
U/M IN
UNIT
EA
32
EA 10
EA
1
EA
1
EA
1
EA 16
EA 16
EA 16
EA
8
EA 16
EA 16
EA
16
EA
16
EA
EA
16
16
EA
8
EA
8
EA 16
EA
8
EA
8
EA
8
EA
8
EA 16
EA 16
EA 16
EA
8
EA
8
EA 16
EA 16
EA
8
EA
8
EA 16
EA
16
EA
EA
EA
2
4
2
EA
8
EA 16
EA
EA
EA
8
8
8
EA
EA
8
2
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
FSCM
B-6
54 PAFZZ
5310-00-062-4407
101499
15434
B-6
55 PAFZZ
5305-00-947-3437
168306
15434
B-6
B-7
56 PAFZZ
1 PAFZZ
2815-00-994-4443
5305-00-269-3213
142992
MS90725-62
15434
96906
B-7
2 PAFZZ
5310-00-637-9541
M535338-46
96906
B-7
B-7
3 PAFZZ
4 PAFZZ
4730-00-018-9566
5330-00-815-0895
189566
158551
21450
15434
B-7
5 PAFZZ
2815-00-772-5352
70645
15434
B-7
6 KFFZZ
186907
15434
B-7
B-7
7 PAHZZ
8 PAHZZ
2815-00-085-7476
3120-00-086-7743
155500
148210
15434
15434
B-7
B-7
B-7
9 PAHZZ
10 PAHZZ
11 PAHZZ
5315-00-987-5340
2815-00-353-9395
5305-00-269-3210
139114
68908
MS90725-59
of set
15434
15434
96906
B-7
12 PAHZZ
3020-00-088-1702
150129
15434
B-7
B-7
13 PAHZZ
14 PAHZZ
2815-00-909-2481
3120-00-082-0447
169747
147160
15434
15434
B-7
15 PAFZZ
2815-00-719-4598
68568
15434
B-7
16 PAFZZ
5305-00-269-3214
MS90725-64
96906
B-7
17 PAFZZ
5305-00-269-3211
MS90725-60
96906
B-7
18 PAFZZ
2815-00-999-5354
158556
15434
B-7
B-7
B-7
PAHZZ
3120-00-939-7137
BM 96104
15434
8
14
B-8
1 PAOZZ
2815-00-909-2451
162761
15434
B-8
2 PAOZZ
5330-00-821-9164
122135
15434
S 915
175505
134325
43828A
69974
176105
68425
MS35338-46
15434
15434
15434
15434
15434
15434
15434
96906
B-8
B-8
B-8
B-8
B-8
B-8
B-8
B-8
3
4
5
6
7
8
9
10
XBOZZ
PAOZZ
PAOZZ
PAOZZ
XBOZZ
XBOZZ
PAOZZ
PAOZZ
2815-00-909-2479
4730-00-081-4203
4730-00-277-5822
5340-00-839-0653
5310-00-637-9541
B-10
(6)
DESCRIPTION
USABLE ON CODE
0105-VALVES AND CAMSHAFT
-Cont
NUT, PLAIN, HEXAGON: rocker..............................
arm adjusting
SCREW, ADJUSTING: valve rotor...........................
tappet
SCREW, ADJUSTING: injector ................................
SCREW, CAP, HEXAGON HEAD:...........................
front cover retaining
WASHER, LOCK: front cover retain-........................
ing
PLUG, PIPE.............................................................
COVER, FRONT: engine cylinder ............................
block
DOWEL, MASTER: front cover to ............................
cylinder block
GASKET: front cover Part of kit ...............................
P/N BM 95886
CAMSHAFT, DIESEL ENGINE ................................
BEARING, SLEEVE, CAMSHAFT: ..........................
intermediate, numbers 2, 3 and 4 Part
P/N BM 96104
KEY, WOODRUFF: camshaft ..................................
LOCKPLATE: thrust plate retaining..........................
SCREW, CAP, HEXAGON HEAD:...........................
thrust plate retaining
GEAR, SPUR: camshaft accessory .........................
drive
PLATE, THRUST: engine camshaft .........................
BEARING, SLEEVE, CAMSHAFT: ..........................
front and rear Part of set P/N BM 96104
DOWEL, DIAMOND: front cover to ..........................
cylinder block
SCREW, CAP, HEXAGON HEAD:...........................
front cover retaining
SCREW, CAP, HEXAGON HEAD: EA ..................2
front cover retaining
SEAL, OIL: front cover Part of kit .............................
P/N BM 95886
BEARING SET, SLEEVE: camshaft ........................
BEARING ................................................................
BEARING ................................................................
0106-ENGINE LUBRICATION
SYSTEM
VALVE, BREATHER, PRESSURIZ- ........................
ING, DEEP WATER FORDING,
ASSEMBLY
GASKET: breather ...................................................
Part of set P/N BM 96854
NIPPLE, PIPE: breather valve .................................
VALVE,BREATHER, CRANKCASE .........................
ELBOW, PIPE: valve to hose ...................................
CLAMP, HOSE: breather valve ................................
HOSE: breather valve ..............................................
TUBE: hose to elbow ...............................................
CLAMP, TUBE.........................................................
WASHER, LOCK: tube clamp ..................................
(7) (8)
QTY
INC
U/M IN
UNIT
EA
16
EA
16
EA
EA
8
2
EA
14
EA
EA
1
1
EA
1
EA
1
EA
EA
1
3
EA
EA
EA
1
2
2
EA
1
EA
EA
1
2
EA
1
EA
10
EA
1
EA
EA
EA
1
3
2
EA
1
EA
1
EA
EA
EA
EA
EA
EA
EA
EA
1
1
1
2
1
1
1
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-8
11 XBOZZ
B-8
B-8
B-8
12 XBOZZ
13 PAOZZ
14 PAOZZ
B-9
B-9
FSCM
S 181B
15434
5310-00-562-6558
5305-00-269-3215
68190
S 626
MS90725-65
15434
15434
96906
1 PAOZZ
2 PAOZZ
6680-00-919-2892
5310-00-521-8595
175802
S 223
15434
15434
B-9
B-9
B-9
3 PAOZZ
4 XBOZZ
5 PAFZZ
5310-00-637-9541
5305-00-269-3213
MS35338-46
164724
MS90725-62
96906
15434
96906
B-9
B-9
6 XBFZZ
7 PAFZZ
5330-00-910-4439
175220
175221
15434
15434
B-9
8 PAFZZ
2815-00-909-2477
175219
15434
B-9
9 PAFZZ
5330-00-994-4404
151101
15434
B-9
10 PAFZZ
5305-00-269-3211
MS90725-60
96906
B-9
B-9
11 PAFZZ
12 PAFZZ
2815-00-353-9395
5305-00-269-3220
68908
MS90725-70
15434
96906
B-9
B-9
B-9
B-9
13
14
15
16
XBFZZ
PAFZZ
XBFZZ
XBFZZ
4730-00-801-8186
BM 97374
S 915A
175229
BM 97375
15434
15434
15434
15434
B-9
17 PAFZZ
5330-00-909-2478
160640
15434
B-9
B-9
18 XBFZZ
19 PAFZZ
5305-00-269-3210
67224
MS90725-59
15434
96906
B-9
B-9
20 XBFZZ
21 PAFZZ
5330-00-903-9525
BM 97373
156467
15434
15434
B-9
B-9
22 PAFZZ
23 PAFZZ
5810-00-846-1056
5305-00-269-3214
S 224
MS90725-64
15434
96906
24
25
26
27
28
1
2
3
PAFZZ
PAOZZ
XBOZZ
XBOZZ
PAOZZ
PAFZZ
XAHZZ
PAHZZ
5310-00-562-6553
4730-00-492-6040
5330-00-401-5108
S 602
163759
175801
S 117
65798
BM 94676
161042
163013
15434
15434
15434
15434
15434
15434
15434
15434
B-10
4 PAHZZ
5315-00-475-2576
70760
15434
B-10
5 PAHZZ
3120-00-132-0286
69514
15434
B-9
B-9
B-9
B-9
B-9
B-10
B-10
B-10
2940-00-417-5800
2815-00-907-8955
B-11
(6)
DESCRIPTION
USABLE ON CODE
0106-ENGINE LUBRICATION
SYSTEM-Cont
SCREW, CAP, HEXAGON HEAD:...........................
tube clamp
SUPPORT, ANGLE .................................................
WASHER: support, angle ........................................
SCREW, CAP, HEXAGON HEAD:...........................
support, angle
GAGE, DIPSTICK....................................................
NUT, PLAIN, HEXAGON: dipstick............................
tube clamp
WASHER, LOCK: oil pan .........................................
BRACKET: tube support, dipstick ............................
SCREW, CAP, HEXAGON HEAD:...........................
inspection plate
COVER, OIL PAN: inspection plate .........................
GASKET: inspection cover, oil pan ..........................
Part of kit P/N BM 95886
PAN, OIL, DIESEL ENGINE: front ...........................
sump
GASKET: oil pan Part of kit P/N ...............................
BM 95886
SCREW, CAP, HEXAGON HEAD:...........................
pump tubes
LOCKPLATE, CAPSCREW: oil pan .........................
SCREW, CAP, HEXAGON HEAD:...........................
pump tubes
TUBE, BY-PASS: oil pump ......................................
PLUG, PIPE: aerator tube........................................
CLAMP, TUBE: pump tubes ....................................
TUBE, SCAVENGER AND AERA-...........................
TOR: oil pump to fan
GASKET, ASBESTOS AND RUB- ...........................
BER: scavenger oil pump cover
Part of kit P/N BM 95886
SPACER: gear cover ...............................................
SCREW, CAP, HEXAGON HEAD:...........................
scavenger tube
TUBE, SUCTION: oil pump......................................
GASKET, ASBESTOS AND RUB- ...........................
BER: oil tube suction flange Part
of kit P/N BM 95886
NUT, PLAIN: tube clamp..........................................
SCREW, CAP, HEXA- .............................................
GON HEAD: oil pan
WASHER, FLAT: oil pan ..........................................
ADAPTER STRAIGHT: dipstick tube .......................
TUBE, DIPSTICK: oil pan ........................................
SCREW, CAP: clamp, dipstick tube .........................
CLAMP, TUBE: dipstick ...........................................
PUMP, OIL, DOUBLE, ASSEMBLY .........................
BODY, SCAVENGER PUMP GAS- .........................
KET: scavenger pump Part of kit .............................
P/N BM 95886
DOWEL: scavenger and lubrication .........................
pump body
BUSHING, DRIVESHAFT: scaven-..........................
ger and lubricating pump
(7) (8)
QTY
INC
U/M IN
UNIT
EA
1
EA
EA
EA
1
1
1
EA
EA
1
1
EA 21
EA
1
EA
6
EA
EA
1
1
EA
1
EA
1
EA
5
EA
EA
12
13
EA
EA
EA
EA
1
1
2
1
EA
1
EA
EA
1
4
EA
EA
1
1
EA
EA
1
12
EA 20
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
2
EA
3
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
FSCM
B-10
B-10
6 PAHZZ
7 PAHZZ
3020-00-682-7710
3040-00-459-7158
43863
162685
15434
15434
B-10
8 PAHZZ
5305-00-269-3214
MS90725-64
96906
3120-00-870-9520
3120-00-566-0480
2815-00-086-8384
2815-00-084-7800
160538
69236
68365
143405
143694
15434
15434
15434
15434
15434
B-10
B-10
B-10
B-10
B-10
9
10
11
12
13
XAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
B-10
B-10
B-10
14 PAHZZ
15 XBHZZ
16 XAHZZ
2815-00-190-8888
146933
114463
157952
15434
15434
15434
B-10
17 PAHZZ
3020-00-082-0461
149151
15434
B-10
B-10
B-10
B-10
B-10
B-10
18
19
20
21
22
23
PAHZZ
XBHZZ
XAHZZ
PAHZZ
PAHZZ
PAHZZ
5305-00-269-3210
3020-00-460-6429
2940-00-459-6558
5305-00-269-3213
MS90725-59
158168
162592
131275
175282
MS90725-62
96906
15434
15434
15434
15434
96906
B-10
24 PAHZZ
5305-00-269-3215
MS90725-65
96906
B-10
25 PAHZZ
5365-00-907-9008
68251
15434
B-10
26 PAHZZ
5360-00-664-5343
68274
15434
B-10
27 PAHZZ
2815-00-907-9012
156083
15434
B-10
B-10
28 XBHZZ
29 PAHZZ
2815-00-791-1453
162653
127558
15434
15434
B-10
B-10
B-10
30 PAHZZ
31 XBHZZ
32 PAHZZ
2815-00-973-0481
2815-00-353-9395
149718
162607
68908
15434
15434
15434
B-10
33 PAHZZ
5305-00-269-3217
MS90725-67
90906
B-11
1 KFHZZ
173298
15434
B-11
2 KFHZZ
173299
15434
B-11
B-11
3 XBHZZ
4 PAOZZ
173297
AMC61S41141PC2
15434
80064
4730-00-142-1851
B-12
(6)
DESCRIPTION
USABLE ON CODE
0106-ENGINE LUBRICATION
SYSTEM-Cont
GEAR: lubricating pump.........................................................
DRIVE SHAFT, SCAVENGER ...............................................
PUMP
SCREW, CAP, HEXAGON HEAD: ........................................
lubricating body
BODY, LUBRICATING PUMP................................................
DOWEL ..................................................................................
BUSHING: lubricating pump...................................................
SHAFT, DRIVE: lubricating pump ..........................................
GASKET: lubricating pump Part of.........................................
kit P/N BM 95886
PLATE, LOCK: capscrew, cover ............................................
SCREW, CAP: gear and pump cover ....................................
PLATE: lubricating pump and gear ........................................
cover
GEAR DRIVE: oil pump..........................................................
pump cover
SCREW, CAP, HEXAGON HEAD: ........................................
LOCKPLATE: capscrew, pump cover ....................................
COVER, LUBRICATING PUMP .............................................
GEAR, DRIVE: lubricating pump............................................
LOCKPLATE: capscrew .........................................................
SCREW, CAP, HEXAGON HEAD .........................................
lubricating pump
SCREW, CAP, HEXAGON HEAD .........................................
lubricating pump
SHIM, PRESSURE REGULATOR: ........................................
oil pump spacer
SPRING, OIL PUMP BYPASS: ..............................................
pressure regulator
GASKET: lockplate pressure regu- ........................................
lator Part of kit P/N BM 95886
CAP: pressure regulator.........................................................
PLUNGER, REGULATOR: lubricat-.......................................
ing pump
SHAFT, IDLER: lubricating oil pump......................................
GEAR: lubricating pump.........................................................
LOCKPLATE: capscrew, scavenger ......................................
pump
SCREW, CAP, HEXAGON HEAD: ........................................
scavenger pump
GASKET: plate to block, left bank..........................................
Part of kit P/N BM 95886
GASKET: water header cover, right.......................................
bank part of kit P/N BM 95886
COVER, WATER HEADER: right bank .................................
PLUG, PIPE: right bank cover................................................
(7) (8)
QTY
INC
U/M IN
UNIT
EA
EA
2
1
EA
2
EA
EA
EA
EA
EA
1
2
2
1
1
EA
EA
EA
4
4
1
EA
1
EA
EA
EA
EA
EA
EA
4
2
1
1
4
1
EA
1
EA
1
EA
1
EA
1
EA
EA
1
1
EA
EA
EA
1
1
6
EA
6
EA
1
EA
1
EA
EA
1
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
FSCM
(6)
DESCRIPTION
USABLE ON CODE
B-11
B-11
B-11
B-11
B-11
9
10
11
12
13
PAOZZ
PAOZZ
PAOZZ
XBOZZ
PAOZZ
5330-00-401-5107
444697
S 915A
189566
173286
173288
B-11
B-11
B-11
14 PAOZZ
15 PAOZZ
16 PAOZZ
2930-00-437-0567
2940-00-470-6701
6620-00-993-5546
142616
173287
MS24539-1
15434
15434
96906
B-11
17 XBOZZ
181374
15434
B-11
18 XBOZZ
181373
15434
B-11
19 PAOZZ
5305-00-269-3216
MS35295-66
96906
B-11
20 PAOZZ
5305-00-269-3217
MS90725-67
96906
B-11
21 PAOZZ
5305-00-269-3214
MS90725-64
96906
B-11
B-11
B-11
22 XBOZZ
23 PAOZZ
24 PAOZZ
5305-00-269-3213
2815-00-813-7765
173296
MS90725-62
158295
15434
96906
15434
B-11
25 KFOZZ
183831
15434
B-11
26 PAOZZ
5330-00-401-5105
183832
15434
B-11
27 PAOZZ
5330-00-401-5106
173291
15434
B-11
28 PAOZZ
5330-00-401-2004
173289
15434
B-11
B-11
B-11
29 XBHZZ
30 PAHZZ
31 XBHZZ
4710-00-927-9304
173292
180099
182008
06840
29510
62983
0106-ENGINE LUBRICATION
SYSTEM-Continued
PLUG, PIPE: left bank cover (2), oil .........................
cooler (2)
SCREW, CAP, HEXAGON HEAD:...........................
left bank (12), right bank (18)
WASHER, LOCK: left bank Plate (12),.....................
right bank cover (22), oil cooler (19)
SCREW, CAP, HEXAGON HEAD:...........................
right bank cover
PLUG, PIPE: right bank cover..................................
PLUG, PIPE: oil cooler cover ...................................
PLUG, PIPE: oil cooler cover ...................................
COVER, OIL COOLER: housing ..............................
GASKET: cooler cover to housing Part ....................
of kit P/N BM 95886
RETAINER: oil cooler element .................................
ELEMENT, OIL COOLER ........................................
TRANSMITTER, OIL PRESSURE: ..........................
oil cooler
BUSHING, OIL TRANSMITTER:..............................
oil cooler
TEE, PIPE, OIL TRANSMITTER:.............................
oil cooler
SCREW, CAP, HEXAGON HEAD:...........................
cooler mounting
SCREW, CAP, HEXAGON HEAD:...........................
cooler mounting
SCREW, CAP, HEXAGON HEAD:...........................
cooler mounting
HOUSING,OIL COOLER .........................................
SCREW, CAP, HEXAGON HEAD............................
PACKING, PREFORMED: oil cooler ........................
Part of kit P/N BM 95886
GASKET: cooler cover, left bank plate .....................
Part of kit P/N BM 95886
GASKET: cooler cover, left bank plate .....................
Part of kit P/N BM 95886
GASKET: cooler cover, left bank plate .....................
Part of kit P/N BM 95886
GASKET: cooler housing, left bank ..........................
plate Part of kit P/N BM 95886
PLATE, WATER HEADER: left bank .......................
BAFFLE,WATER: left bank ......................................
SCREW, MACHINE: water baffle.............................
B-12
B-12
B-12
1 PAOZZ
2 PAOZZ
3 PAOZZ
4730-00-226-8444
2815-00-907-8972
4730-00-142-1851
15434
15434
80064
0108-MANIFOLDS
COUPLING: exhaust manifold .................................
MANIFOLD, EXHAUST: left bank ............................
PLUG, PIPE: right bank exhaust ..............................
B-12
B-12
4 PAOZZ
5 PAOZZ
2815-00-909-2486
5305-00-269-3214
102408
157618
AMC61S41141PC2
166598
MS90725-64
B-12
B-12
B-12
6 PAOZZ
7 PAOZZ
8 PAOZZ
5310-00-637-9.541
5310-00-562-6553
2815-00-909-2476
MS35338-46
S 602
156497
96906
15434
15434
B-11
5 PAOZZ
4730-00-289-4770
S 995
15434
B-11
6 PAHZZ
5305-00-269-3211
MS90725-60
96906
B-11
7 PAHZZ
5310-00-637-9541
MS35338-46
96906
B-11
8 PAHZZ
5305-00-735-8098
S 174B
15434
4730-00-042-6318
4730-00-801-8186
4730-00-018-9566
19207
15434
21450
15434
15434
15434
96906
B-13
MANIFOLD, EXHAUST: right bank ..........................
SCREW, CAP, HEXAGON HEAD:...........................
intake manifold
WASHER, LOCK: intake manifold ...........................
WASHER, PLAIN: intake manifold ...........................
MANIFOLD, INTAKE: left and right ..........................
bank
(7) (8)
QTY
INC
U/M IN
UNIT
EA
4
EA
30
EA
53
EA
4
EA
EA
EA
EA
EA
1
3
1
1
1
EA
EA
EA
1
1
1
EA
1
EA
1
EA
4
EA
5
EA
4
EA
EA
EA
1
6
2
EA
1
EA
1
EA
1
EA
1
EA
EA
EA
1
1
2
EA
EA
EA
2
1
1
EA
EA
1
16
EA
EA
EA
16
16
2
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-12
9 PAOZZ
5330-00-909-2489
156348
15434
B-12
10 PAOZZ
5330-00-994-4410
151707
15434
B-12
11 PAOZZ
2815-00-084-7796
154226
15434
B-12
12 PAOZZ
5330-00-994-4411
154396
B-12
B-12
B-12
13 PAOZZ
14 PAOZZ
15 PAOZZ
5310-00-562-6558
5310-00-407-9566
5306-00-225-8497
S 626
MS35338-45
MS90725-32
15434
set
15434
96906
96906
B-12
16 PAOZZ
5305-00-269-3213
MS90725-62
96906
B-12
17 PAOZZ
2815-00-974-9872
139247
15434
B-12
B-12
18 PAOZZ
19 PAOZZ
5310-00-134-4169
5330-00-993-5101
63842
139677
15434
15434
B-13
B-13
B-13
B-13
1
2
3
4
PAFZZ
XAFZZ
PAFZZ
PAFZZ
B-13
2910-00-920-7557
FSCM
2910-00-920-7556
5330-00-695-3295
BM 97421
163947
BM 93636
70776
15434
15434
15434
15434
5 PAFZZ
5330-00-993-5100
101754
15434
B-13
B-13
6 PAFZZ
7 PAFZZ
2910-00-085-7465
2910-00-085-7465
136749
136042
15434
15434
B-13
B-13
8 PAFZZ
9 PAFZZ
5340-00-459-9937
5360-00-086-7710
148524
128040
15434
15434
B-13
10 PAFZZ
2910-00-912-9104
148504
15434
B-13
B-13
11 PAFZZ
12 PAFZZ
2910-00-912-4554
2910-00-908-7307
170948
BM 91011
15434
15434
B-13
B-13
B-13
B-13
13
14
15
16
PAFZZ
PAFZZ
PAFZZ
PAFZZ
3120-00-062-9559
5330-00-959-1563
3110-00-100-6149
5305-00-062-2230
147558
147559
MS19059-47
131430
15434
15434
96906
15434
B-13
B-13
17 PAFZZ
18 PAFZZ
5310-00-637-9541
2910-00-970-1277
MS35338-46
128002
96906
15434
B-14
(6)
DESCRIPTION
USABLE ON CODE
0108-MANIFOLDS-Contiqued
GASKET: intake manifold Part of set .......................
P/N BM 96854
GASKET: intake manifold to block ...........................
Part of set P/N BM 96854
COVER, PUSH TUBE: right and left ........................
bank
GASKET: Push tube cover Part of ...........................
P/N BM 96854
WASHER, FLAT: tube cover to block ......................
WASHER, LOCK: tube cover to block......................
SCREW, CAP HEXAGON HEAD:............................
tube cover to block
SCREW, CAP, HEXAGON HEAD:...........................
exhaust manifold
LOCKPLATE: exhaust manifolds Part......................
of set P/N BM 96854
WASHER, PLAIN: exhaust manifolds ......................
GASKET: exhaust manifolds....................................
GROUP 03-FUEL SYSTEM
0301-FUEL INJECTOR
INJECTOR ASSEMBLY: cylinder.............................
RETAINER,INJECTOR: body ..................................
CUP, INJECTOR: body............................................
PACKING, PREFORMED: injector...........................
cup
PACKING, PREFORMED: injector...........................
body Part of set P/N BM 96854
SCREEN, INJECTOR: Plunger body .......................
CLAMP, INJECTOR SPRING: plunger ....................
body
SEAT, SPRING: injector plunger..............................
SPRING, HELICALCOMPRESSION:.......................
injector plunger
RETAINER, SLEEVE: injector .................................
plunger
LINK, FUEL INJECTOR PLUNGER .........................
INJECTOR BODY AND PLUNGER .........................
ASSEMBLY: cylinder head
RETAINER, BALL: fuel injector ................................
GASKET: fuel injector ..............................................
BEARING, BALL: fuel injector ..................................
SCREW, CAP, HEXAGON HEAD:...........................
injector pump
WASHER, LOCK: injector clamp .............................
CLAMP, INJECTOR: plunger and body....................
(7) (8)
QTY
INC
U/M IN
UNIT
EA
2
EA
2
EA
2
EA
2
EA 16
EA 26
EA 26
EA
16
EA
8
EA
EA
16
8
EA
EA
EA
EA
8
8
8
8
EA
32
EA
EA
8
8
EA
EA
8
8
EA
8
EA
EA
8
8
EA
EA
EA
EA
8
8
8
8
EA
EA
8
8
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-14
1 PAFHH
2910-00-920-7554
BM 97400
AR50828
15434
15434
B-15
B-15
1 PAHZZ
2 PAHZZ
4730-00-042-8988
3805-00-961-9470
428988
154088
19207
15434
B-15
B-15
B-15
3 PAHZZ
4 PAHZZ
5 PAHZZ
2910-00-507-3271
5360-00-597-4570
2910-00-790-8736
157088
70700
146483
15434
15434
15434
B-15
6 PAHZZ
5310-00-971-7989
MS35691-5
96906
B-15
7 PAHZZ
2910-00-774-4246
109915
15434
B-15
B-15
B-15
8 PAHZZ
9 PAHZZ
10 PAHZZ
5305-00-062-4373
5310-00-045-3299
5315-00-973-0414
142149
MS35338-42
149040
15434
90906
15434
B-15
B-15
11 PAHZZ
12 PAHZZ
5310-00-984-0273
5330-00-081-9289
142179
100478
15434
15434
B-15
B-15
B-15
B-15
B-15
B-15
13
13
14
15
16
17
2910-00-085-7439
2910-00-914-7319
5315-00-253-3408
5310-00-858-3509
2990-00-858-3526
5340-00-786-0102
149030
149031
148976
148916
148977
S 16206
15434
15434
15434
15434
15434
15434
B-15
18 XBHZZ
173708
15434
B-15
19 PAHZZ
5305-00-493-3959
S 159B
15434
B-15
B-15
B-15
20 PAHZZ
21 PAHZZ
22 PAHZZ
5310-00-141-1795
5310-00-562-6552
5310-00-971-7989
AN960-416
S 600
MS35691-5
88044
15434
96906
B-15
B-15
B-15
B-15
B-15
B-15
B-15
B-15
B-15
B-15
23
24
25
26
27
28
29
30
31
32
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
2910-00-065-5544
5340-00-464-7064
5305-00-253-5612
9905-00-733-7622
4730-00-716-6580
2910-00-400-5178
2910-00-759-1299
5315-00-844-0140
2910-00-829-5603
2910-00-910-9637
124019
124020
MS21318-15
105375
68606
163733
BM 76338
118227
140618
BM 75508
15434
15434
96906
15434
15434
15434
15434
15434
15434
15434
B-15
33 PAHZZ
5360-00-905-0042
142698
15434
B-15
34 PAHZZ
5365-00-507-3224
101841
15434
B-15
34 PAHZZ
5365-00-507-3225
101842
15434
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
FSCM
B-15
(6)
DESCRIPTION
USABLE ON CODE
0302-FUEL PUMP
PUMP ASSEMBLY, FUEL: with pump .....................
gear, pump damper, governor and main
shaft cover, governor spring assemblies
PLUG, PIPE: top fuel pump housing ........................
RING, SEALING: fuel filter cap ................................
Part of set P/N BM 68356
CAP, FILTER ELEMENT: fuel pump ........................
SPRING: fuel filter holddown....................................
FILTER ELEMENT, FLUID: fuel...............................
pump
NUT, PLAIN, HEXAGON: jam throt- ........................
tle adjusting
SCREW, SLOTTED, HEADLESS: ...........................
throttle adjusting
SETSCREW, throttle shaft .......................................
WASHER, LOCK: throttle shaft ................................
PLUNGER, FUEL PUMP: throttle ............................
shaft
SPACER: throttle adjusting shim .............................
PACKING, PREFORMED: throttle ...........................
shaft part of set P/N BM 68356
SHAFT, THROTTLE: standard size .........................
SHAFT,THROTTLE: oversize ..................................
PIN: throttle stop ......................................................
SPACER: throttle shaft ............................................
COVER: throttle shaft ..............................................
RING, SNAP, RETAINING: throttle ..........................
shaft
LEVER AND LOCK, THROTTLE: ............................
fuel Pump
SCREW, CAP, HEXAGON HEAD:...........................
throttle shaft lever retaining
WASHER, FLAT: throttle lever .................................
WASHER, LOCK: throttle lever ................................
NUT, PLAIN, HEXAGON: throttle.............................
adjusting
SEAL: throttle shaft cover ........................................
WIRE, SEAL: throttle shaft cover .............................
SCREW, DRIVE: identification plate ........................
PLATE, IDENTIFICATION: fuel pump......................
PLUG, PIPE: fuel pump ...........................................
CLIP: governor barrel...............................................
HOUSING ASSEMBLY ............................................
PIN, HOLLOW: fuel pump housing ..........................
HOUSING, SPRING PACK: fuel pump ....................
BARREL ASSEMBLY, GOVERNOR:.......................
fuel pump
SPRING, HELICAL, COMPRESSION:.....................
mechanical governor torque control
SHIM: mechanical governor torque ..........................
control plunger
SHIM: mechanical governor torque ..........................
control plunger
(7) (8)
QTY
INC
U/M IN
UNIT
EA
1
EA
EA
1
1
EA
EA
EA
1
1
1
EA
2
EA
2
EA
EA
EA
1
1
1
EA
EA
1
1
EA
EA
EA
EA
EA
EA
1
1
1
1
1
1
EA
1
EA
1
EA
EA
EA
1
1
1
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
2
1
2
1
1
1
1
1
1
1
EA
1
EA
V
EA
V
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-15
34 PAHZZ
5365-00-543-3744
101843
15434
B-15
35 PAHZZ
2910-00-907-8961
169660
15434
B-15
B-15
B-15
B-15
35
36
37
38
PAHZZ
PAHZZ
PAHZZ
PAHZZ
2910-00-907-8960
5315-00-907-0711
2910-00-829-5604
3120-00-764-7090
169661
137372
144302
138905
15434
15434
15434
15434
B-15
B-15
39 PAHZZ
40 PAHZZ
2990-00-772-1778
3120-00-810-6032
70690
100193
15434
15434
B-15
41 PAHZZ
5315-00-369-2588
68549
15434
B-15
42 PAHZZ
5330-00-582-7484
MS9021-116
96906
B-15
B-16
B-16
43 PAHZZ
1 PAHZZ
2 PAHZZ
5365-00-988-3668
2910-00-924-3912
5330-00-838-9975
139473
AR 50101
177764
15434
15434
15434
B-16
B-16
3 PAHZZ
4 PAHZZ
3120-00-719-5719
5315-00-014-1244
101468
64816A
15434
15434
B-16
B-16
5 PAHZZ
6 PAHZZ
3020-00-702-3882
2910-00-933-3012
119363
175864
15434
15434
B-16
7 PAHZZ
2910-00-567-4354
100215
15434
B-16
8 PAHZZ
5330-00-567-3463
110855
15434
B-16
B-16
9 PAHZZ
10 PAHZZ
5310-00-484-1718
5305-00-509-8106
181466
171546
15434
15434
B-16
11 PAHZZ
4820-00-130-4820
175836
15434
B-16
B-16
12 PAHZZ
13 PAHZZ
4730-00-506-4880
5305-00-423-7693
70777
171548
15434
15434
B-16
14 XBHZZ
171550
15434
B-16
B-16
B-16
15 XBHZZ
16 PAHZZ
17 PAHZZ
2910-00-829-5617
5330-00-809-2667
AR50100
153338
100099
15434
15434
15434
B-16
18 PAHZZ
5365-00-965-0870
160514
15434
B-16
19 PAHZZ
2910-00-951-3536
139834
15434
FSCM
B-16
(6)
DESCRIPTION
USABLE ON CODE
0302-FUEL PUMP-Continued
SHIM: mechanical governor torque ..........................
control plunger
PLUNGER, FUEL INJECTOR: stan- ........................
dard size
PLUNGER, FUEL INJECTOR: oversize...................
PIN, SPRING, GOVERNOR: plunger.......................
SPACER: governor plunger .....................................
WASHER, THRUST: fuel pump gov- .......................
ernor plunger
PLUNGER, GOVERNOR: drive ...............................
BEARING, SLEEVE: tachometer .............................
drive gear
PIN, STRAIGHT, HEADLESS: fuel ..........................
pump housing to mainshaft
PACKING, PREFORMED: Plug to ...........................
fuel pump housing part of set P/N
BM 68356
PLUG: fuel pump housing ........................................
PUMP ASSEMBLY: gear fuel supply .......................
GASKET: gear pump to fuel pump...........................
part of set P/N BM 68356
PIN, HOLLOW: gear pump cover.............................
PIN, STRAIGHT, HEADLESS: gear .........................
pump cover to housing
GEAR: fuel supply gear pump..................................
SHAFT, DRIVE: fuel supply gear .............................
pump
SHAFT, DRIVE: fuel supply gear .............................
pump
GASKET: gear pump cover to hous- ........................
ing Part of set P/N BM 68356
WASHER, LOCK: gear pump ..................................
SCREW, CAP, HEXAGON HEAD:...........................
gear pump cover to housing
VALVE, ELBOW BALL CHECK: ..............................
gear pump housing
ADAPTER: fuel inlet hose ........................................
SCREW, CAP, HEXAGON HEAD:...........................
gear pump cover to housing
SCREW, CAP, HEXAGON HEAD:...........................
gear pump housing
COVER, HOUSING: gear pump...............................
PLATE: damper .......................................................
PACKING, PREFORMED: Part of set ......................
P/N BM 68356
WASHER, NONMETALLIC: Part of .........................
set P/N BM 68356
DISK, SOLID, PLAIN: fuel pump ..............................
damper
(7) (8)
QTY
INC
U/M IN
UNIT
EA
V
EA
1
EA
EA
EA
EA
1
1
1
1
EA
EA
1
1
EA
1
EA
1
EA
EA
EA
1
1
1
EA
EA
1
1
EA
EA
2
1
EA
1
EA
1
EA 12
EA
2
EA
1
EA
EA
1
6
EA
4
EA
EA
EA
1
1
1
EA
1
EA
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-16
20 PAHZZ
5330-00-809-3276
139988
15434
B-16
B-16
21 XBHZZ
22 PAHZZ
5330-00-080-0483
153336
151900
15434
15434
B-16
23 PAHZZ
5305-00-267-8977
MS90726-10
96906
B-16
24 XBHZZ
24582
78570
B-16
25 PAHZZ
5310-00-141-1795
AN 960-416
88044
B-17
1 PAHZZ
4810-00-512-3534
BM 69979
15434
B-17
2 PAHZZ
4730-00-278-4592
7089727
19207
B-17
3 PAHZZ
5305-00-509-8106
171546
15434
B-17
4 XBHZZ
24582
78570
B-17
5 PAHZZ
5310-00-262-2986
67684
15434
B-17
B-17
6 XBHZZ
7 PAHZZ
2910-00-084-7813
129826
143679
15434
15434
B-17
8 PAHZZ
5330-00-816-8148
114791
15434
B-17
B-17
9 PAHZZ
10 PAHZZ
2910-00-085-3939
5310-00-082-1888
129827
129768
15434
15434
B-17
11 PAHZZ
5330-00-081-9299
129888
15434
B-17
12 PAHZZ
2910-00-084-7787
129839
15434
B-17
13 PAHZZ
2910-00-085-7436
134074
15434
B-17
14 XBHZZ
S 607
15434
B-17
15 PAHZZ
5305-00-858-0037
S 1214
15434
B-17
B-17
16 PAHZZ
17 PAHZZ
4730-00-011-3175
5330-00-951-3538
70295
154087
15434
15434
B-17
18 PAHZZ
5355-00-082-1189
129838
15434
B-17
19 PAHZZ
2815-00-907-8964
137370
15434
B-17
20 PAHZZ
5360-00-082-0124
144195
15434
B-17
21 PAHZZ
5310-00-507-3259
70715
15434
FSCM
B-17
(6)
DESCRIPTION
USABLE ON CODE
0302-FUEL PUMP-Continued
PACKING, PREFORMED: fuel damp- .....................
er body to diaphragm Part of set
P/N BM 68356
HOUSING, FUEL PUMP..........................................
WASHER, NONMETALLIC Part of ..........................
set P/N BM 68356
SCREW, CAP, HEXAGON HEAD:...........................
fuel damper
WASHER, LOCK: fuel damper assem- ....................
bly
WASHER, FLAT: fuel damper assem- .....................
bly
VALVE, SOLENOID: 24 volt, single .........................
terminal
ADAPTER, OUTLET: fuel shut-off ...........................
valve
SCREW, CAP, HEXAGON HEAD:...........................
shutoff valve to fuel pump housing
WASHER, LOCK: shut-off valve to ..........................
fuel pump housing
WASHER, FLAT: shut-off valve to ...........................
fuel pump housing
HOUSING, SHUT-OFF VALVE................................
SHAFT, MANUAL OVERRIDE: fuel .........................
shut-off valve
PACKING, PREFORMED: fuel ................................
shut-off valve part of set P/N BM
68356
DIAPHRAGM: shut-off valve ....................................
WASHER, SPRING TENSION: fuel .........................
shut-off valve
PACKING, PREFORMED: fuel ................................
shut-off valve Part of set P/N BM
68356
COVER, ACCESS: solenoid coil ..............................
assembly
SOLENOID COIL ASSEMBLY: fuel .........................
shut-off valve
WASHER, LOCK: solenoid coil as- ..........................
sembly to housing
SCREW, MACHINE: solenoid coil ...........................
assembly to housing
PLUG, PIPE: fuel shut-off valve ...............................
PACKING, PREFORMED: solenoid .........................
coil assembly sealing Part of set P/N
BM 68356
KNOB, MANUAL OVERRIDE: fuel...........................
shut-off valve
PLUNGER, IDLER SPRING: gover-.........................
nor spring Pack
SPRING, HELICAL, COMPRESSION:.....................
governor spring pack
WASHER, FLAT: governor adjusting .......................
screw
(7) (8)
QTY
INC
U/M IN
UNIT
EA
1
EA
EA
1
1
EA
2
EA
2
EA
2
EA
1
EA
1
EA
2
EA
2
EA
2
EA
EA
1
1
EA
1
EA
EA
1
1
EA
1
EA
1
EA
1
EA
4
EA
4
EA
EA
1
1
EA
1
EA
1
EA
1
EA
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
(6)
DESCRIPTION
FSCM
°
USABLE ON CODE
(7) (8)
QTY
INC
U/M IN
UNIT
0302-FUEL PUMP-Continued
B-17
22 PAHZZ
2910-00-132-0769
BM 70797
15434
B-17
23 PAHZZ
5305-00-506-5722
70716
15434
B-17
24 PAHZZ
5360-00-902-8478
147292
15434
B-17
B-17
B-17
B-17
B-17
25
25
25
26
27
PAHZZ
PAHZZ
PAHZZ
PAHZZ
PAHZZ
5365-00-507-3260
5365-00-507-3261
5365-00-507-3262
5340-00-898-1497
5365-00-598-1070
70717
70717A
70717B
70713
MS16627-93
15434
15434
15434
15434
96906
B-17
28 PAHZZ
5330-00-562-1176
70706
15434
B-17
29 PAHZZ
2910-00-858-3522
44678
15434
B-17
B-17
B-17
30 PAHZZ
31 PAHZZ
32 XBHZZ
5310-00-141-1795
5310-00-484-1718
AN960-416
181466
171552
88044
15434
15434
B-17
B-17
B-17
B-17
33
34
35
36
PAHZZ
PAHZZ
PAHZZ
PAHZZ
5340-00-464-7064
2910-00-065-5544
4730-00-369-7824
5305-00-267-8977
124020
124019
177999
MS90726-10
15434
15434
15434
96906
B-18
1 PAHZZ
2910-00-369-8240
BM 91679
15434
B-18
2 PAFZZ
5330-00-779-2534
103005
15434
B-18
3 PAHZZ
5310-00-562-6557
S 622
15434
B-18
4 PAHZZ
5310-00-209-0965
MS35338-47
96906
B-18
5 PAHZZ
5305-00-045-1988
MS90725-87
96906
B-18
6 PAFZZ
3010-00-507-8347
109859
15434
B-18
7 PAHZZ
5806-00-019-4227
69793
15434
B-18
8 PAHZZ
5310-00-637-9541
MS35338-46
96906
B-18
9 PAHZZ
5310-00-562-6553
S 602
15434
B-18
10 PAHZZ
2910-00-695-3285
101918
15434
B-18
11 PAHZZ
5330-00-507-8346
7451
80201
B-18
B-18
12 PAHZZ
13 PAHZZ
2910-00-773-9369
3110-00-144-8499
100192
S 1650
15434
15434
B-18
GUIDE AND CLIP ASSEMBLY: gov- .......................
ernor spring pack
SCREW, IDLE ADJUSTING: gover- ........................
nor spring pack
SPRING, HELICAL, COMPRESSION:.....................
governor spring pack
SHIM: high speed spring adjusting...........................
SHIM: high speed spring adjusting...........................
SHIM: high speed spring adjusting...........................
RETAINER, SPRING: spring pack ...........................
RING, RETAINING: governor spring ........................
pack
GASKET: spring pack cover to fuel ..........................
pump
COVER, SPRING PACK: fuel pump ........................
assembly
WASHER, FLAT: spring pack cover ........................
WASHER, LOCK: spring pack cover........................
SCREW, CAP, HEXAGON HEAD:...........................
spring pack cover
WIRE, SEAL: spring packing seal ............................
SEAL, SPRING PACK .............................................
PLUG, PIPE: spring pack.........................................
SCREW, CAP, HEXAGON HEAD:...........................
spring pack cover
GOVERNOR AND COVER ASSEM- .......................
BLY: fuel pump
GASKET: mainshaft governor hous- ........................
ing to air compressor Part of kit
P/N BM 95886
WASHER, FLAT: mainshaft hous- ...........................
ing to air compressor
WASHER, LOCK: mainshaft hous- ..........................
ing to air compressor
SCREW CAP, HEXAGON HEAD:............................
mainshaft housing to air compressor
INSERT, FLEXIBLE NYLON: ...................................
mainshaft drive coupling
SCREW, CAP, HEXAGON HEAD:...........................
mainshaft drive coupling
WASHER, LOCK: mainshaft drive ...........................
coupling
WASHER, FLAT: mainshaft drive ............................
coupling
DRIVER, MAINSHAFT, HALF-.................................
HUB: mainshaft to air compressor
counterweight driver
SEAL, OIL, drive shaft Part of set ............................
P/N BM 68356
MAINSHAFT, FUEL PUMP DRIVE ..........................
BEARING, BALL, ANNULAR: fuel ...........................
pump drive mainshaft
EA
1
EA
1
EA
1
EA
EA
EA
EA
EA
V
V
V
1
1
EA
1
EA
1
EA
EA
EA
4
4
2
EA
EA
EA
EA
1
2
1
2
EA
1
EA
1
EA
4
EA
4
EA
4
EA
1
EA
3
EA
3
EA
3
EA
1
EA
2
EA
EA
1
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-18
14 PAHZZ
2990-00-772-1778
70690
15434
B-18
15 PAHZZ
3020-00-562-1173
103036
15434
B-18
B-18
16 PAHZZ
17 PAHZZ
3040-00-788-2762
5330-00-506-4866
100205
100764
15434
15434
B-18
B-18
18 PAHZZ
19 PAHZZ
5315-00-695-3292
2910-00-920-7555
MS20066-116
BM 97398
96906
15434
B-18
20 PAHZZ
3120-00-603-2691
157594
15434
B-18
21 PAHZZ
5360-00-081-8487
143847
15434
B-18
22 XBHZZ
144179
15434
B-18
23 PAHZZ
5315-00-082-0448
144178
15434
B-18
24 PAHZZ
5315-00-805-1674
70693
15434
B-18
25 PAHZZ
5315-00-550-7895
108882
15434
B-18
26 PAHZZ
2990-00-792-1571
107261
15434
B-18
27 PAHZZ
2990-00-735-8564
116000
15434
B-18
28 PAHZZ
3020-00-701-1112
113244
15434
B-18
29 PAHZZ
3120-00-904-9595
163994
15434
B-18
30 XBHZZ
5103-50
15434
B-18
31 PAHZZ
MS90725-59
96906
B-18
32 XBHZZ
164597
15434
B-18
33 PAFZZ
5305-00-071-2241
MS90725-10
96906
B-18
34 PAFZZ
5310-00-562-6552
S 600
15434
B-18
35 PAFZZ
5310-00-141-1795
AN960-416
88044
B-18
PAHZZ
5330-00-888-4988
BM 68356
15434
B-15
B-15
B-15
B-16
B-16
B-16
5305-00-269-3210
FSCM
2
12
42
2
8
17
B-19
(6)
DESCRIPTION
USABLE ON CODE
0302-FUEL PUMP-Cont
RING, RETAINING: .................................................
mainshaft ball bearing
GEAR, DRIVE: fuel pump ........................................
mainshaft
GEAR, DRIVE: tachometer ......................................
GASKET: mainshaft housing ...................................
to fuel pump housing Part of
set P/N BM 68356
KEY: governor drive gear.........................................
WEIGHT ASSEM-....................................................
BLY, GOVERNOR: fuel contol
WASHER, THRUST: ...............................................
governor counterweights
SPRING, HELICAL, .................................................
COMPRESSION:
governor weight assist
WASHER, FLAT: .....................................................
governor weight assist shim
PLUNGER: governor................................................
weight assist
PIN, SHOULDER, ....................................................
HEADLESS: governor
counterweight Pivot
PIN, HOLLOW: ........................................................
governor counterweight
retaining
COUNTERWEIGHT:................................................
fuel supply governor
CARRIER, GOVER-.................................................
NOR COUNTER WEIGHTS
GEAR, GOVERNOR................................................
DRIVE SHAFT
BUSHING, SLEEVE:................................................
governor drive shaft gear
RING, RETAINING: .................................................
governor sleeve bushing
SCREW, CAP, HEXAGON HEAD:...........................
fuel pump bracket to block
BRACKET, SUPPORT, FUEL..................................
PUMP
SCREW, CAP, HEXAGON HEAD:...........................
mainshaft governor housing to fuel
pump
WASHER, LOCK: mainshaft ....................................
governor housing to fuel pump
WASHER, FLAT: mainshaft .....................................
governor housing to fuel pump
GASKET SET, FUEL PUMP: diesel .........................
engine
RING, SEALING ......................................................
PACKING, PREFORMED ........................................
PACKING, PREFORMED ........................................
GASKET ..................................................................
GASKET ..................................................................
PACKING, PREFORMED ........................................
(7) (8)
QTY
INC
U/M IN
UNIT
EA
1
EA
1
EA
EA
1
1
EA
EA
1
1
EA
2
EA
1
EA
1
EA
1
EA
2
EA
2
EA
2
EA
1
EA
1
EA
1
EA
1
EA
2
EA
1
EA
6
EA
6
EA
6
EA
1
EA
EA
EA
EA
EA
EA
1
1
1
1
1
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-16
B-16
B-16
B-17
B-17
B-17
B-17
B-18
B-18
B-27
B-27
0302
0302
18
20
22
8
11
17
32
11
17
4
5
- PAHZZ
- PAHZZ
5330-00-580-5327
5330-00-664-1055
8060396
70415
19207
15434
B-19
1 PAOZZ
5305-00-269-3214
MS90725-64
96906
B-19
2 XBOZZ
159085
56232
B-19
B-19
B-19
3 PAOZZ
4 PAOZZ
5 PAOZZ
5310-00-562-6553
5310-00-637-9541
5305-00-269-3221
S 602
MS35338-46
MS90725-71
15434
96906
96906
B-19
B-19
B-19
6 PAOZZ
7 PAOZZ
8 XBOZZ
4730-00-877-6298
4720-00-458-8079
43828
155790
175285
15434
15434
15434
B-19
9 PAOZZ
5305-00-735-8098
S 163D
15434
B-19
10 PAOZZ
5305-00-269-3213
MS90725-62
96906
B-19
11 PAOZZ
5330-00-903-7701
156659
15434
B-19
B-19
B-19
12 XBOZZ
13 PAOZZ
14 PAOZZ
5310-00-621-8595
4730-00-289-0212
175284
S 223
125740
15434
15434
15434
B-19
15 PAOZZ
4720-00-731-8248
69996
15434
B-19
16 PAOZZ
4730-00-716-6580
68606
15434
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
PAOZZ
4730-00-019-4242
4730-00-803-9527
5330-00-970-3461
5315-00-758-0366
5310-00-393-6475
2815-00-506-5720
5365-00-197-9327
68139
125880
68061-A
43468
68178-1
69215
67946
15434
15434
15434
15434
15434
15434
15434
8 PAOZZ
9 PAOZZ
10 PAOZZ
2920-00-506-5719
5310-00-682-5944
4730-00-716-6580
68812
118273
68606
15434
15434
15434
B-20
B-20
B-20
B-20
B-20
B-20
B-20
B-20
B-20
B-20
1
2
3
4
5
6
7
FSCM
B-20
(6)
DESCRIPTION
USABLE ON CODE
0302-FUEL PUMP-Cont
WASHER, NONMETALLIC......................................
PACKING, PREFORMED ........................................
WASHER, NONMETALLIC......................................
PACKING, PREFORMED ........................................
PACKING ................................................................
PACKING, PREFORMED ........................................
GASKET ..................................................................
SEAL .......................................................................
GASKET ..................................................................
GASKET ..................................................................
GASKET ..................................................................
PACKING WITH RETAINER ...................................
PACKING, PREFORMED ........................................
0304-AIR CLEANER
SCREW, CAP, HEXAGON HEAD:...........................
right bank air intake
CONNECTION, AIR INTAKE: right ..........................
bank
WASHER, FLAT: air intake ......................................
WASHER, LOCK: air intake .....................................
SCREW, CAP, HEXAGON HEAD:...........................
right bank air intake
CLAMP, HOSE: air intake ........................................
HOSE, NONMETALLIC: air intake ...........................
CONNECTION, AIR CLEANER ...............................
ASSEMBLY: air intake
SCREW, CAP, HEXAGON HEAD:..........................
air cleaner assembly
SCREW, CAP, HEXAGON HEAD:...........................
air cleaner assembly
GASKET: air cleaner assembly part.........................
of set P/N BM 96854
CONNECTION, AIR INTAKE ...................................
NUT: air intake assembly .........................................
CLAMP, HOSE: intake manifold ..............................
connection
HOSE, INTAKE: manifold ........................................
connection
PLUG, PIPE: right intake manifold ...........................
0311-STARTING AIDS
ELBOW, PIPE: pre-heater adapter ..........................
ADAPTER: pre-heater adapter.................................
SEAL, PREFORMED: pre-heater adapter................
PIN, TYPE 4 groove: pre-heater ..............................
WASHER, KEY: pre-heater nozzle ..........................
NOZZLE: pre-heater ................................................
SPACER, RING: pre-heater Part of .........................
kit P/N BM 95886
PLUG, GLOW: pre-heater........................................
WASHER, FLAT: glow plug .....................................
PLUG, PIPE: air heater ............................................
(7) (8)
QTY
INC
U/M IN
UNIT
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
EA
7
EA
1
EA 13
EA 13
EA
1
EA
EA
EA
2
1
1
EA
1
EA
4
EA
1
EA
EA
EA
1
1
2
EA
1
EA
1
EA
EA
EA
EA
EA
EA
EA
1
1
1
1
1
1
1
EA
EA
EA
1
1
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-21
1 XBOZZ
B-21
B-21
2 PAOZZ
3 PAOZZ
B-21
B-21
B-21
B-21
4
5
6
7
FSCM
BM 94658
15434
4730-00-877-6298
3805-00-607-7652
43828
69969
15434
15434
XBOZZ
PAOZZ
PAOZZ
PAOZZ
5310-00-637-9541
5305-00-269-3214
5330-00-255-0331
181355
MS35338-46
MS90725-64
9221
15434
96906
96906
15434
B-21
8 PAOZZ
5330-00-918-9646
140514
15434
B-21
B-21
9 XBOZZ
10 PAOZZ
5305-00-269-3213
157647
MS90725-62
15434
96906
B-21
11 PAOZZ
5305-00-269-3220
MS90725-70
96906
B-21
B-21
12 PAOZZ
13 PAOZZ
4730-00-801-8186
6685-00-814-5271
S 915A
MS24537-1
15434
96906
B-21
B-21
14 PAOZZ
15 PAOZZ
6620-00-062-4404
5330-00-086-8294
VD-103118-173
140329
19207
15434
B-21
B-21
B-21
16 XBOZZ
17 PAOZZ
18 PAOZZ
5310-00-562-6553
5305-00-269-3211
147729
S 602
MS90725-68
15434
15434
96906
B-22
1 XBOZZ
187609
15434
B-22
B-22
2 PAOZZ
3 PAOZZ
5310-00-562-6552
2930-00-907-8963
S 600
175209
15434
15434
B-22
4 PAOZZ
2930-00-907-8962
175208
15434
B-22
B-22
5 PAOFF
6 PAFZZ
2930-00-908-7311
2930-00-914-0992
BM 940607
163785
15434
15434
B-22
B-22
7 XBFZZ
8 PAFZZ
3110-00-829-2049
70183
69866
76680
15434
B-22
B-22
B-22
9 PAFZZ
10 XBFZZ
11 PAFZZ
3120-00-810-7040
154639
S 16237
154577
15434
15434
15434
B-22
B-22
B-22
B-22
12
13
14
15
PAFZZ
PAFZZ
XAFZZ
PAFZZ
2930-00-903-7696
4730-00-289-4770
159329
S 995
175206
144306
15434
15434
15434
15434
B-22
B-22
16 PAFZZ
17 XAFZZ
5970-00-086-7709
13509
143913
15434
15434
3110-00-082-1877
4320-00-994-4408
B-21
(6)
DESCRIPTION
USABLE ON CODE
GROUP 05-COOLING SYSTEM
0503-THERMOSTAT
CONNECTION, WATER CROSS- ...........................
OVER: right bank
CLAMP, HOSE ........................................................
HOSE, WATER CONNECTION, ..............................
CROSSOVER PIPE
CONNECTION, WATER: left bank ..........................
WASHER, LOCK .....................................................
SCREW, CAP, HEXAGON HEAD:...........................
GASKET: water connection Part of ..........................
kit P/N BM 95886
GASKET: thermostat housing Part of.......................
set P/N BM 96854
HOUSING, THERMOSTAT......................................
SCREW, CAP, HEXAGON HEAD:...........................
thermostat housing
SCREW, CAP, HEXAGON HEAD:...........................
thermostat housing
PLUG, PIPE: thermostat housing.............................
TRANSMITTER, TEMPERATURE:..........................
thermostat
THERMOSTAT ........................................................
GASKET: thermostat housing cover ........................
Part of set P/N BM 96854
COVER, THERMOSTAT HOUSING ........................
WASHER, FLAT: thermostat ...................................
SCREW, CAP, HEXAGON HEAD:...........................
thermostat housing
SCREW, CAP, HEXAGON HEAD:...........................
half fixed Pulley
WASHER, PULLEY: half fixed pulley .......................
PULLEY, HALF FIXED, WATER..............................
PUMP: front
PULLEY, HALF ADJUSTABLE, ...............................
WATER PUMP: back
PUMP ASSEMBLY, WATER ...................................
SEAL: water pump Part of kit P/N ............................
BM 95886
RETAINER, BEARING: water pump ........................
BEARING, BALL, ANNULAR: water.........................
pump
WASHER, THRUST: water pump ............................
RING, SNAP: shouldered shaft ................................
BEARING, BALL, ANNULAR: ..................................
water pump
SHAFT, SHOULDERED: water pump ......................
PLUG, PIPE: water pump ........................................
BODY, WATER PUMP ............................................
SEAL ASSEMBLY, PLAIN: water.............................
pump
SEAT, CERAMIC: water pump.................................
ADHESIVE BANDING .............................................
(7) (8)
QTY
INC
U/M IN
UNIT
EA
1
EA
EA
2
1
EA
1
EA 14
EA
8
EA
2
EA
1
EA
EA
1
2
EA
2
EA
EA
2
1
EA
EA
1
1
EA
EA
EA
1
2
2
EA
3
EA
EA
3
1
EA
1
EA
EA
1
1
EA
EA
1
1
EA
EA
EA
1
1
1
EA
EA
EA
EA
1
1
1
1
EA
EA
1
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
(5)
NATIONAL
STOCK
NUMBER
PART
NUMBER
FSCM
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-22
B-22
B-22
18 PAFZZ
19 PAOZZ
20 PAOZZ
2930-00-908-7315
5310-00-637-9541
5305-00-269-3213
BM 76114
MS35338-46
MS90725-62
15434
96906
96906
B-22
B-22
21 PAOZZ
22 PAOZZ
4730-00-801-8186
2930-00-085-7421
S 915A
154358
15434
15434
B-22
PAOZZ
3030-00-722-2095
69976
15434
B-23
1 PAOZZ
5305-00-269-3217
MS90725-67
96906
B-23
B-23
B-23
B-23
2
3
4
5
PAOZZ
PAOZZ
XBFZZ
PAFZZ
5310-00-637-9541
2930-00-904-9585
5330-00-973-0040
MIS35338-46
113608
152237
143108
96906
15434
15434
15434
B-23
B-23
B-23
6 PAFZZ
7 PAFZZ
8 PAFZZ
5310-00-062-9556
5310-00-062-9557
3110-00-100-3161
146650
146651
99045-53
15434
15434
15434
B-23
9 PAFZZ
3110-00-198-2170
15245
60038
B-23
B-23
10 XBFZZ
11 PAFZZ
5330-00-551-4007
175203
106276
15434
15434
B-23
B-23
B-23
B-23
B-23
12
13
14
15
16
PAFZZ
XBFZZ
XBFZZ
PAFZZ
PAFZZ
2930-00-914-6042
5306-00-912-9105
5305--00-426-3023
175204
175205
173061
9948
S 131C
15434
15434
15434
15434
15434
B-23
B-23
B-23
17 PAFZZ
18 PAFZZ
19 PAOZZ
5310-00-209-0965
5310-00-753-4099
3030-00 -918-9644
MS35338-47
67532
BM 96103
96906
15434
15434
B-24
1 PAOZZ
B-24
2 XBOZZ
B-24
B-24
B-24
3 PAOZZ
4 PAOZZ
5 PAOZZ
B-24
B-24
B-24
B-24
6
7
8
9
3030-00-918-0605
BM 96101
15434
60136
35510
5310-00-920-0831
3020-00-905-4420
5305-00-269-3210
22082
173058
MS90725-59
35510
15434
96906
PAOZZ
PAOZZ
PAOZZ
PAOFF
5310-00-637-9541
5310-00-562-6553
2920-00-933-2563
2920-00-909-2483
MS35338-46
S 602
121037
10929868
96906
15434
15434
19207
B-24
10 PAOZZ
5305-00-269-3214
MS90725-64
96906
B-24
11 XBOZZ
170629
15434
B-22
(6)
DESCRIPTION
USABLE ON CODE
0504-WATER PUMP-Continued
IMPELLER ASSEMBLY: water pump.......................
WASHER, LOCK: water Pump body ........................
SCREW, CAP, HEXAGON HEAD:...........................
water pump body
PLUG, PIPE: water pump body................................
GASKET: water pump to block Part of .....................
kit P/N BM 95886
BELTS, MATCHED SET: water pump......................
0505-FAN ASSEMBLY
SCREW, CAP, HEXAGON HEAD:...........................
fan to Pulley
WASHER, LOCK: fan to pulley ................................
IMPELLER, FAN AXIAL ...........................................
SPACER, PILOT: fan idler pulley .............................
GASKET: fan pilot spacer Part of kit ........................
P/N BM 95886
NUT: idler shaft........................................................
WASHER, FLAT, KEY: clamp washer .....................
CONE AND ROLLERS, TAPERED..........................
ROLLER BEARING: front and rear
CUP, TAPERED ROLLER BEAR:............................
idler pulley front and rear
PULLEY,FAN,HUB ..................................................
SEAL, OIL: fan hub Part of kit P/N ...........................
BM 95886
SHAFT, IDLER: fan hub...........................................
WASHER: idler shaft ...............................................
BRACKET,FAN........................................................
BOLT, MACHINE .....................................................
SCREW, CAP, HEXAGON HEAD:...........................
fan bracket
WASHER, LOCK: fan bracket ..................................
NUT, SELF-LOCKING: idler shaft ............................
BELT SET: fan drive (3 belts per set).......................
GROUP 06-ELECTRICAL
SYSTEM
0601-GENERATOR
BELT, V, MATCHED SET: alternator .......................
(2 belts per set)
SCREW, MACHINE, ROUND HEAD: ......................
alternator pulley
WASHER, FLAT: alternator pulley ...........................
PULLEY, GROOVE: alternator drive ........................
SCREW, CAP, HEXAGON HEAD:...........................
adjusting link
WASHER, LOCK: adjusting link ...............................
WASHER, FLAT: adjusting link ................................
LINK, ADJUSTING: generator..................................
GENERATOR: model 3002AA, Leece- ....................
Neville, 28 volts
SCREW, CAP, HEXAGON HEAD:...........................
generator mounting
BRACKET,GENERATOR ........................................
(7) (8)
QTY
INC
U/M IN
UNIT
EA
EA
EA
1
5
1
EA
EA
1
1
EA
1
EA
6
EA
EA
EA
EA
6
1
1
1
EA
EA
EA
1
1
2
EA
2
EA
EA
1
1
EA
EA
EA
EA
EA
1
2
1
1
6
EA
EA
EA
6
1
1
EA
1
EA
1
EA
EA
EA
1
1
2
EA
EA
EA
EA
8
8
1
1
EA
6
EA
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B24.1
1 PAOFF
2920-00-785-0833
MS53011-1
96906
B24.1
2 PAOZZ
2920-00-807-2408
1119849
19207
B24.1
B24.1
3 PAOZZ
4 PAOZZ
5330-00-909-2490
5305-00-911-1862
114123
153581
15434
15434
B24.1
- PAOZZ
5330-00-199-5886
119116
15434
FSCM
B-25
B-25
1 PAFHH
2 PAFZZ
2530-00-919-6460
2910-00-084-7785
BB 75284
139845
15434
15434
B-25
3 PAFZZ
3805-00-445-0607
130081
15434
B-25
B-25
4 PAFZZ
5 PAFZZ
3020-00-903-9535
3120-00-445-0606
150139
130080
15434
15434
B-25
6 PAFZZ
2910-00-062-9564
144800
15434
B-25
7 PAFZZ
5330-00-445-0609
117077
15434
B-25
B-25
B-25
8 XBOFF
9 PAFZZ
10 PAFZZ
5310-00-637-9541
5305-00-269-3221
139915
MS35338-46
MS90727-71
15434
96906
96906
B-25
- PAHZZ
3805-00-441-0145
128086
15434
B-25
- PAHZZ
5330-00-821-9162
128087
15434
B-25
B-25
- PAHZZ
- PAHZZ
5330-00-822-3954
5330-00-905-2679
127950
128085
15434
15434
B-26
B-26
B-26
B-26
B-26
B-26
B-26
B-26
B-26
B-26
B-26
1
2
3
4
5
6
7
8
9
10
11
PAOZZ
XBOZZ
PAOZZ
XBOZZ
PAOZZ
XBOZZ
PAOZZ
PAOZZ
XBOZZ
PAOZZ
PAOZZ
3030-00-288-1338
4730-00-927-7272
5305-00-269-2804
MS51069-44
10945942
11649251
11659874
11602730
AN816-16-12E
11649253
AN915-6
144042
MS39158-9
MS90726-61
96906
19207
19207
19207
19207
88044
19207
88044
21450
96906
96906
B-26
B-26
12 PAOZZ
13 PAOZZ
5310-00-637-9541
5310-00-809-4085
MS35338-46
MS27183-16
96906
96906
3020-00-138-8081
2530-00-768-7663
4730-00-363-7007
4730-00-231-3908
B-23
(6)
DESCRIPTION
USABLE ON CODE
0603-STARTING MOTOR
CRANKING MOTOR ASSEMBLY:...........................
Leece-Neville
RELAY SOLENOID: starter assem- .........................
bly
GASKET: starter mounting ......................................
SCREW, CAP, HEXAGON HEAD:...........................
starter mounting
WASHER, SELF-SEALING: starter .........................
mounting capscrew
GROUP 12-BRAKES
1209-AIR COMPRESSOR AND
DRIVE MECHANISM
COMPRESSION, AIR ..............................................
GASKET: compressor flange to fly- .........................
wheel Part of kit P/N BM 95886
WASHER, THRUST: accessory drive ......................
spur gear
GEAR, SPUR: accessory drive ................................
WASHER, THRUST: accessory drive ......................
to compressor support cover
BUSHING, SLEEVE: compressor sup- ....................
port cover
GASKET: support cover Part of kit...........................
P/N BM 95886
COVER, COMPRESSOR SUPPORT ......................
WASHER, LOCK: support cover..............................
SCREW, CAP, HEXAGON HEAD:...........................
support cover
PACKING, PREFORMED: compressor....................
exhaust
PACKING, PREFORMED: compressor....................
unloader
GASKET: compressor air connection.......................
PACKING, PREFORMED: compressor....................
intake valve seat, preformed
GROUP 14-STEERING
1410-HYDRAULIC PUMP
ASSEMBLY
BELT, PUMP DRIVE................................................
NUT, PUMP PULLEY ..............................................
PULLEY, PUMP, GROOVED...................................
BRACKET, PUMP MOUNTING ...............................
PUMP, HYDRAULIC................................................
NIPPLE, PUMP INLET.............................................
ELBOW, PUMP INLET ............................................
ELBOW, PUMP OUTLET ........................................
BUSHING, PIPE: inlet..............................................
ADAPTER, PUMP: outlet .........................................
SCREW, CAP, HEXAGON HEAD:...........................
pump
WASHER, LOCK: Pump ..........................................
WASHER, FLAT: mounting bracket .........................
to pump
(7) (8)
QTY
INC
U/M IN
UNIT
EA
1
EA
1
EA
EA
1
3
EA
3
EA
EA
1
1
EA
1
EA
EA
1
1
EA
1
EA
1
EA
EA
EA
1
6
6
EA
1
EA
1
EA
EA
1
1
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
1
1
1
1
1
1
1
1
1
1
2
EA
EA
3
2
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
(6)
DESCRIPTION
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
FSCM
B-26
14 PAOZZ
5305-00-269-2800
MS90726-57
96906
B-26
B-26
15 PAOZZ
- PAOZZ
5310-00-080-6004
5315-00-616-5525
MS27183-14
MS35756-9
96906
96906
USABLE ON CODE
1410-HYDRAULIC PUMP
ASSEMBLY-Continued
SCREW, CAP, HEXAGON HEAD:...........................
mounting bracket
WASHER, FLAT: mounting bracket .........................
KEY: Pump shaft .....................................................
(7) (8)
QTY
INC
U/M IN
UNIT
EA
1
EA
EA
1
1
EA
1
EA
EA
EA
EA
1
1
1
1
EA
42
EA
42
EA
1
EA
42
EA
1
EA
1
EA
EA
1
2
EA
1
EA
1
EA
1
EA
EA
1
1
GROUP 33-SPECIAL PURPOSE
KITS
B-1
7 PAFDL
8145-00-912-4617
10944664
19207
B-1
B-1
B-1
B-1
8
9
10
11
XAFDL
PAFZZ
PAFZZ
PAFZZ
6685-00-906-0156
4820-00-620-8128
4820-00-242-4064
10924731
83565883
8876456
8876442
19207
19207
19207
19207
B-1
12 PAFZZ
5310-00-763-8920
MS51967-20
96906
B-1
13 PAFZZ
5310-00-232-8194
MS35338-50
96906
B-1
14 XBFZZ
10926305
19207
B-1
15 PAFZZ
MS90725-163
96906
B-1
16 XAFDL
10924730
19207
5305-00-724-5911
3301-REUSABLE SHIPPING
CONTAINERS
CONTAINER, SHIPPING AND STOR- ....................
AGE: V8-300 diesel engine
CONTAINER, UPPER: shipping ..............................
INDICATOR: humidity ..............................................
VALVE ASSEMBLY: air relief ..................................
VALVE, TANK ASSEMBLY: air................................
filling
NUT, HEXAGON: shipping con-...............................
tainer
WASHER, LOCK: shipping con- ..............................
tainer
PACKING, PREFORMED: shipping .........................
container
SCREW, CAP, HEXAGON HEAD:...........................
shipping container
CONTAINER, LOWER: shipping .............................
GROUP 47-GAGES
(NON-ELECTRICAL)
B-27
1 PAOZZ
4730-00-908-6335
155445
15434
B-27
B-27
2 PAOZZ
3 PAFZZ
5340-00-377-3070
5305-00-622-9483
9052-1
MS35265-81
15434
96906
B-27
4 PAOZZ
5330-00-591-8519
70732
15434
B-27
5 PAOZZ
5330-00-641-1149
70809
15434
B-27
6 PAHZZ
2910-00-905-0038
174421
15434
B-27
B-27
7 PAHZZ
8 PAHZZ
3120-00-507-3264
3020-00-790-3417
70723
70720
15434
15434
B-24
4701-TACHOMETER
ADAPTER, CABLE DRIVE: tacho-...........................
meter
CAP,TACHOMETER: adapter..................................
SCREW, SLOTTED HEAD: tacho- ..........................
meter housing
GASKET: tachometer, housing Part.........................
of set P/N BM 68856
SEAL, TACHOMETER: drive shaft ..........................
Part of set P/N BM 68356
SHAFT, SHOULDERED: tachometer.......................
drive
BUSHING, SLEEVE: tachometer .............................
GEAR, HELICAL: tachometer drive .........................
follower
C1, TM 9-2815-213-34
Section III. SPECIAL TOOLS, TEST AND SUPPORT EQUIPMENT
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
(6)
DESCRIPTION
FSCM
USABLE ON CODE
(7) (8)
QTY
INC
U/M IN
UNIT
GROUP 26-TOOLS AND TEST
EQUIPMENT
B-28
1 PAHZZ
4910-00-977-7605
11600040
19207
B-28
2 PAHZZ
4910-00-999-1506
11600028
19207
B-28
3 PAHZZ
4910-00-977-7516
11600037
19207
B-28
4 PAHZZ
3460-00-999-1210
11600069
19207
B-28
5 PAFZZ
4910-00-977-7511
11600066
19207
B-28
6 PAFZZ
5110-00-981-3106
ST 955
15434
B-28
7 PAHZZ
5120-00-963-9665
11600077
19207
B-28
8 PAHZZ
5120-00-953-9664
11600076
19207
B-28
9 PAFZZ
4910-00-999-1503
11600060
19207
B-28
10 PAHZZ
5120-00-999-1262
11600073
19207
B-28
11 PAHZZ
5120-00-999-1263
1160075
19207
B-28
12 PAFZZ
4910-00-999-1269
11600082
19207
B-28
13 PAFZZ
5130-00-999-1268
11600049
19207
B-28
14 PAFZZ
5120-00-981-3108
11600050
19207
B-28
15 PAFZZ
5120-00-620-6222
ST 384
15434
B-28
16 PAFZZ
4910-00-977-7529
ST 772
16434
B-28
17 PAFZZ
4910-00-981-3105
11600086
19207
B-28
18 PAHZZ
5120-00-981-3115
11600063
19207
B-28
19 PAFZZ
5120-00-977-7528
11600093
19207
B-28
20 PAHZZ
3460-00-999-1259
11600079
19207
B-28
21 PAHZZ
3460-00-999-1257
11600070-1
19207
B-28
22 PAHZZ
3460-00-999-1258
11600070-2
19207
B-25
2604-SPECIAL TOOLS
PLATE, MOUNTING, FUEL .....................................
PUMP: used with vise BOI: 1 auth
for 1-20 equip
VISE, BALL JOINT: holding, fuel .............................
pump BOI: 1 auth for 1-20 equip
BLOW-BY CHECKING TOOL: .................................
crankcase pressure BOI: 1 auth for 1-20 equip
MANDREL, ROD LOCATING: used.........................
with fixture P/N ST 561 BOI: 1 auth
for 1-20 Equip
BALL, SEATING TOOL,...........................................
INJECTOR BOI: 1 auth for 1-20
equip
CUTTER, BALL SEAT: injector ................................
body BOI: 1 auth for 1-20 equip
MANDREL: used with driver P/N..............................
11600076 BOI: 1 auth for 1-20 Equip
DRIVER: install/remove camshaft ............................
bushings BOI: 1 auth for 1-20 equip
BURNISHER, ADJUSTABLE: ..................................
burnish injector orifice BOI: 1 auth
for 1-20 equip
PULLER, MECHANICAL: remove............................
cylinder sleeve BOI: 1 auth for 1-20
equip
PLATE, PULLER: used with puller ...........................
P/N 11600073 BOI: 1 auth for 1-20
equip
FIXTURE, TIMING: injector BOI: 1...........................
auth for 1-20 Equip
EXPANDER, SLEEVE: seal injector ........................
sleeve BOI: 1 auth for 1-20 equip
DRIVER: install injector sleeve BOI: ........................
1 auth for 1-20 equip
HOLDING TOOL, INJECTOR BOI: ..........................
1 auth for 1-20 equip
ROLLING TOOL, INJECTOR...................................
SLEEVE BOI: 1 auth for 1-20 equip
CUTTER, INJECTOR SLEEVE................................
BOI: 1 auth for 1-20 equip
BAR, CHECKING: main bearing ..............................
bore alinement BOI: 1 auth for 1-20
equip
PULLER, MECHANICAL: injector ............................
sleeve BOI: 1 auth for 1-20 equip
MANDREL, CRANK PIN: used with .........................
fixture P/N ST 561 BOI: 1 auth for
1-20 equip
MANDREL, ROD LOCATING: used.........................
with fixture P/N ST 561 BOI: 1 auth
for 1-20 equip
MANDREL, ROD LOCATING: used.........................
with fixture P/N ST 561 BOI: 1 auth
for 1-20 equip
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-28
23 PAFZZ
4910-00-202-9488
11600068
19207
B-28
24 PAFZZ
5210-00-690-7949
11600041
19207
B-28
25 PAHZZ
4920-00-711-9307
11600047
19207
B-28
26 PAFZZ
4910-00-977-7510
11600046
19207
B-28
27 PAFZZ
4910-00-977-7506
11600042
19207
B-28
28 PAHZZ
5120-00-999-1504
11600061
19207
B-28
29 PAFZZ
5120-00-364-5417
11600045
19207
B-28
30 PAFZZ
5120-00-980-7346
11600051
19207
B-28
31 PAHZZ
5120-00-999-1206
11600048
19207
B-28
32 PAHZZ
5120-00-999-1497
11600088
19207
B-28
33 PAHZZ
4910-00-999-1499
11600092
19207
B-28
34 PAHZZ
4910-00-499-5428
ST 112
15434
B-28
35 PAHZZ
5120-00-896-8097
11600031
19207
B-28
36 PAFZZ
4910-00-999-1500
11600071
19207
B-28
37 PAHZZ
5120-00-999-1505
11600081
19207
B-28
38 PAHZZ
5120-00-999-1267
11600090
19207
B-28
39 PAFZZ
5120-00-896-8088
11600033
19207
B-28
40 PAHZZ
4910-00-977-7507
ST 561
15434
B-28
41 PAHZZ
4910-00-346-3708
11600027
19207
B-28
42 PAHZZ
5110-00-981-3107
ST 490
15434
B-28
43 PAHZZ
5120-00-981-3110
11600065
19207
B-28
44 PAHZZ
5120-00-999-1207
11600087
19207
B-28
45 PAFZZ
4910-00-977-7489
11600084
19207
FSCM
B-26
(6)
DESCRIPTION
USABLE ON CODE
2604-SPECIAL TOOLS-Cont
ADAPTER, INJECTOR: used with ...........................
test stand P/N J8686-Model B BOI:
1 auth for 1-20 equip
GAGE, PROTRUSION: to check .............................
cylinder sleeve protrusion BOI: 1
auth for 1-20 equip
FIXTURE, CYLINDER HEAD BOI:...........................
1 auth for 1-20 equip
PLATE, ADAPTER: used with..................................
engine stand P/N 11600042 BOI: 1
auth for 1-20 equip
STAND, MAINTENANCE: to ....................................
mount engine for rebuild BOI: 1 auth
for 1-20 equip
PULLER, MECHANICAL: remove............................
fuel pump BOI: 1 auth for 1-20 equip
FIXTURE ASSEMBLY, ............................................
INJECTOR: holding injector BOI: 1
auth for 1-20 equip
WRENCH, CUP: remove and install ........................
injector cup BOI: 1 auth for 1-20
equip
DRIVER, LINER: install cylinder...............................
sleeve BOI: 1 auth for 1-20 equip
TOOL, IDLE ADJUSTING BOI: 1 .............................
auth for 1-20 equip
TOOL, CYLINDER HEAD: to ...................................
groove cylinder head BOI: 1 auth for
1-20 equip
ATTACHMENT, INDICATOR: ..................................
cylinder block attachment BOI: 1
auth for 1-20 equip
FRONT SEAL ASSEMBLY TOOL:...........................
install pump cover oil seal BOI: 1
auth for 1-20 equip
MASTER INJECTOR: calibrate test .........................
stand BOI: 1 auth for 1-20 equip
INSTALLING TOOL, TUBE: install...........................
O-ring on throttle shaft BOI: 1 auth
for 1-20 equip
REPLACER: remove and install...............................
front crankshaft oil seal BOI: 1 auth
for 1-20 equip
O-RING ASSEMBLY TOOL: install ..........................
injector cup O-ring BOI: 1 auth for 120 equip
FIXTURE, CONNECTING ROD:..............................
rod holder BOI: 1 auth for 1-20 equip
INSERT KIT, VALVE SEAT BOI: 1 ..........................
auth for 1-20 equip
REAMER, FIXTURE: fuel pump...............................
main shaft bushing BOI: 1 auth for
1-20 equip
PULLER, CROSSHEAD GUIDE ..............................
BOI: 1 auth for 1-20 equip
COMPRESSOR, VALVE SPRING ...........................
BOI: 1 auth for 1-20 equip
FIXTURE, LIFTING HEAD: ......................................
cylinder head removal BOI: 1 auth
for 1-20 equip
(7) (8)
QTY
INC
U/M IN
UNIT
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
C1, TM 9-2815-213-34
(1)
(2)
(3)
(4)
NATIONAL
STOCK
NUMBER
PART
NUMBER
(5)
ILLUSTRATION
(a)
FIG
NO.
(b)
ITEM SMR
NO. CODE
B-28
46 PAHZZ
4910-00-977-7519
11600085
19207
B-28
47 PAHZZ
5340-00-951-0773
ST 712
15434
B-28
48 PAHZZ
3460-00-999-1173
11600054
19207
B-28
49 PAHZZ
5120-00-981-3109
11600057
19207
B-28
50 PAHZZ
5220-00-981-7010
11600065
19207
B-28
51 PAHZZ
5133-00-999-1208
11600053
19207
B-28
52 PAHZZ
5210-00-999-1209
11600043
19207
B-29
1 PAHZZ
4910-00-999-1502
11600078
19207
B-29
2 PAHZZ
4910-00-999-1496
11600039
19207
B-29
3 PAHZZ
6685-00-78-9004
ST 435
15434
B-29
4 PAHZZ
4910-00-898-0645
ST 417
15434
B-29
5 PAFDL
4910-00-202-9465
J8686-MODEL B
33287
B-29
6 PAFZZ
4910-00-999-1501
1600056
19207
B-29
7 PAHDL
4910-00-817-7431
1020200
19204
B-29
8 PAHDL
4910-00-763-7495
1020519
19204
FSCM
(6)
DESCRIPTION
USABLE ON CODE
2604-SPECIAL TOOLS-Cont
BLOCK AND MANDREL: rod...................................
bushing removal BOI: 1 auth for 1-20
equip
SPACER, SLEEVE: set crosshead ..........................
guide height BOI: 1 auth for 1-20
equip
MANDREL SET, VALVE GUIDE:.............................
used with kit P/N 11600027 BOI: 1
auth for 1-20 equip
DRIVER, VALVE GUIDE: install ..............................
valve guides BOI: 1 auth for 1-20
equip
GAGE, PLUG: measure piston pin...........................
bushing size BOI: 1 auth for 1-20
equip
CUTTER SET, COUNTERBORE:............................
used with kit P/N 11600027 BOI: 1
auth for 1-20 equip
GAGE: groove wear: piston ring...............................
groove BOI: 1 auth for 1-20 equip
2606-TEST EQUIPMENT
LOAD INDICATOR ASSEMBLY: .............................
used with test stand P/N J8686Model B BOI: 1 auth for 1-20 equip
TESTER, FUEL FLOW BOI: 1 auth .........................
for 1-20 equip
GAGE, PRESSURE, DIAL .......................................
INDICATING BOI: 1 auth for 1-20
equip
TESTER, VALVE SEATING BOI: 1 .........................
auth for 1-20 equip
STAND, INJECTOR TEST BOI: 1............................
auth for 1-20 equip
TESTER, INJECTOR CUP: used.............................
with test stand P/N J8686-Model B
BOI: 1 auth for 1-20 equip
STAND, FUEL PUMP TEST BOI: 1 .........................
auth for 1-20 equip
TEST PANEL: used with test stand..........................
P/N 11020200 BOI: 1 auth for 1-20
equip
(7) (8)
QTY
INC
U/M IN
UNIT
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
EA
1
*TM 9-2815-213-34
Figure B-1. Engine and container assembly.
B-39
*TM 9-2815-213-34
Figure B-2. Cylinder block and head assembly.
B-40
*TM 9-2815-213-34
Figure B-3. Crankshaft main bearing and drive pulley.
B-41
*TM 9-2815-213-34
Figure B-4. Flywheel assembly.
B-42
*TM 9-2815-213-34
Figure B-5. Connecting rod, piston and rings.
B-43
*TM 9-2815-213-34
Figure B-6. Cylinder head, valves, rocker arms, and covers.
B-44
*TM 9-2815-213-34
Figure B-7. Front cover and camshaft.
B-45
*TM 9-2815-213-34
Figure B-8. Engine lubrication system (crankcase breather).
B-46
*TM 9-2815-213-34
AT 40285
Figure B-9. Engine lubrication system (oil pan).
B-47
*TM 9-2815-213-34
Figure B-10. Engine lubrication system (pump).
B-48
*TM 9-2815-213-34
Figure B-11. Engine lubrication system (oil cooler).
B-49
*TM 9-2815-213-34
AT 40288
Figure B-12. Manifold-intake and exhaust.
B-50
*TM 9-2815-213-34
AT 40289
Figure B-13. Fuel injector.
B-51
*TM 9-2815-213-34
AT 40290
Figure B-14. Fuel pump assembly.
B-52
*TM 9-2815-213-34
AT 40291
Figure B-15. Fuel pump housing (exploded view).
B-53
*TM 9-2815-213-34
AT 40292
Figure B-16. Fuel pump gear and damper assembly.
B-54
*TM 9-2815-213-34
AT 40293
Figure B-17. Fuel shutoff solenoid valve and governor spring pack.
B-55
*TM 9-2815-213-34
AT 40294
Figure B-18. Governor assembly (main shaft cover).
B-56
*TM 9-2815-213-34
AT 40295
Figure B-19. Air intake components.
B-57
*TM 9-2815-213-34
AT 40296
Figure B-20. Glow plug and heater accessories.
B-58
*TM 9-2815-213-34
Figure B-21. Thermostat and crossover tube.
B-59
*TM 9-2815-213-34
AT 40298
Figure B-22. Water pump.
B-60
*TM 9-2815-213-34
Figure B-23. Fan, hub, and bracket.
B-61
*TM 9-2815-213-34
Figure B-24. Generator.
B-62
*TM 9-2815-213-34
Figure B-24.1. Starter assembly-diesel engine.
B-62.1
*TM 9-2815-213-34
Figure B-25. Air compressor and drive mechanism.
B-63
*TM 9-2815-213-34
Figure B-26. Power steering pump.
B-64
*TM 9-2815-213-34
AT 40303
Figure B-27. Tachometer drive (fuel pump).
B-65
*TM 9-2815-213-34
Figure B-28. Special tools. (Sheet 1 of 9)
B-66
*TM 9-2815-213-34
Figure B-28. Special tools. (Sheet 2 of 9)
B-67
*TM 9-2815-213-34
Figure B-28. Special tools. (Sheet 3 of 9)
B-68
*TM 9-2815-213-34
Figure B-28. Special tools. (Sheet 4 of 9)
B-69
*TM 9-2815-213-34
Figure B-28. Special tools. (Sheet 5 of 9)
B-70
*TM 9-2815-213-34
Figure B-28. Special tools. (Sheet 6 of 9)
B-71
*TM 9-2815-213-34
Figure B-28. Special tools. (Sheet 7 of 9)
B-72
*TM 9-2815-213-34
Figure B-28. Special tools. (Sheet 8 of 9)
B-73
*TM 9-2815-213-34
Figure B-28. Special tools. (Sheet 9 of 9)
B-74
*TM 9-2815-213-34
Figure B-29. Test equipment. (Sheet 1 of 2)
B-75
*TM 9-2815-213-34
Figure B-29. Test equipment. (Sheet 2 of 2)
B-76
C2, TM 9-2815-213-34
SECTION IV
INDEX-NATIONAL STOCK NUMBER AND REFERENCE NUMBER
CROSS-REFERENCE TO FIGURE AND ITEM NUMBER
NATIONAL STOCK NUMBER CROSS-REFERENCE TO FIGURE AND ITEM NUMBER
NATIONAL
STOCK NUMBER
2530-00-768-7663
2530-00-919-6460
2815-00-045-9875
2815-00-045-9876
2815-00-045-9877
2815-00-062-9566
2815-00-082-0462
2815-00-084-7783
2815-00-084-7784
2815-00-084-7796
2815-00-084-7800
2815-00-085-3944
2815-00-085-3952
2815-00-085-3954
2815-00-085-7434
2815-00-085-7438
2815-00-085-7441
2815-00-085-7442
2815-00-085-7444
2815-00-085-7450
2815-00-085-7451
2815-00-085-7452
2815-00-085-7457
2815-00-085-7469
2815-00-085-7470
2815-00-085-7476
2815-00-086-8384
2815-00-104-3637
2815-00-148-7469
2815-00-159-8678
2815-00-190-8888
2815-00-226-8089
2815-00-297-0068
2815-00-297-0619
2815-00-353-9395
2815-00-362-1548
2815-00-453-9077
2815-00-454-5058
2815-00-454-7806
2815-00-505-5119
2815-00-506-5720
2815-00-712-8495
2815-00-719-4598
2815-00-772-5352
2815-00-783-9751
2815-00-791-1453
2815-00-813-7765
2815-00-815-0530
2815-00-842-5330
2815-00-903-1334
2815-00-903-6633
2815-00-905-4453
2815-00-907-8950
2815-00-907-8952
FIGURE
NUMBER
B-26
B-25
B-6
B-6
B-6
B-5
B-5
B-4
B-2
B-12
B-10
B-6
B-6
B-6
B-6
B-6
B-6
B-2
B-3
B-6
B-6
B-6
B-3
B-6
B-3
B-7
B-10
B-4
B-6
B-6
B-10
B-1
B-3
B-4
B- 4
B-7
B-10
B-6
B-3
B-2
B-2
B-6
B-20
B-2
B-7
B-7
B-6
B-10
B-11
B-4
B-3
B-3
B-2
B-6
B-5
B-5
ITEM
NUMBER
NATIONAL
STOCK NUMBER
5
1
30
35
31
11
8
1
19
11
13
49
8
53
37
39
19
6
38
39
20
18
10
9
7
12
4
42
43
14
3
16
2
19
10
32
6
14
21
15
34
6
9
15
5
26
29
24
5
19
26
12
10
4
2815-00-907-8954
2815-00-907-8955
2815-00-907-8964
2815-00-907-8972
2815-00-907-8979
2815-00-907-9012
2815-00-907-9013
2815-00-909-2451
2815-00-909-2476
2815-00-909-2479
2815-00-909-2481
2815-00-909-2485
2815-00-909-2486
2815-00-909-2491
2815-00-909-5956
2815-00-910-8217
2815-00-910-8218
2815-00-910-8219
2815-00-911-7612
2815-00-912-4609
2815-00-912-4611
2815-00-913-1743
2815-00-916-1879
2815-00-924-4491
2815-00-939-8084
2815-00-939-8924
2815-00-972-5388
2815-00-973-0481
2815-00-974-9872
2815-00-981-3160
2815-00-994-4418
2815-00-994-4434
2815-00-994-4437
2815-00-994-4438
2815-00-994-4443
2815-00-994-4444
2815-00-999-5354
2910-00-062-9564
2910-00-065-5544
2910-00-084-7785
2910-00-084-7787
2910-00-084-7813
2910-00-085-3939
2910-00-085-7436
2910-00-085-7439
2910-00-085-7461
2910-00-085-7465
2910-00-132-0769
2910-00-369-8240
2910-00-400-5178
2910-00-507-3271
2910-00-567-4354
2910-00-695-3285
2910-00-759-1299
2910-00-773-9369
B-77
FIGURE
NUMBER
B-6
B-10
B-17
B-12
B-4
B-10
B-3
B-8
B-12
B-8
B-7
B-6
B-12
B-5
B-3
B-1
B-1
B-1
B-5
B-6
B-6
B-2
B-6
B-3
B-6
B-6
B-2
B-10
B-12
B-6
B-2
B-6
B-6
B-6
B-6
B-6
B-7
B-25
B-15
B-17
B-25
B-17
B-17
B-17
B-17
B-15
B-13
B-13
B-17
B-18
B-15
B-15
B-16
B-18
B-15
B-18
ITEM
NUMBER
33
1
19
2
12
27
6
1
8
4
13
28
4
9
4
2
1
47
50
1
46
5
22
25
8
30
17
14
25
9
36
21
56
43
18
6
23
34
2
12
7
9
13
13
7
6
22
1
28
3
7
10
29
12
C2, TM 9-2815-213-34
NATIONAL STOCK NUMBER CROSS-REFERENCE TO FIGURE AND ITEM NUMBER
NATIONAL
STOCK NUMBER
2910-00-774-4246
2910-00-790-8736
2910-00-829-5603
2910-00-829-5604
2910-00-829-5617
2910-00-858-3522
2910-00-905-0038
2910-00-907-8960
2910-00-907-8961
2910-00-908-7307
2910-00-910-9637
2910-00-912-4554
2910-00-912-9104
2910-00-914-7319
2910-00-920-7554
2910-00-920-7555
2910-00-920-7556
2910-00-920-7557
2910-00-924-3912
2910-00-933-3012
2910-00-951-3536
2910-00-970-1277
2920-00-506-5719
2920-00-807-2408
2920-00-909-2483
12920-00-785-0833
2920-00-933-2563
2930-00-085-7421
2930-00-437-0567
2930-00-903-7696
2930-00-904-9585
2930-00-907-8962
2930-00-907-8963
2930-00-908-7311
2930-00-908-7315
2930-00-914-0992
1 2930-00-914-6042
2940-00-417-5800
2940-00-459-6558
2940-00-470-6701
2990-00-735-8564
2990-00-792-1571
2990-00-858-3526
2920-00-970-8930
3010-00-507-8347
3020-00-082-0461
3020-00-082-1899
3020-00-088-1702
3020-00-138-8081
3020-00-460-6429
3020-00-528-5053
3020-00-562-1173
3020-00-682-7710
3020-00-701-1112
3020-00-702-3882
3020-00-790-3417
3020-00-903-9535
3020-00-905-4427
3020-00-905-4420
3030-00-288-1338
3030-00-722-2095
3030-00-918-0605
FIGURE
NUMBER
B-15
B-15
B-15
B-15
B-16
B-17
B-27
B-15
B-15
B-13
B-15
B-13
B-13
B-15
B-14
B-18
B-13
B-13
B-16
B-16
B-16
B-13
B-20
B-24.1
B-24
B-24.1
B-24
B-22
B-l
B-22
B-23
B-22
B-22
B-22
B-22
B-22
B-23
B-9
B-10
B-11
B-18
B-18
B-18
B-15
B-6
B-18
B-10
B-3
B-7
B-26
B-10
B-4
B-18
B-10
B-18
B-16
B-27
B-25
B-243
B-24
B-26
B-22
B-24
ITEM
NUMBER
NATIONAL
STOCK NUMBER
7
5
31
37
6
29
6
35
35
12
32
11
10
13
1
19
3
1
1
6
19
18
8
2
9
1
8
22
14
12
3
4
3
5
18
6
12
28
22
15
27
14
26
16
42
6
17
20
12
3
21
13
15
6
28
5
8
4
3
4
1
1
3030-00-918-9644
3040-00-459-7158
3040-00-788-2762
3110-00-082-1877
3110-00-100-3161
3110-00-100-6149
3110-00-144-8499
3110-00-198-2170
3110-00-829-2049
3120-00-062-9559
3120-00-082-0240
3120-00-082-0241
3120-00-082-0447
3120-00-086-7743
3120-00-132-0286
3120-00-445-0606
3120-00-507-3264
3120-00-566-0480
3120-00-603-2691
3120-00-719-5719
3120-00-764-7090
3120-00-810-6032
3120-00-810-7040
3120-00-870-9520
3120-00-904-9595
3120-00-908-7320
3120-00-910-8220
3120-00-913-9746
3120-00-939-7137
3120-00-973-2972
3120-00-984-1851
3120-00-994-4419
3120-00-994-4420
3120-00-994-4421
3120-00-994-4422
3120-00-994-4423
3120-00-994-4424
3120-00-994-4432
3460-00-999-1173
3460-00-999-1257
3460-00-999-1258
3805-00-441-0145
3805-00-445-0607
3805-00-607-7652
3805-00-961-9470
4320-00-994-4408
4710-00-927-9304
4200-00-458-8079
4720-00-731-8248
4730-00-011-3175
4730-00-018-9566
4730-00-019-4842
4730-00-042-6318
4730-00-041-4203
4730-00-081-4203
4730-00-042-1851
4730-00-226-8444
4731-00-231-3908
4780-00-277-5822
B-78
FIGURE
NUMBER
B-23
B-10
B-18
B-22
B-23
B-13
B-18
B-23
B-22
B-13
B-6
B-6
B-7
B-7
B-10
B-25
B-27
B-10
B-18
B-16
B-15
B-15
B-22
B-10
B-18
B-5
B-5
B-5
B-7
B-6
B-6
B-3
B-3
B-3
B-3
B-3
B-3
B-5
B-28
B-28
B-28
B-25
B-25
B-21
B-15
B-22
B-11
B-19
B-19
B-17
B-2
B-3
B-4
B-6
B-7
B-11
B-20
B-11
B-8
B-15
B-11
B-12
B-12
B-26
B-8
ITEM
NUMBER
191
7
16
11
81
15
13
91
8
13
48
51
14
8
5
5
7
11
20
31
38
40
9
10
29
13
29
27
7
23
8
22
11
21
7
48
21
22
3
3
2
15
30
5
16
20
12
6
16
3
11
1
9
1
5
4
3
1
8
6
C2, TM 9-2815-213-34
NATIONAL STOCK NUMBER CROSS-REFERENCE TO FIGURE AND ITEM NUMBER
NATIONAL
STOCK NUMBER
4730-00-278-4592
4730-00-287-0464
4730-00-289-0212
4730-00-289-4770
4730-00-363-7007
4730-00-369-7824
4730-00-492-6040
4730-00-506-4880
4730-00-716-6580
4730-00-801-8186
4730-00-803-9527
4730-00-877-6298
4730-00-908-6335
4730-00-927-7272
4810-00-512-3534
4820-00-130-4820
4820-00-242-4064
4820-00-620-8123
4910-00-202-9465
4910-00-202-9488
4910-00-345-3708
4910-00-499-5428
4910-00-763-7495
4910-00-817-7431
4910-00-898-0645
4910-00-977-7489
4910-00-977-7505
4910-00-977-7506
4910-00-977-7507
4910-00-977-7510
4910-00-977-7511
4910-00-977-7516
4910-00-977-7519
4910-00-977-7529
4910-00-981-3105
4910-00-999-1269
4910-00-999-1496
4910-00-999-1499
4910-00-999-1500
4910-00-999-1501
4910-00-999-1502
4910-00-999-1503
4910-00-999-1506
4920-00-711-9307
5110-00-981-3106
5110-00-981-3107
5120-00-364-5417
5120-00-620-6222
5120-00-896-8088
5120-00-896-8097
5120-00-953-9664
5120-00-953-9665
5120-00-977-7528
5120-00-980-7346
5120-00-981-3108
FIGURE
NUMBER
B-17
B-26
B-19
B-6
B-4
B-11
B-22
B-26
B-7
B-9
B-16
B-19
B-15
B-20
B-11
B-2
B-21
B-22
B-20
B-21
B-19
B-27
B-26
B-17
B-16
B-1
B-1
B-29
B-28
B-28
B-28
B-29
B-29
B-29
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-29
B-28
B-28
B-29
B-29
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
ITEM
NUMBER
NATIONAL
STOCK NUMBER
2
6
14
18
17
5
13
7
35
25
12
16
27
10
10
22
12
21
2
2
6
1
10
1
11
11
10
5
23
41
34
8
7
4
45
1
9
40
26
5
3
46
16
17
12
2
33
36
6
1
9
2
25
6
42
29
15
39
35
8
7
19
30
14
5120-00-981-3109
5120-00-981-3110
5120-00-981-3115
5120-00-999-1207
5120-00-999-1206
5120-00-999-1262
5120-00-999-1263
5120-00-999-1267
5120-00-999-1497
5120-00-999-1504
5120-00-999-1505
5120-00-999-1209
5120-00-690-7949
5130-00-999-1268
5220-00-981-7010
5133-00-999-1208
5305-00-045-1988
5305-00-062-2230
5305-00-062-4373
5305-00-071-2241
5305-00-177-5552
5305-00-253-5612
5305-00-267-8977
5305-00-269-2800
5305-00-269-2804
5305-00-269-3210
5305-00-269-3211
5305-00-269-3213
5305-00-269-3214
5305-00-269-3215
5305-00-269-3215
5305-00-269-3216
5305-00-269-3217
5305-00-269-3220
5305-00-269-3221
B-79
FIGURE
NUMBER
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-18
B-13
B-5
B-18
B-15
B-4
B-15
B-16
B-17
B-26
B-26
B-4
B-7
B-10
B-18
B-24
B-2
B-7
B-11
B-21
B-7
B-10
B-11
B-12
B-19
B-21
B-22
B-1
B-6
B-7
B-10
B-11
B-12
B-19
B-21
B-24
B-4
B-8
B-10
B-11
B-10
B-11
B-23
B-4
B-21
B-19
B-25
ITEM
NUMBER
49
43
18
44
31
10
11
38
32
28
37
52
24
13
50
51
5
16
6
33
8
11
25
23
36
14
11
18
11
18
31
5
16
17
6
18
1
23
23
16
10
10
20
6
3
16
8
21
5
1
6
10
16
14
24
19
33
20
1
15
11
5
10
C2, TM 9-2815-213-34
NATIONAL STOCK NUMBER CROSS-REFERENCE TO FIGURE AND ITEM NUMBER
NATIONAL
STOCK NUMBER
5305-00-297-4022
5305-00-423-7693
5305-00-426-3023
5305-00-493-3959
5305-00-506-5722
5305-00-509-8106
5305-00-622-9483
5305-00-724-5911
5305-00-735-8098
5305-00-858-0037
5305-00-905-0831
5305-00-911-1862
5305-00-947-3437
5306-00-019-4227
5306-00-062-3995
5306-00-081-8507
5306-00-082-0660
5306-00-082-0661
5306-00-225-8497
5306-00-335-4755
15306-00-426-3023
5306-00-912-9105
5306-00-970-8923
5310-00-045-3299
5310-00-062-4407
5310-00-062-6632
5310-00-062-9556
5310-00-062-9557
5310-00-080-6004
5310-00-081-8500
5310-00-082-1888
5310-00-134-4169
5310-00-141-1795
5310-00-209-0965
5310-00-232-8194
5310-00-262-2986
5310-00-275-3435
5310-00-393-6475
5310-00-407-9566
5310-00-484-1718
5310-00-507-3259
5310-00-521-8595
5310-00-562-6552
5310-00-562-6553
5310-00-562-6557
5310-00-562-6558
5310-00-562-6558
FIGURE
NUMBER
B-6
B-16
B-23
B-15
B-17
B-17
B-16
B-27
B-1
B-19
B-11
B-17
B-3
B-24.1
B-6
B-18
B-2
B-3
B-2
B-2
B-12
B-6
B-4
B-23
B-23
B-2
B-15
B-6
B-5
B-23
B-23
B-26
B-2
B-17
B-12
B-10
B-15
B-17
B-18
B-23
B-18
B-1
B-17
B-6
B-20
B-12
B-6
B-17
B-16
B-17
B-19
B-18
B-15
B-22
B-4
B-2
B-6
B-12
B-18
B-19
B-21
B-24
B-18
B-8
B-12
ITEM
NUMBER
NATIONAL
STOCK NUMBER
44
13
17
19
23
3
10
3
15
9
8
15
1
4
55
7
13
15
3
5
15
24
14
16
15
4
9
54
12
6
7
15
2
10
18
25
20
30
35
17
4
13
5
41
5
14
23
31
9
21
13
34
21
2
9
18
1
7
9
3
17
7
3
13
13
5310-00-595-6612
5310-00-637-9541
5310-00-682-5944
5310-00-753-4099
5310-00-763-8920
5310-00-858-3509
5310-00-809-4085
5310-00-920-0831
5310-00-971-7989
5310-00-984-0273
5330-00-080-0483
5330-00-081-9289
5330-00-081-9299
5330-00-082-0454
5330-00-086-8294
5330-00-199-5886
5330-00-255-0331
5330-00-401-2004
5330-00-401-5105
5330-00-401-5107
5330-00-401-5106
5330-00-401-5108
5330-00-445-0609
5330-00-507-8346
5330-00-506-4866
5330-00-551-4007
5330-00-562-1176
5330-00-567-3463
5330-00-580-5327
5330-00-582-7484
5330-00-641-1149
5330-00-591-8519
5330-00-664-1055
5330-00-695-3295
5330-00-809-2667
5330-00-779-2534
5330-00-809-3276
5330-00-816-8148
5330-00-815-0895
5330-00-821-9162
5330-00-821-9164
5330-00-822-3954
5330-00-838-9975
5330-00-866-5079
5330-00-888-4988
5330-00-903-7701
5330-00-905-2679
5330-00-909-2490
B-80
FIGURE
NUMBER
B-2
B-1
B-2
B-4
B-6
B-11
B-7
B-12
B-13
B-19
B-18
B-21
B-22
B-23
B-24
B-25
B-26
B-20
B-23
B-1
B-15
B-26
B-24
B-15
B-15
B-15
B-16
B-15
B-17
B-2
B-21
B-24.1
B-21
B-11
B-11
B-11
B-11
B-10
B-26
B-18
B-18
B-23
B-17
B-16
GP 0302
B-15
B-2
B-27
B-27
GP0302
B-13
B-16
B-18
B-16
B-17
B-7
B-25
B-8
B-25
B-16
B-2
B-18
B-19
B-25
B-24.1
ITEM
NUMBER
14
5
17
10
12
7
2
6
17
4
8
5
19
2
6
9
12
9
18
12
15
13
3
6
22
11
22
12
11
24
15
7
28
26
13
27
3
7
ill
17
11
28
8
42
28
5
4
4
17
2
20
8
4
2
2
7
11
31
C2, TM 9-2815-213-34
NATIONAL STOCK NUMBER CROSS-REFERENCE TO FIGURE AND ITEM NUMBER
NATIONAL
STOCK NUMBER
5330-00-909-2489
5330-00-913-3949
5330-00-918-0606
5330-00-918-9646
5330-00-961-3638
5330-00-959-1563
5330-00-970-3461
5330-00-973-0040
5330-00-980-9604
5330-00-993-5100
5330-00-993-5101
5330-00-994-4409
5330-00-994-4410
5330-00-994-4411
5330-00-944-4435
5340-00-459-9937
5340-00-464-7064
5340-00-470-6173
5340-00-721-5329
5340-00-786-0102
5340-00-898-1497
5340-00-951-0773
5355-00-082-1189
5360-00-081-8487
5360-00-082-0124
FIGURE
NUMBER
B-12
B-2
B-2
B-21
B-17
B-13
B-20
B-23
B-4
B-13
B-12
B-6
B-12
B-12
B-6
B-13
B-15
B-17
B-6
B-6
B-15
B-17
B-28
B-17
B-18
B-17
ITEM
NUMBER
NATIONAL
STOCK NUMBER
9
23
8
17
14
3
5
3
5
19
7
10
12
13
8
24
33
45
17
17
26
47
18
21
20
5360-00-082-0126
5360-00-086-7710
5360-00-664-5343
5360-00-902-8478
5360-00-905-0042
5365-00-086-8293
5365-00-197-9327
5365-00-507-3224
5365-00-507-3225
5365-00-507-3260
5365-00-507-3261
5365-00-507-3262
5365-00-543-3744
5365-00-598-1070
5365-00-907-9008
5365-00-965-0870
5365-00-988-3668
5970-00-086-7709
6620-00-062-4404
6620-00-993-5546
6685-00-678-9004
6685-00-814-5271
6685-00-906-0156
8145-00-912-4617
9905-00-733-7622
B-81
FIGURE
NUMBER
B-6
B-13
B-10
B-17
B-15
B-2
B-20
B-15
B-15
B-17
B-17
B-17
B-15
B-17
B-10
B-16
B-15
B-22
B-21
B-11
B-29
B-21
B-1
B-1
B-15
ITEM
NUMBER
11
9
26
24
33
27
7
34
34
25
25
25
34
27
25
18
43
16.
14
16
3
13
9
7
26
C2,TM 9-2815-213-34
Part
Number
AN818-16-12B
AN915-6
AN960-416
AR500100
AR50101
1 AR50828
BM68356
BM69979
BM70797
BM71425
BM71531
BM71630
BM75294
BM75508
BM70114
BM76119
BM76338
BM78683
BM79166
BM91011
BM91679
BM92141
BM92350
BM93100
BM93636
BM940607
BM94150
BM94151
BM94173
BM94658
BM94676
BM95886
BM96100
BM96101
1 BM96103
BM96104
BM96M25
BM96830
BM96832
BM96854
1BM97339
BM97370
BM97398
BM97400
BM97421
BM97590
JS686-MODEL B
S117
S1212
S126
S131C
S136
S159B
S16206
S16237
S163D
S1650
S174B
S18SB
S223
Reference Number Cross- Reference to Figure and Item Number
Fig.
Item
Part
FSCM
No.
No.
Number
FSCM
88044
88044
88044
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
33287
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
B-26
B-26
B-15
B-16
B-17
B-18
B-16
B-16
B-14
B-18
B-17
B-17
B-6
B-3
B-3
B-25
B-15
B-22
B-2
B-15
B-4
B-S
B-13
B-18
B-3
B-S
B-S
B-13
B-22
B-6
B-6
B-2
B-21
B-10
B-1
B-2
B-24
B-23
B-7
B-6
B-6
B-6
B-2
B-S
B-6
B-18
B-14
B-13
B-S
B-29
B-9
B-17
B-4
B-23
B-2
B-15
B-15
B-22
B-19
B-18
B-11
B-8
B-19
6
8
20
25
30
35
15
1
1
1
27
46
1
32
18
1
29
12
10
12
1
4
4
3
5
25
33
21
1
1
1
19
50
52
47
10
S
19
1
1
5
27
15
II
16
11
19
17
10
9
13
8
11
13
S 600
15434
5602
15434
S-607
S 622
S 626
15434
15434
15434
S 915
S 915A
15434
15434
S 995
15434
ST 112
ST 384
ST 417
ST 435
ST 490
ST 561
ST 712
ST 772
ST 955
MS16627-93
MS19059-47
MS20002-12
MS20066-16
MS21318-15
MS24537-i
MS24539-1
MS27183-14
MS27183-16
MS35265-81
MS35295-66
MS35338-42
MS35335-45
15434
15434
15434
15434
15434
15434
15434
15434
15434
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
96906
MS35338-46
96906
B-82
Fig.
No.
Item
No.
B-22
B-15
B-18
B-22
B-2
B-4
B-6
B-12
B-12
B-19
B-21
B-24
B-17
B-18
B-5
B-12
B-5
B-2
B11
B-21
B-22
B-4
B-6
B-11
B-22
B-28
B-28
B-29
B-29
B-28
B-28
B-28
B-28
B-28
B-17
B-13
B-2
B-18
B-15
B-21
B-l1
B-26
B-26
B-27
B-11
B-15
B-6
B-12
B-1
B-2
B-4
B-6
B-7
B-S
B-1
B-12
B-3
B-S8
B-19
B-21
B-22
2
21
34
2
18
9
1
7
9
3
17
7
14
3
13
13
3
22
10
12
1
17
18
5
13
34
15
4
3
42
40
47
16
6
27
15
14
18
25
13
16
15
13
3
19
9
23
14
5
17
10
2
2
10
7
6
17
8
4
5
19
C2,TM 9-2815-213-34
Part
Number
Reference Number Cross- Reference to Figure and Item Number
Fig.
Item
Part
FSCM
No.
No.
Number
FSCM
MS35338-47
96906
MS35338-50
96906
MS35691-5
MS35756-9
MS39158-9
MS51069-44
MS51967-20
IMS53011-1
96906
96906
96906
96906
96906
96906
MS9021-116
MS90725-10
96906
96906
MS90725-32
96906
MS90725-59
96906
MS90725-60
96906
MS90725-62
96906
MS90725-64
96906
MS90725-65
96906
MS90725-67
MS90725-68
96906
96906
MS90725-70
96906
MS90725-71
MS90725-87
MS90725-163
96906
96906
96906
MS90726-10
MS90726-57
MS90726-91
VD-103118-173
100099
100192
96906
96906
96906
19207
15434
15434
B-23
B-24
B-25
B-26
B-23
B-18
B-3
B-1
B-15
B-15
B-26
B-26
B-26
B-1
B-24.1
B-15
B-2
B-18
B-12
B-6
B-7
B-10
B-4
B-18
B-24
B-7
B-11
B-2
B-10
B-11
B-7
B-12
B-19
B-21
B-22
B-6
B-7
B-1
B-10
B-11
B-12
B-19
B-21
B-24
B-8
B-10
B-4
B-11
B-23
B-10
B-21
B-21
B-4
B-25
B-19
B-18
B-1
B-17
B-16
B-26
B-26
B-21
B-16
B-18
2
6
9
12
17
4
2
13
22
6
10
1
12
1
42
28
33
15
24
11
18
18
31
5
17
6
16
23
23
1
16
10
10
20
3
16
6
8
21
5
1
6
10
14
24
16
20
1
33
18
11
10
5
5
15
37
23
14
11
14
17
12
100193
100205
100215
100478
100973
100764
101499
101468
101841
101754
101842
101843
101918
102408
102957
103036
103005
105375
107261
106276
108186
108187
107738
108882
10924730
10926305
10929868
10924731
10945942
10946107-1
10944664
109859
109915
11020200
11020519
119849
113244
110855
113608
114123
114223
114463
114791
116000
11600028
11600031
11600027
11600037
11600039
11600033
11600040
11600042
1511600041
11600045
11600043
11600046
11600047
11600049
11600048
11600050
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
19207
19207
19207
19207
19207
19207
15434
15434
19207
19207
19207
15434
15434
15434
15434
15434
15434
15434
15434
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
11600051
19207
B-83
Fig.
No.
Item
No.
B-15
B-18
B-16
B-15
B-2
B-18
B-6
B-16
B-15
B-13
B-15
B-15
B-18
B-12
B-4
B-18
B-18
B-15
B-18
B-23
B-6
B-6
B-6
B-18
B-1
B-1
B-24
B-1
B-26
B-1
B-1
B-18
B-15
B-29
B-29
B-24.1
B-18
B-16
B-23
B-24.1
B-6
B-10
B-17
B-18
B-28
B-28
B-28
B-28
B-29
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
40
16
7
12
27
17
54
3
3
5
34
34
10
1
5
15
2
26
26
118
32
26
34
25
16
14
9
8
2
2
7
7
7
8
2
28
8
3
30
15
8
27
2
35
41
3
2
39
1
27
24
2
52
26
25
13
31
14
51
30
C2,TM 9-2815-213-34
Part
Number
Reference Number Cross- Reference to Figure and Item Number
Fig.
Item
Part
FSCM
No.
No.
Number
FSCM
11600054
11600065
11600056
11600057
11600059
11600060
11600061
11600063
11600065
11600066
11600068
11600070-1
11600070-2
11600071
11600073
11600075
11600076
11600077
11600078
11600079
11600081
11600082
11600084
11600085
11600086
11600087
11600088
11600090
11600092
11600093
11602730
11649251
11649253
11659874
117077
118227
118273
119116
119363
121037
122135
122929
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
19207
15434
15434
15434
15434
15434
15434
15434
15434
124019
124020
125740
125880
126600
127316
127554
127558
127930
127950
128002
128040
128085
128086
128087
128235
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
128765
128766
15434
15434
129768
15434
B-28
B-28
B-29
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-29
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-28
B-26
B-26
B-26
B-26
B-25
B-15
B-20
B-24.1
B-16
B-24
B-8
B-2
B-17
B-15
B-17
B-19
B-20
B-5
B-2
B-6
B-10
B-6
B-25
B-13
B-13
B-25
B-25
B-25
B-6
B-3
B-2
B-2
B-3
B-17
48
43
6
49
4
9
28
18
60
6
23
21
22
86
10
11
8
7
1
20
87
12
45
46
17
44
72
38
33
19
5
3
7
4
7
30
9
5
8
2
24
34
29
33
14
2
7
2
9
29
37
18
9
11
17
31
32
10
10
129826
129827
129838
129839
129888
130080
180081
131168
1312765
131430
132705
134074
134326
136079
136042
136749
137870
137372
138886
138887
138905
138935
138937
138948
139114
139247
139438
139473
139677
139834
139845
139896
139915
139950
139988
140080
140081
140090
140091
140100
140120
140141
140514
140629
140618
141875
142149
142179
142616
142698
142992
143021
143108
143405
143679
143694
14838417
143913
144042
144178
144131
144179
B-84
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
16434
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
21450
15434
15434
15434
Fig.
No.
Item
No.
B-17
B-17
B-17
B-17
B-17
B-25
B-25
B-2
B-10
B-1S
B-2
B-17
B-8
B-22
B-15
B-19
B-17
B-15
B-6
B-6
B-1s
B-6
B-6
B-6
B-7
B-12
B-5
B-15
B-12
B-16
B-25
B-6
B-’25
B-5
B-16
B-3
B-3
B-3
B-3
B-3
B-5
B-3
B-21
B-21
B-15
B-6
B-15
B-15
B-11
B-15
B-6
B-6
B-23
B-10
B-17
B-10
B-18
B-22
B-26
B-18
B-3
B-18
6
9
18
12
11
6
8
Y
21
16
7
17
6
16
7
6
19
86
21
86
88
8
14
38
9
17
12
43
19
19
2
10
8
11
20
23
23
22
8
21
8
11
8
15
31
48
8
11
14
33
56
51
51
12
7
13
21
17
9
23
13
22
C2,TM 9-2815-213-34
Part
Number
144195
144S02
144S06
144800
144896
144807
146064
146120
146488
146500
146591
146601
146610
146611
14660
1146651
146690
146983
146975
147066
147160
147292
147889
147558
147559
147729
148000
148001
148210
148295
148504
148524
148916
148976
148977
149030
149081
149040
149151
14918
149978
150100
150129
150188
150139
151035
151100
151299
151848
151349
151350
151707
151780
151781
151900
152082
152173
152237
115245
158336
153338
153581
153614
Reference Number Cross- Reference to Figure and Item Number
Fig.
Item
Part
FSCM
No.
No.
Number
FSCM
15484
15484
15434
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15434
1544
1544
15484
15484
15484
15434
15484
15484
15434
15484
15434
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15434
15434
15484
15484
15434
15484
15434
15484
15434
15484
15484
60038
15484
15484
15484
15434
B-17
B-IS
B-22
B-25
B-6
B-6
B-6
B-6
B-15
B-8
B-2
B-3
B-11
B-9
B-25
B-8
B-6
B-10
B-6
B-2
B-7
B-17
B-6
B-18
B-15
B-21
B-2
B-2
B-7
B-1l
B-18
B-18
B-15
B-1S
B-S
B-1S
B-1S
B-1S
B-10
B-1
B-2
B-8
B-5
B-3
B-25
B-4
B-4
B-6
B-2
B-2
B-2
B-12
B-4
B-2
B-16
B-6
B-6
B-23
B-23
B-16
B-16
B-24.1
B-6
20
87
15
6
39
59
19
20
5
7
7
22
1
21
6
7
8
14
51
6
14
24
40
18
14
16
29
18
8
24
10
8
15
14
16
18
18
10
17
30
8
9
12
20
4
2
S
7
8
5
4
10
1
19
22
27
49
4
9
21
16
4
43
153615
154087
154088
154166
154167
154227
154858
15436
154542
154716
165445
154689
154643
156172
155267
155445
155500
155790
156088
156144
156304
156810
156811
156348
156438
156439
156497
156641
156659
157088
157504
157618
157647
157952
158168
158370
158551
158556
158680
s o 15 9
159085
159829
160514
160588
161042
161701
161825
161837
161991
161992
162592
162607
162663
162685
162761
168013
168061
163733
163785
168821
163947
163994
164349
B-85
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
1544
15484
15484
15434
15484
15484
15484
15484
15484
15434
15484
15484
15484
15484
15484
15484
15484
15484
15484
15434
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15484
15434
15484
15434
15434
15434
15484
15434
15434
15484
15434
15484
15484
15484
15484
15484
Fig.
No.
Item
No.
B-6
B-17
B-15
B-5
B-25
B-12
B-22
B-12
B-i
B-6
B-22
B-22
B-1
B-2
B-1
B-27
B-7
B-19
B- 0
B-6
B-S
B-S
B-S
B-12
B-6
B-6
B-12
B-6
B-19
B-15
B-18
B-12
B-21
B-10
B-10
B-S
B-7
B-7
B-2
B-s
B-19
B-22
B-16
B-10
B-10
B-S
B-6
B-6
B-2
B-2
B-10
B-10
B-10
B-10
B-B
B-10
B-6
B-15
B-22
B-S
B-13
B-18
B-3
4
17
2
18
19
11
22
12
4
29
11
9
8
25
6
1
7
7
27
4
9
1i
1i
9
81
55
8
19
11
3
20
2
9
16
19
6
4
18
26
16
2
12
18
9
2
14
45
15
10
12
20
31
28
7
1
3
1
28
6
5
2
29
3
C2,TM 9-2815-213-34
Part
Number
Reference Number Cross- Reference to Figure and Item Number
Fig.
Item
Part
FSCM
No.
No.
Number
FSCM
167825
168035
168306
168319
168680
169327
169351
169352
169660
169661
169747
170629
170948
1l1085
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
171546
171548
171550
171552
172550
173058
1173061
173286
173287
173288
173289
173291
173292
173296
173297
173298
173299
173708
174421
174437
175203
175204
175205
175206
175208
175209
175282
175284
175285
175505
175801
175836
176105
177764
177999
180099
181355
181373
181374
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
06840
06840
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
16434
29510
15434
15434
15434
181466
182006
183831
183832
186907
186908
15434
62983
15434
15434
15434
15434
B-2
B-2
B-6
B-6
B-5
B-6
B-6
B-6
B-15
B-15
B-7
B-24
B-13
B-6
B-17
B-16
B-16
B-16
B-17
B-5
B-24
B-23
B-ll
B-ll
B-ll
B-ll
B-ll
B-11
B-ll
B-ll
B-ll
B-ll
B-15
B-27
B-4
B-23
B-23
B-23
B-22
B-22
B-22
B-10
B-19
B-19
B-9
B-9
B-16
B-8
B-16
B-17
B-l11
B-21
B-10
B-11
B-17
B-16
B-11
B-11
B-11
B-7
B-4
15
23
55
44
2
28
43
42
35
35
13
11
11
25
3
10
13
14
32
3
4
14
12
15
13
28
27
29
22
3
1
2
18
6
7
10
12
13
14
4
3
22
12
8
26
26
11
8
2
35
30
4
18
17
31
9
31
25
26
22082
24582
33510
78570
428988
43468
43828
19207
15434
15434
43828A
43863
44678
444697
4797
5103-50
5329388
5703466
60136
63842
64487J
64816A
65798
67532
67684
67946
68061-A
68139
68178-1
68190
68251
68274
68365
68425
68549
68568
68606
15434
15434
15434
19207
15434
15434
19207
19207
35510
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
68812
68908
15434
15434
69215
69236
69514
69562
69793
69866
69969
69974
69976
70183
69996
70295
70415
15434
15434
15434
15434
15434
15434
15434
15434
15434
76680
15434
15434
15434
6
8
B-86
Fig.
No.
Item
No.
B-3
B-4
B-6
B-7
B-11
B-24
B-16
B-17
B-15
B-20
B-19
B-21
B-8
B-10
B-17
B-11
B-4
B-18
B-2
B-1
B-24
B-12
B-3
B-16
B-9
B-23
B-17
B-20
B-20
B-20
B-20
B-8
B-10
B-10
B-10
B-8
B-15
B-7
B-15
B-19
B-20
B-20
B-4
B-7
B-15
B-20
B-10
B-10
B-4
B-18
B-22
B-21
B-8
B-22
B-22
B-19
B-17
GP 0302
12
6
16
3
11
3
24
4
1
4
6
2
6
6
29
13
3
30
2
18
1
28
18
5
7
3
1
5
12
25
26
11
9
41
15
27
16
10
8
19
10
27
7
10
5
4
7
8
3
7
7
15
16
-
C2,TM 9-2815-213-34
Part
Number
Reference Number Cross- Reference to Figure and Item Number
Fig.
Item
Part
FSCM
No.
No.
Number
FSCM
70459
70645
15434
15434
70690
70693
70700
7075
lvil3
70715
70716
70717
70717A
70717B
70720
70723
70732
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
15434
B-6
B-7
B-18
B-15
B-18
B-15
B-17
B-17
B-17
B-17
B-17
B-17
B-17
B-27
B-27
B-27
17
5
14
39
24
4
28
28
21
23
25
25
25
8
7
4
70760
70776
70809
70777
7089727
7451
8060396
8333620
8355883
8376442
8376456
9052-1
9221
99045-53
9948
B-87
15434
15434
15434
15434
19207
80201
19207
19207
19207
19207
19207
15434
15434
15434
15434
Fig.
No.
B-10
B-13
B-27
B-16
B-17
B-18
GP 0302
B-G
B-1
B-1
B-1
B-27
B-21
B-23
B-23
Item
No.
4
4
5
12
2
11
14
9
11
10
2
7
8
15
TM 9-2815-213-34
INDEX
Paragraph
Paragraph
Page
Adapter, crankshaft:
Cleaning .......................................... 3-36
Inspection........................................ 3-37
Installation ....................................... 3-39
Repair ............................................. 3-38
Removal ......................................... 2-11i
Adjustment:
Crossheads, valve .......................... 3-167
Fuel manifold pressure .................. 3-172d(6)
Injectors, engine test ...................... 3-167
Vacuum fuel pump ......................... 3-107g(2)
Valve clearance, engine test ........... 3-167
Air compressor and drive assembly:
Assembly ....................................... 3-100
Cleaning ......................................... 3-97
Disassembly.................................... 3-96
Inspection........................................ 3-98
Installation ....................................... 3-101
Removal .......................................... 2-10m
Repair ............................................. 3-99
Air intake preheater assembly:
Assembly ........................................ 3-118
Cleaning .......................................... 3-115
Description ...................................... 1-4c(4)
Disassembly.................................... 3-114
Inspection........................................ 3-116
Installation ....................................... 3-119
Removal .......................................... 2-10i
Repair ............................................ 3-152
Alternator:
Assembly ........................................ 3-153
Cleaning .......................................... 3-150
Inspection ....................................... 3-149
Installation ....................................... 3-154
Removal .......................................... 2-10c
Repair ............................................ 3-152
Assembly:
Air compressor and drive
assembly ........................................ 3-100
Air intake preheater assembly ........ 3-118
Alternator ........................................ 3-153
Camshaft ........................................ 3-33
Connecting rod and piston
assembly ......................................... 3-17
Crankshaft....................................... 3-11
Cylinder block ................................. 3-6
Cylinder head .................................. 3-68
Cylinder head cover ........................ 2-11
Fan drive pulley, vibration
damper assembly............................ 3-129
Fan, and fan hub assembly ............. 3-141
Flywheel ......................................... 3-56
Flywheel housing ......................... 3-44
Fuel injectors................................... 3-76
Fuel pump damper assembly .......... 3-106f
Fuel pump gear assembly ............... 3-106d
Fuel pump governor spring and
assembly ......................................... 3-106c
Fuel pump housing ......................... 3-106a
Page
Fuel pump mainshaft cover and
governor assembly ......................... 3-106c
Fuel pump shut-off solenoid valve
assembly......................................... 3-106g
Fuel pump tachometer assembly .... 3-106b
Hydraulic pump and bracket
assembly......................................... 3-147
Oil cooler ........................................ 3-161
Oil pan ............................................ 3-50
Oil pump assembly ......................... 3-28
Rocker arm assembly .................... 3-84
Starter ............................................. 3-155
Tappets, valve and injector ............. 3-62
Thermostat assembly .................... 3-135
Water crossover pipe assembly ..... 3-113c
Water pump .................................... 3-123
Assembly data, repair and rebuild
standards ........................................ 3-185
B
Ball Bearings:
Cleaning.......................................... 2-5e
Inspection ....................................... 2-6b
Repair ............................................. 2-7b
Ball valve, injector:
Seating
Seating check ................................. 3-77e
Bearing bore, main .................................... 33-2
Bearing caps, main.................................... 14e(1)
Bearings, bushing type
Inspection ...................................... 2-6
Repair ............................................. 2-7e
Bearings, connecting rod .......................... 2-7
Bearings, crankshaft thrust ........................ 2-11p
Bearings, main:
Cleaning.......................................... 3-8
Installation ...................................... 3-12
Removal.......................................... 3-56
Repair ............................................. 3-10
Bearings, rocker arm ................................. 3-82
Blow-by check ........................................... 3-172c
Break-in run, engine .................................. 3-172b
Breather, crankcase .................................. 3-33
Assembly ........................................ 3-91
Cleaning.......................................... 3-92
Inspection ...................................... 3-93
Removal.......................................... 2-11a(2)
Repair ............................................. 3-194
Bushing, piston pin:
Boring ............................................. 3-16
Inspection ....................................... 3-15
Bushings and bushing-type bearings,
inspection ....................................... 2-6e
Bushings, camshaft:
Inspection. ...................................... 3-4a
Installation ...................................... 3-6
Removal.......................................... 3-2b
Repair and rebuild standards.......... 3-180
C
Calibration
Fuel pump procedure...................... 3-107
A
3-12
3-12
3-12
3-12
2-10
3-57
3-62
3-57
349
357
336
336
336
336
3-36
2-8
3-36
3-53
3-53
1-4
352
3-3
353
2-5
3-53
3-56
3-56
3-56
3-56
2-4
3-56
3-36
3-53
3-56
3-11
3-7
11
3-2
3-19
2-8
3-54
3-55
3-14
3-12
3-25
3-48
3-47
3-47
3-47
Index-1
3-47
3-48
3-47
3-56
3-57
3.13
3-10
3-35
3-56
3-15
3-54
3-52
3-53
3-71
2-1
2-2
2-2
3-31
1-4
2-2
2-3
211
2-13
3-3
3-4
213
3-3
3-34
3-61
3-60
3-11
3-35
3-35
3-35
2-8
3-36
3-7
3-5
2-2
3-1
3-2
3-1
3-66
3-48
TM 9-2815-213-34
Paragraph
Injectors .......................................... 3-77
Mounting fuel pump for ................... 3-104c
Castings
Cleaning. ......................................... 2-5b
Inspection........................................ 2-6a
Repair ............................................. 2-7a
Camshaft:
Assembly ........................................ 3-3
Cleaning ......................................... 3-31
Disassembly ................................... 3-30
Inspection........................................ 3-32
Installation ....................................... 3-35
Removal .......................................... 2-11k
Repair ............................................. 3-34
Repair and rebuild standards .......... 3-180
Camshaft bushings:
Inspection ....................................... 3-4a
Installation ...................................... 3-6a
Removal ......................................... 3-2b
Repair and rebuild standards .......... 3-175
Charts:
Injection timing (chart3-1) .............. 3-79
Troubleshooting, fuel pump
(chart 3-2) ...................................... 3-108
Cleaning:
Air compressor and drive
assembly ........................................ 3-97
Air intake and preheater
assembly ........................................ 3-115
Alternator ........................................ 3-150
Camshaft......................................... 3-31
Castings ......................................... 2-5b
Connecting rod and piston
assembly. ........................................ 3-14
Cylinder block ................................. 3-3
Crankshaft ...................................... 3-8
Cylinder head .................................. 3-65
Cylinder head cover ........................ 3-92
Electrical cable ................................ 2-5d
Fan drive pulley, vibration
damper ............................................ 3-126
Fan, fan hub and bracket
assembly ........................................ 3-138
Flexible hoses ................................. 2-5d
Flywheel .......................................... 3-53
Flywheel housing ........................... 3-41
Front cover ...................................... 3-20
Fuel injectors................................... 3-73
Fuel pump damper assembly .......... 3-103
Fuel pump gear assembly ............... 3-103
Fuel pump governor spring pack
assembly ......................................... 3-103
Fuel pump housing ......................... 3-103
Fuel pump mainshaft cover and
governor assembly ......................... 3-103
Fuel pump shutoff solenoid valve
assembly ........................................ 3-103
Fuel pump tachometer assembly .... 3-103
General. .......................................... 2-5a
Hydraulic pump and bracket
assembly ......................................... 3-144
Oil cooler ......................................... 3-158
INDEX-Continued
Page
3-32
3-40
21
2-1
2-2
3-11
3-11
3-11
3-11
3-11
2-11
3-11
3-66
3-1
3-2
3-1
3-62
3-33
3-51
3-36
3-53
3-56
3-51
2-1
3-6
3-1
3
16
3-353
2-1
3-54
3-55
2-1
3-13
3-12
3-8
3-23
3-40
3-40
3-40
3-40
3-40
3-40
3-40
2-1
3-56
3-56
Paragraph
Oil pan ............................................ 3-47
Oil passages ................................... 2-5C
Oil pump assembly ......................... 3-25
Oil seals ......................................... 2-5d
Rocker arm assembly ..................... 3-81
Starter ............................................ 3-155
Tappets, valve and injector ............. 3-59
Thermostat assembly ...................... 3-132
Water crossover pipe assembly ...... 3-110
Water pump .................................... 3-11
Clearance adjustment, valve ..................... 3-167
Clearance check:
Crankshaft end ............................... 3-12k
Main bearing caps........................... 3-121
Compressor, air:
Assembly ....................................... 3-100
Cleaning ......................................... 3-97
Disassembly ................................... 3-96
Inspection ....................................... 3-98
Installation ...................................... 3-101
Removal .......................................... 2-10m
Repair ............................................. 3-99
Repair and rebuild standards .......... 3-181
Connecting rods:
Assembly ........................................ 3-17
Cleaning .......................................... 3-14
Description ..................................... 1-4e(7)
Disassembly.................................... 3-13
Inspection........................................ 3-15
Installation, rod and piston ............. 3-18
Removal .......................................... 2-11o
Repair ............................................ 3-16
Repair and rebuild standards ......... 3-177
Cooler, oil (see oil cooler)
Cooling system:
Description ...................................... 1-4c(3)
Torque specifications ..................... 3-186g
Cover and governor assembly,
mainshaft (see mainshaft cover
and governor assembly)
Cover, front (see front cover)
Covers, cylinder head (see cylinder
head covers)
Covers, push rod cavity (see push
rod cavity covers)
Crankcase breather:
Assembly ...................................... 3-91
Cleaning .......................................... 3-92
Inspection........................................ 3-99
Removal ......................................... 2-11a(2)
Repair ............................................. 3-94
Crankshaft:
Assembly ........................................ 3-3
Bearings, description ...................... 1-4e(4)
Cleaning . ....................................... 3-3
Description ..................................... 1-4e(3)
Disassembly.................................... 3-167
Inspection ....................................... 3-9
Installation ...................................... 3-12
Removal .......................................... 2-11p
Repair ............................................ 3-10
Repair and rebuild standards ......... 3-176
Index-2
Page
3-13
2-1
3-10
2-1
3-34
3-56
3-14
3-54
3-52
3-53
3-57
3-4
3-5
3-36
3-36
3-36
3-36
3-36
2-8
3-36
3-36
3-7
3-5
1-5
3-5
3-5
3-7
2-11
3-7
3-65
1-3
3-73
3-35
3-35
3-65
2-8
3-35
1-4
3-3
1-4
3-3
1-4
3-4
2-13
3-3
3-65
TM 9-2815-213-34
Paragraph
Crankshaft adapter:
Cleaning .......................................... 3-36
Inspection........................................ 3-37
Installation ....................................... 3-39
Removal .......................................... 2-11i
Repair ............................................. 3-38
Crossheads, valve:
Adjustment ...................................... 3-167
Inspection........................................ 3-82
Installation ....................................... 3-85
Removal .......................................... 2-11e
Crossover, water and lifting eyes:
Assembly ........................................ 3-113c
Cleaning .......................................... 3-110
Inspection........................................ 3-111
Installation ....................................... 3-113
Removal .......................................... 2-10k
Repair ............................................. 3-112
Cylinder block:
Assembly ........................................ 3-6
Cleaning .......................................... 3-3
Description ...................................... 1-4e(1)
Disassembly.................................... 3-2
Inspection........................................ 3-4
Repair ............................................. 3-5
Repair and rebuild standards .......... 3-175
Cylinder heads:
Assembly ........................................ 3-68
Cleaning .......................................... 3-65
Description ...................................... 1-4e(11)
Disassembly.................................... 3-64
Inspection........................................ 3-66
Installation ....................................... 3-70
Regroove ........................................ 3-67b
Removal .......................................... 2-11f
Repair ............................................. 3-67
Repair and rebuild standards .......... 3-183
Resurface........................................ 3-67a
Tests ............................................... 3-69
Cylinder head covers ................................. 2-11a
Cylinder head fuse plugs (see fuse plugs)
Cylinder sleeves:
Assembly ........................................ 3-6c
Cleaning .......................................... 3-3
Disassembly.................................... 3-2c
Inspection........................................ 3-4b
Installation ....................................... 3-6c
Removal .......................................... 3-2c
Repair ............................................. 3-5
Repair and rebuild standards .......... 3-179
D
Damper assembly, fuel pump (see fuel
pump damper assembly)
Damper, vibration (see vibration damper)
Data:
Engine............................................. 1-5
Fuel pump test and calibration ........ 3-107
General ........................................... 1-5a
Oil filter ............................................ 1-5f
Oil Pump ......................................... 1-5c
INDEX-Continued
Page
Paragraph
Valves ............................................. 1-5b
Water pump w/pulley ...................... 1-5d
Description, engine.................................... 1-4
Dipstick assembly...................................... 2-10n
Disassembly:
Air compressor and
drive assembly ................................ 3-96
Air intake and preheater
assembly......................................... 3-114
Alternator assembly ........................ 3-149
Camshaft ........................................ 3-30
Connecting rod and piston
assembly......................................... 3-13
Crankshaft ...................................... 3-7
Cylinder heads ................................ 3-64
Cylinder head cover ........................ 3-91
Fan drive pulley, vibration
damper assembly ........................... 3-125
Fan and fan hub
assembly......................................... 3-137
Flywheel.......................................... 3-52
Fuel injectors .................................. 3-72
Fuel pump damper assembly ......... 3-102a(2)
Fuel pump gear assembly .............. 3-102a(4)
Fuel pump governor spring
pack assembly ................................ 3-102a(5)
Fuel pump housing ......................... 3-102b
Fuel pump shutoff soleniod
valve assembly ............................... 3-102a(1)
Fuel pump tachometer
assembly......................................... 3-102a(6)
Hydraulic pump and bracket
assembly......................................... 3-143
Oil cooler......................................... 3-157
Oil pan ............................................ 3-46
Oil pump ......................................... 3-24
Rocker arm assembly ..................... 3-80
Starter ............................................. 3-155
Tappets, valve and injector ............. 3-58
Thermostat assembly ..................... 3-131
Water pump .................................... 3-120
Drive cover, air compressor
(see air compressor)
Dynamometer test ..................................... 3-169
E
Electrical cables, cleaning ......................... 2-5d
Engine assembly ....................................... 1-4b
Engine external components, description
Exhaust manifolds .......................... 1-4d(5)
Intake manifold heater .................... 1-4d(6)
Oil filler assembly............................ 1-4d(1)
Sending units .................................. 1-4d(2)
Water pump with pulley .................. 1-4d(3)
Water temperature thermostat ........ 1-4d(4)
Engine internal components, description
Camshaft ........................................ 1-4e(10)
Connecting rod bearings................. 1-43(8)
Connecting rod with piston pin
bushings ......................................... 1-4e(7)
Crankshaft ...................................... 1-4e(3)
3-12
3-12
3-12
2-10
3-12
3-57
3-34
3-35
2-9
3-52
3-52
3-52
3-52
2-6
3-52
3-2
3-1
1-4
3-1
3-1
3-2
3-62
3-19
3-16
1-5
3-16
3-16
3-22
3-19
2-9
3-18
3-68
3-18
3-21
2-8
3-2
3-1
3-1
3-1
3-2
3-1
3-2
3-66
1-5
3-48
1-5
1-7
1-7
Index-3
Page
1-6
1-7
1-1
2-8
3-36
3-52
3-56
3-5
3-3
3-16
3-35
3-54
3-55
3-13
3-23
3-36
3-38
3-39
3-40
3-36
3-39
3-55
3-56
3-13
3-9
3-34
3-56
3-14
3-54
3-53
3-59
2-1
1-1
1-4
1-4
1-4
1-4
1-4
1-4
1-5
1-5
1-5
1-4
TM 9-2815-213-34
Paragraph
Crankshaft bearings and thrust
bearings ......................................... 1-4e(4)
Crankshaft gear ............................. 1-4e(5)
Cylinder block with bearing
cap assemblies ............................... 1-4e(1)
Flywheel with ring gear
assembly ......................................... 1-4e(13)
Cylinder heads ............................... 1-4e(11)
Flywheel with ring gear
assembly ........................................ 1-4e(13)
Oil pan ............................................ 1-4e(2)
Oil pump assembly ........................ 1-4e(14)
Pistons ........................................... 1-4e (9)
Valves, valve springs, valve
rocker arms, bearings and
fuel injectors .................................. 1-4e(12)
Vibration damper............................. 1-4e(6)
Engine preparation ................................... 2-5
Engine rebuild stand:
Engine mounting ............................. 2-7
General, engine removal ................. 3-165
Stand removal ................................ 3-166
Engine systems ....................................... 1-4c
Engine test:
Adjust crossheads........................... 3-167
Adjust injectors................................ 3-167
Adjust valve clearance .................... 3-167
Blow-by check ................................ 3-172c
Break-in run ................................... 3-172b
Dynamometer test ......................... 3-169
Filling cooling system ...................... 3-170d
Horsepower rating .......................... 3-172a
Performance curve ......................... 3-173
Preparation for starting .................. 3170
Power check .................................. 3-172d
Priming lubrication system .............. 3-170e
Starting engine ............................... 3-171
Test procedure ............................... 3-172
Errors, reporting of
Exhaust manifold:
Cleaning ......................................... 3-162
Description ..................................... 14d(5)
Inspection ....................................... 3-163
Installation ....................................... 3-164
Removal .......................................... 2-10b
Exhaust system torque specifications ........ 3-186h
Expansion plugs, inspection ...................... 2-6f
F
Fan, fan hub, and bracket assembly:
Assembly ....................................... 3-141
Cleaning-......................................... 3-138
Disassembly ................................... 3-137
Inspection ....................................... 3-139
Installation ...................................... 3-142
Removal ........................................ 2-10e
Repair ............................................ 3-140
Fan drive pulley, vibration damper:
Assembly ........................................ 3-129
Cleaning-......................................... 3-126
Disassembly.................................... 3-125
Inspection ....................................... 3-127
Installation ...................................... 3-130
Removal ......................................... 2-10g
INDEX-Continued
Page
Paragraph
Repair ............................................. 3-128
Flow, checking injector ............................. 3-77d
Flow, fuel pump, setting ........................... 3-107g(3
Flowmeter method, fuel pump
calibration ....................................... 3-107
Flywheel:
Assembly ........................................ 3-5
Cleaning.......................................... 3-1
Description ..................................... 14e(13)
Disassembly .................................. 3-52
Inspection ....................................... 3-54
Installation ..................................... 3-57
Removal ......................................... 2-11h
Repair ............................................. 3-55
Repair and rebuild standards,
assembly data................................. 3-185
Flywheel, crankshaft adapter
installation....................................... 3-9
Flywheel housing:
Assembly ....................................... 3-44
Cleaning ......................................... 3-41
Disassembly ................................... 3-40
Inspection ...................................... 3-42
Installation ..................................... 3-45
Removal.......................................... 2-11j
Repair ............................................. 3-43
Repair and rebuild standards.......... 3-185
Forms, Records and reports:
Forms and records ......................... 1-2
Reporting of errors .......................... 1-3
Front cover:
Assembly ........................................ 3-23d
Cleaning.......................................... 3-20
Disassembly ................................... 3-19
Inspection ...................................... 3-21
Installation ..................................... 3-23
Removal.......................................... 3-10
Repair ............................................ 3-22
Repair and rebuild standards.......... 3-185
Fuel injectors:
Adjustable orifice plug .................... 3-71a
Assembly ........................................ 3-76
Ball valve seating check ............... 3-77e
Calibration....................................... 3-77g
Cleaning ......................................... 3-73
Disassembly ................................... 3-72
Drain orifice .................................... 3-71b
Flow checking ................................. 3-77d
General ........................................... 3-75
Inspection ....................................... 3-74
Installation ...................................... 3-78
Metering orifice ............................... 3-71c
Plunger seat testing- ....................... 3-77a
Removal ......................................... 2-11h
Repair ............................................. 3-75
Seating ball valve - ......................... 3-77f
Spray pattern check ........................ 3-77c
Testing and calibration.................... 3-77
Test stand calibrating...................... 3-77b
Timing ............................................. 3-79
14
1-5
14
1-5
1-5
1-5
14
1-5
1-5
1-5
1-5
2-3
2-3
3-57
3-57
1-1
3-57
3-57
3-57
3-61
3-60
3-59
3-60
360
3-62
3-60
361
3-60\
3-60
3-60
3-57
1-4
357
3-57
2-4
3-73
2-2
3-55
3-55
3-55
3-55
3-55
2-5
3-55
3-54
3-54
3-54
3-54
3-54
2-5
Index-4
Page
3-54
3-30
3-49
3-49
3-14
3-13
1-5
3-13
3-13
314
2-9
3-13
3-71
3-12
3-12
3-12
3-12
3-12
3-12
12-1
3-12
3-71
1-1
1-1
3-9
3-8
3-8
3-8
3-9
2-11
3-9
3-71
3-23
3-25
3-31
3-32
3-23
3-23
3-23
3-25
3-25
3-23
3-23
3-23
3-25
2-9
3-25
3-31
3-28
3-25
3-29
3-33
TM 9-2815-213-34
Paragraph
INDEX-Continued
Page
Fuel lines:
Cleaning .......................................... 3-103
3-40
Inspection ....................................... 3-104
340
Installation ....................................... 3-109
3-51
Removal .......................................... 2-11k
2-11
Fuel pump:
Assembly ........................................ 3-106
347
Calibration ..................................... 3-107
3-48
Calibration, flowmeter method of . 3-107g
3-49
Checkout pressure .......................... 3-1079(7)
3-50
Cleaning .......................................... 3-10
3-340
Disassembly ................................... 3-102
3-36
Governor speed, setting 3-107(4) . 3-49
Idle speed, setting .......................... 3-107g(6)
350
Inspection........................................ 3-104
3-40
Installation ....................................... 3-109
Pump flow, setting .......................... 3-107g(3)
349
Removal ......................................... 3-10
Run-in ............................................ 3107
348
Seals, checking .............................. 3-107g(1)
3-49
Tests ............................................... 3-107d
3-48
Test stand mounting ...................... .3-104c
3-40
Throttle linkage setting ................... 3-107g (5) 3-49
Troubleshooting (chart 3-2). ............ 3-108
3-49
Vacuum adjust ............................... 3-107a(2) 3-49
Fuel pump damper assembly:
Assembly ...................................... 3-106f
3-48
Cleaning. ......................................... 3-103
3-40
Disassembly ................................... 3-102a(2) 3-36
Inspection ....................................... 3-104e (2) 3-41
Repair ........................................... 3-105b
3-44
Fuel pump gear assembly:
Assembly ....................................... 3-106d
3-47
Cleaning ......................................... 3-103
3-40
Disassembly .................................. 102a(4)
3-38
Inspection ....................................... 3-102a(4)
3-38
Repair ............................................ 3-105
3-44
Fuel pump governor spring pack assembly:
Assembly ...................................... 3-47
Cleaning ......................................... 3-103
340
Disassembly.................................... 102a(5)
3-39
Inspection ....................................... 3-104e(5)
3-43
Repair ............................................. 3-105e
3-44
Fuel pump housing:
Assembly ........................................ 3-106a
3-47
Cleaning .......................................... 3-103
3-40
Disassembly.................................... 3102b
340
Inspection........................................ 3-104(7)
3-44
Repair .......................................... 3-105g
3-46
Fuel pump mainshaft cover and
governor assembly:
Assembly ....................................... 3-106c
3-47
Cleaning ......................................... 3-103
3-40
Disassembly.................................... 3-102a(3)
3-37
Inspection........................................ 3-104e(3) 3G41
Repair ............................................. 3-105c
3-44Fuel pump shut-off solenoid valve assembly:
Assembly ...................................... 3-106g
3-48
Cleaning ......................................... 3-103
3-40
Disassembly ................................... 3-102a(1)
3-36
Inspection ....................................... 3-104e(1)
3-41
Repair ........................................... 3-105a
3-44
Paragraph
Fuel pump tachometer:
Assembly ........................................ 3-106
Cleaning ........................................ 3-103
Disassembly .................................. 3-102a(6
Inspection ....................................... 3-104e(6)
Repair ............................................. 3-105f
Fuel system, description .......................... 1-4c(1)
Fuse plugs, cylinder head, inspection ....... 366.a
G
Gears, inspection, general ........................ 2-6d
Gears, repair, general ............................... 2-7d
Gear train, repair and rebuild standards:
Air compressor drive gear .............. 3-181d
Camshaft gear .............................. 3-181c
Crankshaft gear .......................... 3-181
Oil pump drive gear ....................... 3-181b
Governor spring pack assembly (see
fuel pump)
Ground valves, cylinder head .................... 3-67c
Guides, crosshead (see Crosshead guides)
Guides, valve (see Valve guides)
H
Head, cylinder (see Cylinder heads)
Heater, intake manifold (see Intake
manifold heater)
Hoses, flexible, cleaning ............................ 2-5d
Horsepower rating, engine test ................. 3-172a
Housing, flywheel (see Flywheel housing)
Housing, fuel pump (see Fuel pump housing)
Hydraulic pump:
Assembly ....................................... 4-14
Cleaning ......................................... 3-144
Disassembly .................................. 3-143
Inspection ....................................... 3-145
Installation ..................................... 3-148
Removal.......................................... 2-10d
Repair ............................................. 3-146
I
Idle speed, fuel pump, setting ................... 3-107g(6)
Injector, fuel (see Fuel injector)
Inspection, general maintenance .............. 2-6
Inspection of:
Air compressor and drive
assembly ........................................ 3-98
Air intake preheater assembly ........ 3-116
Alternator ........................................ 3-151
Ball bearings ................................... 2-6
Bushings and bushing type
bearings ......................................... 2-6e
Black mating surfaces .................... 3-4e
Camshaft ....................................... 3-83Castings ......................................... 2-6a
Connecting rod and piston
assembly......................................... 3-15
Core hole expansion plugs ............ 2-6f
Crankshaft ...................................... 3-9
Cylinder block ................................. 3-4
Cylinder heads ............................... 3-66
Cylinder head covers ...................... 3-93
Index-5
Page
3-47
3-40
3-39
3-43
3-46
1-1
3-16
2-2
2-3
3-68
368
36
87
3-19
2-1
3-60
3-56
3-56
3-55
3-56
3-56
2-4
3-6
3-50
2-1
3-36
353
3-56
2
2-2
3-4
3-11
2-1
3-5
2-2
33
3-1
3-16
3-35
TM 9-2815-213-34
Paragraph
Cylinder sleeve ............................. 3-4b
Cylinder sleeve counterbore ........... 3-4b(4)
Expansion plugs ............................ 2-6f
Exhaust manifold ........................... 3-163
Fan drive pulley, vibration
damper assembly............................ 3-127
Fan and fan hub assembly .............. 3-139
Flywheel .......................................... 3-54
Flywheel housing .......................... 3-42
Front cover ...................................... 3-21
Fuel injectors................................... 3-74
Fuel pump assembly ...................... 3-104
Fuel pump damper assembly .......... 3-104e(2)
Fuel pump gear assembly ............... 3-104e(4)
Fuel pump governor spring
pack assembly ................................ 3-104e(5)
Fuel pump housing ......................... 3-104e(7)
Fuel pump mainshaft cover and
governor assembly ......................... 3-104e(3)
Fuel pump ...................................... 3-104
Fuel pump solenoid valve
assembly ......................................... 3-104e(1)
Fuel pump tachometer
assembly ........................................ 104e (6)
Fuse plugs, cylinder head .............. 6a
Gears .............................................. 2-6d
Hydraulic pump assembly ............... 3-145
Injector body ................................... 3-74b
Injector cap ..................................... 3-74a
Injector plunger ............................... 3-74c
Injector sleeves ............................ 3-66
Injector spring ................................ 3-74d
Intake manifold ............................... 3-116
Main bearing bore .......................... 3-4c
Main bearing caps .......................... 3-4c
Oil pan............................................. 3-48
Oil pump.......................................... 3-26
Oil seals .......................................... 3-26f
Pistons ........................................... 3-151
Push rods ........................................ 3-82b
Rocker arm assembly ..................... 3-82
Starter ............................................. 3-155
Studs ............................................. 2-6c
Tappet bores ................................... 3-4d
Tappets .......................................... 3-60
Valves ............................................. 3-66d
Valve guides ................................... 3-66g
Valve springs .................................. 3-66h
Vibration damper............................. .3-127
Water crossover pipe. ..................... 3-111
Water pump assembly .................... 12
Installation of:
Air compressor and drive
assembly ......................................... 3-101
Air intake preheater assembly ....... 3-119
Alternator and bracket assembly . 3-39
Connecting rod and piston
assembly ........................................ 3-18
Crankshaft ...................................... 3-12
Crankshaft adapter ........................ 3-39
Cylinder heads ............................... 3-70
INDEX -Continued
Page
3-1
3-2
2-2
3-57
Paragraph
Cylinder head covers ...................... 3-94
Exhaust manifold ............................ 3-164
Fan drive pulley and vibration
damper assembly ........................... 3-130
Fan, fan hub, and bracket
assembly......................................... 3-136
Flywheel.......................................... 3-57
Flywheel housing and spacer plate 3-45
Front cover ..................................... 23
Fuel injectors .................................. 3-78
Fuel pump....................................... 3-109
Hydraulic pump assembly and
bracket ............................................ 3-148
Intake manifold ............................... 3-119
Main bearings ................................. 3-4
Oil cooler......................................... 3-166d
Oil pan. ........................................... 3-31
Oil pump ......................................... 3-29
Push rods........................................ 3-85a
Rocker arm assembly ..................... 3-8Sb
Starter ............................................. 3-156
Tappets........................................... 3-63
Water crossover pipe and lifting
eyes ................................................ 3-113
Water pump assembly .................... 3-124
Intake manifolds:
Cleaning.......................................... 3-115
Description...................................... 1-4d(6)
Inspection ....................................... 3-116
Installation ...................................... 3-119
Removal.......................................... 6
Repair ............................................. 3-117
Intake system torque specifications .......... 3-186h
L
Leakage test, fuel pump ............................ 3-104b
Lifting eyes, rear:
Inspection ....................................... 3-111
Installation . ................................... 3113
Removal.......................................... 2-10lk
Location, engine components ................... 1-4a
Lubrication system, description ................. 1-4e(2)
Lubrication system priming, engine
test .................................................. 3-170e
M
Main bearing:
Cleaning.......................................... 3-3
Inspection ....................................... 3-4c
Installation ...................................... 3-4
Removal.......................................... 2-11p
Main bearing bore, inspection ................... 3-4c
Main, bearing caps, inspection .................. 3-4c
Maintenance repair parts ........................... 2-3
Manifold pressure, fuel pump
adjust .............................................. 3-107g(6)
Mating surface, block inspection ............... 3-4e
Mounting engine on engine stand ............. 2-9
O
Oil cooler:
Assembly ........................................ 3-161
Cleaning.......................................... 3-158
3-54
3-55
3-13
3-12
3-8
3-23
3-40
3-41
3-42
3-43
3-44
3-41
3-40
3-41
3-43
3-16
2-2
3-56
3-24
3-24
3-24
3-16
3-26
3-53
3-2
3-2
3-13
3-10
2-2
3-56
3-34
3-34
3-56
2-2
3-2
3-15
3-172
3-17
3-182
3-154
3-52
3-36
3-53
3-12
3-7
3-4
3-12
3-22
Index-6
Page
3-35
3-57
3-54
3-55
3-14
3-12
3-9
3-32
3-51
3-56
3-5
3-5
3-13
3-10
3-85
3-35
3-56
3-16
3-62
3-54
3-63
1-4
363
3-53
3-53
3-73
3-40
3-62
362
2-6
1-1
14
340
3-1
3-2
2-4
2-13
3-2
3-21
2-1
3-50
3-2
2-3
3-57
3-56
TM 9-2815-213-34
Paragraph
Disassembly.................................... 3-157
Inspection........................................ 3-159
Installation ....................................... 3-166d
Removal .......................................... 2-9d
Repair ............................................. 3-160
Oil dipstick tube assembly, removal . ........ 2-10n
Oil filler assembly:
Data ................................................ 1-e
Description ...................................... 1-4d(1)
Oil filter assembly, data ............................. 1-5f
Oil pan:
Assembly ........................................ 3-50
Cleaning .......................................... 3-47
Description ...................................... 1-4e(2)
Disassembly.................................... 46
Inspection........................................ 3-48
Installation ....................................... 3-51
Removal .......................................... 22-1e
Repair ............................................. 3-9
Oil passages, cleaning .............................. 2-5c
Oil pressure regulator and oil pump,
repair and rebuild standards:
Oil pump.......................................... 3-182
Valve spring measurement ............. 3-182a
Oil pump:
Assembly ........................................ 3-28
Cleaning .......................................... 3-25
Data ................................................ 1-5c
Description ...................................... 1-4e(14)
Disassembly.................................... 3-24
Inspection........................................ 2-6
Installation ....................................... 3-29
Removal .......................................... 2-11m
Repair ............................................. 3-27
Oil seals:
Cleaning .......................................... 2-5d
Inspection........................................ 2-6f
Replacement ................................... 2-7f
Operational theory ..................................... 1-4a (2)
P
Parts, special tools, and equipment:
Maintenance repair parts ................ 2-3
Special tools and equipment ........... 2-2
Tools and equipment ...................... 2-1
Pipe plugs, cylinder block:
Inspection........................................ 3-2a
Installation ....................................... 33-6b
Removal .......................................... 3-2a
Torque specifications ...................... 3-186a
Pistons:
Cleaning .......................................... 3-14
Description ...................................... .1-4e(9)
Disassembly.................................... 3-13
Inspection........................................ 3-15
Installation ....................................... 3-18
Removal .......................................... 2-11o
Repair and rebuild standards .......... 3-178
Piston pin bushing:
Boring.............................................. 3-16
Replacing ........................................ 3-16
Plunger seat, injector, test ......................... 3-77a
INDEX-Continued
Page
3-56
3-57
3-57
2-4
3-57
2-8
Paragraph
Porosity and leakage test, fuel pump ........ 3-104b
Preheater:
Assembly ........................................ 3-8
Cleaning.......................................... 3-15
Disassembly ................................... 3-114
Inspection ....................................... 3-116
Pressure, fuel pump, manifold
adjust .............................................. 3107g(6)
Pressure, check point, fuel pump
compare.......................................... 3-107g
Pressure check, fuel pump, weight
assist .............................................. 3-107g(7)
Priming engine lubrication system,
engine test ...................................... 3-107e
Procedure, engine test .............................. 3-172
Procedure, repair instructions ................... 3-1
Pump, fuel- (see fuel pump)
Pump, hydraulic (see hydraulic pump)
Pump, oil (see oil pump)
Pump, water (see water pump)
Push rod:
Inspection ....................................... 3-82b
Installation ...................................... 3-85a
Removal.......................................... 2-11c
Repair ............................................. 3-83
Push rod cavity covers:
Inspection ....................................... 3-93
Installation ...................................... 3-95
Removal.......................................... 2-11b
Repair ............................................. 3-94
R
Rating horsepower, engine test ................. 3-172a
Regrinding crankshaft ............................... 3-10a
Regrove cylinder head:.............................. 3-67b
Removal of:
Air compressor and drive
assembly......................................... 2-10m
Air intake preheater assembly ........ 2-10i
Alternator and bracket assembly .... 2-10c
Camshaft, gear and spacer plate .... 2-11k
Connecting rod and piston
assembly......................................... 2-11o
Crankshaft ...................................... 2-11p
Crankshaft adapter ......................... 2-11i
Cylinder heads ................................ 2-11f
Cylinder head covers ...................... 2-11a
Engine Components, general ......... 2-8
Engine from rebuild stand ............... 3-166
Exhaust manifolds .......................... 2-9b
External components ...................... 2-8c
Fan drive pulley and vibration
damper assembly ........................... 2-10g
Fan, fan hub, and bracket
assembly......................................... 2-10e
Flywheel.......................................... 2-11h
Flywheel housing ............................ 2-11j
Front cover...................................... 2-11n
Fuel injectors . ................................ 2-11d
Fuel pump....................................... 2-10l
Hydraulic pump assembly and
bracket ............................................ 2-10d
1-7
1-4
1-7
3-13
3-13
1-4
3-13
313
3-13
2-9
3-13
2-1
368
3-68
3-10
3-10
1-7
1-5
3-9
3-10
3-10
2-11
3-10
2-1
2-2
2-3
1-1
2-1
2-1
2-1
3-1
3-2
3-1
371
3-55
1-5
3-5
3-5
3-7
2-11
3-65
3-7
3-7
3-25
Index-7
Page
3-40
3-53
3-53
3-52
3-53
3-50
3-49
3-50
84
360
3-1
334
3-35
2-9
3-34
3-35
3-35
2-9
3-35
3-60
3-3
3-19
2-8
2-5
2-4
2-11
2-11
2-13
210
2-9
2-8
2-3
3-57
2-4
2-3
2-5
2-5
2-9
2-11
2-11
2-9
2-7
2-4
TM 9-2815-213-34
Paragraph
Intake manifolds .............................. 2-10j
Internal components ....................... 2-8c
Main bearings ................................. 2l 2-lp
Oil cooler ......................................... 2-9d
Oil dipstick tube assembly .............. 2-10n
Oil pan............................................. 2-111
Oil pump - ....................................... 2-11m
Push rod cavity covers .................... 11b
Push rods ........................................ 2-lc
Rocker arm assembly ..................... 2-lc
Starter ............................................. 10a
Tappets ........................................... 211g
Thermostat assembly- .................... 2-10
Water crossover pipe assembly ...... 2-lOk
Water pump assembly .................... 2-10h
Repair, general maintenance..................... 2-7
Repair of:
Air compressor and drive
assembly ......................................... 3-33
Air intake preheater assembly ........ 3-117
Alternator and bracket assembly .... 2-10c
Camshaft......................................... 3-324
Connecting rod and piston
assembly ......................................... 3-16
Crankshaft....................................... 3-10
Crankshaft, adapter ........................ 3-39
Cylinder block ................................. 3-5
Cylinder block ................................. 3-5
Cylinder head covers ...................... 3-94
Cylinder heads . .............................. 3-67
Fan drive pulley and vibration
damper assembly............................ 3-128
Fan, fan hub, and bracket
assembly ......................................... 3-140
Flywheel .......................................... 3-55
Flywheel housing and spacer plate . 3-43
Front cover ...................................... 3-22
Fuel Injectors .................................. .3-75
Fuel pump (see fuel pump)
Hydraulic pump assembly and
bracket ............................................ 3-146
Intake manifolds .............................. 3-117
Oil cooler. ........................................ 3-160
Oil pan............................................. 3-49
Oil pump.......................................... 3-27
Push rod cavity covers .................... 3-89
Push rods ........................................ 3-83
Rocker arm assembly ..................... 3-83
Starter ............................................. 3-155
Tappets ........................................... 3-61
Thermostat assembly pipe .............. 3-134
Water crossover pipe assembly ...... 3-112
Water pump assembly . .................. 3-124
Repair and rebuild standards:
Assembly data ................................ 3-185
Camshaft and bearings ................... 3-180
Connecting rod................................ 3-177
Crankshaft and bearings ................. 3-176
Cylinder block ................................. 3-175
Cylinder head .................................. 3-183a
Cylinder sleeve ............................... 3-179
Gear train ........................................ 3-181
General ........................................... 3-174
INDEX-Continued
Page
2-6
2-3
2-13
2-4
2-8
2-11
2-11
2-9
22-9
2-4
2-9
2-5
2-6
2-5
2-2
Paragraph
Oil pressure regulator and pump .... 3-182
Piston.............................................. 3-178
Rocker arm and shaft ..................... 3-183c
Tappets and push rods ................... 3-183b
Torque specifications ...................... 3-186
Water pump .................................... 3-184
Reporting of errors .................................... 1-3
Resurface cylinder head ............................ 3-67a
Ring gap, piston, inspection ...................... 3-15
Ring gear (see Flywheel)
Rocker arm assembly:
Assembly ........................................ 3-84
Cleaning.......................................... 3-81
Description...................................... 1-4e(12)
Disassembly ................................... 3-80
Inspection ....................................... 3-82
Installation ...................................... 3-85
Removal.......................................... 3-11e
Repair ............................................. 3-83
Repair and rebuild standards.......... 3-183
Rods connecting (see Connecting rods)
Rods, push (see Push rods)
Run-in, fuel pump ...................................... 3-107
S
Scope, general maintenance ..................... 2-4
Seals, fuel pump, check ............................ 3-107g
Seals, oil:
Cleaning.......................................... 2-5d
Inspection ....................................... 2-6f
Repair ............................................. 2-7f
Seating check, injector ball valve . ............ 3-77e
Seating, injector ball valve ......................... 3-77f
Seating, valve ............................................ 3-69
Seats, valve (see Valve seats)
Sending units............................................. 1-4d(2)
Set idle speed, fuel pump .......................... 3-107g(6)
Setting, fuel pump flow .............................. 3-107g(3)
Setting, fuel pump governed
speed .............................................. 3-107g(4)
Setting fuel pump throttle linkage .............. 3-107g(5)
Scope ........................................................ 1-1
Shut-off, solenoid, fuel (see Fuel pump
shut-off solenoid valve)
Skirt diameter, piston ................................. 3-15
Special, tools, and equipment ................... 2-2
Speed, setting fuel pump idle .................... 3-107g(6)
Starter:
Cleaning.......................................... 3-155
Inspection ....................................... 3-155
Installation ...................................... 3-156
Removal.......................................... 2-10a
Repair ............................................. 3-155
Studs:
Inspection ....................................... 2-6c
Oversize.......................................... 2-7c(3)
Removal.......................................... 2-7c(1)
Replacement................................... 27c(2)
3-36
3-53
3-24
3-11
3-16
3-10
3-12
3-2
3-2
3-5
3-18
354
3-55
3-13
3-12
3-9
3-25
3-56
3-53
3-57
3-13
3-10
3-35
3-34
3-34
3-56
3-15
3-54
3-52
3-54
3-71
3-66
3-65
3-65
3-62
3-68
3-66
3-66
3-62
Index-8
Page
3-68
3-65
3-70
3-70
3-71
3-71
1-1
3-18
3-5
3-3
344
1-5
3-34
3-34
3-35
2-9
334
3-68
3-48
2-1
49
2-1
2-2
2-3
3-31
3-31
3-21
14
3-50
3-49
3-49
3-49
1-1
3-5
2-1
3-50
3-56
3-56
3-56
2-4
3-6
2-2
2-3
2-2
2-2
TM 9-2815-213-34
Paragraph
T
Tabulated data ........................................... 1-5
Tachometer drive assembly:
Assembly ........................................ 3-106b
Cleaning .......................................... 3-103
Inspection........................................ 3-104e(6)
Disassembly.................................... 3-102a(6)
Repair ............................................. 3-105f
Tappets:
Assembly ........................................ 3-62
Cleaning .......................................... 3-59
Disassembly.................................... 3-58
Inspection........................................ 3-60
Installation ....................................... 3-63
Removal .......................................... 2-11g
Repair ............................................. 3-61
Testing ............................................ 3-62
Tappet bores, inspection ........................... 3-4d
Tests:
Ball valve seating, injector .............. 3-77f
Engine (see Engine test)
Fuel injectors................................... 3-77
Fuel pump ....................................... 3-107d
Fuel shut-off solenoid valve ............ 3-104e(1)
Gear assembly test, fuel pump ....... 3-107d
Head assembly ............................... 3-69b
Housing porosity fuel pump ............ 3-104b
Injector flow ..................................... 3-77
Injector plunger seat ....................... 3-77
Injector sprat pattern ....................... 3-77
Leakage, fuel pump ........................ 3-104d
Oil cooler ......................................... 3-159
Pre-calibration, fuel pump ............... 3-107d
Tappets ........................................... 3-62
Thermostat ...................................... 3-133
Valve seating .................................. 3-69
Test fuel, fuel pump ................................... 3-107c
Test procedure, engine .............................. 3-172
Test stand, injector, calibrating .................. 3-77b
Thermostat:
Assembly ........................................ 3-135
Cleaning .......................................... 3-132
Disassembly.................................... 3-131
Inspection........................................ 3-133
Installation ....................................... 3-136
Removal .......................................... 2-10f
Thrust flange, crankshaft regrinding .......... 3-9b
Throttle linkage, fuel pump, set .................. 3-107g
Timing injection .......................................... 3-79
Tools and equipment ................................. 2-1
Torque specifications:
Air compressor group...................... 3-186i
Cooling system group ..................... 3-186g
Cylinder block group ....................... 3-186g
Cylinder head group........................ 3-186
INDEX-Continued
Page
Paragraph
Engine mounting group................... 3-186j
Injector and connections group ...... 3-186e
Intake and exhaust system group... 3-186h
Lubrication system group................ 3-186f
PT fuel pump group ........................ 3-186d
Rocker arm, cam follower, and
tappet group.................................... 3-186d
Troubleshooting: fuel pump
(chart 3-2) ....................................... 3-108
V
Vacuum adjust fuel pump .......................... 3-107g(2)
Valve Crossheads ..................................... 2-11e
Valve guides .............................................. 1-4e(12)
Valves:
Clearance adjustment ..................... 3-167
Data ................................................ 1-5b
Description...................................... 1-4e(12)
Grinding .......................................... 3-67c
Inspection ....................................... 3-66d
Valve seats:
Assembly ........................................ 3-68d
Inspection ....................................... 3-68b
Grinding .......................................... 3-68
Valve springs:
Description...................................... 1-4e(12)
Inspection ....................................... 3-66
Ventilation system ..................................... 1-4c(5)
Vibration damper:
Assembly ........................................ 3-129
Cleaning.......................................... 3-126
Description...................................... 1-4e(6)
Disassembly ................................... 3-125
Inspection ....................................... 3-127
Installation ...................................... 3-130
Removal.......................................... 2-10g
Repair ............................................. 3-128
W
Water crossover pipe:
Cleaning.......................................... 3-110
Inspection ....................................... 3-111
Installation ...................................... 3-113
Removal.......................................... 2-10k
Repair ............................................. 3-112
Water Pump:
Assembly ........................................ 3-123
Cleaning.......................................... 3-121
Data ................................................ 1-5d
Description...................................... 1-4d(3)
Disassembly ................................... 3-120
Inspection ....................................... 3-122
Installation ...................................... 3-124
Removal.......................................... 2-10h
Repair and rebuild standards.......... 3-184
Weight assist pressure check ................... 3-107g(7)
1-5
3-47
3-40
3-40
3-39
3-46
3-15
3-14
3-14
3-15
3-15
2-9
3-15
3-15
3-2
3-31
3-25
3-48
3-41
3-41
3-22
3-41
3-3
3-30
3-25
3-41
3-57
3-48
3-15
3-54
3-21
3-48
3-60
3-27
3-54
3-54
3-54
3-54
3-54
2-5
3-3
3-49
3-33
2-1
3-73
3-73
3-71
3-72
Index-9
Page
3-73
3-72
3-73
3-72
3-72
3-72
3-51
3-49
2-9
1-5
3-57
1-6
1-5
3-19
3-17
3-20
3-16
3-20
1-5
3-15
1-4
3-54
3-54
1-5
3-54
3-54
3-54
2-5
3-54
3-52
3-52
3-52
2-6
3-52
3-53
3-53
1-7
1-4
3-53
3-53
3-54
2-5
3-71
3-50
By Order of the Secretary of the Army:
Official:
VERNE L. BOWERS,
Major General, United States Army,
The Adjutant General.
W. C. WESTMORELAND,
General, United States Army,
Chief of Staff.
Distribution:
To be distributed in accordance with DA Form 12-38, Direct and General Support Maintenance requirements for
Truck, Tractor, 10 Ton, 6X6 Model M123A1C and M123E2.
žUS GOVERNMENT PRINTING OFFICE: 1992 0-311-831 (60111)
PIN: 018426-000
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