Attachment_0009_NMWR_9-2815-242_Authenticated_Engine.pdf

*NMWR 9-2815-242

U.S. ARMY TACOM LIFE CYCLE MANAGEMENT COMMAND

15 MAY 2012

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING

NATIONAL MAINTENANCE REPAIR STANDARDS INCLUDING

REPAIR PARTS AND SPECIAL TOOLS LIST

FOR

ENGINE DIESEL: LIQUID COOLED V-TYPE

EIGHT CYLINDER TURBOCHARGED

CUMMINS MODEL VTA-903T-600 NON WHITE SMOKE REDUCED WITH

ENGINE CONTAINER ASSEMBLY

(NSN 2815-01-423-0929)

AND

CUMMINS MODEL VTA-903T-600 CENTRY WITH ENGINE

CONTAINER ASSEMBLY

(NSN 2815-01-509-3958)

*SUPERSEDURE NOTICE – This manual supersedes TM 9-2815-242-34 dated 20 October 2003 and TM 9-2815-242- 34P dated 15 January 1997, including all changes.

DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors only for administrative or operational use, as determined on 09 May 1987. Other requests for this document shall be referred to U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCG-L, 6501 E. 11 Mile Road, Warren, MI 48397- 5000.

WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq.

Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DOD Directive 5230.25.

DESTRUCTION NOTICE – Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

AV AILIBILITY STATEMENT– This publication is not available through the St. Louis Media Distribution Division. This publication is available through U.S. Army TACOM Life Cycle Management Command, Warren MI 48397-5000.

NMWR 9-2815-242

WARNING SUMMARY

a

This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. It includes an explanation of safety and hazardous materials icons used within the technical manual. Also review the materials list in the INITIAL SETUP of the WP for hazardous materials used during maintenance of the equipment. Then refer to the detailed WARNINGs for hazardous materials listed separately in this WARNING SUMMARY under the heading.

FIRST AID

For first aid information, see FM 4-25.11.

For hazardous materials, refer to the label and/or material safety data sheet (MSDS).

EXPLANATION OF SAFETY WARNING ICONS

Hot Area – Hand over object radiating heat shows that part is hot and can burn.

GENERAL SAFETY WARNINGS DESCRIPTION

WARNING

Use protection for your hands when installing hot parts to prevent injury.

Use care when removing snap and retaining rings. Snap and retaining rings are under spring tension and can act as projectiles when released and could cause severe eye injury.

COMPRESSED AIR

Compressed air source will not exceed 30 psi (207 kPa). Particles blown by compressed air are hazardous. Direct the air stream away from personnel. When cleaning with compressed air, eyeshields must be worn. Failure to wear eye shields may result in injury to the eyes and loss of sight.

b

EXPLANATION OF HAZARDOUS MATERIALS DESCRIPTION ICONS

Chemical – Drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

Eye Protection - person with goggles shows that the material will injure the eyes.

Vapor – Human figure in a cloud shows that material vapors present a danger or life or health.

DEGREASER SOLVENT

Degreaser solvent MIL-PRF-680 has a high flash point. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes. Do not breathe vapors. Do not use near open flame or excessive heat. If you become dizzy while using solvent, get fresh air immediately and get medical aid. If contact with eyes is made, wash eyes with water and get medical aid immediately.

ADHESIVE

Adhesive, primer, sealant compounds, and isopropyl alcohol are toxic and flammable. These compounds are toxic to eyes, skin, and respiratory tract.

Continued exposure can make you dizzy and irritate your eyes and throat.

Always use in well ventilated areas, away from heat, sparks, and flames. Do not breathe fumes. Do not allow into contact with skin and eyes. Use goggles or face shield and protective gloves.

ACETONE

Acetone is toxic and flammable. When using acetone, the room or area will be well-ventilated. Do not use near an open flame. A fire extinguisher will be kept in the immediate area when acetone is used. Acetone can irritate the eyes and skin. Wear safety glasses or goggles and gloves when using acetone. Improper use of acetone can cause personnel injury.

c

CLEANING SOLVENT

Dry cleaning solvent is flammable. Do not use near an open flame. A fire extinguisher will be kept in the immediate area when solvent is used. Solvent will be used only in open or well-ventilated areas. Failure to provide proper ventilation may result in injury to personnel.

Prussian blue dye is poisonous and can burn. Overexposure to dye can cause heart and skin problems, dizziness, and unconsciousness. Always use in an area with good air flow, away from heat or flames. Do not breathe fumes. Wear gloves and goggles when you use dye. If dye gets onto skin, wash skin. If dye gets into eyes flush with fresh water and seek medical attention. Wipe up spilled dye and place in appropriate container.

End clearance of shaft of turbine wheel and shaft is very important. Turbocharger may explode during operation if shaft end clearance is more or less than measurement range. Soldiers may be injured and turbocharger destroyed.

Engine sling hooks can slip from lifting eyes if not attached properly. Injury to personnel can result. All hooks must face outward to avoid injury to personnel.

Hanging loads could kill or injure you. Keep away from hanging loads and overhead equipment. Keep away from container and frame while frame is being moved by lifting device.

d

Hanging loads could kill or injure you. Keep away from hanging loads and overhead equipment. Keep hands out of container while engine is being placed in container.

Engine may come loose from stand and injure you. Make sure screws on adapter are secure before you remove sling.

Parts may slip and cause eye injury or blindness. Always wear goggles when using power tool or when you have parts under pressure.

Use protection for your hands when installing hot gears to prevent injury.

Flywheel could fall and hurt you. Have helper support flywheel with lifting device during installation.

Flywheel adapter could fall and hurt you. Have helper support flywheel at final removal.

e/f blank

Springs under compression can slip and injure you. Wear goggles to protect your eyes when springs are removed or installed.

A/B blank

LIST OF EFFECTIVE PAGES

Dates of issue for original manual is:

Original 15 May 2012

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 36 AND

TOTAL NUMBER OF WORK PACKAGES IS 28 CONSISTING OF THE

FOLLOWING:

Page / WP No. Change No. Page / WP No. Change No.

Front Cover (2 pgs) 0 Warning Summary (6 pgs) 0 i – xxxiv (34 pgs) 0 WP 0001 (4 pgs) 0 WP 0002 (4 pgs) 0 WP 0003 (4 pgs) 0 WP 0004 (10 pgs) 0 WP 0005 (6 pgs) 0 WP 0006 (122 pgs) 0 WP 0007 (36 pgs) 0 WP 0008 (4 pgs) 0 WP 0009 (38 pgs) 0 WP 0010 (12 pgs) 0 WP 0011 (28 pgs) 0 WP 0012 (18 pgs) 0 WP 0013 (30 pgs) 0 WP 0014 (48 pgs) 0 WP 0015 (16 pgs) 0 WP 0016 (64 pgs) 0 WP 0017 (50 pgs) 0 WP 0018 (36 pgs) 0 WP 0019 (178 pgs) 0 WP 0020 (6 pgs) 0 WP 0021 (12 pgs) 0 WP 0022 (2 pgs) 0 WP 0023 (2 pgs) 0 WP 0024 (2 pgs) 0 WP 0025 (4 pgs) 0 WP 0026 (4 pgs) 0 WP 0027 (2 pgs) 0 WP 0028 (6 pgs) 0 Metric Chart 0 Back Cover 0

RWMN* 9-2815-242

i/ii blank

HEADQUARTERS

U.S. ARMY TACOM LIFE CYCLE MANAGEMENT COMMAND

WARREN, MI., 15 MAY 2012

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING

NATIONAL MAINTENANCE REPAIR STANDARDS INCLUDING

REPAIR PARTS AND SPECIAL TOOLS LIST

FOR

ENGINE DIESEL: LIQUID COOLED V-TYPE

EIGHT CYLINDER TURBOCHARGED

CUMMINS MODEL VTA-903-T-600 NON WHITE SMOKE REDUCED WITH

ENGINE CONTAINER ASSEMBLY

(NSN 2815-01-423-0929)

AND

CUMMINS MODEL VTA-903T-600 CENTRY WITH ENGINE

CONTAINER ASSEMBLY

(NSN 2815-01-509-3958)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it.

The DA Form 2028 is located under the Tulsa Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.

*SUPERSEDURE NOTICE – This manual supersedes TM 9-2815-242-34 dated 20 October 2003 and TM 9-2815-242-34P dated 15 January 1997, including all changes.

DISTRIBUTION STATEMENT C. Distribution authorized to U.S. Government agencies and their contractors only for administrative or operational use, as determined 09 May 1987. Other requests for this document shall be referred to U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCG-L, 6501 E. 11 Mile Road, Warren, MI 48397-5000.

WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DOD Directive 5230.25.

DESTRUCTION NOTICE. Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

AV AILIBILITY STATEMENT– This publication is not available through the St. Louis Media Distribution Division. This publication is available through U.S. Army TACOM Life Cycle Management Command, Warren MI 48397-5000.

TABLE OF CONTENTS

Page No.

WP Sequence No.

iii

How to Use This Manual .................................................................................................................................... v

Chapter 1 – General Information and Equipment Description for Diesel Engine

General Information

Equipment Description and Data

Figure 1. Location of Major Components .................................................................................... 0002-1

Figure 2. Location of Major Components .................................................................................... 0002-2

Chapter 2 – Diesel Engine Check-in and Inventory

Diesel Engine Check-in and Inventory

Table 1. Diesel Engine Check-In ................................................................................................ 0003-3

Chapter 3 – Maintenance Instructions for Diesel Engine

Remove Engine from Shipping Container

Figure 1. Container, Shipping and Storage, Engine ................................................................... 0004-2

Table 1. Engine Shipping/Storage Container Item Number Descriptions ................................... 0004-3

Figure 2. Container Depressurization ......................................................................................... 0004-4

Figure 3. Attaching Sling ............................................................................................................. 0004-4

Figure 4. Upper Container Half Removal .................................................................................... 0004-5

Figure 5. Engine Sling to Engine Installation .............................................................................. 0004-6

Figure 6. Rear Engine Mount to Case Removal ......................................................................... 0004-7

Figure 7. Front Mount Removal .................................................................................................. 0004-7

Figure 8. Lifting Engine ............................................................................................................... 0004-8

Figure 9. Engine on Blocks Placement ....................................................................................... 0004-9

Figure 10. Rear Engine Mount Removal ................................................................................... 0004-10

General Maintenance Instructions

Figure 1. Torque Wrench, Adapter, and Conversion Formula .................................................... 0005-6

Figure 2. Torque Wrench, Adapter, and Conversion Formula .................................................... 0005-6

Engine Disassembly

Figure 1. Left Flexible Exhaust Tube Removal ........................................................................... 0006-2

Figure 2. Left Exhaust Manifold Removal ................................................................................... 0006-2

Figure 3. Oil Cooler Bypass Host Removal ................................................................................ 0006-3

Figure 4. Engine Oil Cooler /Flanges Removal .......................................................................... 0006-3

Figure 5. Tube Removal.............................................................................................................. 0006-3

Figure 6. Engine Oil Cooler Clamps and Hose Removal............................................................ 0006-4 iv

Figure 7. Engine Oil Cooler Removal ......................................................................................... 0006-4

Figure 8. Engine Oil Cooler Support Removal ............................................................................ 0006-5

Figure 9. Clamp Removal ........................................................................................................... 0006-5

Figure 10. Oil Cooler Removal .................................................................................................... 0006-6

Figure 11. Seal Removal............................................................................................................. 0006-6

Figure 12. Fitting Removal .......................................................................................................... 0006-7

Figure 13. Clamp Removal ......................................................................................................... 0006-7

Figure 14. Preformed Packing Removal ..................................................................................... 0006-8

Figure 15. Oil Cooler Support Removal ...................................................................................... 0006-8

Figure 16. Seal Removal............................................................................................................. 0006-9

Figure 17. Ring Spacer and Spring Removal ............................................................................. 0006-9

Figure 18. Left Water Header Cover/Gasket Removal ............................................................. 0006-10

Figure 19. Adapter Installation .................................................................................................. 0006-10

Figure 20. Engine to Stand Installation ..................................................................................... 0006-11

Figure 21. Engine Sling Removal ............................................................................................. 0006-12

Figure 22. Screw and Retainer Removal .................................................................................. 0006-12

Figure 23. Preformed Packing Removal ................................................................................... 0006-13

Figure 24. Pipe Plug and Clamp Removal ................................................................................ 0006-13

Figure 25. Clamp Removal ....................................................................................................... 0006-14

Figure 26. Clamp Removal ....................................................................................................... 0006-14

Figure 27. Clamp Removal ....................................................................................................... 0006-15

Figure 28. Tube Removal ......................................................................................................... 0006-15

Figure 29. Tube Removal ......................................................................................................... 0006-16

Figure 30. Mounting Bracket Hardware Removal ..................................................................... 0006-16

Figure 31. Transmission Fluid Cooler Removal ........................................................................ 0006-17

Figure 32. Mounting Bracket Removal ...................................................................................... 0006-17

Figure 33. Gasket Removal ...................................................................................................... 0006-18

Figure 34. Gasket Removal ...................................................................................................... 0006-18

Figure 35. Tube and Gasket Removal ...................................................................................... 0006-19

Figure 36. Hose and Clamp Removal ....................................................................................... 0006-19

Figure 37. Oil Cooler Cover and Support Removal .................................................................. 0006-20

Figure 38. Thermostat Housing Removal ................................................................................. 0006-20

Figure 39. Gasket Removal ...................................................................................................... 0006-20

Figure 40. Seal and Plug Removal ........................................................................................... 0006-21 v

Figure 41. Step Timing Control Wiring Harness Removal ........................................................ 0006-21

Figure 42. Step Timing Control Wiring Harness Removal ........................................................ 0006-22

Figure 43. Step Timing Control Wiring Harness Removal ........................................................ 0006-22

Figure 44. Time Delay Removal ............................................................................................... 0006-23

Figure 45. Cold Start Tube Removal ........................................................................................ 0006-23

Figure 46. Smoke Generator Hose Removal ............................................................................ 0006-24

Figure 47. Smoke Generator Hose Removal ............................................................................ 0006-24

Figure 48. Smoke Generator Tube Removal ............................................................................ 0006-25

Figure 49. Smoke Generator Tube Removal ............................................................................ 0006-25

Figure 50. Smoke Generator Tube Removal ............................................................................ 0006-25

Figure 51. Smoke Generator Tube Removal ............................................................................ 0006-26

Figure 52. Smoke Generator Tube Removal ............................................................................ 0006-26

Figure 53. STC Oil Supply Tube Removal ................................................................................ 0006-27

Figure 54. STC Oil Supply Tube Removal ................................................................................ 0006-27

Figure 55. STC Oil Supply Hose Removal................................................................................ 0006-28

Figure 56. STC Oil Supply Hose Removal................................................................................ 0006-28

Figure 57. STC Tube Removal ................................................................................................. 0006-29

Figure 58. STC Tube Removal ................................................................................................. 0006-29

Figure 59. STC Tube Removal ................................................................................................. 0006-30

Figure 60. STC Hose Removal ................................................................................................. 0006-30

Figure 61. STC Hose Removal ................................................................................................. 0006-31

Figure 62. STC Hose Removal ................................................................................................. 0006-31

Figure 63. STC Tube Removal ................................................................................................. 0006-32

Figure 64. STC Tube Removal ................................................................................................. 0006-32

Figure 65. STC Hose Removal ................................................................................................. 0006-33

Figure 66. Cold Start Tube Removal ........................................................................................ 0006-34

Figure 67. Cold Start Tube Removal ........................................................................................ 0006-34

Figure 68. Cold Start Tube Removal ........................................................................................ 0006-35

Figure 69. Cold Start Tube Removal ........................................................................................ 0006-35

Figure 70. Fuel Tube Removal ................................................................................................. 0006-36

Figure 71. Crankcase Breather Removal .................................................................................. 0006-36

Figure 72. Starting Aid Nozzle Removal ................................................................................... 0006-37

Figure 73. Cold Start Solenoid Removal ................................................................................... 0006-37

Figure 74. Cold Start Solenoid Removal ................................................................................... 0006-38 vi

Figure 75. Cold Start Solenoid Removal ................................................................................... 0006-38

Figure 76. Smoke Generator Solenoid Removal ...................................................................... 0006-39

Figure 77. Smoke Generator Solenoid Removal ...................................................................... 0006-39

Figure 78. STC Control Solenoid/Housing Removal ................................................................ 0006-40

Figure 79. STC Control Solenoid/Housing Removal ................................................................ 0006-40

Figure 80. STC Control Solenoid/Housing Removal ................................................................ 0006-41

Figure 81. Engine Oil Filler Cap Removal................................................................................. 0006-41

Figure 82. Rocker Arm Cover/Gasket Removal ....................................................................... 0006-42

Figure 83. Right Flexible Exhaust Tube Removal .................................................................... 0006-42

Figure 84. Right Exhaust Manifold Removal............................................................................. 0006-43

Figure 85. Turbocharger Oil Drain Tube Removal .................................................................... 0006-43

Figure 86. Turbocharger Oil Drain Tube Removal .................................................................... 0006-44

Figure 87. Turbocharger Removal ............................................................................................ 0006-44

Figure 88. Turbocharger Removal ............................................................................................ 0006-45

Figure 89. Turbocharger Removal ............................................................................................ 0006-45

Figure 90. Turbocharger Removal ............................................................................................ 0006-46

Figure 91. Turbocharger Exhaust Collector Removal ............................................................... 0006-46

Figure 92. Coolant Inlet Tube/Hose Removal ........................................................................... 0006-47

Figure 93. Coolant Outlet Hose/Tube Removal ........................................................................ 0006-47

Figure 94. Aftercooler Drain Tube Removal ............................................................................. 0006-48

Figure 95. Aftercooler Removal ................................................................................................ 0006-48

Figure 96. Aftercooler Removal ................................................................................................ 0006-49

Figure 97. Aftercooler Removal ................................................................................................ 0006-49

Figure 98. Intake Manifold Removal ......................................................................................... 0006-50

Figure 99. Intake Manifold Removal ......................................................................................... 0006-50

Figure 100. Intake Manifold Removal ....................................................................................... 0006-50

Figure 101. Oil Feed Hose and Bracket Removal .................................................................... 0006-51

Figure 102. Oil Feed Hose and Bracket Removal .................................................................... 0006-51

Figure 103. Oil Feed Hose and Bracket Removal .................................................................... 0006-51

Figure 104. Oil Feed Hose and Bracket Removal .................................................................... 0006-52

Figure 105. Oil Feed Hose and Bracket Removal .................................................................... 0006-52

Figure 106. Engine Oil Dipstick Removal ................................................................................. 0006-53

Figure 107. Engine Oil Dipstick Removal ................................................................................. 0006-53

Figure 108. Engine Oil Dipstick Removal ................................................................................. 0006-54 vii

Figure 109. Transmission Coupling Removal ........................................................................... 0006-54

Figure 110. Transmission Coupling Removal ........................................................................... 0006-55

Figure 111. Flywheel Removal ................................................................................................. 0006-55

Figure 112. Flywheel Removal ................................................................................................. 0006-56

Figure 113. Rear Crankshaft Seal Removal ............................................................................. 0006-56

Figure 114. Rear Crankshaft Seal Removal ............................................................................. 0006-57

Figure 115. Rear Crankshaft Seal Removal ............................................................................. 0006-57

Figure 116. Rear Crankshaft Seal Removal ............................................................................. 0006-58

Figure 117. Coolant Pump Belt Removal .................................................................................. 0006-58

Figure 118. Coolant Pump Belt Removal .................................................................................. 0006-59

Figure 119. Coolant Pump Belt Removal .................................................................................. 0006-59

Figure 120. Coolant Pump Belt Removal .................................................................................. 0006-60

Figure 121. Coolant Pump Removal ......................................................................................... 0006-60

Figure 122. Coolant Pump Removal ......................................................................................... 0006-61

Figure 123. Starter Removal ..................................................................................................... 0006-61

Figure 124. Left Water Header Cover Removal ....................................................................... 0006-62

Figure 125. Right Water Header Cover Removal ..................................................................... 0006-62

Figure 126. Right Water Header Cover Removal ..................................................................... 0006-63

Figure 127. Vibration Damper Removal .................................................................................... 0006-63

Figure 128. Vibration Damper Removal .................................................................................... 0006-64

Figure 129. Vibration Damper Removal .................................................................................... 0006-64

Figure 130. Vibration Damper Removal .................................................................................... 0006-65

Figure 131. Front Cover/Seal Removal .................................................................................... 0006-65

Figure 132. Front Cover/Seal Removal .................................................................................... 0006-66

Figure 133. Front Cover/Seal Removal .................................................................................... 0006-66

Figure 134. Front Cover/Seal Removal .................................................................................... 0006-67

Figure 135. Front Cover/Seal Removal .................................................................................... 0006-67

Figure 136. Camshaft Cover Gasket Removal ......................................................................... 0006-68

Figure 137. Manifold to AFT Tube Removal ............................................................................. 0006-68

Figure 138. Supply Tube Removal ........................................................................................... 0006-69

Figure 139. Supply Tube Removal ........................................................................................... 0006-69

Figure 140. Right Bank Fuel Supply Tube Removal ................................................................. 0006-70

Figure 141. Right Bank Fuel Supply Tube Removal ................................................................. 0006-70

Figure 142. Left Bank Fuel Supply Tube Removal ................................................................... 0006-71 viii

Figure 143. Left Bank Fuel Supply Tube Removal ................................................................... 0006-71

Figure 144. Left Bank Fuel Supply Tube Removal ................................................................... 0006-72

Figure 145. Fuel Pressure Switch Removal ............................................................................. 0006-72

Figure 146. Fuel Pressure Switch Removal ............................................................................. 0006-73

Figure 147. Check Valve Removal ........................................................................................... 0006-73

Figure 148. Check Valve Removal ........................................................................................... 0006-74

Figure 149. Check Valve Removal ........................................................................................... 0006-74

Figure 150. Fuel Drain Tube ..................................................................................................... 0006-75

Figure 151. Fuel Drain Tube ..................................................................................................... 0006-75

Figure 152. Fuel Drain Tube ..................................................................................................... 0006-76

Figure 153. Fuel Drain Tube ..................................................................................................... 0006-76

Figure 154. Check Valve Removal ........................................................................................... 0006-77

Figure 155. Check Valve Removal ........................................................................................... 0006-77

Figure 156. Check Valve Removal ........................................................................................... 0006-78

Figure 157. Check Valve Removal ........................................................................................... 0006-78

Figure 158. Fuel Pump Bypass Tube Removal ........................................................................ 0006-78

Figure 159. Fuel Pump Bypass Tube Removal ........................................................................ 0006-79

Figure 160. Fuel Pump Removal .............................................................................................. 0006-79

Figure 161. Fuel Pump Removal .............................................................................................. 0006-80

Figure 162. Fuel Pump Removal .............................................................................................. 0006-80

Figure 163. Fuel Pump Removal .............................................................................................. 0006-81

Figure 164. Fuel Pump Removal .............................................................................................. 0006-81

Figure 165. Fuel Pump Removal .............................................................................................. 0006-82

Figure 166. Fuel Pump Removal .............................................................................................. 0006-82

Figure 167. Support and Bushing Removal .............................................................................. 0006-83

Figure 168. Support and Bushing Removal .............................................................................. 0006-83

Figure 169. Support and Bushing Removal .............................................................................. 0006-84

Figure 170. Support and Bushing Removal .............................................................................. 0006-84

Figure 171. Support and Bushing Removal .............................................................................. 0006-85

Figure 172. Support and Bushing Removal .............................................................................. 0006-85

Figure 173. Fuel Injector Removal ............................................................................................ 0006-86

Figure 174. Fuel Injector Removal ............................................................................................ 0006-86

Figure 175. Fuel Injector Removal ............................................................................................ 0006-87

Figure 176. Fuel Injector Removal ............................................................................................ 0006-87 ix

Figure 177. Fuel Injector Removal ............................................................................................ 0006-88

Figure 178. Right Cylinder Head Removal ............................................................................... 0006-89

Figure 179. Right Cylinder Head Removal ............................................................................... 0006-89

Figure 180. Right Cylinder Head Removal ............................................................................... 0006-90

Figure 181. Right Cylinder Head Removal ............................................................................... 0006-90

Figure 182. Right Cylinder Head Removal ............................................................................... 0006-91

Figure 183. Right Cylinder Head Removal ............................................................................... 0006-91

Figure 184. Right Cylinder Head Removal ............................................................................... 0006-91

Figure 185. Right Cylinder Head Removal ............................................................................... 0006-92

Figure 186. Right Cylinder Head Removal ............................................................................... 0006-92

Figure 187. Right Cylinder Head Removal ............................................................................... 0006-93

Figure 188. Right Cylinder Head Removal ............................................................................... 0006-93

Figure 189. Right Cylinder Head Removal ............................................................................... 0006-94

Figure 190. Right Cylinder Head Removal ............................................................................... 0006-94

Figure 191. Left Cylinder Head Removal .................................................................................. 0006-95

Figure 192. Left Cylinder Head Removal .................................................................................. 0006-96

Figure 193. Left Cylinder Head Removal .................................................................................. 0006-96

Figure 194. Left Cylinder Head Removal .................................................................................. 0006-97

Figure 195. Left Cylinder Head Removal .................................................................................. 0006-98

Figure 196. Left Cylinder Head Removal .................................................................................. 0006-98

Figure 197. Left Cylinder Head Removal .................................................................................. 0006-98

Figure 198. Left Cylinder Head Removal .................................................................................. 0006-99

Figure 199. Left Cylinder Head Removal .................................................................................. 0006-99

Figure 200. Left Cylinder Head Removal ................................................................................ 0006-100

Figure 201. Left Cylinder Head Removal ................................................................................ 0006-100

Figure 202. Left Cylinder Head Removal ................................................................................ 0006-101

Figure 203. Left Cylinder Head Removal ................................................................................ 0006-101

Figure 204. Left Cylinder Head Removal ................................................................................ 0006-102

Figure 205. Left Cylinder Head Removal ................................................................................ 0006-102

Figure 206. Engine Oil Pan Removal ...................................................................................... 0006-103

Figure 207. Engine Oil Pan Removal ...................................................................................... 0006-103

Figure 208. Engine Oil Pan Removal ...................................................................................... 0006-104

Figure 209. Engine Oil Pan Removal ...................................................................................... 0006-104

Figure 210. Engine Oil Pan Removal ...................................................................................... 0006-105 x

Figure 211. Engine Oil Pan Removal ...................................................................................... 0006-105

Figure 212. Oil Pump Removal ............................................................................................... 0006-106

Figure 213. Oil Pump Removal ............................................................................................... 0006-106

Figure 214. Oil Pump Removal ............................................................................................... 0006-107

Figure 215. Oil Pump Removal ............................................................................................... 0006-107

Figure 216. Flywheel and Gear Housing Removal ................................................................. 0006-109

Figure 217. Flywheel and Gear Housing Removal ................................................................. 0006-110

Figure 218. Piston Assembly Removal ................................................................................... 0006-110

Figure 219. Piston Assembly Removal ................................................................................... 0006-111

Figure 220. Piston Assembly Removal ................................................................................... 0006-111

Figure 221. Piston Assembly Removal ................................................................................... 0006-112

Figure 222. Piston Assembly Removal ................................................................................... 0006-112

Figure 223. Piston Assembly Removal ................................................................................... 0006-113

Figure 224. Piston Assembly Removal ................................................................................... 0006-113

Figure 225. Piston Assembly Removal ................................................................................... 0006-114

Figure 226. Liner Assembly Removal ..................................................................................... 0006-115

Figure 227. Liner Assembly Removal ..................................................................................... 0006-115

Figure 228. Liner Assembly Removal ..................................................................................... 0006-116

Figure 229. Liner Assembly Removal ..................................................................................... 0006-116

Figure 230. Camshaft and Gear Housing Removal ................................................................ 0006-117

Figure 231. Camshaft and Gear Housing Removal ................................................................ 0006-118

Figure 232. Pin, Dowel, and Sleeve Bushing Removal .......................................................... 0006-118

Figure 233. Camshaft and Internal Parts Removal ................................................................. 0006-119

Figure 234. Camshaft and Internal Parts Removal ................................................................. 0006-120

Figure 235. Camshaft and Internal Parts Removal ................................................................. 0006-121

Component Inspection

Figure 1. Check Top and Second Ring ....................................................................................... 0007-6

Figure 2. Piston Diameter Measured .......................................................................................... 0007-7

Figure 3. Pin Diameter Measured ............................................................................................... 0007-7

Figure 4. Liner Inspection ........................................................................................................... 0007-8

Figure 5. Inside Diameter Measured ........................................................................................... 0007-9

Figure 6. Liner Counterbore Measurement ................................................................................. 0007-9

Figure 7. Lower Bore Measurement ........................................................................................... 0007-9

Figure 8. Counterbore Measurement on Cylinder Block ........................................................... 0007-10 xi

Figure 9. Liner Installation ......................................................................................................... 0007-11

Figure 10. Liner Installation in Counterbore .............................................................................. 0007-11

Figure 11. Piston to Liner Inspection ........................................................................................ 0007-12

Figure 12. Liner Clamp Installation ........................................................................................... 0007-13

Figure 13. Liner Protrusion Height Measurement ..................................................................... 0007-15

Figure 14. Liner Removed ........................................................................................................ 0007-15

Figure 15. Oil Pressure Valve Inspection .................................................................................. 0007-17

Figure 16. Transmission Cooler Inspection .............................................................................. 0007-17

Figure 17. Air Plate Cover Installation ...................................................................................... 0007-18

Figure 18. Fluid Cooler Pressurized ......................................................................................... 0007-19

Figure 19. Air Plate Cover Removal ......................................................................................... 0007-20

Figure 20. Bushing Measurement ............................................................................................. 0007-21

Figure 21. Rocker Arm Inspection ............................................................................................ 0007-22

Figure 22. Injector Rocker Arm Link Inspection ........................................................................ 0007-23

Figure 23. Shaft Inspection ....................................................................................................... 0007-24

Figure 24. Support Inspection ................................................................................................... 0007-24

Figure 25. Crosshead Inspection .............................................................................................. 0007-25

Figure 26. Contact Surface Inspection ...................................................................................... 0007-25

Figure 27. Valve Stem Inspection ............................................................................................. 0007-26

Figure 28. Bore Measurement .................................................................................................. 0007-27

Figure 29. Screw Measurement ................................................................................................ 0007-27

Figure 30. Socket End of Push Rod Inspection ........................................................................ 0007-28

Figure 31. Tappet Inspection and Measurement ...................................................................... 0007-29

Figure 32. Socket Inspection .................................................................................................... 0007-30

Figure 33. Ball End of Push Rod Inspection ............................................................................. 0007-30

Figure 34. Push Rod Bend Inspection ...................................................................................... 0007-31

Figure 35. Camshaft, Gear, and Thrust Plate Inspection ......................................................... 0007-31

Table 1. Overhaul Inspection Procedure (OIP 3063041) .......................................................... 0007-33

Table 2. Overhaul Inspection Procedure (OIP 214940) ............................................................ 0007-34

Table 2. Overhaul Inspection Procedure (OIP 214940) – Continued ....................................... 0007-35

Cleaning

Repair of Engine Block

Figure 1. Engine Block ................................................................................................................ 0009-2

Table 1. Engine Block Item Number Descriptions ...................................................................... 0009-3 xii

Table 2. Cylinder Block (OIP 3063701) ...................................................................................... 0009-6

Figure 2. Tools ............................................................................................................................ 0009-9

Figure 3. Measurements ........................................................................................................... 0009-10

Table 3. Measurements ............................................................................................................ 0009-11

Figure 4. Cylinder Blocks with Counterbore Cracks ................................................................. 0009-11

Figure 5. Counterbore Depth Measurement ............................................................................. 0009-12

Figure 6. Counterbore Radial Cracks ....................................................................................... 0009-12

Figure 7. Bores .......................................................................................................................... 0009-14

Figure 8. Measurements ........................................................................................................... 0009-15

Figure 9. Cylinder Sleeve Counterbore…