*TM 9-2815-200-35

DEPARTMENT

OF

THE

ARMY

TECHNICAL

MANUAL

DIRECT AND

SUPPORT,

GENERAL

SUPPORT MANUAL

DEPOT

MAINTENANCE REPAIR TOOLS

INCLUDING AND

PARTS LISTS

SPECIAL

FOR

ENGINE,

WITH

CONTAINER: DIESEL,

TURBOSUPERCHARGED, FUEL 90-DEGREE V

I N .J E C T I O N , TYPE, AIR-COOLED,

12-CYLINDER, MODELS

ASSEMBLY; (2815-856-4996),

AVDS-1790-2M AND

AVDS-1790-2A

AVDS-1790-2AM

(2815-856-9005)
H E A D Q U A R T E R S , D E P A R T M E N T 15 OCTOBER 1970 O F T H E A R M Y

ERRATA SHEET TM 9-2815-200-35, 15 October 1970 To all account holders of DA Form 12-37, Direct and General Support Maintenance requirements for Tanks, M60, M60A1, M48A3; Combat Engineer Vehicle M728 and Launcher, M60A1 Tank Chassis Transporting: You have received printed copies of TM 9-2815-200-34, TM 9-2815-200-35 and TM 9-2815-200-35P dated 15 October 1970. These three manuals are actually one manual and the correct number is TM 9-2815-200-35. Remove all covers and destroy covers designated TM 9-2815-200-34 and TM 9-2815-200-35P. Assemble manual in numerical order with cover for

TM 9-2815-200-35 as the basic cover.

CAUTION/WARNING
Caution: The splined coupler halves are a matched set. Damage or wear to the sleeve or hub of either coupling half requires the replacement of a complete coupler assembly. (Figure 4-59)

Caution: Overtightening will damage tube ferrule causing fuel leaks. (Figure 4-86)

Caution: Do not run engine above idle and not longer than ten minutes without cooling fans. (Figure 4-87)

Warning: The valve cover is spring loaded. Exercise care when removing cover. (Figure 4-93)

Caution: Check to be certain the original seating gasket has been removed and discarded before installing a new gasket on the nozzle. The inadvertent installation of two seating gaskets would damage the nozzle retainer spring. (Figure 4-1 53) ... Caution: Do not damage sealing surface on flange of intercylinder preformed hose as it will cause oil leaks and replacement of hose will be required. (Figure 4-157) . . .. Warning: When only one cylinder is checked, there is the possibility of the engine firing on the other cylinders when compression check is being made. To prevent engine firing, remove all nozzles then check cylinder compression. Unless all nozzles are removed, the engine motoring rpm will be below desired cylinder checking rpm. (Paragraph 4-22a)

Caution: Make certain the improvised tool is properly secured before removing housing and that the fan drive housing is being lifted straight up off the studs. (Figure 5-124)

Caution: Use care in removing the flywheel from the dowel pins so as not to bind the flywheel on the pins. (Figure 5-162)

Warning: Particles blown by compressed air are hazardous. Make certain air stream is directed away from user and that other persons are not exposed. Protect eyes and face with appropriate shields. (Paragraph 6-2b(4)) I [

Caution: Do not attempt to preheat by using welding torch. (Paragraph 6-4c(5 ) )

CAUTION / WARNING Continued

Warning: Use goggles, rubber gloves, and rubber apron when cleaning parts in carbon removing compound. Provide adequate ventilation. Avoid inhalation of fumes and skin contact. If compound is splashed on skin, flush with fresh water and wash with alcohol, Alcohol containing 2 to 3 percent camphor is preferable. (Paragraph 6-24a(1) )

Warning: The valves and locks are under heavy spring tension. Exercise extreme care when removing locks, retainers, and springs. (Figure 6-48 )

Caution: Do not use an arbor press to remove ball bearings from drive cluster gear. The gear is designed with a shoulder between the two bearings. (Figure 6-83)

Caution: The piston oil cooling valve is a spring loaded assembly. Exercise care when disassembling. (Figure 6-86 )

Warning: The oil pressure regulator cover is spring loaded. Exercise care when removing cover. (Figure 6-103)

Caution: Do not attempt to remove the diaphragm drive coupler half from the shaft using a standard puller as shown in figure 6-163. This may distort the coupler and render it unserviceable. Use puller as shown. (Figure 6-165)

Caution: Use extreme care in this operation to prevent damage to vane cover on gearshaft. (Paragraph 6-42a(6) (c))

Warning: Cleaning solvents and solvent cleaning compounds are toxic and flammable and must be used only in a well ventilated room. Take adequate safe guards for fire prevention in work area. Use protective clothing and avoid contact of these solutions with the skin. (Paragraph 6-47c(3 ) )

Caution: If lubricant is extended to face of washer nut, reliable retaining torque cannot be obtained. (Figure 7-13)

Caution: The fuel injector pump advance assembly must always be installed and secured before operating test stand. (Paragraph 6-42, d., (4), (g) )

Caution: Do not operate the starter motor continuously for more than one minute. Allow a two-minute cool-off period before re-energizing the starter. (Paragraph 8-4c)

*TM 9-2815-200-35 TECHNICAL MANUAL No. 9-2815-200-35 HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D. C. 20025, 15 October 1970

DIRECT SUPPORT, GENERAL SUPPORT, AND DEPOT MAINTENANCE MANUAL INCLUDING REPAIR PARTS AND SPECIAL TOOLS LISTS FOR

ENGINE, WITH CONTAINER: TURBOSUPERCHARGED, DIESEL, FUEL INJECTION, 90-DEGRE "V"TYPE, AIR COOLED, 12 CYLINDER, ASSEMBLY; MODELS AVDS-1790-2M (2815-856-4996), AVDS-1790-2A AND AVDS-1790-2AM (2815-856-9005)

Paragraphs

CHAPTER 1.
Section I. Section II.

INTRODUCTION General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1-5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6-1-25 PARTS, SPECIAL TOOLS AND E Q U I P M E N T , 1-1 1-2

CHAPTER 2.
Section I. Section II. Section III.

IMPROVISED TOOLS AND SHOP LAYOUT

Repair and replacement parts . . . . . . . . . . . . . . . . . . . . . 2-1-2-3 Special tools and equipment for direct support, general support and depot maintenance . . . . . . . . . . . . . . . . . . . 2-4-2-6 Shop layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-2-8 TROUBLESHOOTING General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3-1-3-2 Troubleshooting procedures . . . . . . . . . . . . . . . . . . . . . . 3-3-3-11 REPLACEMENT OF ENGINE ACCESSORIES, COMPONENTS AND RELATED SERVICE OPERATIONS 4-1 4-2 3-1 3-1 2-1 2-1 2-7

CHAPTER 3.
Section I. Section II.

CHAPTER

4.

Section I. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14-2 Section II. Removal or installation of engine accessories . . . . . . 4-34-4 This manual supersedes TM 9-2815-200-34 dated February 1963, TM 92815-200-35 dated August 1960 and TM 9-2815-200-35P dated November 1962 and all published changes thereto.

Section III.

Section IV. Section V. Section VI. Section VII. Section VIII. Section IX. Section X.

Paragraphs Replacement of main and auxiliary oil filter by pass valve, oil pressure regulator valve and fuel/water separator filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5-4-6 Replacement of cooling fan clutch assembly and fan drive housing outer flange bearing . . . . . . . . . . . . . . . . . . . . . . 4-7-4-8 Replacement of intake manifold tubes and intake manifold assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9-4-11 Replacement of engine oil pan . . . . . . . . . . . . . . . . . . . . . 4-12-4-13 Replacement of valve rocker arms, rocker arm shafts, and valve clearance adjusting screws . . . . . . . . . . . . . . . . . 4-14-4-15 Overhaul of fuel injector nozzle and holder assembly . . . 4-16-4-18 Replacement of flywheel and crankshaft oil seal . . . . . . . 4-19-4-20 Service operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21-4-23

4-44 4-50 4-53 4-58 4-62 4-80 4-88 4-93

CHAPTER 5.
Section I. Section II.

DISASSEMBLY OF ENGINE
Preparation of engine for disassembly . . . . . . . . . . . . . . . Installation of engine on overhaul stand for disassembly into subassemblies . . . . . . . . . . . . . . . . . . . . . . . 5-1-5-3 5-4-5-15 5-1 5-3

CHAPTER 6 . Section I.

OVERHAUL OF ENGINE COMPONENTS

6-1 6-10 6-33

ii

General cleaning, inspection, repair, and assembly 6-1-6-7 procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhaul of crankcase assembly, transmission adapter, and Section II. starter and generator drive components . . . . . . . . . . . 6 - 8 - 6 - 1 3 Section III. Overhaul of connecting rod, crankshaft, and associated parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14-6-18 Section IV. Overhaul of torsional vibration damper, flywheel, accessory drive gear, and transmission drive gearshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6-19-6-21 S e c t i o n V . Overhaul of pistons, rings, and piston pins . . . . . . . . . 6-22-6-27 Section VI. Overhaul of cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . 6-28-6-34 Section VII. Overhaul of oil pump, oil pan, damper and oil filter housing and associated parts.... . . . . . . . . . . . . . . . . . . . . . . . ..6-35-6-38 Section VIII. Overhaul of front fan drive housing and clutch assembly 6-39-6-40 Section IX. Overhaul of rear fan drive housing and clutch assembly and accessory drive housing . . . . . . . . . . . . . . . . . . . . . . . . . .6-41-6-42 S e c t i o n X . Overhaul of camshaft and throttle control cross shaft and fuel injection pump linkage . . . . . . . . . . . . . . . . . . . . . . 6-43-6-45 Section XI. Overhaul of engine and transmission oil coolers and engine cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46-6-48 Section XII. Overhaul of engine shrouding and associated parts . . . .6-49-6-50 Section XIII. Overhaul of intake manifolds, exhaust manifolds and tubes, cylinder head oil drain tubes, and oil filler and indicator tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6-51-6-53 Section XIV. Overhaul of generator and starter supports, fuel check valve, primary and secondary fuel filters, and fuel /water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6-54-6-58 Section XV. Overhaul of fuel injection pump fuel tubes, fuel injector nozzle fuel return tubes, injection pump and turbosupercharger oil hoses, and generator air intake and exhaust tubes and associated parts . . . . . . . . . . . . . . . . . . . . . . ..6-59-6-62

6-42 6-47 6-51 6-75 6-108 6-134 6-173 6-184 6-191

6-193

6-201

6-209

Paragraphs Overhaul of crankcase breather tubes, fire extinguisher tube, injection pump electrical lead, and manifold heater fuel tubes, filter, and electrical components . . . . . . . . . . . 6-636-65 Section XVII. Overhaul of fuel injection pump drive couplers, fuel injector nozzles, piston oiler nozzles, and time totalizing meter . 6-66-6-70 Section XVI.

Pages

6-213 6-214

CHAPTER 7.
Section I. Section II.

ASSEMBLY OF ENGINE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-7-3 Assembly of engine from subassemblies 7-4-7-17 7-1 7-2

CHAPTER 8.
Section I. Section II.

ENGINE TEST AND ENGINE CONTAINER

8-1 8-13 9-1 A-1

Engine test and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-8-7 Engine and container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8-8-8-11 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX A. APPENDIX B.

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIRECT SUPPORT, GENERAL SUPPORT, AND DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST

B-1 Section I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 S e c t i o n I I . Repair parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 01 -Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 0100 - Engine assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12 0101 - Crankcase, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15 0102 - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18 0103 - Flywheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104 - Pistons, connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18 0105 - Valves, camshafts and timing system . . . . . . . . . . . . . . . . . . . B-20 0106 - Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . B-27 0108 - Manifolds and connecting parts . . . . . . . . . . . . . . . . . . . . . B-53 0109 - Accessory driving mechanisms and related pa; . . . . . . . . B-57 03 -Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-68 0301 - Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-68 0302 - Fuel pumps, lines and fittings . . . . . . . . . . . . . . . . . . . . . . . B-74 0305 - Turbosupercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-78 0308 - Engine speed governor and controls . . . . . . . . . . . . . . . . B-81 0309 - Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-84 0311 - Engine starting aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-89 05 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-94 0502 -Deflectors and shrouds . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-94 0505 - Fanassembly . . . . . . . . . . . . . . . . . . . . . . . . . B-103 06 -Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-113 0601 - Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-113 B-116 0603 - Starting mater 0610 - Sending units and warning switches . . . . . . . . . . . . . . B-117 33 -Special purpose kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-118 3301 - Reusable shipping containers . . . . . . . . . . . . . . . . B-118

iii

Paragraphs Pages

Section III.

Section IV. Section V.

42 - Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-119 4210 - Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-119 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-120 26 - Tools and test equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-120 2604 . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-120 General use standardized parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-125 Federal stock number and ordnance part number indexes . . . . . . . . . . . B-145

iv

LIST OF ILLUSTRATIONS
Figure Number 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 1-15 1-16 2-1 2-2 2-3 2-4 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 Title AVDS-1790-2M, AVDS-1790-2AM, and AVDS-1790-2A engine assembly without time totalizing meter-right front view. AVDS-1790-2M, AVDS-1790-2AM, and AVDS-1790-2A engine assembly with secondary fuel filter-left front view. AVDS-1790-2M, AVDS-1790-2AM, and AVDS-1790-2A engine assembly with secondary fuel filter-front view. AVDS-1790-2A engine assembly with time totalizing meter-right front view. AVDS-1790-2A engine assembly with fuel/ water separator filter-left front view. AVDS-1790-2A engine assembly with fuel/ water separator filter-front view. AVDS-1790-2A engine assembly with relocated oil filler tube-rear view. Engine major working parts-schematic diagram. Engine lubrication system. Engine oil flow control-schematic diagram. Main fuel system-schematic diagram. Manifold air induction heater system-schematic diagram. Piston actuated cooling fan clutch-sectional view. Mechanical cooling fan clutch-sectional view. Early crankcase breather and fire extinguisher system. Late crankcase breather and fire extinguisher system. Improvised tools-ring compressor, and lifting tool. Improvised tool-coupling puller. Improvised tool-valve sleeve remover. Typical shop layout. Disconnecting or connecting fuel hose at fuel pump outlet adapter and fuel pump inlet tube at fuel pump. Disconnecting or connecting fuel pump. Removing or installing fuel pump. Removing or installing starter solenoid jumper lead. Removing starter retaining U bolt. Removing starter support and cradle. Removing or installing starter mounting nuts using open end wrench-5120678-5288. Removing or installing starter assembly. Installing starter support, cradle, and U bolt, Disconnecting or connecting time totalizing meter electrical lead at generator. Removing or installing generator air intake tube. Removing generator support, cradle, and U bolt. Disconnecting or connecting cylinder head right rear oil drain tube and generator boot hose clamps. Loosening or tightening generator mounting nuts using box wrench-5120789-4881. Removing or installing generator and boot. Removing or installing generator gasket. Installing generator support, cradle, and U bolt. Page ... xxviii xxix xxx xxxi xxxii ... xxxiii xxxiv 1-5 1-9 1-11 1-13 1-15 1-17 1-18 1-19 1-20 2-2 2-3 2-4 2-7 4-2 4-3 4-3 4-3 4-4 4-4 4-4 4-5 4-5 4-6 4-6 4-7 4-7 4-8 4-8 4-9 4-9

Figure Number Title Loosening or tightening oil filler upper and lower tube hose connection 4-18 (relocated oil filler tube installation ). Removing or installing upper oil filler tube (relocated oil filler tube in4-19 stallation ). Removing or installing crankcase rear breather tube and lower left rear 4-20 shroud plate. Removing or installing upper oil filler tube support bracket and tur4-21 bosupercharger end shroud. Disconnecting or connecting turbosupercharger oil inlet hose elbow from 4-22 nipple using open end wrench-5120-448-0404. Removing or installing turbosupercharger outer shroud plate. 4-23 Removing or installing oil inlet hose, elbow, and nipple. 4-24 Removing or installing generator exhaust tube cap (right side only). 4-25 Removing or installing generator exhaust tube support clamp (right side 4-26 only). 4-27 Removing or installing generator exhaust tube (right side only). 4-28 Disconnecting or connecting inner shroud plate (rear view). 4-29 Removing or installing transmission oil cooler end shroud and inner shroud plate. Disconnecting or connecting turbosupercharger oil drain tube at tur4-30 bosupercharger. Disconnecting or connecting turbosupercharger air outlet elbow. 4-31 Disconnecting or connecting turbosupercharger at mounting base. 4-32 Disconnecting or connecting exhaust pipes at turbine housing and removing 4-33 or installing turbosupercharger. 4-34 Removing or installing cooling fan vanes. 4-35 Removing or installing cooling fans. 4-36 Disconnecting or connecting front end of cooling fan shroud. 4-37 Disconnecting or connecting cooling fan shroud on top frame. Disconnecting or connecting rear end of cooling fan shroud and removing or 4-38 installing cooling fan shroud and fan housings. 4-39 Fuel injection pump-installed view. 4-40 Removing or installing left rear upper cover. Removing or installing fuel injector left tube clamps. 4-41 4-42 Removing or installing fuel injector right tube clamps. Fuel injector tubes-installed view. 4-43 Disconnecting fuel injector tubes from fuel injection pump. 4-44 Disconnecting or connecting crankcase breather tube, electrical lead, throttle 4-45 control, and fuel return hose-engines prior to relocated crankcase breather tube. 4-46 Disconnecting or connecting throttle control, fuel return hose, and electrical lead-engines with relocated crankcase breather tube. 4-47 Disconnecting or connecting crankcase breather tube at front of engine. 4-48 Disconnecting or connecting rear intermediate crankcase breather tube at tube tee-engines prior to relocated crankcase breather tube. Removing or installing angle bracket from fuel injection pump. 4-49 Disconnecting or connecting fuel injection pump oil and fuel inlet hoses 4-50 Positioning fuel injection pump coupler by turning flywheel using splined 4-51 wrench - 5120-793-7895.

Page 4-10 4-10 4-11 4-12 4-12 4-13 4-13 4-14 4-14 4-15 4-15 4-16 4-16 4-16 4-17 4-17 4-18 4-18 4-19 4-20 4-20 4-21 4-21 4-22 4-23 4-24 4-24

4-25 4-25 4-26 4-26 4-26 4-26 4-27

vi

Figure Number 4-52 4-53 4-54 4-55 4-56 4-57 4-58 4-59 4-60 4-61 4-62 4-63 4-64 4-65 4-66 4-67 4-68 4-69 4-70 4-71 4-72 4-73 4-74 4-75 4-76 4-77 4-78 4-79 4-80 4-81 4-82 4-83 4-84 4-85 4-86

Title Removing fuel injection pump splined coupler bolts. Separating fuel injection pump coupler sleeves. Removing fuel injection pump diaphragm coupler bolts. Removing or installing fuel injection pump mounting bolts and breather tube bracket-engines with breather tube routed around injection pump. Separating fuel injection pump diaphragm coupler and removing or installing fuel injection pump mounting bolts Removing fuel injection pump and preformed packing-splined coupler. Removing fuel injection pump and preformed packing-diaphragm coupler. Removing fuel injection pump front splined coupler sleeve nut and lock washer. Removing fuel injection pump diaphragm coupler nut and lock washer. Removing fuel injection pump splined coupler sleeve and hub. Removing fuel injection pump diaphragm coupler. Installing coupler half and torque tightening fuel injection pump splined coupler nut. Installing coupler half and torque tightening fuel injection pump diaphragm coupler nut. Removing or installing fuel injection pump timing hole plug. Fuel injection pump timing hole cover removed showing marked gear tooth in timed position. Timing marks on fuel injection bearing retaining plate and splined coupler hub alined. Timing marks on fuel injection pump bearing retaining plate and diaphragm coupler hub alined. Disconnecting or connecting primary fuel filter drain line. Removing or installing primary fuel filter bracket and throttle linkage, Flywheel in position for fuel injection pump timing (Models AVDS-1790-2M and AVDS-1790-2AM only). Flywheel in position for fuel injection pump timing (Model AVDS-1790-2A only ) Position of camshaft lobes for injection pump timing.. Installing preformed packing (B) on mounting base oil transfer tube. Correct position of fuel injection pump drive coupler on hub before pump installation. Fuel injection pump diaphragm coupling and pilot ring on hub before pump installation. Installing fuel injection pump assembly on engine. Positioning fuel injection pump coupler sleeves-splined coupler. Removing fuel injection pump drive gear train backlash and setting advanced unit retard position-splined coupler. Fuel injection pump splined drive coupler with lubrication fitting installed. Checking diaphragm coupler assembly clearance. Removing fuel injection pump drive gear train backlash and setting advance unit retard positiondiaphragm coupler. Installing gasket on cylinder 1 R before installing primary fuel filter and throttle linkage. Checking throttle linkage for free movement. Throttle linkage adjustment-schematic diagram. Connecting fuel injector tubes-schematic diagram.

Page 4-27 4-27 4-28 4-29 4-30 4-30 4-31 4-31 4-32 4-32 4-33 4-34 4-34 4-35 4-35 4-35 4-36 4-36 4-36 4-37 4-37 4-38 4-38 4-38 4-39 4-39 4-39 4-40 4-40 4-40 4-41 4-41 4-41 4-42 4-43

vii

Figure Number 4-87 4-88 4-89 4-90 4-91 4-92 4-93 4-94 4-95 4-96 4-97 4-98 4-99 4-100 4-101 4-102 4-103 4-104 4-105 4-106 4-107 4-108 4-109 4-110 4-111 4-112 4-113 4-114 4-115 4-116 4-117 4-118 4-119 4-120 4-121 4-122 4-123 4-124

Title Front fan drive housing fan rotor hub sleeve spacer-4910-795-7952 installed for leakage test. Checking cooling fan blade clearance. Removing or installing main oil filter bypass valve plug, gasket and spring. Removing or installing main oil filter bypass valve. Removing or installing auxiliary oil filter bypass valve plug, gasket, and spring. Removing or installing auxiliary oil filter bypass valve. Removing or installing engine oil pressure regulating valve. Disconnecting or connecting fuel/ water separator filter inlet hose at fuel pump. Disconnecting or connecting fuel hoses and drain line at fuel/ water separator filter. Removing or installing fuel/ water separator filter assembly. Removing or installing fuel/ water separator filter cover bolts. Removing or installing fuel/ water separator filter cover. Removing or installing rear fan drive housing cover attaching parts. Removing or installing rear fan drive housing cover and clutch assembly. Removing or installing fan drive housing cover preformed packing. Comparison between piston actuated and mechanical fan drive housing and cover assemblies. Removing housing cover and bearing from vertical drive shaft. Removing fan drive clutch upper ball bearing from housing cover. Pressing fan drive clutch upper ball bearing into housing cover. Disconnecting or connecting cylinder head oil drain tube hoses-cylinders 1 L and 2L. Disconnecting or connecting intermediate cylinder head oil drain tubescylinder 2L. Rem oving or installing intermediate cylinder head oil drain tube-cylinder 2L. Disconnecting or connecting intake manifold tube from intake manifold and cylinder 2L. Removing or installing intake manifold tube-cylinder 2L. Left intake manifold-installed view. Disconnecting or connecting manifold heater fuel inlet tube. Disconnecting or connecting cylinder head oil drain tube-left front. Disconnecting or connecting cylinder head oil drain tube-left rear. Disconnecting or connecting heater fuel inlet and outlet tubes from intake manifold heater Disconnecting or connecting turbosupercharger air outlet elbow and heater tube. Removing or installing intake manifold assembly-left side. Disassembling or assembling intake manifold assembly. Disconnecting or connecting right front cylinder head oil drain tube. Disconnecting or connecting left rear cylinder head oil drain tube. Disconnecting or connecting right rear cylinder head oil drain tube. Disconnecting or connecting oil filler and oil level indicator tubes from oil pan. Removing or installing oil pan rear bolts, Removing or installing engine oil pan.

Page 4-44 4-44 4-45 4-45 4-46 4-46 4-47 4-48 4-48 4-49 4-49 4-49 4-50 4-50 4-51 4-51 4-52 4-52 4-52 4-53 4-53 4-53 4-54 4-54 4-55 4-55 4-56 4-56 4-56 4-57 4-57 4-58 4-59 4-59 4-60 4-60 4-61 4-61

viii

...

Figure Number 4-125 4-126 4-127 4-128 4-129 4-130 4-131 4-132 4-133 4-134 4-135 4-136 4-137 4-138 4-139 4-140 4-141 4-142 4-143 4-144 4-145 4-146 4-147 4-148 4-149 4-150 4-151 4-152 4-153 4-154 4-155 4-156

Title Removing or installing oil pan sealing thread. Removing or installing right front upper cover. Removing or installing right rear upper cover. Removing or installing oil filler and oil level indicator tube shroud platesone piece type oil filler and indicator tubes installation. Removing or installing oil level indicator tube shroud plate-modified shroud plate installation. Removing or installing left front upper cover-modified upper cover installation. Disconnecting or connecting oil filler and oil level indicator tube retaining straps-one piece type oil filler and indicator tubes installation shown. Oil level indicator and oil filler tube upper shroud-tubes with splash pan installation installed view. Disconnecting or connecting fuel drain tubes-tubes with splash pan installation. Removing or installing oil level indicator and oil filler and oil level indicator tube shroud plate bolts-tubes with splash pan installation. Removing or installing oil level indicator and oil filter tube upper coverwith splash pan installation. Oil level indicator tube upper cover plate-relocated oil filler tube modified installed view. Oil level indicator tube upper cover plate-relocated oil filler tube installed view. Disconnecting or connecting fuel drain tubes-relocated oil filler tube installation. Removing or installing oil level indicator tube upper cover plate-located oil filler tube installation. Removing or installing oil level indicator upper cover plate-relocated oil filler tube installation. Removing or installing left rear upper cover. Disconnecting or connecting oil cooler hoses-left side. Removing or installing manifold heater ignition unit-right side. Disconnecting or connecting oil cooler support beam-right side. Disconnecting or connecting shroud from top frame-right front side. Disconnecting or connecting right oil cooler end shroud and upper transmission shroud. Disconnecting or connecting right rear shroud from top frame. Removing or installing oil coolers and top frame as an assembly. Removing or installing top frame retaining brackets. Disconnecting or connecting fuel injector nozzle holder fuel inlet and return tubes. Removing or installing fuel injector nozzle fuel tube adapters. Loosening fuel injector nozzle and holder retainer using wrench-5120-8717198. Removing or installing fuel injector nozzle and holder assembly. Removing or installing cylinder head shroud plate. Disconnecting or connecting inner cylinder air deflector, Disconnecting or connecting inter cylinder connector flange and valve adjusting screw covers.

Page 4-62 4-63 4-63 4-63 4-64 4-64 4-64 4-65 4-65 4-66 4-66 4-66 4-67 4-67 4-68 4-68 4-68 4-69 4-69 4-69 4-70 4-70 4-70 4-71 4-72 4-73 4-73 4-74 4-74 4-75 4-75 4-76

ix

Figure Number 4-157 4-158 4-159 4-160 4-161 4-162 4-163 4-164 4-165 4-166 4-167 4-168 4-169 4-170 4-171 4-172 4-173 4-174 4-175 4-176 4-177 4-178 4-179 4-180 4-181 4-182 4-183 4-184 4-185 4-186 4-187 4-188 4-189 4-190 4-191 4-192 4-193 4-194 4-195 4-196 4-197 4-198

Title Removing or installing valve rocker arm cover bolts and removing valve rocker arm cover. Rem oving or installing valve adjusting screw. Removing or installing valve rocker arm shaft plugs. Removing valve rocker arm shafts and valve rocker arms. Installing valve rocker arms and valve rocker arm shafts. Installing valve rocker arm cover. Positioning lip of intercylinder preformed hose. Positioning valve adjusting screw pad on end of valve stem. Torque tightening fuel injector nozzle. Fuel injector nozzle and holder assembly, Fuel injector nozzle and holder assemblysectional view. Testing fuel injector nozzle and holder assembly. Partial disassembly or assembling fuel injector nozzle and holder assembly. Disassembling or assembling fuel injector nozzle components. Removing or installing transmission drive gearshaft and flywheel mounting bolts. Removing transmission drive gearshaft using bolts as puller screws. Installing eye bolt - 5306-050-0348. Removing or installing flywheel. Removing or installing crankshaft oil seal retainer. Removing or installing oil seal cap and oil seal housing mounting bolts. Removing oil seal housing using mechanical pullers - 5120-473-7222. Removing or installing oil seal housing cap and housing. Removing or installing crankshaft oil seal, Removing crankshaft oil seal spring. Installing crankshaft oil seal spring. Correct position for crankshaft oil seal split line before installing seal retainer. Installing flywheel, rising bolts to draw flywheel against crankshaft. Installing or removing compression adapter - 4910-795-7961 (cylinder compression test ). Checking cylinder compression using gage assembly - 4910-870-6283 and compression adapter - 4910-795-7961. Removing or installing valve adjusting screw cover plates - right side, Removing or installing valve adjusting screw cover plates - left side. Setting exhaust valve clearance using thickness gage blade -5210-793-7899. Setting intake valve clearance using thickness gage blade -5210-793-7898, Flywheel timing mark locations. Disconnecting or connecting oil cooler inlet and outlet hoses. Removing or installing engine and transmission oil coolers. Removing or installing oil cooler end shroud. Removing or installing intake valve cover plate. Cross section of cylinder 6R showing position of camshaft lobes for valve timing. Flywheel timing marks alined with pointer for valve timing - right bank of cylinders. Setting intake valve clearance for cylinders 6R using thickness gage blade 5120-793-7897. Removing or installing camshaft gear housing cover.

Page
4-77 4-78 4-78 4-78 4-78 4-79 4-79 4-80 4-80 4-81 4-82 4-83 4-84 4-85 4-88 4-88 4-89 4-89 4-90 4-90 4-91 4-91 4-91 4-91 4-92 4-92 4-93 4-94 4-95 4-96 4-97 4-98 4-98 4-98 4-99 4-99 4-100 4-100 4-100 4-101 4-101 4-102

Figure Number 4-199 4-200 4-201 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25 5-26 5-27 5-28 5-29 5-30 5-31 5-32 5-33 5-34

Title Removing or installing camshaft drive gearshaft plug retaining ring. Removing or installing camshaft drive gearshaft plug using mechanical puller -5120-678-5282, Removing or installing camshaft drive shaft using mechanical puller -5120678-5282. Lifting engine using multiple leg sling - 4910-919-2884. Removing or installing oil pan drain plugs (Model AVDS-1790-2-M ). Removing or installing oil pan drain plugs (Models AVDS-1790-2AM and AVDS-1790-2A). Disconnecting or connecting time totalizing meter electrical lead clamps. Removing or installing time totaliz.ing meter. Engine on maintenance and overhaul stand - 4910-856-4137. Removing or installing oil filler and oil level indicator tube shroud plate oil drain hose - engines with oil filler and indicator with splash pan drain, Removing or installing oil filler and oil level indicator tube shroud plate and oil drain hose - engines with oil filler and indicator with splash pan drain Oil filler and oil level indicator tube shroud plate oil drain hose grommet installed view - engines with oil filler and indicator with splash pan drain. Removing or installing manifold heater ignition unit - right side. Removing or installing right oil cooler screens. Disconnecting or connecting right oil cooler hose and primary fuel filter drain tubes. Removing or installing oil cooler to support bolts. Removing or installing right engine oil cooler. Removing or installing right transmission oil cooler. Disconnecting or connecting upper cover frame - right front view. Disconnecting or connecting upper cover frame - right rear view. Removing or installing oil indicator and oil filler tube to upper frame retaining strap - left side engines without relocated oil filler tube. Removing or installing right oil cooler end shroud. Rem oving or installing right oil cooler support beam. Removing or installing upper cover frame support brackets - right side. Rem oving or installing right turbosupercharger oil inlet hose and transmission shroud. Removing or installing right manifold heater fuel return tube. Disconnecting or connecting manifold heater fuel inlet tube at manifold heater and cylinder head oil drain manifolds. Removing or installing fuel check valve. Removing or installing manifold heater fuel inlet solenoid valve and fuel filter. Removing or installing manifold heater fuel return solenoid valve and bracket. Removing or installing right rear cylinder head oil drain tube and turbosupercharger oil drain tube. Disconnecting or connecting right front cylinder head oil drain tube. Disconnecting or connecting left front cylinder head oil drain tube. Disconnecting or connecting left rear cylinder head oil drain tube. Removing or installing right cylinder head oil drain manifold tubes. Removing or installing right intake manifold. Removing or installing primary fuel filter drain tube.

Page 4-102 4-102 4-102 5-1 5-2 5-2 5-3 5-3 5-4 5-5 5-5 5-6 5-6 5-7 5-8 5-8 5-9 5-9 5-9 5-10 5-10 5-11 5-11 5-12 5-13 5-13 5-14 5-14 5-15 5-15 5-16 5-16 5-16 5-17 5-17 5-18 5-19
xi

Figure Number 5-35 5-36 5-37 5-38 5-39 5-40 5-41 5-42 5-43 5-44 5-45 5-46 5-47 5-48 5-49 5-50 5-51 5-52 5-53 5-54 5-55 5-56 5-57 5-58 5-59 5-60 5-61 5-62 5-63 5-64 5-65 5-66

Title
Removing or installing primary fuel filter. Removing or installing secondary fuel filter. Disconnecting or connecting fuel/ water separator fuel outlet hose from bulkhead elbow. Removing or installing fuel/ water separator filter. Removing or installing primary fuel filter bracket, throttle linkage cross shaft, and camshaft end plate. Removing or installing secondary fuel filter mounting bracket, camshaft cover plate, and tachometer drive cover. Removing or installing fuel/ water separator filter mounting bracket. Removing or installing cylinder barrel shroud - cylinder No, lR. Removing or installing right front shroud. Removing or installing cylinder baffle - cylinder No. lR. Disconnecting or connecting fire extinguisher and fuel inlet tubes - front shroud. Removing or installing top and side filler plates - cylinder No. lL. Removing or installing left front shroud. Disconnecting or connecting fuel and oil tubes - rear center shrouds. Removing or installing exhaust manifold left and right rear center shrouds. Removing or installing right rear shroud. Removing or installing cylinder head plates - right side. Removing or installing oil filler and oil level indicator tube plates - engines with one piece oil filler tube. Removing or installing oil filler and oil level indicator tubes - engines with one piece oil filler tube. Removing or installing cylinder head plates at oil filler and oil level indicator tubes - engines without splash pan installation. Removing or installing oil filler and oil level indicator tubes - engines with splash pan installation. Removing or installing oil filler and oil level indicator tube plates - engines with splash pan installation. Removing or installing cylinder head plates at oil filler and oil level indicator tubes - engines with splash pan installation. Removing or installing oil level indicator tube plate - engines with relocated oil filler tube installation. Removing or installing oil filler and oil level indicator tubes - engines with relocated oil filler tube installation. Removing or installing oil level indicator tube cylinder plate - engines with relocated oil filler tube installation. Rem oving or installing fuel injector nozzle fuel return tubes - engines with metallic tubes. Removing or installing fuel injector nozzle fuel return tubes - engines with flexible tubes. Removing or installing fuel injector nozzle fuel tube connectors and elbow connector - right side. Removing fuel injector clamps - engines without additional clamps. Removing or installing fuel injector tube clamps - engines with additional clamps. Disconnecting or connecting fuel injector tubes - at fuel injector nozzle and holder assemblies.

Page
5-19 5-20 5-20 5-21 5-21 5-22 5-22 5-23 5-23 5-24 5-24 5-25 5-25 5-26 5-26 5-27 5-28 5-28 5-29 5-29 5-30 5-30 5-31 5-31 5-32 5-33 5-34 5-35 5-36 5-37 5-38 5-39

xii

Figure Number 5-67 5-68 5-69 5-70 5-71 5-72 5-73 5-74 5-75 5-76 5-77 5-78 5-79 5-80 5-81 5-82 5-83 5-84 5-85 5-86 5-87 5-88 5-89 5-90 5-91 5-92 5-93 5-94 5-95 5-96 5-97 5-98

Title
Removing or installing fuel injector tubes at fuel injection pump. Removing or installing exhaust manifold and exhaust pipe retaining straps. Removing or installing exhaust manifolds and exhaust pipes - cylinder Nos. lR, 2R, and 3R and cylinder Nos. lL, 2L, and 3L - engines prior to rerouting of crankcase breather tube. Removing or installing manifolds and exhaust pipes - cylinder Nos. lR, 2R, and 3R and cylinder Nos. lL, 2L, and 3L, - engines with rerouted crankcase breather tube. Removing or installing fuel return hose and crankcase breather tube tee engines prior to rerouting of fuel return hose. Disconnecting of connecting intermediate crankcase breather tubes at fuel injection pump clamp. Removing or installing fuel return hose - engines with rerouted fuel return hose. Removing or installing crankcase breather tube tee - engines with rerouted crankcase breather tube. Removing or installing breather tube cushioned clamp at rear fan drive housing - engines with rerouted crankcase breather tube. Removing or installing fuel inlet hose and crankcase breather tube. Removing fan drive control valve - engines with fan control valve. Removing or installing exhaust manifolds and exhaust pipes - cylinder Nos. 4R, 5R, and 6R and cylinder Nos. 4L, 5L, and 6L. Removing or installing right turbosupercharger mounting base. Removing or installing right and left turbosupercharger mounting base tie rod. Removing or installing right turbosupercharger mounting base support. Disconnecting or connecting throttle rods at intermediate throttle lever. Removing or installing intermediate throttle lever support. Removing or installing fuel injector tube angle brackets. Disconnecting or connecting fuel injection pump oil inlet hose - engines prior to rerouting of hose and clamps. Disconnecting fan clutch oil transfer hose - engines with transfer hose. Disconnecting or connecting fuel injection pump oil inlet hose - engines with relocated hose clamps. Disconnecting or connecting turbosupercharger oil inlet hose - engines prior to rerouting of hoses and clamps. Removing or installing fire extinguisher tube - engines prior to new tube and clamps. Removing or installing turbosupercharger oil inlet hose and fire extinguisher tube - engines with new tube and relocated clamps. Positioning injection pump coupler by turning flywheel using splined wrench -5120-793-7895. Removing fuel injection pump splined coupler bolts. Separating fuel injection pump splined coupler sleeves. Removing fuel injection pump diaphragm coupler bolts. Separating fuel injection pump diaphragm coupler. Removing fuel injection pump. Removing or installing camshaft drive shrouds - right side. Disconnecting or connecting lower right engine shroud - top view.

Page
5-40 5-40

5-41

5-42 5-43 5-43 5-44 5-44 5-45 5-45 5-46 5-47 5-48 5-48 5-49 5-50 5-50 5-51 5-51 5-51 5-52 5-53 5-54 5-55 5-56 5-56 5-57 5-57 5-57 5-57 5-58 5-58

xiii

Figure Number 5-99 5-100 5-101 5-102 5-103 5-104 5-105 5-106 5-107 5-108 5-109 5-110 5-111 5-112 5-113 5-114 5-115 5-116 5-117 5-118 5-119 5-120 5-121 5-122 5-123 5-124 5-125 5-126 5-127 5-128 5-129 5-130 5-131 5-132 5-133 xiv

Title Removing or installing lower right rear engine shroud - side view. Removing or installing intercylinder head deflectors - right side. Disconnecting or connecting right intercylinder deflector hooks. Removing or installing right intercylinder deflectors. Removing or installing fuel injector nozzle and holder assembly. Rem oving or installing valve adjusting screw cover plates. Location of valve rocker arm cover and cylinder identifying marks. Disconnecting or connecting right front lifting eye and inter-cylinder hose flanges. Disconnecting or connecting right camshaft gear housing at cylinder 6R rocker arm cover, Removing or installing rocker arm cover bolts and cap screws. Checking valve clearance before removing valve rocker arm covers and removing or installing cover bolts. Removing valve rocker arm covers. Removing or installing right camshaft gear housing cover. Removing or installing camshaft drive gearshaft oil transfer plug retaining ring. Removing camshaft drive gearshaft oil transfer plug using mechanical puller - 5120-678-5282. Removing camshaft drive shaft using mechanical puller - 5120-678-5282. Disconnecting or connecting right camshaft gear housing at cylinder 6R. Removing or installing right camshaft. Disconnecting or connecting horizontal fan drive shaft front and rear cover adapters. Front and rear fan drive shaft covers disconnected showing location of preformed packings. Removing or installing horizontal fan drive shaft retaining ring using retaining ring pliers -5120-752-9755. Positioning horizontal fan drive shaft in rear fan drive housing. Horizontal fan drive shaft positioned for removal of front fan drive housing. Removing or installing front fan drive housing attaching parts. Removing or installing front fan drive housing attaching parts. Removing front fan drive housing and clutch assembly using improvised lifting tool. Rem oving or installing front fan drive housing mounting base assembly from crankcase assembly. Location of preformed packing at oil transfer boss in crankcase assembly. Removing or installing fuel injection pump mounting base. Location of preformed packing at oil transfer tube for fuel injection pump mounting base. Removing or installing attaching parts for rear fan and accessory drive housing assemblies - right side. Removing or installing attaching parts for rear fan and accessory drive housing assemblies - left side. Installing or removing rear fan drive housing using fan and advance unit housing sling - 4910-795-7954. Removing rear fan and accessory drive housing assemblies. Removing or installing rear fan and accessory drive housing mounting base.

Page 5-59 5-59 5-60 5-60 5-61 5-62 5-63 5-63 5-64 5-64 5-65 5-65 5-65 5-66 5-66 5-66 5-66 5-67 5-67 5-67 5-68 5-68 5-68 5-68 5-69 5-70 5-71 5-71 5-71 5-71 5-72 5-72 5-73 5-73 5-74

Figure Number 5-134 5-135 5-136 5-137 5-138 5-139 5-140 5-141 5-142 5-143 5-144 5-145 5-146 5-147 5-148 5-149 5-150 5-151 5-152 5-153 5-154 5-155 5-156 5-157 5-158 5-159 5-160 5-161 5-162 5-163 5-164 5-165 5-166 5-167 5-168 5-169

Title Location of preformed packings at oil transfer tubes in crankcase assembly rear fan and accessory drive housing mounting base. Removing or installing oil pan rear bolts. Removing or installing oil pan bolts - right front view. Removing or installing oil pan. Removing or installing crankshaft damper and oil filter housing attaching parts. Removing or installing crankshaft damper and oil filter housing. Front end of crankcase assembly showing locations of oil transfer tube preformed packings. Disconnecting or connecting cylinder deflectors at cylinders. Removing or installing lower cylinder deflector straps and deflectors - right side. Checking breaking torque of cylinder base nuts, using box wrench - 5120678-5287. Right bank cylinders in vertical position for removing or installing cylinders from crankcase. Removing cylinder No. lR. Removing piston pin and piston - cylinder No. lR. Engine with cylinder assemblies and pistons removed showing crankcase protectors - 4910-795-7951 installed. Removing or installing scavenge oil pickup, oil pan pressure relief tube, and oil spill tube. Removing or installing oil pump assembly. Removing or installing oil pressure sending unit, oil pressure warning switch and generator air intake tube support brackets. Removing or installing fuel pump drive coupling adapter and coupling. Removing crankshaft torsional vibration damper using mechanical pullers 5120-473-7222. Removing or installing starter drive adapter. Removing or installing starter driven gear attaching parts. Removing starter driven gear. Removing or installing generator drive adapter attaching parts - engines with mounting nuts. Removing or installing generator drive adapter attaching parts - engines with mounting studs. Removing or installing generator drive adapter and associated parts. Removing or installing transmission drive gearshaft attaching parts. Removing transmission drive gearshaft assembly using mounting bolts as puller screws. Preparing flywheel for removal. Removing flywheel using eye bolt - 5306-050-0348. Removing or installing transmission adapter attaching parts. Removing or installing transmission adapter. Removing or installing crankshaft oil seal retainers. Removing or installing crankshaft oil seal cap and housing attaching parts. Removing or installing oil seal cap and housing. Removing or installing oil seal housing support. Removing or installing accessory drive gear attaching parts.

Page 5-74 5-75 5-75 5-76 5-76 5-77 5-78 5-78 5-79 5-80 5-80 5-81 5-82 5-83 5-84 5-85 5-86 5-87 5-87 5-88 5-88 5-89 5-89 5-90 5-90 5-91 5-91 5-92 5-92 5-93 5-94 5-94 5-95 5-95 5-96 5-97

xv

Figure Number 5-170 5-171 5-172 5-173 5-174

5-175

5-176 5-177 5-178 5-179 5-180 5-181 5-182 5-183 5-184 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 6-15 6-16 6-17 6-18 6-19 6-20 6-21 6-22 xvi

Title Removing accessory drive gear using mounting bolts as puller screws. Removing or installing crankcase tie rod attaching parts - right front view. Removing or installing tie rods and attaching parts - left side view. Removing or installing main bearing attaching parts. Removing main bearing cap using crankcase spreading tool - 5120-5757767, mechanical adapter -5120-837-5091, and mechanical puller -5120310-4668. Crankshaft with main bearing caps removed showing correct position of crankshaft counterweights before removal or after installation of crankshaft. Installing or removing crankshaft and connecting rod sling -4910-795-7955 at crankshaft flywheel flange. Installing or removing crankshaft and connecting rod sling - 4910-795-7955 at crankshaft torsional vibration damper flange. Removing or installing crankshaft and connecting rod assemblies using crankshaft and connecting rod sling - 4910-795-7955. Removing or installing upper main sleeve bearing halves. Removing or installing piston oiler nozzle assemblies. Rem oving or installing starter and generator idler gearshaft flange nuts. Removing starter and /or generator idler gearshaft. Removing or installing starter driven gearshaft bearing cage attaching parts. Removing or installing starter gearshaft bearing cage. Standard and oversize stud identification. Removing helical-coil threaded insert from cylinder assembly using screw thread extractor -5120-251-1527. Installing helical-coil threaded insert in cylinder assembly using screw thread inserter -5120-797-2407. Engine name plate. Removing or installing pipe plugs and fuel pump driven gearshaft replacement cover. Removing or installing pipe plugs and fuel supply pump adapter replacement cover. Removing or installing crankcase oil gallery pipe plugs. Removing or installing crankcase from engine overhaul stand using improvised rope sling. Crankcase oil passages - schematic diagram. Checking torque of main bearing cap studs. Checking clearance between upper main thrust bearing flange and crankcase. Checking inside diameter of main bearings. Crankcase restricted welding areas, Points of measurement for checking crankcase. Crankcase studding - right rear exposed view. Crankcase studding - left rear view. Crankcase studding - bottom view. Rem oving or installing transmission adapter lifting eye and timing pointer. Pressing starter driven gearshaft and bearings from bearing cage. Pressing starter driven gearshaft from ball bearings. Starter drive gear - rework. Pressing ball bearings on starter driven gearshaft.

Page 5-97 5-98 5-99 5-100

5-101

5-102 5-103 5-103 5-104 5-105 5-105 5-106 5-106 5-106 5-107 6-7 6-8 6-9 6-11 6-12 6-12 6-13 6-14 6-15 6-16 6-16 6-17 6-19 6-20 6-21 6-21 6-22 6-24 6-25 6-25 6-26 6-27

Figure Number 6-23 6-24 6-25 6-26 6-27 6-28 6-29 6-30 6-31 6-32 6-33 6-34 6-35 6-36 6-37 6-38 6-39 6-40 6-41 6-42 6-43 6-44 6-45 6-46 6-47 6-48 6-49 6-50 6-51 6-52 6-53 6-54 6-55 6-56 6-57 6-58 6-59 6-60 6-61

Title Pressing oil seal into bearing cage. Removing generator adapter oil seal. Pressing generator drive gearshaft from ball bearings. Pressing ball bearings on generator drive gearshaft. Pressing oil seal into generator drive gearshaft adapter. Removing generator idler gear retaining ring and ball bearing. Pressing ball bearing into generator idler gear. Removing or installing connecting rod assemblies. Connecting rod and bearing identification marks. Removing or installing crankshaft oil seal. Removing or installing crankshaft oil retaining plugs. Checking connecting rod bearing bore using dial bore indicator. Break and polish sharp edges of connecting rod counterbore and rod contour. Connecting rod bore center dimensions. Checking connecting rod side clearance. Torsional vibration damper warning plate. Torsional vibration damper name plate. Original production engine flywheel fuel injection pump timing mark location. Improved design engine flywheel fuel injection pump timing mark location. Pressing bushing-type bearing from transmission drive gearshaft. Pressing bushing-type bearing into transmission drive gearshaft. Removing or installing piston compression rings using remover and replacer 5120-795-0177. Removing or installing oil control piston ring expander spring. Checking piston ring side clearance. Cylinder showing position of valve lifter assembly - 5120-678-5285 and removing and inserting valve stand - 4910-554-1317. Compressing exhaust valve springs to remove or install upper valve spring retainer and locks. Removing or installing valve springs, upper retainers, and exhaust valve rotor. Cleaning carbon deposits from fuel injector nozzle seal using nozzle carbon cutter - 4910-795-7958. Cylinder identifying groove. Cylinder barrel tester - 4910-937-4261. Reflectoscope wave forms. Ultrasonic search fixture installed on master checking cylinder. Installing plug - 10935522 in cylinder bore. Positioning ultrasonic search fixture in cylinder bore. Ultrasonic search fixture installed in cylinder barrel mounting flange. Removing intake valve guide using mechanical puller -5120-448-0400. Positioning intake valve guide on valve guide replacer -5120-448-0402. Installing intake valve guide using valve guide replacer -5120-448-0402. Intake valve guide hand reamer - 5110-708-3698 or 5110-708-3699 and reamer bushing - 4910-795-7950 positioned in cylinder head - sectional view. Reaming intake valve guide, using hand reamer - 5110-708-3698 or 5110708-3699 and reamer bushing - 4910-795-7950. Valve and valve seat insert grinding diagram.

Page 6-28 6-28 6-29 6-30 6-31 6-31 6-32 6-34 6-35 6-35 6-36 6-37 6-40 6-41 6-41 6-42 6-42 6-43 6-44 6-46 6-46 6-47 6-47 6-50 6-52 6-52 6-53 6-54 6-55 6-60 6-62 6-63 6-65 6-65 6-66 6-66 6-67 6-67

6-68 6-69 6-70 xvii

6-62 6-63

Figure Number 6-64 6-65 6-66 6-67 6-68 6-69 6-70 6-71 6-72 6-73 6-74 6-75 6-76 6-77 6-78 6-79 6-80 6-81 6-82 6-83 6-84 6-85 6-86 6-87 6-88 6-89 6-90 6-91 6-92 6-93 6-94 6-95

Title Valve rocker arm cover welding standards. Compressing valve springs using valve lifter assembly -5120-678-5285. FSN 2815-895-6430 oil pump assembly as removed from engine. Rem oving or installing locking wire securing oil pump pressure relief valve and piston cooling control valve bodies. Removing or installing oil pump pressure relief valve. Removing or installing piston cooling control valve. Removing or installing oil pump driven gear attaching parts and preformed packing. Removing or installing oil pump drive shaft lock plate (FSN 2815-895-6430 oil pump). Removing or installing oil pump drive shaft lock nut. Removing or installing oil pump drive shaft and cluster gear (FSN 2815-8956430 oil pump). Removing oil pump driven gear from impeller drive shaft using suitable puller. Removing or installing scavenge housing cover and oil pickup elbow (FSN 2815-679-4965 oil pump). Removing or installing scavenge housing cover and oil pickup elbow (FSN 2815-895-6430 oil pump). Removing or installing oil pump scavenge driven impellers, driven impeller shaft, and scavenge housing. Removing or installing oil pump driven impeller and shaft. Removing or installing pressure housing cover (FSN 2815-679-4965 oil pump). Removing or installing pressure housing cover (FSN 2815-895-6430 oil pump). Removing or installing oil pump piston cooling drive and driven impellers. Removing or installing scavenge oil pump inlet scoop (FSN 2815-679-4965 oil pump). Removing or installing scavenge oil pump oil inlet scoop (FSN 2815-8956430 oil pump). Pressing impeller drive shaft from ball bearings in drive cluster gear. Drive cluster gear - exploded view. Disassembling or assembling piston oil cooling valve assembly. Pressing ball bearing into drive cluster gear. Removing or installing oil pan baffles. Removing or installing oil separator drain and oil level replacement covers. Removing or installing pressure oil pump elbow adapter and oil pickup screen assembly attaching parts (M60 series vehicle application engines). Removing or installing pressure oil pickup screen assembly (M60 series vehicle application engines ). Removing or installing pressure oil pump elbow adapter and oil pickup screen assembly attaching parts (universal vehicle application engines ). Removing or installing pressure oil pickup screen assembly (universal vehicle application engines ). Removing or installing oil pump elbow adapter. Removing or installing oil pickup funnel assembly and magnetic drain plugs (M60 series vehicle application engines).

Page 6-73 6-74 6-76 6-76 6-76 6-76 6-77 6-77 6-78 6-78 6-78 6-79 6-80 6-80 6-81 6-81 6-82 6-82 6-82 6-83 6-83 6-84 6-84 6-88 6-89 6-90 6-91 6-92 6-93 6-94 6-94 6-95

xviii

Figure Nu-mber 6-96 6-97 6-98 6-99 6-100 6-101 6-102 6-103 6-104 6-105 6-106 6-107 6-108 6-109 6-110 6-111 6-112 6-113 6-114 6-115 6-116 6-117 6-118 6-119 6-120 6-121 6-122 6-123 6-124 6-125 6-126 6-127 6-128 6-129 6-130 6-131 6-132 6-133 6-134 6-135 6-136 6-137

Title Removing or installing oil pickup funnel assembly and drain plugs (universal vehicle application engines). Removing or installing pressure oil pickup cover. Crankshaft damper and oil filter housing as removed from engine. Removing or installing main oil cooler bypass valve plug, gasket, and spring. Removing or installing main oil cooler bypass valve. Removing or installing auxiliary and main oil filter attaching parts. Removing or installing main and auxiliary oil filters. Removing or installing oil pressure regulator valve cover and gasket. Disassembling or assembling oil pressure regulator valve. Removing or installing fuel pump adapter using mechanical pullers - 5120473-7222. Removing or installing damper and oil filter housing switches, bushings, and pipe plugs - front view. Removing or installing damper and oil filter housing pipe plugs - rear view. Disassembling or assembling main oil filter body and filter element pack. Removing or installing filter element pack from tube. Disconnecting or connecting auxiliary oil filter element retainer and bushing. Removing or installing auxiliary oil filter element. Crankshaft damper and oil filter housing oil passages. Crankshaft damper and oil filter housing studs. Removing or installing fan drive oil seal housing, Removing or installing fan drive housing cover. Removing clutch cover and fan drive vertical shaft bearing using puller. Remove fan drive clutch upper ball bearing from housing cover. Removing fan vertical drive shaft oil seal from housing. Removing or installing fan drive bevel gearshaft and associated parts. Removing or installing lower driven gearshaft ball bearing lock plate. Removing or installing fan driven gearshaft and bearings. Removing or installing fan drive bevel gearshaft bearing retaining ring. Removing fan drive bevel gearshaft ball bearings. Removing or installing fan driven gearshaft bearing retaining ring. Pressing fan driven gearshaft from upper gearshaft ball bearing. Pressing fan driven gearshaft from lower driven gearshaft ball bearing. Removing or installing front fan drive housing oil restrictor (engines have oil restrictors ). Piston actuated clutch assembly - sectional view. Mechanical clutch assembly - sectional view. Removing or installing fan drive housing cover preformed packing. Removing or installing fan drive hub attaching parts. Separating or positioning fan drive hub and vertical drive shaft (piston actuated clutch). Separating or positioning fan drive hub and vertical drive shaft (mechanical clutch). Removing or installing fan drive vertical shaft from fan drive hub (piston actuated clutch ). Removing or installing clutch discs from fan drive hub (mechanical clutch). Removing or installing fan drive vertical drive shaft, balls, and springs from fan drive hub (mechanical clutch ). Removing or installing fan drive disc (piston actuated clutch).

Page 6-95 6-96 6-97 6-98 6-98 6-99 6-100 6-100 6-101 6-101 6-102 6-102 6-103 6-103 6-104 6-104 6-105 6-107 6-109 6-110 6-110 6-110 6-111 6-111 6-112 6-112 6-113 6-113 6-113 6-114 6-114 6-114 6-115 6-116 6-117 6-117 6-118

6-118 6-119 6-119 6-120 6-120 xix

Figure Number 6-138 6-139 6-140 6-141 6-142 6-143 6-144 6-145 6-146 6-147 6-148 6-149 6-150 6-151 6-152 6-153 6-154 6-155 6-156 6-157 6-158 6-159 6-160 6-161 6-162 6-163 6-164 6-165 6-166 6-167 6-168 6-169 6-170 6-171 6-172 6-173 6-174

Title Fan drive shaft oil distributor location. Removing or installing fan drive bottom clutch disc (piston actuated clutch). Straightening or bending tabs on key washer securing actuating clutch piston spanner nut (piston actuated clutch). Removing or installing actuating clutch piston spanner nut using face wrench socket -5120-795-7896. Removing or installing clutch pressure plate, clutch springs, and balls (piston actuated clutch ). Removing actuating clutch piston and piston rings (piston actuated clutch ). Removing or installing ball bearing from drive hub. Removing or installing intermediate clutch and drive discs. Separating or positioning vertical drive shaft, top clutch disc, and housing assembly (piston actuated clutch ). Separating or positioning vertical drive shaft and disc housing (mechanical clutch ). Front fan drive housing and mounting base - studding assembly. Installing outer piston ring on actuating piston (piston actuated clutch). Determining shim thickness for front fan drive gearshaft and drive bevel gearshaft. Pressing fan driven gearshaft into lower drive gearshaft ball bearing. Pressing fan driven gearshaft into upper driven gearshaft ball bearing. Pressing front bevel gearshaft ball bearing on gearshaft. Pressing oil seal into fan drive oil seal housing. Pressing clutch upper ball bearing into fan drive housing cover. Removing or installing rear fan drive housing cover. Removing or installing bearing cap and bearing support attaching parts. Removing or installing injection pump advance assembly, Removing or installing left and right camshaft drive inner support attaching parts. Removing or installing right and left camshaft drive inner supports and preformed packing. Removing or installing fan driven gearshaft and ball bearings as a unit. Removing or installing fuel injection pump splined drive coupler attaching parts. Removing fuel injection pump splined drive coupler half. Removing or installing fuel injection pump diaphragm drive coupler half. Removing fuel injection pump diaphragm drive coupler half. Separating or attaching rear fan and accessory drive housings (housings equipped with control covers ). Separating or attaching rear fan and accessory drive housing (housings equipped with oil restrictors ). Removing or installing fuel injection pump spur gear shaft and bearing. Removing or installing oil seal. Removing or installing needle roller bearing retaining ring and bearing. Removing fuel injection pump spur gearshaft ball bearing. Removing or installing oil transfer plug from camshaft drive gearshafts. Removing or installing fan drive gearshaft, bearing, and support. Removing or installing rear fan drive shaft.

Page 6-121 6-121 6-121 6-121 6-122 6-122 6-123 6-123 6-124 6-125 6-126 6-129 6-130 6-131 6-131 6-132 6-132 6-133 6-135 6-136 6-137 6-137 6-138 6-138 6-139 6-139 6-140 6-140 6-141 6-142 6-143 6-143 6-143 6-144 6-144 6-145 6-145

xx

Figure Number 6-175 6-176 6-177 6-178 6-179 6-180 6-181 6-182 6-183 6-184 6-185 6-186 6-187 6-188 6-189 6-190 6-191 6-192 6-193 6-194 6-195 6-196 6-197 6-198 6-199a 6-199b 6-199c 6-200 6-201 6-202 6-203 6-204 6-205 6-206 6-207 6-208 6-209 6-210 6-211 6-212 6-213 6-214

Page Title Removing advance flyweight adjusting ring and injection pump drive 6-146 gearshaft attaching parts (adjusting ring secured with nuts and washers). Removing advance flyweight adjusting ring and injection pump drive 6-146 gearshaft attaching parts (adjusting ring secured with bolts). 6-147 Removing injection pump drive gearshaft. Removing advance flyweight adjusting ring and flyweight. 6-147 Removing flyweight housing. 6-148 Removing advance vane housing and vane. 6-148 Removing or installing injection pump drive gearshaft ball bearing retaining ring. 6-149 Removing injection pump drive gearshaft ball bearing. 6-149 Removing or installing automatic advance vane, housing, seals, and springs. 6-150 Removing rear bearing support using suitable gear puller. 6-150 Removing accessory drive bevel gearshaft ball bearing using suitable gear puller. 6-150 Removing advance vane housing cover, gearshaft plug, and retaining ring. 6-151 Rear fan and accessory drive housing and base studding assembly. 6-153 Determining shim thickness for rear fan driven gearshaft and rear fan drive bevel gearshaft. 6-158 6-159 Determining shim thickness for accessory drive bevel gearshaft bearing. Pressing bevel gearshaft ball bearing on gearshaft, 6-160 Installing advance vane housing cover on accessory drive bevel gearshaft. 6-160 Pressing drive gearshaft ball bearing on drive gearshaft. 6-161 Installing advance vane housing and vane. 6-161 Installing flyweight housing. 6-162 6-162 Installing advance flyweight adjusting ring and flyweight. Installing injection pump drive gearshaft. 6-163 Installing advance flyweight adjusting ring and injection pump drive 6-163 gearshaft attaching parts (adjusting ring secured with nuts). Installing advance flyweight adjusting ring and injection pump drive 6-164 gearshaft attaching parts (adjusting ring secured with bolts). 6-165 Test stand assembly - FSN -4910-986-9873. 6-166 Test stand with coupling guard and housing cover removed. 6-167 Test stand heater control and supply tanks. 6-168 Fuel injector advance unit curve. 6-169 Fuel injection pump advance assembly adjusting ring. 6-170 Pressing driven gearshaft ball bearing on spur gearshaft. 6-171 Assembling rear fan and accessory drive housing. 6-172 Installing fuel injection pump splined drive coupler half. 6-172 Installing fuel injection pump diaphragm drive coupler half. 6-173 Installing fuel injection advance bearing cap. 6-174 Removing or installing lifting eye, intercylinder hose flanges, and hoses. Removing or installing camshaft drive adapter and associated parts. 6-175 Disassembling or assembling camshaft drive adapter and associated parts 6-175 Removing or installing right camshaft assembly. 6-176 Disassembling or assembling camshaft assembly. 6-176 6-177 Removing or installing right camshaft end plate. Disassembling or assembling right camshaft cover plate. 6-178 Improvised camshaft trueing device. 6-179

xxi

Figure Number 6-215 6-216 6-217 6-218 6-219 6-220 6-221 6-222 6-223 6-224 6-225 6-226 6-227 6-228 6-229 6-230 6-231 6-232 6-233 6-234 6-235 6-236 6-237 6-238 6-239 6-240 6-241 6-242 6-243 6-244 6-245 6-246 6-247 6-248 6-249 6-250 6-251 6-252 6-253 6-254 6-255 6-256 xxii

Title Removing or installing camshaft end plate ball bearing retaining ring and ball bearing. Removing camshaft end plate ball bearing. Removing or installing cross shaft levers and bracket. Removing or installing cross shaft shock spring and control lever. Disassembling or assembling intermediate throttle lever support. Disassembling or assembling cross shaft lever, bracket, and adjustable control rod. Removing or installing transmission oil cooler bypass valve and shroud plate. Removing or installing engine right oil cooler hose connector elbows. Removing or installing engine right oil cooler thermostatic bypass valve. Oil cooler cleaning equipment setup - schematic diagram. Disassembling or assembling cooling fan and cooling fan hub. Removing or installing front and rear cooling fan housings. Removing or installing cooling fan shroud rails and cover plates. Removing or installing manifold heater assembly. Disassembling or assembling manifold heater assembly. Removing or installing air outlet tube and associated parts. Removing or installing heater tube. Removing or installing intake manifold tube attaching parts. Removing or installing flanges and associated parts from cylinder Nos. 5R and 6R intake manifold tubes. Removing or installing intake manifold tubes for cylinder Nos. 3R and 4R. Removing or installing right intake manifold elbow. Right and left intake manifold - stud identification. Disassembling or assembling oil filler and oil level indicator tubes (one piece oil filler and indicator tubes without splash pan drain ). Disassembling or assembling oil filler and oil level indicator tubes (improved oil filler indicator tubes with splash pan drain ). Disassembling or assembling oil level indicator tube cap (relocated oil filler tube ), Disassembling generator cradle, support, and U bolt. Removing or installing fuel check valve tubes and fittings. Deleted Fuel check valve flow diaphragm. Disassembling or assembling primary fuel filter. Disassembling or assembling secondary fuel filter. Disassembling or assembling fuel/ water separator. Disassembling or assembling secondary fuel filter and fuel / water separator drain valves. Comparison of serviceable original production and improvised design sleeves - fuel injection pump tube ends. Comparison of serviceable sleeves - injector nozzle tube ends. Disassembling or assembling generator air intake tube assembly. Disassembling or assembling manifold heater fuel filter. Disassembling or assembling fuel injection pump drive splined coupler. Disassembling or assembling fuel injection pump drive diaphragm coupler. Piston oiler nozzle and holder assembly. Time totalizing meter. Time totalizing meter electric reset device - 6645-179-2712.

Page 6-181 6-181 6-181 6-182 6-182 6-183 6-185 6-186 6-186 6-187 6-190 6-191 6-192 6-194 6-195 6-195 6-196 6-196 6-196 6-197 6-197 6-198 6-199 6-200 6-200 6-201 6-203 6-204 6-204 6-205 6-206 6-207 6-208 6-210 6-211 6-212 6-214 6-215 6-216 6-216 6-217 6-218

Figure Number 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9 7-10 7-11 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21 7-22 7-23 7-24 7-25 7-26 7-27 7-28 7-29 7-30 7-31 7-32 7-33 7-34 7-35 8-1 8-2 8-3

Title Installing starter idler gear. Installing main bearing caps using crankcase spreading tool - 5120-5757767. Checking crankshaft end play. Measuring main bearing stud stretch using dial indicator. Checking accessory drive gear and starter idler gear backlash. Installing candlewick packing between crankcase and oil seal housing support. Correct position of crankshaft oil seal split line before installing seal retainer. Installing flywheel using eye bolt - 5306-017-6143. Checking flywheel runout using dial indicator. Oil pump mounting flange oil discharge locations. Piston installation position marks. Installing piston in cylinder assembly using compressor and gage - 4910-7957956. Installing cylinder assemblies on crankcase. Early oil pan ( 10865039) drain plug location - limited to M60 series vehicles. Late oil pan ( 10912261) drain plug location for universal vehicle application. Protecting openings to prevent entrance of dust and foreign objects. Installing rear fan and accessory drivehousing using fan and advance unit housing sling - 4910-795-7954. Installing front fan drive housing assembly using improvised lifting tool. Engine with cylinders, front fan drive housing, and rear fan and accessory drive housing assemblies installed. Flywheel timing mark locations. Positioning engine flywheel using splined wrench - 5120-793-7895. Installing valve rocker arm cover and adjusting intake valve clearance (cylinder No. 6R). Adjusting exhaust valve clearance. Determining closing point of No. 6 intake valve. Installing camshaft drive shaft. Installing right camshaft oiltransfer plug. Correct position of cylinder 1 R camshaft lobes (cams) for fuel injection pump installation - installed view. Correct position of camshaft lobes (cams) for fuel injection pump installation . sectional view. Removing fuel injection pump drive gear train backlash and setting advance unit retard position - diaphragm coupling. Installing camshaft intercylinder hose flange bolts. Fuel injector clamps, supports and tubes - installed view. Fuel injector nozzle fuel return tube between cylinder numbers 6L and 5L engines with tubes. Fuel injector nozzle fuel return hose between cylinder numbers 6L and 5L engines with hoses. Overall view of engine showing progress of engine assembly at this point. Assembling generator cradle, support, and U bolt. Engine connection points - right front view. Engine connection points - left rear view. Mean perform ante curve.

7-2 7-3 7-3 7-4 7-5 7-5 7-5 7-6 7-6 7-7 7-8 7-9 7-10 7-11 7-11 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-18 7-19 7-19 7-20 7-20 7-21 7-21 7-22 7-25 7-25 7-26 7-28 7-29 8-4 8-5 8-6 xxiii

Figure Number 8-4 8-5 8-6 8-7 8-8 8-9 8-10 B-1 B-2 B-3 B-4 B-5 B-6 B-7 B-8 B -9 B-10 B-11 B-12 B-13 B-14 B-15 B-16 B-17 B-18 B-19 B-20 B-21 B-22 B-23 B-24 B-25 B-26 B-27 B-28 B-29 B-30 B-31 B-32 xxiv

Title Borescope instrument. Checking piston position with brass rod. Borescope instrument in position for cylinder bore inspection. Pressure relief valve, humidity indicator, and pneumatic valve - installed view. Engine mounting bracket - installed view. Interior of lower section of engine container. Transmission adapter - installed view. Engine shipping and storage container. Crankcase and associated parts - partially exploded view. Crankshaft assembly, flywheel damper, bearings and associated parts exploded view. Cylinder and head assembly, piston, connecting rod and associated parts exploded view. Camshaft and drive gears - exploded view. Damper Housing, oil filters and associated parts - exploded view. Oil pan, tubes, brackets, and associated parts - exploded view. Oil pan, baffles, studs, inserts and associated parts - exploded view. Oil pump, tubes and associated parts - exploded view. Cylinder head oil drain tubes and associated parts - exploded view. Breather tube, fire extinguisher tube, electrical lead, oil lines and associated parts - exploded view. Exhaust manifolds and associated parts - exploded view. Intake manifold, tubes, turbosupercharger tie rod and support and associated parts - exploded view. Generator and starter idler and driven gears and shafts - exploded view. Engine and accessories - exploded view. Fuel injection pump coupler assembly and nozzle and holder assembly exploded view. Fuel injection pump lines, injector nozzle lines and associated parts - exploded view. Throttle linkage - exploded view. Primary and secondary pressure fluid filters, water separator, brackets, hoses and associated parts - exploded view. Secondary pressure fluid filter, primary pressure fluid filter, water separator and pressure fluid filter assemblies - exploded view. Induction heater system - exploded view. Engine shroud - exploded view. Cylinder deflectors and plates - exploded view. Radiators, Shrouds and associated parts - exploded view. Engine cooling fans - exploded view. Front and rear fan drive housing and base assemblies and associated parts exploded view. Automatic injection advance assembly, fan drive clutch assembly and associated parts - exploded view. Generator exhaust tube, boot and associated parts - exploded view. Special tools Special tools. Test equipment Reusable shipping container - exploded view.

Page 8-9 8-9 8-9 8-14 8-14 8-15 8-17 B-168B B-169B B-170B B-171B B-172B B-173B B-174B B-175B B-176B B-177B B-178B B-179B B-180B B-181B B-182B B-183B B-184B B-185B B-186B B-187B B-188B B-189B B-190B B-191B B-192B B-193B B-194B B-195B B-196B B-197B B-198B B-199B

List of Tables Table Number 2-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 5-1 5-2 5-3 5-4 5-5 Title Special Tools and Equipment for Direct Support, General Support and Depot Maintenance Engine Accessories Main and Auxiliary Oil Filter Bypass Valves, Oil Pressure Regulating Valve, and Fuel / Water Separator Filter Assembly Cooling Fan Clutch Assembly Intake Manifold Tubes and Intake Manifold Assembly Engine Oil Pan Valve Rocker Arms, Rocker Arm Shafts and Valve Clearance Adjusting Screws Fuel Injector Nozzle and Holder Assembly Flywheel and Crankshaft Oil Seal Service Operations Draining Engine Oil and Removing Engine Accessories Shrouding, Cooling Fans, Oil Coolers, Beams, and Associated Parts Manifold Heater Tubes, Solenoids and Filter, Cylinder Head Oil Drain Lines, and Intake Manifold Assemblies Fuel Filters, Throttle Linkage, Front and Rear Shrouds, and Oil Filler and Indicator Tubes Fuel Injector Tubes, Supports, and Clamps, Exhaust Pipes and Manifold, Fuel Inlet and Return Hoses, Crankcase Breather Tubes, and Turbosupercharger Base, Supports and Tie Rods Throttle Control Rods and Lever, Fuel Injection Pump Oil Inlet Hose, Turbosupercharger Oil Inlet Hose and Fire Extinguisher Tube, and Fuel Injection Pump Shrouds, Cylinder Deflectors, and Nozzle Holder Assemblies Camshafts, Fan Drives, Housings, and Bases Oil Pan, Crankshaft Damper and Oil Filter Housing, Cylinder Air Deflectors, Cylinder Assemblies, and Pistons and Pins Oil Pump, Oil Tubes, Vibration Damper, Starter and Generator Drive Adapters Flywheel, Transmission Adapter, Crankshaft Oil Seal, and Accessory Drive Gear Crankshaft and Connecting Rod Assembly, Piston Oiler Nozzles, Generator and Starter Idler Gears, and Starter Driven Shaft Crankcase Assembly, Transmission Adapter, and Starter and Generator Drive Components Crankcase Assembly Overhaul Standards Crankcase Standard and Oversize Stud Identification Starter Driven Gearshaft Overhaul Standards Generator Drive Overhaul Standards Generator Adapter Standard and Oversize Stud Identification Generator and Starter Idler Gears Overhaul Standards Connecting Rods, Crankshaft and Associated Parts Connecting Rods, Crankshaft and Associated Parts Overhaul Standards Torsional Vibration Damper, Flywheel, Accessory Drive Gear, and Transmission Drive- GearShaft Page 2-4 4-2 4-45 4-50 4-53 4-58 4-62 4-80 4-88 4-94 5-1 5-4 5-13 5-18

5-33

5-6

5-7 5-8 5-9 5-10 5-11 5-12 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10

5-49 5-58 5-61 5-74 5-83 5-91 5-97 6-11 6-18 6-22 6-27 6-29 6-30 6-32 6-33 6-37 6-42 xxv

Table Number 6-11 6-12 6-13 6-14 6-15 6-16 6-17 6-18 6-19 6-20 6-21 6-22 6-23 6-24 6-25 6-26 6-27 6-28 6-29 6-30 6-31 6-32 6-33 6-34 6-35 6-36 6-37 6-38 6-39 6-40 6-41 6-42 6-43 6-44

Title Torsional Vibration Damper, Flywheel, Accessory Drive Gear, and Transmission Drive Gearshaft Overhaul Standards Pistons, Rings, and Piston Pins Pistons, Piston Rings, and Piston Pins Overhaul Standards Cylinder Assembly Cylinder Assembly Overhaul Standards Cylinder Standard and Oversize Stud Identification Oil Pump, Oil Pan, Damper and Oil Filter Housing and Associated Parts Visual Oil Pump Identification Characteristics Oil Pump Overhaul Standards Oil Pump Standard and Oversize Stud Identification Oil Pan Standard and Oversize Stud Identification Crankshaft Damper and Oil Filter Housing Control Valves - Overhaul Standards Crankshaft Damper and Oil Filter Housing Standard and Oversize Stud Identification Front Fan Drive Housing and Clutch Assembly Front Fan Drive Housing Assembly Overhaul Standards Early Cooling Fan Clutch Overhaul Standards Late Cooling Fan Clutch Overhaul Standards Front Fan Drive Housing Standard and Oversize Stud Identification Rear Fan Drive Housing and Clutch Assembly and Accessory Drive Housing Rear Fan and Accessory Drive Housing Assembly Overhaul Standards Fuel Injection Pump Advance Unit Assembly Overhaul Standards Rear Fan and Accessory Drive Housings Standard and Oversize Stud Identification Camshaft and Throttle Control Cross Shaft and Fuel Injection Pump Linkage Camshafts and Drives Overhaul Standards Camshaft Drive Housing and Cover Plate Standard and Oversize Stud Identification Throttle Control Cross Shaft and Fuel Injection Pump Linkage Overhaul Standards Engine and Transmission Oil Coolers and Engine Cooling Fan Engine Oil Cooler Standard and Oversize Stud Identification Engine Shrouding and Associated Components Intake Manifolds, Exhaust Manifolds and Tubes, Cylinder Head Oil Drain Tubes, and Oil Filler and Indicator Tubes Manifold Heater Induction and Intake Manifold Standard and Oversize Stud Identification Generator and Starter Supports, Fuel Check Valve, Primary and Secondary Fuel Filters, and Fuel / Water Separator Generator and Starter Support Standard and Oversize Stud Identification Fuel Injection Pump Fuel Tubes, Fuel Injector Nozzle Fuel Return Tubes, Injection Pump and Turbosupercharger Oil Hoses, and Generator Air Intake and Exhaust Tubes and Associated Parts Crankcase Breather Tubes, Fire Extinguisher Tube, Injection Pump Electrical Lead, and Manifold Heater Fuel Tubes, Filter, and Electrical Components

Page 6-45 6-47 6-49 6-51 6-57 6-72 6-75 6-75 6-85 6-87 6-96 6-106 6-108 6-109 6-127 6-128 6-128 6-129 6-134 6-154 6-155 6-156 6-174 6-180 6-180 6-184 6-185 6-189 6-191 6-193 6-198 6-201 6-202

6-209

6-45

6-213

xxvi

Table Number 6-46 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9

7-10 7-11 7-12 7-13 8-1 8-2 8-3 8-4 8-5 8-6

Title Fuel Injection Pump Drive Couplers, Fuel Injector Nozzles, Piston Oiler Nozzles and Time Totalizing Meter Starter Drive Gearshaft, Generator and Idler Gears, Piston Oiler Nozzles, and Crankshaft and Connecting Rod Assembly Accessory Drive Gear, Crankshaft Oil Seal, Transmission Adapter, and Flywheel Starter and Generator Drive Adapters, Vibration Damper, Sending Units, Oil Pump, and Oil Tubes Pistons and Pins, Cylinder Assemblies, Cylinder Air Deflectors, Crankshaft Damper and Oil Filter Housing, and Oil Pan Fan Drives, Housings, and Bases Cam shafts, Fuel Injection Pump, and Rocker Arm Covers Nozzle and Holder Assemblies, Cylinder De-Flectors, and Shrouds Turbosupercharger Oil Inlet Hose and Fire Extinguisher Tube, Fuel Injection Pump Oil Inlet Hose, and Throttle Control Rods and Lever Turbosupercharger Base, Supports, and Tie Rods, Fuel Inlet and Return Hoses, Crankcase Breather Tubes, Exhaust Pipes and Manifolds, and Fuel Injector Clamps, Supports, and Tubes Oil Filler and Indicator Tubes, Rear and Front Shrouds, Throttle Linkage, and Fuel Filters Intake Manifold Assemblies, Cylinder Head Oil Drain Lines, and Manifold Heater Tubes, Solenoids, and Filter Oil Coolers, Beams, Cooling Fans, Shrouding, and Associated Parts Installing Engine Accessories Overhaul Test Schedule - Beam Length 1.75 Ft. (or 21.008 in. ) Air Entrance Temperature Correction Air Entrance Pressure Correction Fuel Temperature Correction Fan Horsepower to be Used for Correcting Engine Gross Horsepower 50 Hour Quality Control Test

Page 6-215 7-2 7-4 7-7 7-8 7-12 7-16 7-23 7-23

7-23 7-26 7-27 7-27 7-28 8-7 8-10 8-10 8-11 8-11 8-13

xxvii

Figure 1-1. AVDS-1790-2-M, AVDS-1790-2-AM, and AVDS-1790-2A engine assembly without time totalizing meter-right front view.

xxviii

Figure 1-2. AVDS-1790-2-M, AVDS-1790-2-AM, and AVDS-1790-2A engine assembly with secondary fuel filter-left front view.

xxix

Figure 1-3. AVDS-1790-2-M, AVDS-1790-2-AM, and AVDS-1790-2A engine assembly with secondary fuel filter-front view.

xxx

Figure 1-4. AVDS-1790-2A engine assembly with time totalizing meter-right front view.

xxxi

Figure 1-5. AVDS-1790-2A engine assembly with fuel / water separator filter-left front view.

xxxii

Figure 1-6. AVDS-1790-2A engine assembly with fuel/ water separator filter-front view.

xxxi

Figure 1-7. AVDS-1790-2A engine assembly with relocated oil filler tube-rear view.

xxxiv

CHAPTER 1 INTRODUCTION

Section I. GENERAL
1-1. Scope a. This technical manual contains instructions for direct support, general support and depot maintenance, and listings of repair parts and special tools for the 12-cylinder, Model AVDS1790-2-M, AVDS-1790-2AM, and AVDS-17902A engines (figs. 1-1 through 1-3 and 1-7) and the AVDS-1790-2A engine (figs. 1-4 through 17). Included are descriptions of and procedures for, removal of engine accessories and components, troubleshooting, disassembly, inspection, including engine overhaul standards, repair, reassembly, and testing of the engines. b. Appendix A contains a list of current references, including supply manuals, forms, technical manuals, and other available publications applicable to the materiel. c. Appendix B contains an illustrated list of all parts and special tools with the estimated quantities of component parts and equipment authorized and stocked for Direct Support, General Support and Depot Maintenance of the engines. d. Appendix B also contains illustrated parts on fold-out pages for rapid reference. e. This edition of the manual supersedes Field Maintenance edition of TM 9-2815-200-34 (February 1963), Field and Depot Maintenance edition of TM 9-2815-200-35 (August 1960) with changes, and Field and Depot Maintenance Repair Parts and Special Tool List edition of TM 9-2815-200-35P (November 1962). Record any errors or omissions on DA Form 2028 (Recommended Changes for DA Publications), and forward it to: The Commanding General, U.S. Army Tank Automotive Command, 28251 Van Dyke, Warren, Michigan 48090, Attn: AMSTRA-TP. 1-2. Reference to Other Manuals a. TM 9-2350-214-10, TM 9-2350-215-10, TM 9-2350-222-10, TM 9-2350-224-10, TM 55420-202-10, and TM 9-2350-232-10 contain operating instructions for the materiel as well as instructions for performing operator / crew maintenance functions. b. TM 9-2350-214-20, TM 9-2350-215-20, TM 9-2350-222-20, TM 9-2350-224-20, TM 55420-202-20, and TM 9-2350-232-20 contain pertinent Maintenance Allocation Charts (MAC ) and instructions for the maintenance of the materiel within the scope of organizational maintenance. c. L() 9-2350-214-12, LO 9-2350-215-12, LO 9-2350-222-12, LO 9-2350-224-10, LO 5-5420202-20-1, LO 5-5420-202-20-1, and LO 9-2350232-10 contain lubricating instructions for the materiel. d. TM 9-2910-212-34 contains service information on the American Bosch fuel injection metering pump. e. TM 9-2910-213-34 contains service information on the Viking vane type fuel pump. f. TM 9-2920-224-35 contains service information on the Model G22-6 and G22-6F Lear Siegler (formerly Jack and Hientz) generators. g. TM 9-2920-232-34 contains service information on the Delco-Remy starter. h. TM 9-2990-200-34 contains service information on the Schwitzer turbosuperchargers. 1-3. Scope of Manual a. Chapters 1 through 3. Chapter 1 provides general inform ation, description, and tabulated data. Chapter 2 contains a list of special tools and equipment required for field maintenance, illustrates three improvised tools, and includes a shop layout for engine rebuild. Chapter 3 covers engine troubleshooting and includes a chart to assist in location of troubles, and corrective action necessary. b. Chapter 4. This chapter covers the direct support maintenance service operations supplementing the Organizational Maintenance Manuals in paragraph 1-2, above. c. Chapters 5 and 6. Chapter 5 gives information - on preparation of the engine for disassembly, removal of engine accessories, and

1-1

the disassembly of the engine into subassemblies. Chapter 6 gives information for cleaning, inspection, handling of parts and general repair procedures including overhaul standards, and the disassembly and assembly of the various engine subassemblies and components. d. Chapter 7. This chapter covers the assembly of the engine from subassemblies, and provides pertinent assembly information peculiar to the engine, including installation of accessories. e. Chapter 8. This chapter outlines the test and adjustment procedures required to insure that an engine has been properly repaired. Also included in this chapter is the information relating to the engine container. Complete instructions concerning the removal or installation of the engine, repair of the container and engine preservation and storage have been covered. f. Appendixes and Indexes. ( 1 ) Following Chapter 8 is an alphabetical index for maintenance services outlined in the manual. This index provides a rapid reference to a paragraph and figure in accordance with the subject operation. (2) Appendix A provides a list of

publications which are related to the materiel or its maintenance. (3) Appendix B contains an introduction, a list of parts and special tools, and a Federal Stock Number index. (4) At the back of Appendix B of the manual are fold-out illustrations which provide rapid reference for repair parts identification. These illustrations are numerically keyed to the items in the repair parts text, and also include alphabetical keys for points of measurement for the maintenance manual overhaul standards. 1-4. Organizational, Direct Support, General Support, and Depot Maintenance Allocation Refer to the pertinent maintenance allocation chart in the Organizational Maintenance Manuals (para 1-2). 1-5. Forms, Records and Reports For listings of all authorized forms, refer to the current issue of DA PAM 310-2. TM 38-750 contains instructions on the use of forms for records and reports. Authorized forms for units maintaining this materiel are listed in Appendix A.

Section II D E S C R I P T I O N 1-6. Differences Between Engine Models a. Engineering improvements were developed on the AVDS-1790 series engines to improve engine performance and reliability. b. The following engine models are available in the field : ( 1 ) AVDS-1790-2-M. This original AVDS1790 series engine developed for the M60 vehicle had engine oil pan, Part No. 10865039. In order to use the engine in other vehicles, the oil pan had to be redesigned. Because engine interchangeability was affected it was necessary to change the engine model when the new oil pan was installed on the engine. AVDS-1790-2-M engines with the new oil pan are identified as AVDS-1790-2-AM models. (2) AVDS-1790-2-AM. This was an original AVDS-1790 series engine with a new engine oil pan, Part No. 10912261, which permitted the engine to be used as a replacement engine in certain gasoline engine powered vehicles. The oil pan change was the only dif1-2 ference between this engine model and the AVDS-1790-2-M model. (3) AVDS-1790-2A. The AVDS-1790 series engines, having the new oil pan and numerous other changes to improve engine performance and reliability, is identified as the AVDS-1790-2A model. Basically all models of the engine are similar except for the oil pan, and other improvements which are as follows: (a) Secondary fuel / water separator filter unit (fig. 1-6) replaced the conventional dual replaceable element type filter (fig. 1-3) in late production. All engines produced with secondary fuel filter shall be updated to water separator filter unit at time of engine overhaul. (b) Relocated oil temperature and pressure transmitters and switches to the front of the engine for ease of maintenance. (c) Optional splined or diaphragm type fuel injection pump drive coupling. (d) Flexible fuel injector nozzle fuel return lines replaced rigid steel tubes to improve service life.

(e) Double lip oil seal in cooling fan drive for deep-water fording to prevent water from entering the engine. (f) An improved fuel injection pump incorporating a filter at the fuel inlet to prevent foreign materials from entering the pump, thereby extending pump life. (g) Simplified and improved cooling fan clutch, eliminating the hydraulic engagement feature. (h) Oil filler tube has been relocated at left rear of left turbosupercharger to prevent oil spillage from plugging cylinder cooling fins and restricting air flow through the engine and transmission oil coolers. The relocation eliminated the need for the oil filler and indicator tube splash pan drain. (i) Primary fuel filter screen type element has been replaced with a high capacity replaceable-type element. (j) Wall thickness of cylinders has been increased to improve service life. Cylinders with increased wall thickness can be identified by machine groove around mounting base flange. (k) Drain cocks and hoses on fuel filters were replaced with rigid lines and drain valves located on top of the engine. (l) Additional clamps and supports have been added to fuel injection lines to reduce line breakage from vibration. (m) Added numerous tube and hose clamps and rerouted lines to prevent line failures from chaffing and vibration. (n) Added a preformed packing to starter drive bearing cage, and a flat gasket to the drive adapter to prevent oil leaks. Preformed packings cannot be used on engines which have bearing cages without the groove for the preformed packing. (o) Time totalizing meter added to record total engine operating hours.

left bank of cylinders is numbered IL through 6L. d. Starting from the front, the main bearings are numbered 1 through 7. e. The cylinders, pistons, connecting rods, and connecting rod bearings are numbered with their respective cylinder number locations. 1-8.

General Description

1-7. Location of Engine Components

a. In this manual the terms defined in b through e, below will be used to identify the location of parts and assemblies on the engines. b. The ends of the engines will be called the damper end or front and the flywheel end or rear. c. As viewed from the front end toward the rear, the side to the right will be called the right side and the side to the left will be called the left side. Beginning at the front, the right bank of cylinders is numbered lR through 6R and the

a. The Model AVDS-1790-2-M, AVDS-17902-AM and the AVDS-1790-2A engines are 12cylinder, 90 degree, V-type, 4-cycle, air-cooled, turbosupercharged, diesel engines. The cylinder assemblies are individually replaceable units, with overhead valves and valve rocker assemblies in the head. The cylinders are arranged in two banks of six cylinders each. Each bank of cylinders has an overhead camshaft arrangement to actuate the valves of each cylinder. b. The engines feature a fuel injection system and a turbosupercharged air induction system which obtains optimum engine performance. The fuel injection system has a fuel injection metering pump which supplies metered fuel to through fuel injector individual cylinders nozzles. The fuel supply pump assembly (figs. 13 and 1-6) located at the front of the engine, draws fuel through the primary and secondary fuel systems from the vehicle fuel tanks and delivers it to the injection pump. A turbosupercharger assembly (figs. 1-1, 1-2, 1-4, and 1-5 ) is located on each side of the engine at the rear. The turbosuperchargers are exhaust-gas driven and increase the air flow pressure entering the air intake manifolds (figs. 1-1, 1-2, 1-4, and 1-5). c. The engines are equipped with a 28 volt, 300 amp, dc generator (figs. 1-1 and 1-4) and a 24 volt solenoid operated starter (figs. 1-2 and 15). d. The engines are lubricated by a forced feed system. The system consists of three circuits; i.e., the scavenge circuit, the main or pressure oil circuit, and the piston cooling circuit. These circuits are operated independently by one oil pump which consists of three separate sections. e. The engines are equipped with two intake manifold heaters (figs. 1-1, 1-2, 1-4, and 1-5) which are installed in the air intake systems between the intake manifold elbows and the The heaters, when turbo superchargers. operated, preheat the air entering the cylinders to facilitate cold weather starting and cold weather idle operation. 1-3

f. The engine crankcase is vented by an enclosed crankcase breather system which is vented through the crankcase breather tube (fig. 1-7) at the left turbosupercharger exhaust pipe. g. The engine primary and secondary fuel filters (fig. 1-3) have individual drain lines, with drain cocks, which provide a means of draining the filters to remove water which may be accumulated and to purge the fuel system. Late production AVDS-1790-2A engines have a filter / water separator type secondary filter and drain lines to remove entrained moisture from the fuel (fig. 1-6). 1-9. Accessories Refer to paragraph 1-2 for information on engine accessories. 1-10. The crankcase (fig. l-l) is a one-piece

aluminum casting with forged aluminum main bearing caps. The bearing caps function as an integral part of the crankcase. Each cap is secured on studs with four slotted nuts. Two through bolts clamp the main bearing cap in the tunnel slot of the crankcase. With this type of crankcase and bearing cap construction, uniform load distribution in the bearing area is obtained making possible uniform distribution of combustion forces over the entire crankcase. 1-11. Main Bearings The seven replaceable main bearings are the steel-backed, split type, having copper-lead alloy bearing surfaces. The center main bearing is double-flanged with bearing material to control crankshaft end play and thrust.

Figure 1-8. Legend A - Intake valve rocker arm assembly B - Exhaust valve rocker arm assembly C - Left camshaft assembly D - Camshaft driven gear E - Camshaft drive gearshaft F - Camshaft drive shaft G - Camshaft drive bevel gearshaft H - Accessory drive gearshaft assembly J - Fuel injector pump advance assembly K - Right camshaft assembly L - Transmission accessory drive gearshaft M - Accessory drive gear N - Flywheel P - Generator drive gearshaft Q - Generator idler gear R - Oil pump driven gear S - Piston cooling oil pump driven impeller T - Pressure oil pump driven impeller U - Scavenge oil pump driven impeller V - Oil pump driven shaft W - Scavenge oil pump drive impeller X - Scavenge oil pump driven impeller shaft 1-4

Y - Pressure oil pump drive impeller Z - Piston cooling oil pump drive impeller AA - Oil pump drive gear BB - Starter idler gear CC - Starter driven gearshaft DD - Starter drive gear EE - Front fan drive shaft FF - Fan drive bevel gearshaft GG - Rear fan drive shaft HH - Fan driven gearshaft JJ - Fuel injector pump drive gear shaft KK - Fuel injector pump driven shaft gear LL - Fan drive clutch assembly MM - Cooling fan adapter NN - Rear cooling fan assembly PP - Fan drive bevel gearshaft QQ - Crankshaft assembly RR - Fuel pump drive coupling SS - Fuel pump drive adapter TT - Crankshaft torsional vibration damper UU - Connecting rod assembly VV - Piston WW - Front cooling fan assembly X X - Exhaust valve YY - Intake valve

Figure 1-8. Engine major working parts

1-5

1-12. Crankshaft, Flywheel, and Damper Note. The key letters shown below in parentheses refer to figure 1-8. a. Crankshaft assembly (QQ) is a nitrided steel forging with seven main bearing journals and six crankpins. Each crankpin accommodates two opposing connecting rod assemblies (UU ). Flanges are provided on the crankshaft for mounting the flywheel (N ) on the rear end and a torsional vibration damper (TT ) on the front end. b. All crankpin and main bearing journals are hollow to reduce weight. Holes are drilled diagonally through each main bearing journal and extend through the crank cheek and crankpin to provide a direct passage for oil under pressure to the connecting rod and crankshaft main bearings as shown in figure 1-9. c. The crankshaft and flywheel are statically and dynamically balanced. d. The torsional vibration damper (TT) is a precision viscous type and is replaceable only as an assembly. 1-13. Connecting Rods and Bearings The connecting rod assemblies (UU, fig. 1-8) are tapered, I-beam section steel forgings. A bronze-lined, steel-backed, split, bushing type bearing is pressed into the piston pin end of the rod. The replaceable precision connecting rod bearings are the steel-backed, split type having copper-lead alloy bearing surfaces. 1-14. Pistons, Pins and Rings The pistons (VV, fig. 1-8) are aluminum forgings, cam ground and tapered to provide an accurate fit in the cylinders at operating tern. peratures. The piston dome is machined to the shape of a conical section (toridal shape) so that it tapers into the open type combustion chamber. Each piston is fitted with four rings. The upper three rings are compression rings and the bottom ring is an oil control ring. The heavy walled, tubular, steel piston pins are full-floating in the piston and the connecting rod. Domed aluminum plugs are inserted into each end of the piston pin to center it in the piston and prevent scoring of the cylinder wall.

1-15. Cylinders and Valves Note. The key letters shown below in parentheses refer to figure 1-8 except where otherwise indicated. a. Each cylinder assembly (fig. 1-1) is an individually replaceable unit that consists of a barrel, cooling fin muff, and a cylinder head. The cooling fin muff is cast directly on the steel barrel. The finned, cast aluminum cylinder head is threaded and shrunk on the barrel. Cooling fins, exhaust and intake ports, and a single rocker box are cast integrally with the cylinder head. Valve guides and seats are shrunk into place in the head, The cylinder barrel is choked at the head end to provide a straight bore under running conditions. A mounting flange is machined on the cylinder barrel near the base to provide an attachment of the cylinder to the crankcase. The cylinder assembly is secured to the crankcase with studs and nuts. An outer extension of the cylinder head encloses a recess or rocker box, which houses the valves, valve springs, and related parts. Rocker arm assemblies (A and B ) are held in place by rocker shafts in the cylinder head valve rocker support cover. b. A camshaft bearing surface is provided in each cylinder. The camshaft bearing is bored with the cylinder head valve rocker support cover in place. Therefore the covers are not interchangeable and each must remain as a part of a specific cylinder assembly. Identifying numbers are used on cylinder and covers to prevent mismatching. Counterbores in the rocker box. and rocker support covers accommodate the intercylinder rubber hoses and the steel flanges which enclose the camshaft between the cylinders. c. The stem of the intake valve (YY) and exhaust valve (XX ), for each cylinder, extends into the rocker box. Three nested springs, compressed between two retainers and secured to the valve stem by two cone-shaped locks, hold each valve to its seat. Each exhaust valve has a positive valve rotator which also serves as the lower spring retainer. Valve clearance adjusting screws with flat swivel pusher pads are mounted on one end of the valve rocker arms (A and B).

1-6

d. Forged steel valve rocker arms (A and B ) with roller cam-followers are used. The rollers are hardened and honed to provide an extremely smooth and permanent contact surface. Hollow rocker arm shafts and drilled passages in the rocker arms convey oil to all moving parts. 1-16. Camshafts Note. T h e k e y letters shown below in parentheses refer to figure 1-8. a. The left and right camshaft assemblies (C and K) are mounted, one on each bank, on the cylinders and operate the valve mechanism. The camshafts are hollow to provide oil passages for pressure lubrication to the valve parts and to permit deflection when the cylinders fire, Tubular molded rubber hoses enclose the camshafts between cylinders. b. Each camshaft is driven by the accessory drive gear (M), accessory drive gearshaft assembly (H), camshaft drive bevel gearshaft (G), camshaft drive gearshaft (E), and camshaft driven gear (D) through an inclined quill type camshaft drive shaft (F). The drive shafts can be rem oved to permit separate rotation of the camshafts for engine timing. When camshafts are correctly positioned in relation to the crankshaft, the drive shafts have different number of splines on each end and this allows them to be inserted in the camshaft bevel gearshafts without disturbing relationship between camshafts and crankshaft.

1-17. Lubrication System (figs. 1-9 and 110) a. General. The main pressure oil pump draws oil from the pressure oil pump compartment in the oil pan. This compartment is fed by the scavenge oil pump which picks up oil from both ends of the engine oil pan. The pressurized oil is forced through the engine oil coolers and main oil filter to the engine oil galleries and bearings. A pressure regulator valve, located on the right side of the crankshaft damper and oil filter housing, is influenced by the pressure in the main bearing oil gallery and returns the incoming excess unfiltered oil to the oil pan. A small portion of the pressure oil is diverted, after passing through the main oil filter, and passes through the auxiliary oil filter to provide the turbosuperchargers and the fuel injection pump with oil having a greater degree of filtration. The piston cooling oil pump picks up oil from the end compartment (rear) of the oil pan and delivers it to the piston oil sprayer nozzles. These nozzles are located in the crankcase, below each cylinder, and provide a continuous oil spray to the pistons and cylinder walls. b. Oil Pan. The oil pan (figs. 1-1 and 1-4) is a one-piece, aluminum alloy casting divided into a pressure oil pump compartment, oil reserve compartment, and the end compartments at the front and rear of the pan. The oil pan is designed to maintain a constant oil level above the main pressure oil pump pickup tube in the pressure oil pump compartment during vehicle operation regardless of the angle at which the engine may be inclined.

1-7

Figure 1-9. Engine lubrication) system.

1-9

Figure 1-10. Engine oil flow controlschematic diagram.

1-11

c. Oil Pump. The oil pump assembly consists of three sections combined as a single unit. The twin scavenge oil pump section of the unit picks up oil from the front and rear compartments of the oil pan and delivers it to the main pressure pump oil compartment. The main pressure oil pump section picks up oil from its respective compartment and supplies oil to the engine oil galleries and bearings. The piston cooling oil pump section picks up oil from the rear sump section of the oil pan and supplies oil to the piston oil sprayer nozzles (a, above). d. Oil Filters and Control Valves. The main and auxiliary oil filters (figs. 1-3 and 1-6) and the bypass valves are located in the crankshaft damper and oil filter housing at the front of the engine. All engine oil passes through a screen type main oil filter. Engine oil, which lubricates the fuel injection pump and the two turbosuperchargers (figs. 1-1, 1-2, and 1-4), is further filtered by a replaceable element type auxiliary oil filter. Two oil filter bypass valves are used, one for the main oil filter and one for the auxiliary oil filter. The main oil filter bypass valve opens at a differential pressure of 35.6 psi and the auxiliary oil filter bypass valve at a differential pressure of 15 psi. The bypass valves permit oil to bypass the filters in the event that they become clogged. 1-18. Fuel System a. Fuel Supply Pump Assembly. The engine driven vane type fuel supply pump assembly (figs. 1-3 and 1-6) is used to supply fuel under pressure to the fuel injection pump. The fuel pump is crankshaft driven by the fuel pump

drive adapter (SS, fig. 1-8) and the drive coupling (RR ) located at the front of the engine. b. Fuel Injection Metering Pump. The fuel injection metering pump is located in the V of the engine between the fan drive housings, and supplies fuel under high pressure to each cylinder. The pump is driven at engine speed from the fan drive housing located at the rear of the engine. A fuel injector pump advance assembly (J, fig. 1-8) is incorporated in the accessory drive housing to automatically provide a gradual degree advance of injection timing during the engine speed range from idle to 1800 rpm. c. Fuel Injector Nozzles and Tubes. T w e l v e fuel injector nozzles (fig. 1-11), one per cylinder, are used to inject fuel into the combustion chambers, Twelve fuel injector tubes of equal length carry the fuel from the fuel injection pump to the nozzles. The nozzles on each cylinder bank are interconnected by fuel return lines to provide a path for the return of excess fuel. d. Fuel Purge System. A manually operated purge pump is provided in the vehicle operators compartment and is used to clear the engine main fuel system and flame heater system of air, and fill them with fuel. Purged air is forced through the main fuel tubes into the fuel return lines and on to the vehicle fuel tanks. The fuel filters contain drain lines, with manually operated valves, which are used to drain the water from the filters, and for purging the fuel system.

1-12

Figure 1-11. Main fuel systemschematic diagram.

1-13

e. Fuel Filters (figs. 1-3 and 1-6). T h e replaceable element type primary fuel filter is mounted on the right front of the engine and contains a fuel drain or purging line. The replaceable element type secondary fuel filter, or the water / separator type filter, is mounted on the left front of the engine. Each filter has a drain or purging line connected to separate drain cocks mounted on a common bracket on top of the engine. Each drain cock is fitted with a flexible hose for dumping drainage from the filters. Fuel from the vehicle fuel tank passes through the primary filter before entering the engine fuel pump. The pump delivers fuel to the secondary filter, or the fuel / water separator filter on late engines and on to the fuel injection pump. Excess fuel bypasses the fuel injection pump and is returned to the fuel tanks (fig. 111). The fuel/ water separator filter unit has three replaceable elements, and contains a chamber for collecting water. The unit provides moisture-free and uncontaminated fuel to the injection pump. f. Fuel Cutoff Solenoid. An electrically operated fuel cutoff solenoid is mounted in the

fuel injection pump. The solenoid is normally open. A switch in the vehicle drivers compartment actuates the ciruit to close the solenoid. Closing the solenoid cuts off fuel delivery from the fuel injection pump and stops the engine. g. Fuel Return Check Valve. A fuel return check valve (fig. 1-11) is installed between the fuel injection pump fuel return outlet and the fuel return hose assembly. The valve prevents fuel flowing back to the injection pump when the fuel supply is closed. 1-19. Manifold Air Induction and Heater System a. Turbosupercharger Assemblies. Exhaust gas driven turbosupercharger assemblies (figs. 11, 1-2, and 1-4), one for each bank of cylinders, are mounted on each side of the engine, at the rear. The turbosuperchargers increase the pressure of the intake air, thereby delivering a higher density air to the cylinders as compared with a non-supercharged engine. This higher density air, with a proper fuel flow, increases engine power.

1-15

Figure 1-12. Manifold air induction heater systemschematic diagram.

1-16

b. Intake Manifold Heater (fig. 1-12). (1) The intake manifold (figs. 1-1 and 1-5) which distributes induction air to each bank of cylinders is equipped with an electrically operated flame type intake manifold heater. The heater is provided as an aid for cold weather starting and cold weather operations. Operation of the heater switch (in the vehicle operators compartment) energizes the manifold heater fuel solenoid valve, the heater ignition unit, and spark plug for each heater simultaneously. Fuel is hand pumped through the manifold heater fuel filter and fuel solenoid valve and sprayed into the intake manifold. The fuel is ignited by the spark plug and burns in the intake manifold as the engine is cranking, and the flame heats the incoming air. This flame-heated air and the products of combustion are fed directly into the cylinders with little heat loss. This results in an immediate engine response, and assures complete combustion at low engine rpm and at noload operating conditions with low ambient temperature. (2) The manifold heater fuel inlet solenoid valve prevents fuel pumped by the fuel pump assembly from entering the air intake manifold heater unless the heater system is energized. A manifold heater fuel return solenoid valve is located at the rear of the engine. The valve is also energized (opened ) when the ignition unit and heater spark plugs are energized to permit excess fuel to be returned to the fuel tanks. The main fuel check valve prevents back flow of the fuel when the purge pump in the drivers compartment is actuated. 1-20. System Exhaust and Turbosupercharger a. The exhaust system consists of four manifolds, one for each group of three adjacent

cylinders. The two exhaust manifolds on each cylinder bank are connected to the turbosupercharger on their respective side of the engine. b. Exhaust gases from each side of the engine enter a turbosupercharger and are forced around a turbine housing, radially inward, and through a nozzle ring, toward the turbine wheel. The exhaust gases drive the turbine wheel which in turn, drives the compressor wheel since both wheels are on a common shaft. Intake manifold air enters at the center of the compressor wheel and flows radially outward through a diffuser section into the compressor housing. The air at increased velocity then leaves through a tangential outlet on the outside of the compressor housing, and enters the intake manifold. c. The exhaust gases are expelled from the turbosuperchargers into the vehicle exhaust system. 1-21. Cooling System Note. The key letters shown below in parentheses refer to figure 1-8. a. Fans. The top of the engine is shrouded to house two cooling fans (WW and NN) which draw cool air from the underside of the engine, through the cylinder fins, and discharge the hot air vertically from the top shroud. The fans are attached to adapters (MM) and are mounted on shafts which are driven through a fan drive clutch assembly (LL). The rear fan clutch is driven by the rear fan drive shaft (GG), fan drive bevel gearshaft (FF), and fan driven gearshaft (HH). The front fan clutch is driven by the front fan drive shaft (EE ) and another fan driven gearshaft (HH).

1-17

Figure 1-13. Piston actuated cooling fan clutchsectional view.

1-18

b. Fan Drive and Clutch (figs. 1-13 and 1-14). The fan clutch is oil cooled. The fan clutch drive and driven disks are loaded by the centrifugal action of clutch balls and springs housed in the clutch assembly. The balls and springs are in the driven member and apply upward force to the clutch disks. The clutch oil enters the fan drive vertical shaft from the fan drive housing through an annular groove in the shaft. The oil flows through a central hole in the shaft to a

distributor where it is dispersed to the ball bearings and to the clutch disks. The oil moves between the clutch disks by centrifugal action and drains back through the fan drive housing into the engine oil pan. Early cooling fan clutches had a hydraulic disengagement feature, The clutch actuating piston (fig. 1-13) for this hydraulic disengagement feature was eliminated on late engines, and the clutch has been greatly simplified and improved (fig. 1-14).

Figure 1-14. Mechanical cooling fan clutchsectional view.

1-19

c. figs. 1-1 figs. 1-4

Figure 1-15.

1-22. figs. 1-15 a. figs. 1-16

b.

1-20

Figure 1-16. Late crankcase breather and fire extinguisher system. 1-23. Sending Units and Switches a. Oil Pressure Sending Unit (fig. 1-1). The
electrical oil pressure gage sending unit on early engines was located at the right rear of the right side of the crankcase in the main oil gallery line. On late engines, for ease of maintenance, the sending unit is relocated to the front of the crankcase at the opening in the gallery line at No. 1 right cylinder. This sealed sending unit consists of a threaded plate to which a diaphragm, a radially notched spring, and an overload guard plate are crimped. Electrical resistance in the sending unit varies directly as the oil pressure varies. The resulting variation in the current is transmitted to the electrical oil gage on the vehicle instrument panel.

b. Low Oil Pressure Warning Light Switch.

The low oil pressure warning light switch is furnished with the engine and it is located at the right rear of the right side of the engine crankcase in the main oil gallery line near No. 5 right cylinder. The electrical contact points in this switch close when the oil pressure in the main oil gallery falls to 1132 psi. The completion of the electrical circuit lights the low pressure warning lamp on the vehicle instrument panel. c. Oil Temperature Sending Unit (figs. 1-1). The oil temperature sending unit is located at the 1-21

upper right side of the crankshaft damper and oil filter housing, d. High Engine Oil Temperature Warning Light Switch (fig. 1-6). The oil temperature warning light switch is located in the oil passage immediately above the oil temperature sending unit in the upper right side of the crankshaft

damper and oil filter housing. The warning light sending switch thermostatically controlled electrical contact points close when oil temperature in the engine main oil passage reaches 245 z65 degrees. The completion of the electrical circuit lights the oil high temperature warning lam p on the vehicle instrument panel.

Section Ill. ENGINE SPECIFICATIONS 1-24. Tabulated Data

a. General. Refer to pertinent Organizational M a i n t e n a n c e M a n u a l s (para 1-2) for the
b.

tabulated data pertaining to the general characteristics and performance of the engine,

c.

1-22

1-23

1-25. Drive Ratios and Rotation (From Front)

1-24

CHAPTER 2 PARTS, SPECIAL TOOLS AND EQUIPMENT, IMPROVISED TOOLS AND SHOP LAYOUT

Section I. REPAIR AND REPLACEMENT PARTS 2-1. General

Authorized repair parts for the engine are listed in Appendix B, which is the authority for requisitioning replacement parts. (1) TM 9-2910-212-34, Pump, Metering, Fuel Injection, Assembly ( 2 ) T M 9 - 2 9 1 0 - 2 1 3 - 3 41 P u m p , F u e l , Engine, Assembly (3) TM 9-2920-224-35, Generator, Engine, Assembly (4) TM 9-2920-232-34, Starter, Engine, Electrical, Assembly (5) TM 9-2990-200-34, charger, Engine, Assembly Turbosuper-

2-2. Repair Parts

a. Repair parts required for the maintenance of the engines are issued to supporting maintenance personnel for the replacement of parts which have been worn, broken or are otherwise unserviceable, and for parts which have been salvaged and stocked for future use on repairable engines. b. Repair parts for engine installation or replacement (attaching or associated external parts) are listed in Organizational repair parts manuals. c. Repair parts for engine accessories are listed in the following technical manuals:

2-3. Mandatory Replacement Parts

To expedite repair and rebuild of the engines, it is economically advantageous to replace certain parts rather than perform the required cleaning and inspection necessary to assure that the parts are suitable for continued use. Gaskets, packings, oil seals, and other similar parts are always replaced at engine rebuild. Refer to Appendix B for 100 percent replacement items.

Section II. SPECIAL TOO LS AND EQUIPMENT FOR DIRECT SUPPORT, GENERAL SUPPORT AND DEPOT MAINTENANCE 2-4. Common Tools and Equipment
Standard and commonly used tools and equipment having general application to the engines are authorized by tables of allowance (TA) and tables of organization and equipment (TOE). 2-5. Special Tools and Equipment The special tools and equipment illustrated in figures B-29 through B-31 and listed in Table 21 are necessary to perform the field maintenance repair, and overhaul operations described in this manual. Refer to Appendix B which is the authority for requisitioning special tools, kits, and equipment. 2-6. Improvised Tools and Equipment The improvised tools illustrated in figures 2-1 and 2-2 apply only to direct support, general support and depot maintenance shops. Principal dimensions are shown to enable maintenance personnel to fabricate tools locally, if desired. These tools are of chief value to maintenance organizations engaged in overhauling a large number of identical components. However, these improvised tools are not available for issue. One of the improvised tools illustrated in figure 2-1 is used for lifting the front fan drive housing and clutch assembly and the other is used for compressing the advance unit cover internal retaining ring. The puller for removing the fuel injection pump diaphragm type coupling is illustrated in figure 2-2. The improvised tool illustrated in figure 2-3 is used to remove the oil pressure regulating valve sleeve.

2-1

Figure 2-1.

2-2

Figure 2-2. Improvised toolcoupling puller

2-3

Figure 2-3 Table 2-1.

Fig. 4-185 Fig. 5-174 Fig. 5-182

Par. 4-22

Par. 5-15

Fig. 4-189 Par. 4-23 Fig. 4-188 Fig. 7-23 Fig. 4-197 Fig. 7-22 Fig. 4-173 Fig. 5-161 Fig. 5-162 Fig. 7-8 Par. 7-10 Par. 4-24 Par. 7-10 Par. 4-20 Par. 5-14 Par. 7-6

Fig. 6-61 Par. 6-33 Fig. 6-62 Par. 7-8

Fig. 7-12

Fig. 4-152 Fig. 4-165 Fig. 4-153 Fig. 6-50

Par. 4-15 Par. 4-14 Par. 6-30

Fig. 6-2 Fig. 4-185

Par. 6-5

Par. 4-22

2-4

Table 2-1. Special Tools and Equipment for Direct Support,

Fig. 6-3

Par. 6-5

Fig. 6-47 Fig. 6-48 Fig. 6-65 Fig. 5-119

Par. 6-29

Par. 6-34 Par. 5-11

Fig. 5-145 Fig. 5-147 Fig. 4-152

Par. 5-12

Par. 4-15

Fig. 4-200 Fig. 5-113 Fig. 5-114 Fig. 7-25 Fig. 7-26 Fig. 5-174 Fig. 5-182

Par. 4-24 Par. 5-11 Par. 7-10

Par. 5-15

Fig. 6-58

Par. 6-33

Fig. 5-152

Par. 5-13

Fig. 6-61

Fig.6-62

Fig. 6-61 Fig. 6-62 Par. 6-33

Fig. 6-61 Fig. 6-62

Fig. 6-44

Fig. 6-59

2-5

Table 2-1. Special Tools and Equipment for Direct SUpport.

Fig. 6-59 Fig. 6-256

Par. 6-33 Par. 6-70

Fig. 5-176 Fig. 5-177 Fig. 5-178 Fig. 5-131 Fig. 7-17 Fig. 5-1 Fig. 4-152 Par. 5-11 Par. 7-9 Par. 5-2 Par. 4-15 Par. 5-15

Fig. 6-141

Par. 6-40

Fig. 4-87 Fig. 5-174 Fig. 7-2 Fig. 5-6 Fig. 6-47

Par. 4-4 Par. 8-2 Par. 5-15 Par. 7-5 Par. 5-5

Par. 6-29 Fig. 6-49 Fig. 6-65 Fig. 6-199 Fig. 6-52 Par. 6-34 Par. 6-42

Par. 6-32

Fig. 6-45 thru 6-57 Par. 4-17

Fig. 4-168

Fig. 4-14

Par. 4-4

Fig. 5-143

Par. 5-12

Fig. 4-7 Par. 4-4 Fig. 4-22

Fig. 4-51 Fig. 5-91 Fig. 7-21 Par. 5-9 Par. 7-10

2-6

Section Ill. SHOP LAYOUT 2-7. General

This section discusses the purpose and maintenance policy pertaining to depot maintenance prescribed in this manual for production-line overhaul or rebuild of the engine. 2-8. Shop Layout The subassemblies are then routed to the various overhaul stations for disassembly, cleaning, inspection, r e p a i r a n d reassembly. The overhauled assemblies are returned to the main assembly l i n e f o r b a s i c e n g i n e a s s e m b l y . Overhauled accessories are installed on the basic engine, a n d t h e e n g i n e i s subjected to a dynamometer acceptance test. b. In actual practice, specific shop layouts will vary according to the physical facilities available and the quantity of engines to be overhauled. Planning for a depot overhaul program must he sufficiently flexible to allow for variations in the condition of the materiel received for processing.

a. The layout (fig. 2-4) shows a typical stationby-station production line setup for overhaul or rebuild of the engine. The engine is steam cleaned and engine oil is drained. The engine accessories are removed and routed to their respective rebuild stations. The basic engine moves along the assembly line through the various stages of disassembly into subassemblies.

Figure 2-4. Typical shop layout.

2-7

CHAPTER 3 TROUBLESHOOTING
Section I. GENERAL 3-1. Purpose of Troubleshooting Note. Information in this chapter is for use of
Direct Support and General Support maintenance personnel in conjunction with and as a supplement to the troubleshooting section in the pertinent organizational manual (refer to Appendix A). It provides the instructions where a remedy in the organizational maintenance maintenance manual refers t o s u p p o r t i n g personnel for corrective action. for determining the trouble without completely disassembling the engine. 3-2. General

Instructions Note. This chapter contains inspection and

troubleshooting procedures to be performed while a malfunctioning engine is still mounted in the vehicle and after it has been removed. a. Visual inspections made while the engine is mounted in the vehicle are performed before attempting to operate the vehicle to avoid damage or injury as well as to determine the cause of the malfunctioning engine. b. T r o u b l e s h o o t i n g p e r f o r m e d w h i l e t h e engine is installed in the vehicle beyond the scope of the using organization, is performed to determine if the malfunction can be remedied without removing the engine from the vehicle, and, when subsequent removal is necessary, to indicate when repair can be made without complete engine disassembly. c. Troubleshooting a malfunctioning engine after it has been removed from the vehicle c o n s i s t s o f subjecting it to tests on a dynamometer. This chapter discusses those symptoms which can be diagnosed by using testing equipment, interprets results in terms of probable causes, and recommends appropriate corrective action. d. Tests and adjustments prescribed for an engine after assembly (para 8-5) may be applied to the engine in which the malfunction is suspected. Particular attention should be given to proper oil level, fuel pressures and proper adjustments when operating the engine to determine appropriate corrective action to be taken for the malfunction.

a. Prevent Damage. Operation of a deadlined vehicle without a preliminary examination can cause further damage to the engine and possible injury to personnel. By careful inspection and troubleshooting, such damage and injury can be avoided. In addition, the cause of faulty operation can often be determined without extensive disassembly. b. Precautions by Inspection. Most of the inspections are visual inspection and are to be perform ed before attempting to operate the vehicle. These inspections are mainly to determine the condition and to take precautions to prevent further damage. c. Troubleshooting While Mounted. T h e troubleshooting performed while the engine is mounted in the vehicle is that which is beyond the normal scope of the using organization. Check the troubleshooting section of the pertinent organizational manual, then proceed as outlined in this chapter. d. Troubleshooting Engine only. If the engine only is received, inspection should be performed to verify the diagnosis made while the engine was installed in the vehicle. This inspection, to uncover further defects or to determine malfunction, is important as it is the only means

Section II. TROUBLESHOOTING PROCEDURES 3-3. General

Most engine troubles are actually engine accessory troubles. The troubleshooting portion of pertinent organizational maintenance manuals, normally, will cover troubleshooting of all engine accessories while mounted on the engine. For complete coverage of accessories, refer to pertinent manuals listed in paragraph 12 4 . T h e p r o c e d u r e s for troubleshooting the engine assembly and the accessory systems are listed in paragraphs 3-4 through 3-11. Engine malfunctions are referenced to the appropriate accessory system for corrective action, when applicable. 3-1

3-4. Troubleshooting Engine Assembly

TM 9-2920-232-34 Table 4-1 TM 9-2920-232-34

Table 4-1 Table 4-1 para 5-13 para 5-14 para 5-14 para 5-15 para 6-11b para 7-5a(1) para 7-5a(2) para 7-6b para 7-6f para 7-7b para 7-17c figs. 4-126 through 4-135

fig. 4-150 figs. 4-152 and 4-153 fig. 4-51

figs. 4-153 and 4-165

fig. 4-150

chapter 5 chapter 6 chapter 7 chapter 5 chapter 6 chapter 7

TM 9-2920-232-34 fig. 4-51

fig. 4-1 fig. 5-25 figs. 5-25,4-1

Appenidix A.

3-2

Malfunction

Probable Cause

Corrective Action

f. Fuel injection pump not properly timed. (Initial engine starting. ) g. Failed fuel injection pump. h. Fuel injection pump fails to turn when engine is cranking or turned by hand. i. Low cylinder compression.

f. Time fuel injection pump (para 4-4). Also refer to TM 9-2910-212-34. g. Remove fuel injection pump (para 4-4). Install new fuel injection pump (para 4-4). h. Disassemble engine (chapter 5 ) and replace defective parts. Assemble engine (chapter 7). i. Check valve clearance (para 4-23) and make cylinder compression check (para 4-22 ) and take appropriate corrective action as noted below:

3. Engine runs rough, one or more cylinders not fiiing:

a. Engine operating at below normal

temperature. b. Water in fuel, dirty fuel, or restricted fuel filters. c. Leaking or failed fuel injector tubes. d. Improper valve adjustment. e. Fuel injector nozzles dribbling or not functioning properly.

f. Fuel injection pump not functioning properly. g. Low compression on one or more cylinders. 4. Engine low on power, stall speed below normal of 1850 to 1950 rpm: a. Improper fuel being used or inadequate fuel delivery to engine.

1. Worn piston rings Remove cylinders (para 5-1 2) and replace worn piston rings (para 6-23 through 627). Install pistons and cylinders (para 78a). 2. Leaking valves Remove cylinders ( para 5-1 2) and repair leaking valves (para 6-33a). Install pistons and cylinders (para 7-8a). a. Check oil cooler thermostat (para 647d(2)). Operate engine at higher rpm. b. Check fuel filters for water, dirt, and ob structions. Refer to pertinent vehicle Technical Manual, Appendix A. If clean, replace fuel pump (para 4-4). c. Tighten or remove leaking fuel injector tubes (Table 5-5). Install fuel injector tubes (Table 5-5). d. Check and reset valve clearance (para 423). e. Check and clean fuel filter elements. Refer to pertinent vehicle Technical Manual, Appendix A. Remove fuel injector nozzle and overhaul nozzle and holder assembly (Table 4-7). f. Remove fuel injection pump (Table 4-1). Install fuel injection pump (Table 4-1). Inspect fuel filters for dirt and service if necessary. Refer to b, above. g. Refer to item 2j, above, for corrective action. a. Drain fuel tanks and fill with proper specification fuel. Refer to pertinent vehicle Technical Manual, Appendix A for proper fuel. Refer to fuel system troubleshooting, paragraph 3-8. b. Clean filters and fuel lines and remove restrictions. Refer to pertinent vehicle Technical Manual, Appendix A. c. Replace fuel pump assembly (para 4-4). d. Refer to cooling system troubleshooting, paragraph 3-10.

b. Restricted fuel filters or lines. c. Faulty fuel pump assembly. d. Engine overheated.

3-3

Probable Cause

Corrective Action

e. Improper fuel injection pump operating lever travel or engine linkage adjustment. f. One or more cylinders not firing. Fuel injector nozzles not functioning properly. g. Fuel injection pump not properly timed. h. Low cylinder compression. (Worn piston rings or burned valves.) j. Failed turbosupercharger. (in turfor a failed checking bosupercharger, a quick check should be made to see that turbosupercharger vanes turn freely. Vanes which have excessive drag will have low output.) k. Leaking engine exhauet system causing reduced pressure to turbosuperchargers. l. Fuel injection pump advance unit not functioning properly.

e. Adjust fuel injection pump linkage to get complete travel. Refer to TM 9-2910-21234 for procedures on adjusting pump and figures 4-84 and 4-85 for adjustment of linkage. f. Refer to item 3, above, for corrective action.

g. Time fuel injection pump (para 4-4). Also refer to TM 9-2910-212-34. h. Check valve clearance (para 4-23). Check cylinder compression (para 4-22) and take appropriate corrective action tabulated in item 2h, above. j. Remove turbosupercharger (Table 5-1). Overhaul turbosupercharger, refer to TM 92990-200-34. Install serviceable turbosupercharger (para 7-17b).

k. Repair exhaust system. Refer to pertinent vehicle Technical Manual, Appendix A. Remove engine exhaust manifold (table 55). Repair exhaust manifolds. Install exhaust manifolds (table 7-9). l. Remove rear fan and accessory drive housing assembly (table 5-8). Rebuild fuel injection pump advance unit (table 6-29). Install rear fan and accessory drive housing assembly (table 7-5). a. Refer to paragraph 3-10 for corrective action. b. Adjust fuel injection pump high idle screw. Refer to TM 9-2910-212-34 for procedures. c. Time fuel injection pump (para 4-4). Also refer to TM 9-2910-212-34. Adjust fuel injection pump governor. Refer to TM 9-2910-212-34 for procedures. a. Operate engine at part load to increase cylinder head temperature or use intake manifold heater. b. Reset idle screw and check for sticking linkage. c. Remove fuel injector nozzles. Refer to table 4-7 for references on removing, repairing, checking, and installing nozzle and holder assembly. d. Adjust fuel injection pump governor. Refer to TM 9-2910-212-34 for procedures. e. Remove fuel injection pump (table 4-1). Overhaul fuel injection pump. Refer to TM 9-2910-212-34 for instructions. Install injection pum P (table 4-1). a. Operate engine under load to increase cylinder head temperatures. Increase idle speed, use manifold heater.

5. Excess engine power:

a. Cooling fans not operating. b. Improper fuel injection pump high idle screw or bridge setting. c. Improper fuel injection pump timing.

6. Engine overspeeds beyond 2640 rpm at on load: 7. Engine will not idle, but runs well under load.

Fuel injection pump governor not properly adjusted. a. Some cylinders not firing (low ambient temperatures). b. Improper adjustment of engine idle screw or linkage sticking. c. Fuel injector nozzles not functioning properly. d. Fuel injection pump governor not properly adjusted. e. Fuel injection pump not functioning properly.

8. Engine smokes: (a) White or grey smoke indicating unburned fuel. 3-4

a. Engine cylinders and intake air too cold for efficient combustion.

Malfunction

Probable Cause

Corrective Action

b. Defective fuel injector nozzle gaskets. c. Water in fuel. d. Low compression. (b) Blue smoke indicating presence of engine oil in combustion chamber. a. One or more cylinders not firing. b. Worn or stuck piston rings or worn cylinder. c. Worn valve guides. d. Worn turboeupercharger oil seals.

b. Replace fuel injector nozzle gaskets (para 711a). Refer to item 7c, above, for other corrective action. c. Service fuel filters and drain fuel tanks. Refer to 4a, above. d. Check cylinder compression, refer to 2j, above. Replace defective parts. a. Refer to 3, above, for corrective action. (Replace engine.) b. Remove cylinders and pistons and replace rings and worn parts. Refer to 2h, above. c. Remove cylinder and replace valve guides. d. Remove turbosupercharger (Table 5-1). Overhaul turbosupercharger refer to TM 92990-200-34 for procedures. Install turbosupercharger (para 7-17b). a. Refer to para 3-7. b. Remove turbosupercharger (Table 5-1). Overhaul turbosupercharger refer to TM 92990-200-34 for procedures. Install turbosupercharger (para 7-17b). c. Overhaul fuel injector nozzle and holder assemblies. Refer to 7c, above, for corrective action. Replace springs. d. Check fuel. Refer to 4a, above. e. Adiust fuel iniection pump. Refer to TM 92910-212-34 for adjustment procedures. f. Time fuel injection pump (para 4-4). Also refer to TM 9-2910-212-34. g. Refer to 41, above, for corrective action. a. Remove cylinders and pistons (table 5-9). Rebuild pistons, rings, and pins (table 612). Install pistons and cylinders (table 74). b. Disassemble engine (chapter 5). Rebuild crankshaft, connecting rod assemblies, and bearings (table 6-8). Assemble engine (chapter 7). c. Remove cylinder and piston (table 5-9). Overhaul cylinder (table 6-14). Install piston and cylinder (table 7-4). a. Adjust valve clearances ( para 4-23). b. Remove valve rocker arm covers. (Refer to table 4-6. ) Disassemble rocker arm covers. Replace valve rocker arm assemblies. Assemble rocker arm covers. Install valve rocker arm covers. a. Replace damaged engine accessories. 1. Remove fuel injection pump (table 4-1). Refer to TM 9-2910-212-34 and overhaul fuel injection pump. Install injection pump (table 4-1). 2. Remove generator (table 4-1). Refer to TM 9-2920-224-35 and overhaul generator. Install generator (table 4-1).

(c) Black smoke indicating a rich fuel mixture. Note: Black smoke during acceleration is normal.

a. Restriction in air supply system. b. Failed turbosupercharger (excessive smoke for afflicted engine bank). c. Fuel injector nozzles not functioning, dripping, or retaining d. Operating with improper fuel. e. Fuel injection pump improperly adjusted. f. Fuel injection pump not properly timed. g. Fuel injection pump advance unit not functioning properly. a. Loose piston pin or pins or broken piston rings. b. Worn engine bearings.

9. Engine noise. (a) Abnormal knocking noise.

c. Scored piston or cylinder.

(b) Tapping noise.

a. Excessive valve clearances. b. Worn or damaged valve rocker arm

(c) Grinding or squeaking noise.

a. Accessories damaged. 1. Fuel injection pump.

2. Generator.

3-5

Probable Cause

Corrective Action 3. Remove turboeupercharger (table 4-1). Refer to TM 9-2990-200-34 and overhaul Install turturbosupercharger. bosupercharger (table 4-1). 4. Remove fuel pump (table 4-1). Refer to TM 9-2910-213-34 and overhaul pump. Install fuel pump (table 4-1). b. Use wrench - 5120-793-7895 and turn engine over by hand. If engine turns hard and grinding or squealing noiee persists, disassemble engine (chapter 5) and inspect. Replace damaged parta. Assemble engine (chapter 7). c. New or dry engine must be run at fast idle to get oil up to rocker arm bushing-type bearings. d. Adjust cooling fan clearance (fig. 4-88). a. Refer to 7, above for corrective action. b. Refer to 7c, above, for corrective action. c. Refer to para 3-7 for corrective action. d. Time fuel injection pump (para 4-4). Also refer to TM 9-2910-212-34. a. Adjust fuel injection pump governor. Refer to TM 9-2910-212-34 for procedure. b. Clean linkage and inspect for binding or sticking condition. Refer to pertinent vehicle Technical Manual, Appendix A. Lubricate linkage. a. Refer to 7 and 8, above, for corrective action. Increase engine operating temperature. b. Drain fuel tanks and refill with proper fuel. Refer to pertinent vehicle Technical Manual, Appendix A, for proper fuel. c. Refer to para 3-7 for corrective action. d. Repair exhaust system. Refer to pertinent vehicle Technical Manual, Appendix A. Remove engine exhaust manifold (table 55). Repair exhaust manifolds. Install exhaust manifolds (table 7-9). e. Refer to 4, above, for corrective action. a. Refer to para 3-8 for corrective action. b. Replace coupling. Refer to table 4-1 for replacement instructions. c. Refer to 2g, above, for corrective action. d. Disassemble engine (chapter 5) and inspect. Replace damaged parts. Assemble engine (chapter 7). a. Check electrical lead. Refer to 2g, above, for corrective action. b. Refer to 2g, above, for corrective action.

3. Turbosupercharger.

4. Fuel pump b. Failed engine bearings or gears.

c. Dry valve rocker arm shafts and rocker arm bushing-type bearings. d. Cooling fans rubbing housing. 10. Rough or poor idling. a. Some cylinders not firing. b. Nozzles not functioning properly. c. Air leak in intake manifold system. d. Fuel injection pump not properly timed. a. Fuel injection pump governor improperly adjusted. b. Injection pump linkage sticking or binding. a. Engine operating at below normal temperature. b. Operating with improper fuel. c. Air intake system restricted. d. Exhaust system restricted.

11. Engine surges at all speeds.

12. Poor fuel economy.

e. Loss of power or low power. 13. Engine stops suddenly. a. Plugged or damaged fuel supply system or fuel pump fails to operate properly. b. Failed fuel injection pump coupling. c. Fuel injection pump fails to operate properly. d. Seizure of internal engine components. a. Fuel cutoff in fuel injection pump inoperative. b. Binding fuel injection pump control linkage.

14. Engine will not stop when shut off.

3-6

3-5. Troubleshooting Starting System

Malfunction Probable Cause Corrective Action

1. Starter will not operate.

a. Improper starting procedure being used. b. Starter not receiving electrical current.

c. Failed starter. d. Failed starter relay. 2. Starter runs but will not crank engine. 3. Starter operates but fails to c r a n k e n g i n e a t proper cranking speed. a. Failed starter drive gear. b. Failed starter drive clutch. a. Improper grade engine oil. b. Defective starter. c. Partially seized engine caused by tight engine bearings.

a. Refer to pertinent vehicle Technical Manual, Appendix A for proper starting procedures. b. Refer to pertinent vehicle Technical Manual, Appendix A for procedures covering troubleshooting vehicle electrical system. c. Refer to 1b, para 3-4. d. Refer to 1b, para 3-7. a. Refer to 1c, para 3-4. b. Refer to 1b, para 3-4. a. Drain and refill with proper grade oil for prevailing temperature. b. Refer to 1b, para 3-4. c. Turn engine manually. If engine does not turn freely, disassemble engine and replace or repair damaged parts.

3-6. Troubleshooting Generating System

1. Generator runs but will not produce electrical current. a. Generator regulator not operating. Refer to pertinent vehicle Technical Manual, Appendix A for troubleshooting generator regulator. Refer to pertinent vehicle Technical Manual, Appendix A for correct cable connections and procedures. Remove generator (table 4-1). Refer to TM 9-2920-224-35 and overhaul generator. Install generator (table 4-1). Replace generator, Refer to 1c, above. Remove generator (table 4-1). Remove generator drive adapter and drive gearshaft (table 5-10). Rebuild adapters and drive gearshaft (table 6-1). Check generator idler gears in crankcase for damaged teeth. If damaged, disassemble engine and remove idler gear. Install new gear (table 7-1) and assemble engine. Install generator (table 41).

b. Improperly connected generator cables. c. Generator not producing electrical current.

2. Generator does not turn or operate.

a. Failed generator shaft. b. Generator drive gear failed.

3-7. Troubleshooting Air I n t a k e

1. Restricted air to turbosuperchargers (engine will not develop full power).

System
a. Service air cleaner. Refer to pertinent vehicle Technical Manual, Appendix A for procedures. b. Repair or replace air induction hose. Refer to pertinent vehicle Technical Manual, Appendix A for procedures. c. Remove turbosuperchargers (table 4-1). Refer to TM 9-2990-200-34 for overhaul instructions. Install turbosuperchargers (table 4-1). d. Remove intake manifolds (table 4-4). Remove restrictions. I n s t a l l i n t a k e manifolds (table 4-4).

a. Plugged air cleaner.

b. Collapsed air induction hose.

c. Turbosuperchargers worn or fail to operate.

d. Restrictions in air intake manifolds.

3-7

Malfunction

Probable Cause

Corrective Action

2. Loss of engine power.

a. Air leak in intake manifold.

b. Turbosuperchargers worn, plugged, or failed. c. Leak in exhaust pipes or manifolds.

a. Remove turbosuperchargers (table 4-1). Remove intake manifolds (table 4-4). Repair air leak. Install intake manifolds (table 4-4) and install turbosuperchargers (table 4-1). b. Refer to 1c, above for corrective action. c. Repair or replace exhaust pipes and manifolds (table 5-5).

3-8. Troubleshooting Fuel System

1. No fuel being delivered from fuel injector nozzles. a. Plugged primary fuel filter, secondary fuel filter, or fuel/water separator filter or fuel system not free of air. b. Defect in vehicle fuel system. a. Service primary fuel filter, secondary fuel filter, or fuel/water separator filter. Refer to pertinent vehicle Technical Manual, Appendix A for procedures. b. Troubleshoot vehicle fuel system. Refer to pertinent vehicle Technical Manual, Appendix A for procedures. c. Remove damaged fuel hoses (table 4-1). Install new fuel hoses (table 4-1). d. Troubleshoot fuel pump. Refer to TM 92910-213-34 for procedures. If trouble cannot be corrected remove pump (table 41). Refer to TM 9-2910-213-34 for overhaul. Install pump (table 4-1). e. Remove fuel injection pump (table 4-1). Refer to TM 9-2910-212-34 and overhaul pump. Install injection pump (table 4-1). f. Remove fuel injection pump (table 4-1). Replace coupling (tables 6-29 or 6-45). Install injection pump (table 4-1). a. Drain fuel tank and refill with proper fuel. Refer to pertinent vehicle Technical Manual, Appendix A, for proper fuel. b. Refer to para 3-4 (2 and 3) for corrective action. c. Remove fuel injector nozzle and holders (table. 4-7). Rebuild nozzle and holders (table 4-7). Install nozzle and holder (table 4-7 ). d. Time fuel injection pump (para 4-4). Also refer to TM 9-2910-212-34. e. Remove fuel injection pump (table 4-1). Refer to TM 9-2910-212-34 for overhaul procedures. Install pump (table 4-1). a. Service air cleaner. Refer to pertinent vehicle Technical Manual, Appendix A, for proper fuel. b. Remove fuel supply pump (table 4-1). Refer to TM 9-2910-213-34 for overhaul procedures. Install pump (para 7-17a). Tighten all connections and replace damaged hoses. c . Remove engine fan (table 4-3). d. Tighten connections. Remove fuel injector tubes (table 4-1). Replace damaged tubes. Install injector tubes (table 4-1).

c. Damaged fuel hoses (fuel pump to filter or filter to fuel injection pump). d. Defective fuel pump

a. Failed fuel injection pump.

f. Failed fuel injection pump coupling.

2. Fuel being delivered at nozzles but engine will not stare run, or runs rough on one or more cylinders.

a. Operating with contaminated fuel or partially plugged fuel filters, refer to 1a, above. b. Flame heater not operating (low ambient temperature). c. Fuel injector nozzle and holder not functioning properly.

d. Fuel injection pump not timed properly. e. Fuel injection pump not functioning properly.

3. Engine runs hot, misfires, or runs rough.

a. Restricted induction air supply.

b. Low fuel pressure from fuel supply pump or leaking hoses and connections.

c. Fan clutch slipping. d. Leaking fuel tubes at nozzle and holder assemblies.

3-8

Malfunction

Probable Cause

Corrective Action

e. Improperly adjusted fuel injection pump. f. Fuel bleeder valve in injection pump not functioning properly.

e. Adjust fuel injection pump. Refer to TM 92910-212-34 for procedures. f. Remove fuel injection pump (table 4-1). Refer to TM 9-2910-212-34 for overhaul procedures. Install fuel injection pump (table 4-1). a. Adjust fuel injection pump. Refer to TM 92910-212-34 for procedures. b. Refer to item 2c, above, for corrective action.

4. Excessive exhaust smoke.

a . Fuel injection pump improperly adjusted causing excessive fuel delivery. b. Fuel injector nozzle and holder functioning assemblies not properly. Nozzles dripping or nozzle holder spring broken. c. T u r b o s u p e r c h a r g e r f a i l e d o r restricted induction system. d. Fuel injection pump not properly timed. e. Worn or scored pistons, cylinder, or rings.

Refer to above, for para 3-7, troubleshooting procedures. d. Time fuel injection pump (table 4-1). Also refer to TM 9-2910-212-34. e. Remove cylinders and pistons (table 5-9) and replace defective parts (tables 6-12 and 6-14). Install pistons and cylinders (table 59).

c.

3-9.

Troubleshooting

Lubricating

System
a. Drain oil pan and refill with proper grade oil for prevailing temperature. Refer to pertinent vehicle Technical Manual, Ap pendix A. b. Check engine idle speed and reset to 700 to 750 rpm. c. Fill oil pan to proper level. Refer to pertinent vehicle Technical Manual, Appendix A. d. Remove oil pressure sending unit (table 510). Install new unit (table 5-10). e. Refer to 4, below, for corrective action. f. Remove oil pressure regulator valve (table 42). Replace damaged parts (para 6-38d). Install oil pressure regulator valve (table 42). g. Refer to pertinent vehicle Technical Manual, Appendix A for service procedures. h. Disassemble engine (chapter 5). Clean oil passages (para 6-9c). Assemble engine (chapter 7). j. Remove oil pan (table 4-5). Clean obstructions from pickup tube screen. Install oil pan, (table 4-5). k. Remove oil pan (table 4-5). Remove oil pump (table 5-10). Rebuild oil pump (table 6-17). Install oil pan (table 4-5). l. Disassemble engine (chapter 5). Replace worn bearings and necessary parts. Assemble engine (chapter 7). a. Refer to 1d, above, for corrective action. b. Refer to 1f, above, for corrective action.

1. Low engine oil pressure.

a. Improper grade oil for prevailing temperature.

b. Engine idle speed too low. c. Insufficient oil in oil pan.

d. Engine oil pressure sending unit not functioning properly. e. High engine oil temperature or diluted oil. f. Oil pressure regulator valve not operating properly.

g. Oil filters partially obstructed. h. Crankcase oil passages obstructed.

j. Oil pump pickup tube screen obstructed. k. Oil pump properly. not functioning

l. Engine bearings worn.

2. High engine oil pressure.

a. O i l p r e s s u r e s e n d i n g u n i t n o t functioning properly. b. Oil pressure regulator valve not functioning properly.

3-9

Malfunction

Probable Cause

Corrective Action

c. Improper grade of oil for prevailing ambient temperatures. d. Obstructed crankcase oil passages. 3. No engine oil pressure. a. Low oil level.

Drain crankcase oil and fill with proper grade oil. Refer to pertinent vehicle Technical Manual, Appendix A. d. Refer to 1h, above, for corrective action.
c.

b. Oil pressure sending unit not functioning properly. c. Obstructed crankcase oil passages. d. Oil pressure regulator valve not functioning properly. e. Oil pump or drive gears failed. 4. High engine oil temperature. a. Restricted air flow through oil coolers. b. Oil temperature sending unit not functioning properly. c. High oil temperature warning light sending switch not functioning properly ). d. Oil cooler thermostatic bypass valve not functioning properly. e. Restricted engine oil cooler. f. Cooling fan clutch slipping or inoperative. Engine runs hot. g. Excessive fuel, engine runs hot. h. Defective pieton cooling nozzles.

a. Fill oil pan to proper level Refer to pertinent vehicle Technical Manual, Appendix A for proper grade oil for prevailing temperature. b. Refer to 1 d, above, for corrective action. c. Refer to 1 h, above, for corrective action. d. Refer to 1 f, above, for corrective action. e. Refer to 1 k, above, for corrective action. a. Remove oil cooler air restrictions or replace damaged screens, deflectors, and baffles (tables 5-2 and 5-7 ). b. Replace aending unit (tables 5-10 and 7-3). c. Replace switch (tables 5-10 and 7-3). d. Replace valve ( para 6-38). e. Remove engine oil cooler (table 5-2). Clean and repair oil cooler (table 6-3 7). Install oil cooler (table 7-1 2). f. Refer to para 3-10 for corrective action. g. Refer to fuel system troubleshooting, para 3-8, for corrective action. h. Remove oil pan (table 4-5). Inspect pump and nozzle. Replace defective parts. Install oil pan (table 4-5). a. Refer to 4, above, for corrective action. Repair oil leaks. b. Refer to pertinent vehicle Technical Manual, Appendix A, for proper grade for prevailing temperature. c. Remove (table 5-5), clean (para 6-2) and install (para 7-9) breather tubes d. Refer to para 3-8, 4e. e. Remove cylinders and replace defective parts. Assemble cylinders. f. Refer to para 3-7, 1c for corrective action.

5. Excessive oil consumption.

a. High oil temperature or oil leaks. b. Improper grade oil for prevailing temperature. c. Restricted crankcase breather system. d. Worn or scored pistons, cylinders, or rings. e. Worn valve stems or valve guides. f. Worn or leaking turbosupercharger oil scale.

3-10. T r o u b l e s h o o t i n g
1. Cooling fans not operating.

Cooling

System
a. Rebuild front fan drive clutch (table 6-24). Rebuild rear fan drive clutch (table 6-24). b. Disassemble engine (chapter 5). Replace damaged parts. Assemble engine (chapter 7). a. Refer to 4d, above. b. Replace valve (table 6-37).

a. Fan drive clutch slipping or inoperative. b. Fan drive gear train not functioning. a. Oil cooler thermostatic bypass valve not functioning properly. b. Defective oil cooler bypass valve.

2, Cooling fam operate but engine does not cool.

3-10

Malfunction

Probable Cause

Corrective Action

c. Obstructed passages.

oil

cooler

co re

d. Low engine oil pressure. e. Damaged baffles or deflectors. f. Plugged baffles and air deflectors.

c. Remove oil coolers (table 5-2) and remove obstructions from oil cooler core passages (table 6-37). Install oil coolers (table 7-12). d. Refer to para 3-9, above, for corrective action. e. Refer to para 3-9, 4a. f. Remove engine (chapter 5) and clean thoroughly. Replace engine (chapter 7). a. Increase engine warm-up speed from 1100 rpm to 1400 rpm. b. Refer to 2e, above, for corrective action. Fuel System

3. Engine fails to reach normal operating temperature. 3-11. Troubleshooting

a. Engine warm-up rpm too low for prevailing temperature. b. Damaged baffles or deflectors. Intake Manifold Flame Heater

1. No fuel to intake manifold flame heater.

a. Purge pump inoperative. b. Flame heater fuel filter plugged. c . F u e l i n l e t s o l e n o i d v a l v e not operating due to electrical or mechanical failure. d. Manifold heater spray nozzle restricted or plugged. e. Restricted or plugged fuel supply tubes. f. Fuel check valve inoperative.

a. R e f e r t o p e r t i n e n t v e h i c l e T e c h n i c a l Manual, Appendix A, for corrective action. b. Remove filter and clean or replace element (table 6-44). c. Remove fuel inlet solenoid valve (table 5-3). Replace damaged or inoperative valve. Install solenoid valve (table 7-11). d. Remove, overhaul, and install manifold heater (table 6-40). e. Clean tubes. f. Remove fuel check valve. a. Always crank engine as heater is operated. b. Refer to pertinent vehicle Technical Manual, Appendix A, for corrective action. c. Replace spark plug (table 6-40). d. Remove electrical lead and install new electrical lead (table 6-44). e. Replace heater spray nozzle (table 6-40). a. Remove electrical lead or unit and install new lead or unit (table 6-44). b. Remove and replace line (table 6-40). c. Remove and replace nozzle (table 6-40).

2. Fuel to intake manifold, but flame heater will not ignite fuel.

3. Intake manifold heater on one side of engine fails to operate.

a. Insufficient air for combustion in chamber. b. No electrical current to ignition unit. c. Spark plug not operating. d. Electrical lead to ignition unit damaged. e. Improper heater spray nozzle pattern. a. Electrical lead to ignition unit damaged, unit defective or spark plug not operating. b. Spray nozzle line plugged or damaged. c. Spray nozzle plugged.

3-11

CHAPTER 4 REPLACEMENT OF ENGINE ACCESSORIES, COMPONENTS AND RELATED SERVICE OPERATIONS

Section l. GENERAL 4-1. Purpose

of the manual and related covers removal to inaccessories, and service reference to other pertinent operations per-

This chapter a. replacement of engine and replacement of spection, adjustment

formed in this technical manual. Note. Parts mentioned in the instructions that accompany the operational sequence letters will be called out separately on the illustration only when required to further clarify the instructions, Special Instructions. (1) Notes and Cautions. Instructional Notes or Cautions accompany some of the illustrations and are used to further define the instructions, eliminate procedures that might result in the equipment being damaged, or injury to personnel. (2) Cleanliness. Extreme care must be exercised to insure that dust and dirt, even in minute quantities, does not enter the engine. Plug or cover all fuel and oil line connections to prevent entry of dirt. Clean parts thoroughly and coat all surfaces of bearings, shafts and contact surfaces with engine oil (OE). Surface must be protected from dirt after oiling. (3) G a s k e t s . Always use new gaskets and preformed packings when reinstalling engine components. (4) Torque tightening attaching hardware. All hardware must be torque tightened to When a torque value is not specified limits. specified in the text or on an illustration, refer to Standard Torque Values, para 6-7. Special torque values are specified in the text and / or illustrations. Refer also to Special Torque Values, para 6-7. Note. Do not vary from torque specified. Under-torquing will result in premature failure of studs and bolts. Over-torquing can result in yielding of bolts and studs. (5) Safety devices. All bolts and nuts must be secured with lock washers, lock nuts, tab washers, locking wire or cotter pins, as specified. e.

components

operations

allocated to Direct Support maintenance personnel. Some accessories, engine components or service operations can be accomplished while engine is installed in vehicle, but is dependent upon how accessible the item is. Engines which have been removed from the vehicle for acreplacement should be thoroughly cessory cleaned before replacement of accessory is attempted. Refer to pertinent technical manuals for instructions on the removal or installation of the power plant and separation of the transmission from the engine.

Removal 4-2. structions

and

Installation

In-

a. Illustrations. The illustration sequences provided in the following subparagraphs depict the procedure for removal or installation of a particular item or an adjustment and service operation. When necessary, illustrations covering variations between engine models are included to clarify any differences in disassembly or assembly procedures. b. Tables. This chapter has been grouped into sections. Each section has a contents table for easy reference for removing, cleaning, testing, installing number table. c. I n s t r u c t i o n s . T h e s t e p - b y - s t e p p r o c e d u r e t o be followed for removal, installation, adjustment, mediately or service operation is listed imfollowing each illustration. and adjustment an procedures heading required in the for a given operation and are listed by figure under appropriate

d. Parts Identification. Callouts will be used to point out related parts involved in the removal operation being performed. Callouts not mentioned in the instructions are related to subsequent installation procedures or are used as

4-1

Section Il. REMOVAL OR INSTALLATION OF ENGINE ACCESSORIES 4-3. GeneraI

This engine one of section covers the replacement of the accessories. P r o p e r p r o c e d u r e s a n d i n the engine accessories can easily be determined by referring to Table 4-1. This table lists the illustrations applicable for removing or installing an Engine Accessory Reference figures are listed under the appropriate heading in the table.

structions for the removal and installation of any

Table 4-1. Engine Accessories

4-4. Removal or Installation Instructions

Disconnect 1. Disconnect fuel hose (A) from fuel pump outlet adapter. Collect fuel in a suitable container and discard. 2. Disconnect fuel pump inlet tube nuts (B). 3. Remove two screws (C), lock washers, one flat washer, and one clip. Pull check valve away from mounting bracket as necessary, and remove fuel inlet tube. Connect 1. Position fuel inlet tube on check valve and fuel pump. Loosely install two cap screws (C), lock washers, one flat washer, and one clip securing check valve to mounting bracket. 2. Connect fuel inlet tube nuts (B). 3. Tighten cap screws (C). 4. Connect fuel hose (A) to fuel pump outlet adapter. Figure 4-1. Disconnecting or connecting fuel hose at fuel pump outlet adapter and fuel pump inlet tube at fuel pump.

4-2

Remove 1. Remove 2. Remove Install 1. Position 2. Position Disconnect 1. Remove adapter (A) from pump outlet. 2. Remove connector (B) from pump inlet. 3. Remove four self-locking nuts (C) and flat washers securing fuel pump to adapter. Connect 1. Install four self-locking nuts (C) and flat washers securing fuel pump to adapter. 2. Install connector (B) in pump inlet. 3. Install adapter (A) in pump outlet. Figure 4-2. Disconnecting fuel pump. or connecting

fuel pump (A) from pump adapter. and discard mounting gasket (B). new mounting gasket (B) on studs. fuel pump (A) on pump adapter.

Note. When installing fuel pump make sure fuel pump shaft splines are properly alined with drive coupling before securing pump to adapter. Figure 4-3. Removing or installing fuel pump.

Remove 1. Remove hexagon head cap screw (A) and clip securing starter jumper lead to solenoid. 2. Remove large starter jumper lead clip from terminal (B). Install 1. Position large starter jumper lead clip on terminal (B). 2. Position jumper lead on solenoid lug and secure with clip and hexagon head cap screw (A). Figure 4-4. Removing or installing starter solenoid jumper lead.

4-3

1. Remove two self-locking nuts (A). 2. Remove two clamping bars (B). 3. Remove starter retaining U bolt (C). Figure 4-5. Removing starter U bolt. retaining

Figure 4-7. Removing or installing starter mounting nuts using open end wrench-5120-678-5288.

1. Cut and remove locking wire (A). 2. Remove four bolts (B) and flat washers securing starter support to oil pan. 3. Remove starter support and starter cradle as an assembly (C). Figure 4-6. Removing starter and cradle. retaining

4-4

Remove 1. Remove 2. Remove Install 1. Position 2. Position 3. Position assembly

starter assembly (A) from starter adapter. and discard mounting gasket (B). new mounting gasket (B) on starter adapter. starter assembly (A) on starter adapter. suitable blocks (A, fig. 4-7) under starter for support.

Figure 4-8. Removing or installing starter assembly.

N o t e . It is of u t m o s t i m p o r t a n c e t h a t t h e starter support, cradle, and "U" bolt be installed in a m a n n e r t h a t w i l l n o t d i s t u r b s t a r t e r mounting alinement and still furnish adequate support to minimize vibration. Misalignment of 0.010-in. in any direction is sufficient to cause a leak (pressure loss) between the starter mounting flange and the starter housing. Refer to paragraph 8-2 for procedure to determine if there is a pressure loss.
1. Position the assembled support and cradle on oil pan and install four hexagon head bolts (A) and plain washers. Tighten only until bolt heads engage the washers (finger-tight). 2. Loosen four self-locking nuts (B) securing cradle to support allowing cradle studs to move freely in elongated holes in support. 3. Position the U bolt over the starter and secure to cradle with two clamping bars and self-locking nuts (C). Torque tighten nuts evenly. 4. Torque tighten the four self-locking nuts (B) securing cradle to support, then torque tighten the four hexagon head bolts (A) securing support to oil pan. Secure oil pan bolts with locking wire (A, fig. 4-6).

Figure 4-9. Installing starter support, cradle, and "U" bolt.

4-5

Figure 4-10.

Figure 4-11.

4-6

1. Remove one self-locking nut (A). 2. Remove clamping bar (B). 3. Loosen two self-locking nuts (C). 4. Cut locking wire and remove four bolts (D) and flat washers. 5. Remove generator support and cradle (E) and U bolt as an assembly. Figure 4-12. Removing generator cradle, and U bolt. support,

Disconnect 1. Remove two bolts (A) and lock washers. 2. Remove and discard oil drain tube gasket (B). 3. Loosen generator boot to exhaust tube hose clamp (C). 4. Remove two generator boot hose clamps (D). 5. Rotate generator boot (E) to position shown in figure 4-14, then remove hose clamp (C). Connect 1. Position generator boot (E) to install exhaust tube hose clamp (C) on boot and rotate boot to position shown. 2. Install two generator boot hose clamps (D). 3. Tighten hose clamp (C). 4. Position new oil drain tube gasket (B) on oil drain tube. 5. Install two bolts (A) and lock washers securing oil drain tube to oil pan. Figure 4-13. Disconnecting or connecting

cylinder head right rear oil drain tube and generator boot hose clamps.

4-7

Loosen 1. Slide boot back on generator far enough to expose the mounting nut access openings (A). 2. Loosen, but do not remove, six self-locking nuts (B), using box wrench -5120-789-4881 to permit rotation of generator to align the large openings in the elongated mounting slots. Note. In cases where boot is rigid, it may be necessary to slide one side of boot back and loosen three mounting nuts, then repeat the procedure for the other three nuts. Do not cut or otherwise mutilate boot. Tighten 1. Position boot on generator just far enough so that the mounting nut access openings (A) are exposed. 2. Tighten six self-locking nuts (B) using box wrench5120-789-4881. Figure 4-14. Loosening or tightening using box

Remove 1. Rotate generator (A) counterclockwise until large elongated openings in flange are alined with mounting nuts, and remove generator and boot. 2. Remove boot (B) from generator. Install 1. Position boot (B) on generator. 2. Position generator (A) so that large elongated openings in flange are alined with mounting nuts, and install generator and boot. Figure 4-15. Removing and or installing

generator

boot.

generator

mounting

nuts

wrench-5120-789-4881.

4-8

Remove 1. Remove six self-locking nuts (A). 2. Remove and discard generator mounting gasket (B). Install 1. Position new generator mounting gasket (B) on studs. 2. Install, but do not tighten, six self-locking nuts (A). Figure 4-16. Removing or installing generator gasket.

It is important that the generator Note. cradle, support, and U bolt be installed in a manner that will not disturb generator alinement and still furnish adequate support to minimize vibration. 1. Position the assembled generator cradle, support, and U bolt and install four bolts (A) and flat washers. Tighten bolts only until bolt heads engage washers (finger-tight). 2. Install U bolt over generator and secure with one clamping bar and self-locking nut (B) and torque tighten. Torque tighten two self-locking nuts (C). 3. Torque tighten four bolts (A) and secure with locking wire as shown in figure 4-12. Figure 4-17. Installing generator support, cradle, and U bolt.

4-9

Similar procedures are required to Note. remove the left and right turbosupercharges. For instructional purposes, removal of the left turbo supercharger is described. Removal procedures for the right turbosupercharger are the same, except for the relocated oil filler tube installation and the generator air exhaust tube and cap. Figure 4-18. Loosening or tightening oil filler upper and lower tube hose connection (relocated oil filler tube installation).

Remove 1. Remove one bolt (A) attaching upper oil filler tube support bracket to turbosupercharger tie rod. 2. Remove one bolt (B) and lock washer attaching upper oil filler tube support clamp to tie rod. 3. Remove one bolt (C) and self-locking nut attaching upper oil filler tube support clamp to support bracket. 4. Remove upper oil filler tube (D) from lower left rear shroud plate. Install 1. Position upper oil filler tube (D) through aperture in lower left rear shroud plate. Make cure lower end of tube enters hose connection (fig. 4-18). 2. Install one bolt (C) and self-locking nut securing upper oil filler tube support clamp to support bracket. 3. Install one bolt (B) and lock washer securing upper oil filler tube support clamp to turbosupercharger tie rod. 4. Install one bolt (A) securing upper oil filler tube support bracket to tie rod. Figure 4-19. Removing or installing upper oil filler tube (relocated oil filler tube installation).

4-10

Figure 4-20. Removing or installing crankcase rear breather tube and lower left rear shroud plate.

4-11

Remove 1. Remove two self-locking nuts and bolts (A). 2. Remove upper oil filler tube support bracket (B) from bolt (relocated oil filler tube installation only). 3. Remove turbosupercharger end shroud (C). Install 1. Position turbosupercharger end shroud (C) over turbosupercharger. 2. Position upper oil filler tube support bracket (B) on one bolt (A) relocated oil filler tube installation only). 3. Install two bolts (A) and self-locking nuts securing end shroud. Bolt with support bracket must be installed at top of shroud. Figure 4-21. Removing or installing upper oil filler tube support bracket and turbosupercharger end shroud.

Disconnect 1. Disconnect turbosupercharger oil inlet hose elbow from nipple using open end wrench - 5120-448-0404 (A). 2. Remove self-locking nut and bolt (B) attaching inner shroud plate to transmission oil cooler end shroud. Connect 1. Install self-locking nut and bolt (B) securing inner shroud plate to transmission oil cooler end shroud. 2. Connect turbosupercharger oil inlet hose elbow to nipple using open end wrench - 5120-448-0404 (A). Figure 4-22. Disconnecting or connecting

turbosupercharger oil inlet hose elbow from nipple using open end wrench5120-448-0404.

4-12

Remove 1. Remove two bolts (A) attaching outer shroud plate. 2. Remove outer shroud plate (B). Install 1. Position outer shroud plate (B) on turbosupercharger. 2. Install two bolts (A) securing outer shroud plate. Figure 4-23. Removing or installing turbo supercharger outer shroud plate.

Remove 1. Remove grommet (A) from inner shroud plate. 2. Remove elbow (B) from oil inlet hose. 3. Pull oil inlet hose (C) through grommet hole opening in inner shroud plate. 4. Remove nipple (D). Install 1. Install nipple (D) in turbosupercharger. 2. Push oil inlet hose (C) through grommet hole opening in inner shroud plate. 3. Install elbow (B) in oil inlet hose. 4. Install grommet (A) in inner shroud plate. Figure 4-24. Removing or installing oil inlet hose, elbow, and nipple.

4-13

Remove 1. Remove hose clamp (A). 2. Remove generator exhaust tube cap (B). Install

Remove 1. Remove two bolts (A), lock washers, and flat washers securing generator exhaust tube.

2. Tighten hose clamp (A) securing cap on exhaust tube. Figure 4-25. Removing or installing generator exhaust tube cap (right side only).

1. Position support clamp (B) and support around generator exhaust tube. 2. Install two bolts (A), lock washers, and flat washers securing clamp and support to inner shroud plate. Figure 4-26. Removing or installing generator

exhaust tube support clamp (right side only).

4-14

Remove 1. Remove two cap screws (A), lock washers, and plain washers securing generator e x h a u s t t u b e t o t u r bosupercharger tie rod. 2. Remove exhaust tube (B) through bottom of right inner shroud. Install 1. Position generator exhaust tube (B) through bottom of right inner shroud. 2. Install two cap screws (A), lock washers, and plain washers securing exhaust tube to turbosupercharger tie rod. Figure 4-27. Removing or installing generator exhaust tube (right side only).

(fig. 4-29) Figure 4-28.

4-15

2. Remove long bolt (B) and lock washer. 3. Separate oil drain tube (C) from turbosupercharger. Remove and discard gasket. Connect 1. Position new gasket between turbosupercharger and oil drain tube (C). 2. Install long bolt (B) and lock washer. 3. Install short cap screw (A) and lock washer. Figure 4-30. Disconnecting or connecting turbosupercharger oil drain tube at

Remove 1. Remove two bolts (A) attaching the transmission oil cooler end shroud. 2. Remove end shroud and inner shroud plate (B). Install 1. Position inner shroud plate and transmission oil cooler end shroud (B) on engine. 2. Install two bolts (A) securing end shroud. Figure 4-29. Removing or installing transmission oil cooler end shroud and inner shroud plate.

Disconnect 1. Loosen hose clamps (A) on air outlet elbow hose. 2. Remove six self-locking nuts (B) attaching elbow to turbosupercharger compressor housing and remove elbow. 3. Remove and discard elbow gasket (C). 4. Remove outer self-locking nut (D) and flat washer attaching turbosupercharger to mounting base. 5. Loosen hose clamps (E) and remove oil drain tube. Connect 1. Position oil drain tube and tighten hose clamps (E). 2. Install outer self-locking nut (D) and flat washer securing turbosupercharger to mounting base. 3. Position new elbow gasket (C) on studs. 4 . P o s i t i o n a i r o u t l e t e l b o w o n turbosupercharger compressor housing and install six self-locking nuts (B) securing elbow to housing. 5. Tighten hose clamps (A) on air outlet elbow. Disconnect 1. Remove short cap screw (A) and lock washer. 4-16 Figure 4-31. Disconnecting air or connecting elbow.

turbosupercharger

outlet

Figure

4-32.

Disconnecting at

or

connecting base. Disconnect and remove 1. Remove eight self-locking nuts (A), flat washers, and cap screws attaching exhaust pipes to turbine housing. 2. Separate exhaust pipes from turbine housing and remove and discard two gaskets (B). assembly (C) from 3 . R e m o t e turbosupercharger mounting base. Connect and install 1. Position turbosupercharger assembly ( C ) o n mounting base. 2. Position new gaskets (B) between exhaust pipes and turbine housing. 3. Install eight cap screws, flat washers, and self-locking nuts (A) securing exhaust pipes to housing. Figure 4-33. or Disconnecting installing or connecting

turbosupercharger

mounting

exhaust pipes at turbine housing and removing turbosupercharger.

4-17

Remove 1. Remove two bolts (A) and lock washers. 2. Remove two cap screws (B) and lock washers and remove cooling fan vane from front fan housing. 3. Remove two bolts (C) and lock washers. 4. Remove two cap screws (D) and lock washers and remove cooling fan vane from rear fan housing. Install Note. When installing the cooling fan vanes, it is important that the proper cooling fan vane is installed on the correct fan housing. The rear fan housing (flywheel end) mounts noticeably higher than the front fan housing and takes the wide lip cooling fan vane (item 3, fig. B-25). The front

fan housing mounts lower into the cooling fan shroud and takes the narrow lip cooling fan v a n e . B e s u r e t h e w i d e l i p is not i n s t a l l e d o n t h e front fan housing as this will interfere with the fan and cause damage to both fan and vane housing. 1. Position cooling fan install two cap screws 2. Install two bolts (C) 3. Position cooling fan install two cap screws 4. Install two bolts (A) vane in rear fan housing and (D) and lock washers. and lock washers. vane in front fan housing and (B) and lock washers. and lock washers.

Figure 4-34. Removing or installing cooling fan vanes.

Remove 1. Remove cotter pin, slotted nut (A), and flat washer. Discard cotter pin. 2. Remove front cooling fan and hub assembly (B) from vertical drive shaft. 3. Remove rear cooling fan and hub assembly (C) in the same manner. Install 1. Position front cooling fan and hub assembly (B) on vertical drive shaft. 2. Install flat washer, slotted nut (A), and new cotter pin securing fan and hub assembly. 3. Install rear cooling fan and hub assembly (C) in the same manner. Figure 4-35. Removing or installing

cooling 4-18

fans.

Figure 4-36.

4-19

Disconnect 1. Remove six self-locking nuts (A) attaching right side of cooling fan shroud to top frame. 2. Remove six self-locking nuts (B) attaching left side of shroud to top frame.

Connect 1. Install six self-locking nuts (B) securing left side of cooling fan shroud to top frame. 2. Install six self-locking nuts (A) securing right side of shroud tn frame.

Figure 4-37. Disconnecting or connecting cooling fan shroud on top frame.

Figure

4-38.

Disconnecting

or

connecting

rear end of cooling fan shroud and removing or installing cooling fan shroud and fan housings.

Disconnect and remove 1. Remove four screws (A) attaching right rear shroud and right rear center shroud to cooling fan shroud. 2. Remove three screws (B) attaching left rear shroud and left rear center shroud to cooling fan shroud. 3. Remove cooling fan shroud (C) and fan housings from engine. Connect and install 1. Position cooling fan shroud (C) and fan housings on engine. Be sure raised fan housing is to the rear of the engine. 2. Install three screws (B) securing left rear shroud and left rear center shroud to cooling fan shroud. 3. Install four screws (A) securing right rear shroud and right rear center shroud to cooling fan shroud.

4-20

Figure 4-39.

Figure 4-40.

4-21

Figure 4-41.

4-22

Remove 1. Remove eight self-locking nuts (A), bolts, and clamps from the right bank injector tubes. 2. Loosen but do not remove the four bolts (B) attaching injector tube clamps to supports.

Install Note.
1.

Space floating clamps, as shown.

Tighten the four bolts (B) securing injector tube clamps to supports. 2. Install eight clamps, bolts, and self-locking nuts (A) on the right bank injector tubes.

Figure 4-42. Removing or installing fuel injector right tube clamps.

4-23

Figure 4-43. Fuel injector tubes-installed view.

1. Slip 12 dust caps (A) from fuel tube fittings and disconnect tubes from fuel injection pump,

2. Cap or plug tube openings (B) in fuel injection pump and tubes (C).

Figure 4-44. Disconnecting fued injector tubes from fuel injection pump.

4-24

Disconnect 1. Disconnect electrical lead (A). 2. Disconnect fuel return hose (B). 3. Remove nut and screw attaching clamp (C) to cushioned loop clam p. 4. Remove self-locking nut and bolt (D) attaching loop clamp to bracket. 5. Loosen hoee clamps (E), separate crankcase breather tubes, and remove hose and clamps. 6. Remove cotter pin, nut (F), flat washer, and bolt. Discard cotter pin. Disconnect throttle rod from injection pump. Connect 1. Connect throttle control rod to fuel injection pump operating lever with bolt, flat washer, nut (F), and new cotter pin. 2. Connect crankcase breather tubes with hose and install hose clamps (E). Tighten clamps. 3. Install self-locking nut and bolt (D) securing loop clamp to bracket 4. Install nut and screw securing clamp (C) to cushioned loop clamp. 5. Connect fuel return hose (B). .6. Connect electrical lead (A).

Disconnect 1. Remove cotter pin, nut (A), flat washer, and bolt. Discard cotter pin. Disconnect throttle rod from injection pump. 2. Disconnect electrical lead (B). 3. Disconnect fuel return hose (C). Connect 1. Connect fuel return hose (C). 2. Connect electrical lead [If). 3. Connect throttle control rod to fuel injection pump operating lever with bolt, flat washer, nut (A), and new cotter pin.

Figure 4-46. Disconnecting or connecting throttle control, fuel return hose, and electrical lead-engines with relocated crankcase breather tube.

Figure 4-45. Disconnecting or connecting crankcase breather tube, electrical lead, throttle control, and fuel return hose-engines prior to relocated crankcase breather tube.

4-25

Note. Screws injection installed removed. pump after

and

lock

washers

are

part

of

assembly the angle

and must be rebracket has been

Figure

4-47.

Disconnecting

or

connecting

crankcase breather tube at front of engine.

Figure 4-49. Removing or installing angle

Disconnect 1. Loosen hose clamps (A) and separate rear intermediate crankcase breather tube (B) from breather tube tee. 2. Move breather tube (B) aside so fuel injection angle bracket can be removed. Connect 1. Connect rear intermediate crankcase breather tube (B) to breather tube tee. 2. Tighten hose clamps (A). Figure 4-48. Disconnecting or connecting rear intermediate crankcase breather tube at tube tee-engines prior to relocated crankcase breather tube. 4-26

Disconnect 1. Disconnect fuel inlet hose (A) from adapter. 2. Disconnect oil inlet hose (B) from nipple. Connect 1. Connect oil inlet hose (B) to nipple. 2. Connect fuel inlet hose (A) to adapter. Figure 4-50. Disconnecting or connecting

fuel injection pump oil and fuel inlet hoses.

Note. The fuel injection pump splined coupler sleeves and hubs must be identified with identical marks to prevent mismating of parts. The sleeves and hubs are matched for each assembly and must not be interchanged between assemblies. Figure 4-52. Removing fuel injection pump splined coupler bolts.

Figure 4-51. Positioning fuel injection pump coupler by turning flywheel using splined wrench -5l2O-793-7895.
1 . Separate coupler sleeves (.4). 2. Remove and discard preformed packing (B) from fuel injection pump coupler sleeve.

Figure 4-53. Separating fuel injection pump coupler sleeves.

1. Torn engine using splined wrench -5120-793-7895 as shown in figure 4-51, until fuel injection pump coupler bolts are accessible. 2. Stamp identification marks (B) on both injection coupler sleeves. 3. Remove four bolts (C), lock washers, and lock plates. 4-27

1. Turn engine using splined wrench -5120-793-7895 as shown in figure 4-51 until one pair of bolts (A) on the diaphragm coupler is exposed for removal. 2. Remove two bolts and lock washers. Turn engine until remaining pair of bolts are accessible and remove them. Figure 4-54. Removing fuel injection diaphragm coupler bolts. pump

4-28

Remove 1. Cut lockingwire and remove two screws (A) attaching breather tube bracket to pump. Remove bracket. Install the two screws in the pump (early pump only). 2. Cut locking wire and remove two bolts (B) and washers. 3. Remove bolt (C) and washer. 4. Loosen bolt (D) until threads are free. Bolt cannot be removed until after fuel injection pump is removed from engine. Install Note. Be sure lower right hand fuel injection pump long mounting bolt (D) and washer are Figure 4-55. Removing tube or

inserted in injection pump before pump is seated on mounting base. It cannot be installed with pump in position. 1. Tighten bolt (D). 2. Install long bolt (C) and washer. 3. Install two short bolts (B) and washers. Install locking wire on bolts (B and C) and on bolts (B and D). 4. Remove two screws (A) from pump (early pump only). Position breather tube bracket on pump and install two screws (A). Install locking wire.

installing

fuel

injection

pump

mounting

bolts and breather tube bracket-engines with breather routed around injection pump.

4-29

Remove 1. Separate fuel injection pump diaphragm coupler halves (A). 2. Cut locking wire and remove two bolts (B) and washers. 3. Remove bolt (C) and washer. 4. Loosen bolt (D) until threads are free. Bolt cannot be removed until after fuel injection pump is removed from engine. Install Note. Be sure lower right hand fuel injection pump long mounting bolt (D) and washer are inserted in injection pump before pump is seated on mounting base. It cannot be installed with pump in position. 1. Tighten bolt (D). 2. Install long bolt (C) and washer. 3. Install two short bolts (B) and washers. Install locking wire on bolts (B and C) and on bolts (B and D). Figure 4-56. Separating fuel injection pump diaphragm fuel coupler injection and removing or installing bolts. pump mounting

1. Remove fuel injection pump (A) from mounting base. 2. Remove and discard preformed packing (B) from mounting base. 3. Remove bolt (C) and washer. Note. Plug or cap fuel and oil openings in pump. Figure and 4-57. Removing fuel injection pump coupler.

preformed

packing-splined

4-30

1. Remove fuel injection pump (A) from mounting base. 2. Remove and discard preformed packing (B) from mounting base. 3. Remove bolt (C) and washer. Note. Plug or cap fuel and oil openings in p u m p . Figure and 4-58. Removing fuel injection pump 1. Place a metal rod in one of the sleeve alinement holes (A) as shown in figure 4-63. Coupler sleeve must be in rigid position to remove nut. 2. Remove plain nut (B) and lock washer. Note. The nut, lock washer, and key are part of the pump assembly and must be installed on pump after hub is removed. Caution: The splined coupler halves are a matched set. Damage or wear to the sleeve or hub of either coupling half requires the replacement of a complete coupler assembly. Figure 4-59. Removing fuel injection pump

preformed

packing-diaphragm

coupler.

front splined coupler sleeve nut and lock washer.

4-31

1. Place a metal rod in one of the injection pump coupler alinement holes (A) as shown in figure 4-64. Injection pump coupling must be in a rigid position to remove nut. 2. Remove plain nut (B) and lock washer. Note. The nut, lock washer, and key are part of the pump assembly and must be installed on the pump after the coupler sleeve is removed. Figure 4-60. Removing fuel injection pump Figure 4-61. Removing fuel injection pump splined coupler sleeve and hub. diaphragm coupler nut and lock washer.

4-32

1. Position improvised puller (fig. 2-2) on diaphragm coupler and install two 5 / 16-24 UNF-2A x 2-1 / 2 in. hex head cap screws (A) into puller screw holes provided in the diaphragm coupler.

2. Hold improvised puller with a 1 in. open end wrench (B). 3. Tighten 1 / 2-13 UNC-2A x 2 in. hex head cap screw (C) to remove diaphragm coupler from injection pump tapered shaft.

Figure 4-62. Removing fuel injection pump diaphragm coupler.

4-33

1. Install new preformed packing (A) in groove in face of coupler sleeve. Use a light coating of grease to hold preformed packing in position. 2. Position Woodruff key and injection pump coupler half (B) on pump shaft and install lock washer and plain nut (B, fig. 4-59). 3. Insert a metal rod (C) in one of the alinement holes in the injection pump coupler. 4. Tighten plain nut to 900 pound-inches using a torque wrench (D). Figure 4-63. Installing coupler half and torque tightening splined fuel injection nut. pump coupler

1. Position Woodruff key and injection pump coupler half (A) on pump shaft and install lock washer and plain nut (B, fig. 4-60). 2. Insert a metal rod (B) in one of the alinement holes in the injection pump coupler. 3. Tighten plain nut to 900 pound-inches using a torque wrench (C). Figure torque 4-64. Installing coupler half and tightening fuel injection diaphragm coupler nut. pump

4-34

Figure 4-65. Removing or installing fuel injection pump timing hole plug.

N o t e . It is possible to have timing marks on both splined coupler and diaphragm coupler alined with mark on injection pump and not have the marked gear tooth visible in timing hole. Make sure marked tooth (fig. 4-66) is visible when timing marks are alined. If the marked tooth is not visible, rotate the coupler 360 degrees, in either direction. Aline the timing marks and the marked tooth will be visible. Install timing plug. Figure 4-67. Timing marks on fuel injection bearing retaining plate and splined coupler hub alined.

Figure 4-66. Fuel injection pump timing hole cover removed showing marked gear tooth in timed position. 4-35

Remove Note. Before the fuel injection pump is installed on the engine, the engine must be properly timed with number one right bank cylinder in the firing position. In order to set Figure 4-68. Timing marks on fuel injection pump bearing retaining plate and coupler hub alined. diaphragm engine timing, it is necessary to remove the primary fuel filter bracket and throttle linkage to check position of camshaft. lobes (fig. 4-73). 1. Remove three screws (A) and lock washers attaching primary fuel filter bracket and throttle linkage plate to number 1R cylinder assembly. 2. Remove two bolts (B) attaching throttle linkage bracket to crankshaft damper and oil fiber housing. 3. Remove cotter pin, nut (C), flat washer, and bolt and disconnect rod from lever. Discard cotter pin. 4. Move filter, bracket and plate (D), and throttle linkage to expose camshaft lobes. Discard gasket. Install 1. Position filter, bracket and plate (D), and throttle linkage on engine using new gasket. 2. Install three screws (A) and lock washers securing primary fuel filter bracket and throttle linkage plate to number 1R cylinder assembly. 3. Install two bolts (B) securing throttle linkage bracket to camshaft damper and oil filter housing. 4. Install bolt, flat washer, nut (C), and new cotter pin connecting rod to lever. Figure 4-70. Removing or installing primary fuel filter bracket and throttle linkage.

Figure

4-69. Disconnecting or connecting primary fuel filter drain line.

4-36

1. Turn flywheel (A) using splined wrench - 5120-7937895 (fig. 4-51). 2. A line 1R INJ PORT CLOSE timing mark on flywheel with timing pointer (B). C a u t i o n : Be sure pointer alines with correct timing mark on flywheel. Refer to figure 6-40 to check timing mark location. Figure 4-71. Flywheel and in position for only). fuel injection pump timing (Models AVDS-1790-2-M AVDS-1790-2-AM

1. Turn flywheel (A) using splined wrench -5120-7937895 (fig. 4-51). 2. Aline 1R INJ PORT CLOSE modified timing mark on flywheel with timing pointer (B). C a u t i o n : Be sure pointer alines with correct timing mark location on flywheel. Refer to figure 6-41 to check timing mark location. Figure 4-72. Flywheel in position for fuel injection pump timing (Model AVDS-1790-2A only).

4-37

Note. Camshaft lobes must be in position Shown for proper injection pump timing. Figure 4-73. Position of camshaft lobes for injection pump timing.
Figure 4-75

1. Check length of bolts (A) securing fuel injection pump mounting base to crankcase. Discard bolts that are 17 / 32 in. long and replace with the correct 1-3 / 8 in. long bolts (5305-725-0154) and lock washers (5310584-5272). Torque tighten bolts to 720 to 780 poundsinch. 2. Position new preformed packing (B) on mounting base oil transfer tube. Figure 4-74. Installing preformed packing on fuel injection pump mounting base oil transfer tube.

4-38

Note. Be sure preformed packing (fig. 4-63) is installed in coupler sleeve. Note. The fuel injection pump diaphragm 1. Postion fuel injection pump coupler sleeves (A) making sure timing marks on bearing retaining plate and coupler hub remain alined as shown. These marks must be alined before attempting to assemble the coupler. 2. Loosely position four lock plates, lock washers, and bolts (B) in drive shaft coupler sleeves. These bolts will not be tightened until gear backlash has been removed, with timing marks on pump alined as instructed in figure 4-79. Figure 4-78. Positioning fuel injection pump coupler sleeve s-splined coupler.

coupler parts are not matched sets, and parts are interchangeable between assemblies. The coupler hub and pilot ring on the drive shaft need not be removed or replaced unless they are damaged. Check torque tightness of nut securing coupler to drive shaft (900 lb-in.). Figure 4-76. Fuel injection pump diaphragm coupling and pilot ring on hub before pump installation.

Note. Be sure lower right fuel injection pump mounting bolt is inserted in injection pump before pump is seated on mounting base. It cannot be installed with pump in position. Refer to figures 4-55 and 4-56 to secure pump to base. Figure 4-77. Installing fuel injection pump assembly on engine. 4-39

Figure 4-80

1. Using two 5 / 16-in. steel rods (A), hold fuel injection pump drive coupler sleeve (nearest the pump) stationary and rotate the other drive coupler sleeve counterclockwise to remove backlash from the pump drive shaft. 2. When backlash is removed and flat sides of drive coupler mate, tighten four drive coupler bolts (B) securely. 3. When flat sides of drive coupler sleeves (C) do not mate when backlash is removed, the coupler sleeves must be separated and reset. Separate coupler and push sleeve of drive coupler on rear fan and accessory drive housing (fig. 4-75) shaft toward drive shaft and from hub splines. Adjust sleeve on splines so flat sides of coupler half are alined. Torque tighten coupler bolts. Lubricate drive coupler (fig. 4-80). Figure 4-79. gear Removing train unit fuel injection and pump drive backlash setting

advanced

retard position-splined coupler. Note. For proper assembly of coupler half to diaphragm pack, place a pry bar between rear fan and accessory drive housing and coupler half and apply pressure to take up the end thrust of drive gear. Measure clearance between coupler half and diaphragm pack. This clearance cannot exceed 0.050-inch or it will put undue stress on the diaphragm pack causing early failure. If the 0.050-inch dimension cannot be achieved, it will be necessary to remove fuel injection pump and replace coupler hall or complete coupling assembly. Torque coupler half retaining nut to 900 inch-pounds when installing new coupler half. Figure 4-81. Checking diaphragm coupler assembly clearance.

4-40

1. Using two 5 / 16-in. steel rods (A) hold fuel injection pump drive coupling flange (nearest the pump) stationary and rotate the other coupling half counterclockwise to remove backlash from the pump drive shaft. 2. Making certain timing marks (B) are a lined and backlash is removed, position pilot ring (C) on coupler half and install four lock washers and bolts. Figure 4-82. Removing fuel injection pump drive unit gear train backlash and setting advance retard position-diaphragm coupler.

Figure 4-83.

figure 4-85 Figure 4-84.

4-41

1. With throttle linkage in full throttle position (A), clearance between lever stop pin and stop on bracket must be 1/8 to 3 / 16 inch. 2. With throttle linkage in idle position (B), clearance between lever stop pin and stop on bracket must be 3 / 16 inch. 3. When the foregoing clearances are not met, loosen lock nuts on adjustable rod (C) and adjust rod as necessary to obtain required clearance. Tighten lock nuts after adjustment. 4. The idle adjusting screw (D) must not be set until engine is installed and tested. Figure 4-85. Throttle linkage

5. Check the fuel supply as follows: a. Connect the necessary fuel and oil hoses and electrical harnesses to the engine to permit slave operation from the vehicle to check for fuel and / or oil leaks. Activate the vehicle in-tank fuel pumps to make certain fuel is supplied to and through the fuel injection pump. Fuel should flow from the fuel return outlet (fig. 4-85). b. Crank the engine with the starter until fuel flows from all outlet ports in the fuel injection pump hydraulic head. adjustment-schematic diagram.

4-42

Note. The hydraulic head outlet ports are numbered on late fuel injection pumps. 1. Connect the left bank fuel injector tubes to the rear injection pump hydraulic head (A) in the following order: No. 5, 3, 1, 6, 2, and 4. 2. Connect the right bank fuel injector tubes to the front injection pump hydraulic head (B) in the following order: No. 2, 4, 1, 6, 5, and 3.

Note. Tighten fuel injector tube fittings until a sharp increase in torque becomes apparent. This will indicate that the fitting sleeve is seated. When this point is reached, draw the nut up approximately 1 / 6 of a turn (minimum) but not more than 1 / 3 of a turn (maximum), to complete tightening operation. Caution: Overtightening ferrule causing fuel leaks. will damage tube

Figure 4-86. Connecting fuel injector tubes-schematic diagram.

4-43

Note. The fuel injection pump, fuel tubes, and fuel tube connections must be checked for fuel leaks with the engine running before the cooling fans are installed.

Caution: Do not run engine above idle and not longer than ten minutes without cooling fans. 1. Install a fan rotor hub sleeve spacer -4910-795-7952 (A) on each fan drive vertical drive shaft to prevent oil seepage at fan drive oil seals while operating engine. 2. Secure the sleeve spacer (A) to each drive shaft with the same nut (B) used to secure the cooling fan. Start engine and check for fuel leaks. If leaks are evident loosen the tube fittings and retighten. Replace fuel injection tubes if leak persists. 3. Slide the 12 fuel injector tube dust caps (C) over tube fittings at fuel injection pump hydraulic head. Figure 4-87. Front fan drive housing fan rotor hub sleeve spacer-4910-795-7952 installed for leakage test.

Figure 4-88.

Section

Ill.

REPLACEMENT OF MAIN AND AUXILIARY OIL F I L T E R B Y P A S S VALVE, OIL PRESSURE REGULATOR VALVE A N D FUEL / WATER SEPARATOR FILTER

4-5. General
This section covers the replacement of the main and auxiliary oil filter bypass valves, the oil pressure regulating valve, and the fuel / water separator filter. The valves are not periodic maintenance items, and should only be removed for inspection or replaced in case of malfunction. The two outer elements in the fuel / water separator filter are periodic maintenance items and are allocated to the organizational maintenance personnel. These are coalescer elements designated t o s e p a r a t e w a t e r f r o m t h e f u e l system. The center element is a final fuel filter

4-44

e l e m e n t and is replaced annually or at time of engine overhaul. Refer to Table 4-2 for replacement and service instructions. Reference

figures are listed under appropriate headings in the table.

Table 4-2. Main and Auxiliary Oil Filter Bypass Valves, Oil Pressure Regulating Valve, and Fuel / Water Separator Filter Assembly Component Main Oil Filter Bypass Valve Auxiliary Oil Filter Bypass Valve Oil Pressure Regulating Valve Fuel / Water Separator Filter Assembly Fuel / Water Separator Filter Elements 4-89, 4-91, 4-93 4-94 4-94, Removal 4-90 4-92 through 4-96 4-97, 4-98 4-90, 4-92, 4-93 4-96 4-98, Installation 4-89 4-91 through 4-94 4-97, 4-94

4-6.

Replacement Instructions

Remove 1. Remove main oil filter bypass valve plug (A). 2. Remove and discard plug gasket (B). 3. Remove bypass valve spring (C). Install 1. Install bypass valve spring (C). 2. Install new gasket (B) on valve plug (A). 3. Install main oil filter bypass valve plug (A). Figure 4-89. Removing or installing main oil filter bypass valve plug, gasket and spring.

Figure 4-90. Removing or installing main oil filter bypass valve.

4-45

Figure 4-92

Remove 1. Remove auxiliary oil filter bypass valve plug (A). 2. Remove and discard plug gasket (B). 3. Remove bypass valve spring (C). Install 1. Install bypass valve spring (C). 2. Install new gasket (B) on valve plug (A). 3. Install auxiliary oil filter bypass valve plug (A). Figure 4-91. Removing or installing auxiliary oil-filter bypass valve plug, gasket, and spring.

4-46

Warning: The valve cover is spring loaded. Excercise care when removing cover. Remove 1. Remove two self-locking nuts and flat washers attaching cover to crankshaft damper and oil filter housing. 2. Remove cover shim washers, and gasket. Discard gasket. 3. Remove stop, spring, and valve. 4. Remove valve sleeve. Note. The valve sleeve may be difficult to remove because of the presence of varnish from the oil. An improvised tool (fig. 2-3) used with mechanical puller-5120-310-4668 may be used

to assist in removing valve sleeve. Insert hook end of tool into hole in sleeve and gently tap until sleeve is free. Install 1. Install valve sleeve. 2. Install valve, spring, and stop. 3. Install new gasket, shim washers, and cover. 4. Install two self-locking nuts and flat washers securing cover to crankshaft damper and oil filter housing. Note. To increase engine oil pressure, one or more shim washers can be installed between the cover and the spring. To decrease oil pressure remove shim washers. Refer to paragraph 1-24 for recommended oil pressures.

Figure 4-93. Removing or installing engine oil pressure regulating valve.

4-47

Disconnect 1. Remove vent plug (A) from fuel / water separator filter cover. 2. Disconnect fuel / water separator filter inlet hose (B) at fuel pump outlet and drain fuel into a suitable container. Connect 1. Connect fuel / water separator filter inlet hose (B) to fuel pump outlet. 2. Instnll vent plug (A) in fuel / water separator filter cover. Figure 4-94. Disconnecting or connecting fuel water separator filter inlet hose at fuel pump.

Disconnect 1. Disconnect fuel outlet hose (A) and remove fueloutlet elbow. 2. Disconnect fuel drain tube (B) and remove fuel drain elbow. 3. Disconnect fuel inlet hose (C) and remove fuel inlet elbow. Connect 1. Install fuel inlet elbow and connect fuel inlet hose (C). 2. Install fuel drain elbow and connect fuel drain tube (B). 3. Install fuel outlet elbow and connect fuel outlet hose (A). Figure 4-95. Disconnecting or connecting fuel hoses and drain line at fuel / water separater filter.

4-48

Remove 1. Remove cover (A). 2. Remove and discard preformed packing (B). Install Note. Replacement coalescer elements

and

Remove 1. Remove lower two cap screws (A), lock washers, and plain washers. 2. Remove upper two cap screws (B) and lock washers and remove filter assembly from bracket. Note. Fuel inlet, outlet, and drain elbows are not part of the filter assembly and must be installed in the replacement filter. Install 1. Position filter assembly on bracket and install upper two cap screws (B) and lock washers. 2. Install lower two cap screws (A), lock washers, and plain washers. Figure 4-96. Removing or installing fuel / water separator filter assembly.

preformed packing are available in parts kit 2910-801-1152. Purge fuel system, refer to pertinent operators manual. 1. Install new preformed packing (B). 2. Install cover (A). Figure 4-98 Removing or installing fuel / water separator filter cover.

Note. Entire

area

around

the

fuel

water

separator filter should be thoroughly cleaned to prevent the entry of dirt or other foreign objects before removing the cover. Figure 4-97. Removing or installing

fuel / water separator filter cover bolts. 4-49

Section lV. REPLACEMENT OF COOLING FAN CLUTCH ASSEMBLY AND FAN DRIVE HOUSING OUTER FLANGE BEARING 4-7. General
This section covers the removal and installation of the cooling fan clutch assembly and the replacement of the outer flange bearing. The front and rear cooling fan clutch assemblies are interchangeable. Replace both clutch assemblies following the same procedure. For instructional purposes in this section, the rear fan clutch assembly has been used for typical procedure. Refer to Table 4-3 for applicable illustrations and instructions required for removing or installing cooling fan clutch and flange bearing.

Table 4-3. Cooling Fan Clutch Assembly

Remove 1. Cut locking wire (A). 2. Remove 12 slotted nuts (B). 3. Install jack screws (5 / 16-24NF thread) (C) into three threaded holes in the fan drive housing cover. Alternately tighten jack screws until fan drive housing and clutch assembly are separated from housing. Remove jack screws. Install 1. Install 12 slotted nuts (B) securing fan drive housing and clutch assembly. 2. Install locking wire (A). Figure 4-99. Removing or installing rear fan drive housing cover attaching parts.

Remove 1. Remove housing cover and clutch assembly (A). 2. Cut locking wire (B). 3. Remove six bolts (C) and flat washers attaching the oil seal housing to the cover. 4. Install two mechanical pullers -5120-473-7222 in oil seal housing puller screw holes (D). Turn pullers alternately to remove housing. Install 1. Position oil seal housing on cover and install six bolts (C) and flat washers securing housing on cover. 2. Install locking wire (B). 3. Install housing cover and clutch assembly (A). Figure 4-100. Removing or installing rear fan drive housing cover and clutch assembly.

4-50

Figure 4-101. Removing or installing fan drive housing cover preformed packing.

Figure

4-102.

Comparison between piston actuated and fan drive housing and cover assemblies.

mechanical

4-51

4-8. Difference Between Piston Actuated and Mechanical Fan Drive Clutch
The basic difference between the piston actuated and mechanical fan drive clutch is the redesign of the late clutch to eliminate the hydraulic disengagement feature. The mechanical design provides complete interchangeability between piston actuated and mechanical housing and cover assemblies. However, individual parts contained within the assemblies are not interchangeable.

Figure 4-104. Removing fan drive clutch Figure 4-103. Removing from housing drive cover shaft. and upper ball hearing from housing cover. bearing vertical

1. Position fan drive housing cover (A) on arbor press using suitable support blocks. 2. Press ball bearing (B) in cover. 3. Install housing cover and bearing on vertical drive shaft. Figure 4-105. Pressing fan drive clutch upper ball bearing into housing cover.
4-52

Section V. REPLACEMENT OF INTAKE MANIFOLD TUBES AND INTAKE MANIFOLD ASSEMBLY 4-9. General
This section covers the replacement of intake manifold tubes and the intake manifold assembly. Intake manifold tubes for cylinder 1, 2, 5, and 6, on each side of the engine can be replaced without removing the complete intake manifold. Intake manifold tubes for cylinder 3 and 4 on each side of engine cannot be replaced unless the complete intake manifold system is removed from the engine. In order to remove any cylinder intake manifold tube, it is necessary to remove the oil drain tube on that cylinder. Refer to Table 4-4 for illustrations and instructions on removal and installation of the manifold tubes or manifold assemblies. Figure references are listed under appropriate headings in the table.

Table 4-4. Intake Manifold Tubes and Intake Manifold Assembly

4-10. Intake Manifold Tubes

For instructional purposes replacement of intake manifold tube for cylinder 2L is described in this section. Tubes for cylinders lL, 5L, 6L, lR, 2R, 5R, and 6R are replaced in the same manner.

Figure 4-107. Disconnecting or connecting intermediate cylinder head oil drain tubes- cylinder 2L.

Disconnect 1. Loosen four hose clamps (A) and side hoses from intermediate cylinder head oil drain tube. 2. Remove screw and nut attaching flame heater fuel inlet line cushioned clamp (B) to loop clamp on cylinder head oil drain tube, if necessary. Connect 1. Install screw and nut securing flame heater fuel inlet line cushioned clamp (B) to loop clamp on cylinder head oil drain tube. 2. Slide hoses on intermediate cylinder head OR drain tube and tighten four hose clamps (A). Figure 4-106. Disconnecting or connecting cylinder head oil drain tube hoses-cylinders IL and 2L. Figure 4-108. Removing or installing intermediate cylinder head oil drain tubecylinder 2L. 4-53

Disconnect 1. Remove three nuts (A) and lock washers attaching flange of intake manifold tube to cylinder. 2. Remove four self-locking nuts (B) attaching flange which secures tube to intake manifold. Connect 1. Install four self-locking nuts (B) to attach flange which secures tube to intake manifold. 2. Install three nuts (A) and lock washers securing flange of intake manifold tube to cylinder. Figure 4-109. Disconnecting or connecting

intake manifold tube from intake manifold and cylinder 2L.

Remove 1. Separate manifold flange, spring washer, flat washer, and preformed packing from intake manifold. 2. Remove intake manifold tube from studs at cylinder. Remove and discard gasket. 3. Remove intake manifold tube from intake manifold and discard preformed packing. 4. Remove flat washer, spring washers, manifold flange, and cylinder flange in order listed and reinstall on replacement tube. Note. R e p l a c e m e n t tubes do not include flanges. Install 1. With cylinder flange, manifold flange, spring washer, and flat washer installed on intake manifold tube, install new preformed packing against flat washer. 2. Install new gasket on studs at cylinder. 3. Install assembled intake manifold tube on intake manifold and studs at cylinder. Figure 4-110. Removing or installing intake manifold tube-cylinder 2L.

4-54

4-11.

Figure 4-111

Disconnect 1. Disconnect manifold heater fuel inlet tube (A) from manifold heater fuel solenoid valve tee. 2. Remove self-locking nut and screw (B) attaching cushioned loop clamp to loop clamp on oil cooler outlet hose. Connect 1. Install self-locking nut and screw (B) securing cushioned loop clamp to loop clamp on oil cooler outlet hose. 2. Connect manifold heater fuel inlet tube (A) to manifold heater fuel solenoid valve tee. Figure 4-112. Disconnecting or connecting

manifold heater fuel inlet tube.

4-55

Disconnect 1. Remove screw and nut attaching flame heater fuel inlet line cushioned clamp (A) to loop type clamp on cylinder head oil drain tube. 2. Loosen two hose clamps (B) and slide hose down on lower front drain tube. Connect 1. Position hose between cylinder head oil drain tube and lower front drain tube and tighten two hose clamps (B). 2. Install screw and nut securing flame heater fuel inlet line cushioned clamp (A) to loop type clamp on cylinder head oil drain tube. Figure 4-113. head Disconnecting oil drain or connecting front.

cylinder

tube-left

Disconnect 1. Disconnect manifold heater fuel inlet line (A). 2. Disconnect heater fuel outlet tube (B). 3. Cut locking wire and remove six body bolts (C) and remove oil drain tubes as an assembly. Remove and discard 12 gaskets. Connect 1. Position oil drain tubes as an assembly on engine. Install new solid copper gaskets on six body bolts (C), insert bolts through oil drain tubes and install second new annular copper asbestos gasket on each bolt. Tighten bolts securing drain tube and install locking wire. 2. Connect heater fuel outlet tube (B). 3. Connect manifold heater fuel inlet line (A). Figure 4-115. Disconnecting or connecting heater fuel inlet and outlet tubes from intake manifold heater.

Figure

4-114.

Disconnecting oil drain

or

connecting rear.

cylinder 4-56

head

tube-left

Disconnect 1. Loosen four hose clamps (A). 2. Separate hoses (B), sliding one hose on the heater tube and the other hose on the turbosupercharger air outlet elbow. 3. Remove turbosupercharger outlet elbow tube sleeve (C). Connect 1. Position turbosupercharger outlet elbow tube sleeve (C) between elbow tube and heater tube. 2. Slide one hose (B) from elbow tube on sleeve (C). Slide second hose (B) from heater tube on sleeve (C). 3. Tighten four hose clamps (A). Figure 4-116. Disconnecting or connecting turbosupercharger air outlet elbow and heater tube.

Remove 1. Remove 12 nuts (A) and lock washers attaching intake manifold tubes to cylinders 1L, 2L, 5L, and 6L. 2. Remove six nuts (B), lock washers, and flat washers attaching intake manifold tubes to cylinders 3L and 4L. Remove manifold assembly. 3. Remove and discard six intake manifold gaskets (C).

Install 1. Install six new intake manifold gaskets (C). 2. Position manifold assembly on cylinder studs. Install six nuts (B), lock washers, and flat washers securing intake manifold tubes to cylinders 3L and 4L. 3. Install 12 nuts (A) and lock washers securing intake manifold tubes to cylinders 1L, 2L, 5L, and 6L.

Figure 4-117. Removing or installing intake manifold assembly-left side.

4-57

Disassemble 1. Remove six nuts (A) and flat washers attaching intake manifold elbow to intake manifold. Remove elbow and heater tube as a unit. Remove and discard gasket. 2. Remove four nuts (B) attaching intake manifold tubes 3L and 4L to intake manifold and remove tubes, Remove and discard gaskets. 3. Remove intake manifold tubes for cylinders 1L, 2L, 5L, and 6L following instructions accompanying figure 4-110.

Assemble 1. Install intake manifold tubes for cylinders 1L, 2L, 5L, and 6L following instructions accompanying figure 4110. 2. Install new gaskets on studs on intake manifold for cylinders 3L and 4L intake manifold tubes. Position tubes on manifold and install four nuts (B) securing each tube to manifold. 3. Install new intake manifold elbow gasket on manifold studs. Position intake manifold elbow and heater tube as a unit on manifold. Install six nuts (A) and flat washers securing elbow to manifold. assembling intake manifold assembly.

Figure

4-118.

Disassembling

or

Section 4-12. General

VI.

REPLACEMENT

OF

ENGINE

OIL

PAN

section covers the replacement of the o i l p a n . Refer to Table 4-5 for instructions covering the illustrations and

This engine

removal and installation of the oil pan. Figure references are listed under appropriate headings in the table.

Table 4-5. Engine Oil Pan

4-58

4-13.

Replacement

Instructions

Disconnect Note. The left front drain tube may be disconnected in the same manner. 1. Remove two cap screws (A) and lock washers attaching right front cylinder head oil drain tube (B) to oil pan. 2. Separate drain tube from oil pan and remove and discard gasket. Connect N o t e . The left front drain tube may be connected in the same manner. 1. Install new gasket between right front cylinder head oil drain tube (B) and oil pan. 2. Install two cap screws (A) and lock washers securing drain tube to oil pan. Figure 4-119. Disconnecting or connecting

Disconnect 1. Remove two cap screws (A) and lock washers attaching left rear cylinder head oil drain tube to oil pan. 2. Separate drain tube front oil pan and remove and discard gasket (B). Connect 1. Install new gasket (B) between left rear cylinder head oil drain tube and oil pan. 2. Install two cap screws (A) and lock washers securing drain tube to oil pan. Figure 4-120. Disconnecting left rear cylinder head oil or connecting drain tube.

right front cylinder head oil drain tube.

4-59

Disconnect 1. Remove two cap screws (A) and lock washers attaching right rear cylinder head oil drain tube to oil pan. 2. Separate drain tube from oil pan and remove and discard gasket (B). Connect 1. Install new gasket (B) between right rear cylinder head oil drain tube and oil pan. 2. Install two cap screws (A) and lock washers securing drain tubes to oil pan. Figure 4-121. Disconnecting or connecting right rear cylinder head oil drain tube.

Disconnect 1. Remove three assembled washer screws (A) and seal washers attaching oil filler tube to oil pan. Discard seal washers. 2. Remove and discard filler tube gasket (B). 3. Remove three self-locking nuts (C) attaching oil level indicator tube to oil pan. 4. Remove and discard indicator tube gasket (D). Connect 1. Position new oil filler indicator tube gasket (D) on oil pan. 2. Install three self-locking nuts (C) securing indicator tube to oil pan. 3. Position new oil filler tube gasket (B) on oil pan. 4. Assemble new seal washers on washer screws (A). Install assembled washer screws securing filler tube to oil pan. Figure 4-122. Disconnecting or connecting

oil-filler and oil level indicator tubes from oilpan.

4-60

Figure 4-123

Remove 1. Cut locking wire and remove 12 drilled head bolts (A) and flat washers attaching the oil pan to crankshaft damper and oil filter housing. 2. Remove 27 of the 28 self-locking nuts (B) and flat washers attaching oil pan to each side of the crankcase assembly. Note. One nut and washer are left installed on each side of the oil pan, near the center, to prevent oil pan from falling and being damaged.

Support

oil

pan

adequately

before

removing

remaining two nuts and washers then remove oil pan. Install 1. Install 28 self-locking nuts securing oil pan to each aide of 2. Install 12 drilled head bolts securing oil pan to crankshaft housing.

(B) and flat washers the crankcase assembly. (A) and flat washers damper and oil filter

Figure 4-124. Removing or installing engine oilpan.

4-61

Remove Remove oil pan sealing thread and clean oil pan mating surfaces thoroughly. Figure 4-125. Removing or

Install Apply a thin coat of gasket cement, Specification MIL-C10523 (ORD), on the oil pan flange and install sealing thread. oil pan sealing thread.

installing

Section VIl. REPLACEMENT OF VALVE ROCKER ARMS, ROCKER ARMSHAFTS, AND VALVE CLEARANCE ADJUSTING SCREWS 4-14. General
This section contains instructions for the replacement of valve rocker arms, rocker arm shafts and valve clearance adjusting screws. Refer to Table 4-6 for illustrations and inon removal installation and procedures. Figure references are listed under appropriate headings in the table. Instructions apply to either left or right side of the engine. structions

Table 4-6. Valve Rocker Arms, Rocker Arm Shafts and Valve Clearance Adjusting Screws

4-62

4-15.

Figure 4-126. Removing or installing right front upper cover.

Remove 1. Remove six bolts (A) and remove oil filler tube shroud plate. 2. Remove six bolts (B) and remove oil level indicator tube shroud plate. Install 1. Position oil level indicator tube shroud plate and install six bolts (B). 2. Position oil filler tube shroud plate and install six bolts (A).

Figure 4-127. Removing or installing right rear upper cover.

Figure 4-128. Removing or installing oil filier and oil level indicator tube shroud plates-one piece type oil filler and indicator tubes installation.

4-63

Remove 1. Remove six bolts (A) and remove oil level indicator tube shroud plate. 2. Remove three bolts (B) attaching modification cover plate and upper cover to frame. Note. Do not remove remaining three bolts attaching modification cover plate to upper cover. Maintain upper cover as an assembly. Install 1. Install three bolts (B) securing modification cover plate and upper cover to frame. 2. Position oil level indicator tube shroud plate and install six bolts (A). Figure 4-129. Removing or installing oil level indicator tube shroud plate-modified shroud plate installation.

lieu of self-locking nuts, 2. Remove two self-locking nuts (A), cap screws, and retaining straps attaching oil level indicator tube to frame. Connect Note. On installations that have been modified, oil filler tube will be relocated behind turbosupercharger and retaining straps will be discarded. 1. Position retaining straps nuts (A) and cap screws, indicator tube to frame. 2. Position retaining straps nuts (B) and cap screws indicator tube to frame. Figure 4-131. and install two self-locking securing straps and oil level and install two self-locking securing straps and oil level

Disconnecting

or

connecting

oil filler and oil level indicator tube retaining straps-one piece type oil filler and indicator tubes installation shown.

Figure 4-130. Removing or installing left front upper cover-modified cover installation. upper-

4-64

Disconnect 1. Disconnect primary fuel filter drain line (A) from drain valve. 2. Disconnect fuel / water separator filter drain line (B) from drain valve. Connect 1. Connect fuel / water separator filter drain line (B) to drain valve. 2. Connect primary fuel filter drain line (A) to drain valve. Figure 4-133 Disconnecting or connecting Figure 4-132. Oil level indicator and oil filler tube upper shroud-tubes with splash installation installed view. pan fuel drain tubes-tubes with splash pan installation.

4-65

Remove 1. Lift cover and remove oil level indicator (A). 2. Remove drain hose (B) from retaining brackets. 3. Remove seven cap screws (C) attaching valve and hose brackets to shroud plate. 4. Remove five cap screws (D) attaching plate to frame. Install 1. Install five cap screws (D) securing plate to frame. 2. Install seven cap screws (C) securing valve and hose brackets to shroud plate. 3. Install drain hose (B) on retaining brackets. 4. Install oil level indicator (A) I and close cover. Figure 4-134. Removing or installing oil level indicator and oil filler and oil level indicator tube shroud plate bolts-tubes with splash pan installation.

Remove 1. Raise cover plate (A) until oil drain hose clamp (B) is accessable. 2. Loosen hose clamp (B) and disconnect oil drain hose from cover plate. 3. Remove cover plate (A) and remove and discard four preformed packings (C). Install 1. Install four new preformed packings (C) and position cover plate (A) on frame. 2. With cover plate partially raised, connect oil drain hose to cover plate and tighten hose clamp (B). 3. Position cover plate (A) on frame. Figure 4-135. Removing or installing oil level indicator and oil filter tube upper cover-with splash pan installation.

Figure 4-136. Oil level indicator tube upper cover p l a t e -relocated modified oil filler view. tube installed

4-66

Figure 4-137. Oil level indicator tube upper cover plate-relocated oil filler tube installed view.

Disconnect 1. Disconnect primary fuel drain tube (A) from drain valve. 2. Disconnect fuel / water separator filter drain tube (B) from drain valve. Connect 1. Connect Fuel / water separator filter drain tube (B) to drain valve. 2. Connect primary fuel filter drain tube (A) to drain valve. Figure 4-138. Disconnecting or connecting

fuel drain tubes-relocated oil filler tube installation.

4-67

Figure 4-139

Figure 4-141

Figure 4-140. Removing or installing oil level indicator upper cover plate-relocated oil filler tube installation.

4-68

Remove 1. Disconnect manifold heater spark plug cable (A). 2. Remove two screws (B), spacers, and flat washers attaching ignition unit bracket to oil coolers. Remove ignition unit, bracket and cable. 3. Remove grommets (C) from brackets. Replace damaged grommets. Install 1. Install grommets (C) in ignition unit bracket. 2. Position ignition unit, bracket, and cable on oil coolers and install two screws (B), spacers, and flat washers securing bracket to oil coolers. 3. Connect manifold heater spark plug cable (A). Figure 4-143. Removing or installing manifold heater ignition unit-right side.

Disconnect 1. Disconnect oil cooler outlet hose (A) and drain oil into a suitable container. 2. Disconnect oil cooler inlet hose (B). Connect 1. Connect oil cooler inlet hose (B). 2. Connect oil cooler outlet hose (A). Figure 4-142. Disconnecting or connecting oil cooler hoses-left side.

Disconnect 1. Loosen, but do not remove, bolt (A) and self-locking nut attaching brace to turbosupercharger tie rod. 2. Remove self-locking nut (B), flat washer, and cap screw attaching brace to support beam. 3. Remove six self-locking nuts (C) and flat washers attaching support beam to cylinders. Note. The flat washers are located at cylinder Nos. 2, 4 , a n d 5 o n b o t h b a n k s . Connect 1. Install six self-locking nuts (C) and flat washers securing support beam to cylinders. 2. Install self-locking nut (B), flat washer, and cap screw securing brace to support beam. 3. Tighten bolt (A) and self-locking nut attaching brace to turbosupercharger tie rod. Figure 4-144. Disconnecting or connecting oil cooler support beam-right side. 4-69

Figure 4-145. Disconnecting or connecting shroud from top frame-right front side.

Disconnect 1. Remove two screws (A) attaching frame to right rear shroud. 2. Remove two screws (B) attaching turbosupercharger shroud to right rear shroud. Connect 1. Install two screws (B) securing turbosupercharger shroud to right rear shroud. 2. Install two screws (A) securing frame to right rear shroud. Figure 4-147. Disconnecting or connecting right rear shroud from top frame.

Disconnect 1. Remove one pan head screw (A) attaching right oil cooler end shroud. 2. Remove one self-locking nut and bolt (B) and remove right upper transmission shroud. Connect 1. Position right upper transmission shroud and install one bolt (B) and self-locking nut. 2. Install one pan head screw (A) securing right oil cooler end shroud. Figure 4-146. Disconnecting or connecting right oil cooler end shroud and upper transmission 4-70 shroud.

Remove 1. Attach a straight-link chain (A) around top frame. 2. Remove oil cooler and top frame (B) as an assembly. Install 1. Attach a straight-link chain (A) around top frame and

oil cooler assembly. 2. Position assembly on side of engine making sure six mounting holes in top frame are located on studs on top frame retaining brackets.

Figure 4-148. Removing or installing oil coolers and top frame as an assembly.

4-71

Remove 1. Remove 24 self-locking nuts (A). 2. Remove 12 top frame retaining brackets (B).

Install 1. Position 12 top frame retaining brackets (B) on cylinder mounting studs. 2. Install 24 self-locking nuts (A).

Figure 4-149. Removing or installing top frame retaining brackets.

4-72

Disconnect 1. Disconnect fuel injector nozzle fuel inlet tube (A). 2. Disconnect fuel injector nozzle fuel return tubes (B) at nozzle adapter. Connect 1. Connect fuel injector nozzle fuel return tubes (B) at nozzle adapter. 2. Connect fuel injector nozzle fuel inlet tube (A). Figure 4-150. Disconnecting return tubes. or connecting fuel injector nozzle holder fuel inlet and

Remove 1. Remove nozzle adapter bolt (A). 2. Remove nozzle adapter and discard two gaskets (B). Install 1. Install one gasket (B) on nozzle adapter bolt (A), install bolt through adapter, and install second gasket (B). 2. Install nozzle adapter and tighten bolt (A). Figure 4-151. Removing or installing fuel injector nozzle fuel tube adapters.

4-73

Note. In stubborn cases, when the nozzle is frozen, it will be necessary to remove the fuel inlet connector from the nozzle and turn the nozzle using wrench socket - 5120-875-9556. When the nozzle is free of cylinder threads, install mechanical puller - 5120-873-6943 in the 7 / 16-20 tapped hole in the end of the nozzle holder. Remove nozzle and holder using puller. Figure 4-152. Loosening fuel injector nozzle and holder retainer using wrench-5120-871-7198.

Remove 1. Remove fuel injector nozzle and holder assembly. Remove and discard gasket (A). 2. Remove and discard fuel injector nozzle holder preformed packing (B). Install Note. Use only the dead soft copper gasket 5310-861-1406 for replacement seal whenever the fuel injector nozzle and holder assembly has been removed from the cylinder. The dead soft copper gasket conforms to the specific contours of the nozzle cylinder head seat in an individual installation. be Because of this, it is the only gasket apin p r o v e d g a sk e t f o r t h i s f u n c t i o n a n d s h o u l d n e v e r reused. Before installing new cylinder nozzle seat, always check to be sure that original gasket has been removed as an inadvertent installation of two seating gaskets would damage the fuel injector nozzle retaining spring. Check to be sure cylinder nozzle seat is free from excessive carbon deposit and that the seat face is free from deposits and / surface roughness. Remove carbon or surface roughness using nozzle

carbon cutter - 4910-795-7958. 1. Install new preformed packing (B) on fuel injector nozzle holder. 2. Install new gasket (A) and install fuel injector nozzle and holder assembly. Figure 4-153. Removing or installing fuel injector nozzle and holder assembly.

4-74

Remove 1. Remove fuel injector nozzle fuel return hose (A). 2. Remove four screws (B) and external tooth lock washers attaching each cylinder head shroud plate. 3. Remove two cylinder head plates (C). Install 1. Position each cylinder head shroud plate (C) between cylinders. 2. Install four screws (B) and external tooth lock washers securing each plate. 3. Install fuel injector nozzle fuel return hose (A). Figure 4-154. Removing or installing cylinder head shroud plate.

Disconnect 1. Remove self-locking nuts (A) from hooks attaching inner cylinder air deflectors. 2. Lift air deflector (B) from cylinder fins and rocker arm covers. It is not necessary to remove deflectors. Connect 1. Position inner cylinder air deflectors (B) between cylinder fins and rocker arm covers 2. Install self-locking nuts (A) on hooks securing deflectors. Figure 4-155. Disconnecting or connecting inner cylinder air deflector.

4-75

Disconnect 1. Remove the outer screw (A) attaching the intercylinder connector flanges to the rocker arm cover. 2. Loosen the inner two connector flange attaching screws (B). 3. Remove two self-locking nuts and screws (C) attaching plate and fuel tube clamps to the support. 4. Remove two bolts (D) attaching support and exhaust valve adjusting screw cover plate. Remove support cover plate and gasket. Discard gasket. 5. Remove two bolts (E) and flat washers. Remove the intake valve adjusting screw cover plate and gasket. Discard gasket. 6. Disconnect fuel tubes (F) from the two adjacent injector nozzles.

Connect 1. Connect fuel tubes (F) to the two adjacent injector nozzles. 2. Position new gasket on cylinder and install intake valve adjusting screw cover plate. Install two bolts (E) and flat washers. 3. Position new gasket on cylinder and install exhaust valve adjusting screw cover plate. Install two bolts (D). 4. Position plate and fuel tube clamp support. Install two self-locking nuts and screws (C). 5. Tighten the inner two connector flange attaching screws (B). 6. Install the outer screw (A) securing intercylinder connector flanges to the rocker arm cover.

Figure 4-156. Disconnecting or connecting intercylinder connector flange and valve adjusting screw covers.

4-76

Remove Note. All valve rocker arm covers are removed in the same manner. 1. Separate intercylinder connector flanges (A) from valve rocker arm cover. Note. Use a piece of shim stock to loosen flanges of intercylinder preformed hose. Caution; Do not damage sealing surface on flange of intercylinder preformed hose as it will cause oil leaks and replacement of hose will be required. 2. Remove four bolts (B) and flat washers. 3. Remove seven bolts (C) and flat washers. 4. Remove two screws (D) and flat washers. Note. Before removing rocker arm cover bolts (E), instruction 5, below, the tension on the valve rocker arms, caused by the valve springs. must be released. Turn engine, figure 4-51, until valve rocker arm rollers are on camshaft base circle, or until both valves are closed, to relieve spring tension before removing cover. Check rocker arms to see that they move up and down. If movement (clearance) cannot be felt, turn engine until clearance is evident. When clearance is obtained between both adjusting screw pads

and valve stems, the rocker arm rollers are on the camshaft base circle, and the valves are completely closed. 5. Remove four bolts (E) and packings with retainer and remove valve rocker arm cover. Install Note. The cylinder and valve rocker arm cover are machined as an assembly. The number on the rocker cover must be kept with its mating number on cylinder to insure camshaft bearing alinement and running bolts and clearance. screws securing valve Note. The

rocker arm cover to cylinder must be torqued carefully to prevent stripping of heli-coil inserts. 1. Position valve rocker arm cover on cylinder and install four bolts (E) and packings with retainer and tighten to 275-325 pounds inch torque. 2. Install two screws (D) and flat washers and tighten to 100 pounds inch torque. 3. Install seven bolts (C) and flat washers and tighten to 100 pounds-inch torque. 4. Install four bolts (B) and flat washers and tighten to 100 pounds inch torque. 5. Position intercylinder connector flanges (A) on valve rocker arm cover.

Figure 4-157. Removing or installing valve rocker arm cover bolts and removing valve rocker arm cover.

4-77

Note. Valve rockers do not have to be removed to replace adjusting screws. Figure 4-158. Removing or installing valve adjusting screw.

Figure 4-160. Removing valve rocker arm shafts and valve rocker arms.

Figure 4-159. Removing or installing valve rocker arm shaft plugs.

1. Position valve rocker arms in reeker arm cover. Insert valve rocker arm shaft ( A ) through bore in rocker arm cover and rocker arm. 2. Use one rocker arm cover bolt (B) to a line hole in shaft with bolt hole in cover. Push shaft into position, without twisting, to retain alinement. Note. Under normal circumstances, if rocker arm cover is damaged, the entire cylinder and cover must be replaced. In cases of emergency. the rocker arm covers can be changed hut it will require special attention to insure alinement of the two halves of the camshaft base. Figure 4-161. Installing valve rocker arms and valve rocker arm shafts.

4-78

Figure 4-163.

Figure 4-162.

4-79

Figure 4-165.

Note. Make certain adjusting screw pad is positioned squarely on end of valve stem. Refer to Section X, figures 4-188 and 4-189 for valve adjustment. Figure 4-164. Positioning valve adjusting screw pad on end of valve stem. Section 4-16. General This section covers the overhaul of the fuel injector nozzle and holder assembly. Refer to Table 4-7 for illustrations and instructions on removal, testing, disassembly, cleaning, inspection, repair, assembly, and installation. Vlll. OVER HAUL OF FUEL INJECTOR HOLDER ASSEMBLY NOZZLE AND

Figure references are listed under appropriate headings in the table. Note. Table 4-7 provides illustrations for removal and installation of all upper covers to gain access to the fuel injector nozzle and holder assemblies. It is not necessary to remove all covers unless all assemblies are to be rebuilt.

Table 4-7. Fuel Injector Nozzle and Holder Assembly

Para 4-17 4-126 through 4-130 Figs.

Para 4-18a Figs. 4-167, 4-168

Para 4-18

Para 4-18d

Figs. 4-157 through 4-133, 4-130 through 4-126 Para 4-18e 4-166 through 4-168 Figs.

4-80

4-17. Removal and Testing

a. General. The fuel injector nozzle and holder assemblies are generally removed while troubleshooting the fuel system, particularly when a fuel injection pump has failed. The nozzles should be tested on a nozzle tester for opening pressure, spray pattern, leakage and nozzle chatter before reinstalling in engine.

Check the nozzle retaining spring to dimensions shown in figure 4-166, as springs that have been installed over a period of time tend to take a permanent set. The nozzles are to be replaced 100% at time of overhaul. Nozzle pressure adjusting shims are furnished in shim set FSN 5365-235-1941.

Figure 4-166.

4-81

b. Removal. Refer to Table 4-7 for figure references and instructions pertinent to the removal of the fuel injector nozzle and holder assembly. c. Testing. Note. Before installing injector nozzle on nozzle tester, thoroughly clean external area to remove carbon and dirt. Do not allow dirt to enter nozzle fuel inlet opening. For nozzles that do not perform properly on nozzle tester refer to paragraph 4-18 for disassembly sequence and necessary procedures required to assure a properly functioning nozzle and holder assembly. (1) Nozzle installation. Mount the fuel injector nozzle and holder assembly on the fuel injector nozzle tester using nozzle attaching tube

-4910-795-7953. The tube should be connected to the lower connection on the injector nozzle tester. Close the pressure gage valve and actuate the pump handle rapidly (approximately 2S strokes per minute) to expel air from nozzle and holder and to settle spring and nozzle holding column. (2) Nozzle opening pressure. Fill reservoir with sufficient fuel to perform test. Open pressure gage valve and actuate tester slowly to raise pressure. When nozzle opens, gage pressure must be between 3050 psi (minimum), 3150 psi (maximum). If this gage reading is not achieved, nozzle a n d h o l d e r a s s e m b l y m u s t b e disassembled and spring adjusting spacers (fig. 4-167) added or removed to obtain the proper pressure reading.

Figure 4-167. Fuel injector nozzle and holder assemblysectional view.

4-82

fig. 4-168

Figure 4-168. Testing fuel injector nozzle and holder assembly.

4-83

4-18. Overhaul of Fuel Injector Nozzle and Holder Assembly a. Disassembly. Refer to figures 4-169 and 4170 for disassembly of the fuel injector nozzle and holder assembly.

Figure 4-169. Partial disassembly or assembling fuel injector nozzle and holder assembly.

4-84

Disassemble 1. Remove fuel injector nozzle assembly (K), with nozzle body (K-1) and nozzle valve (K-2) from valve stop spacer (L). 2. Remove valve stop spacer (L) and nozzle opening pressure adjusting spring (N) with spring upper and lower seats (D and M) from holder body (A). Do not remove the spring adjusting upper and lower spacers ( B and C) from spring upper seat (D) unless ajustment of the nozzle opening pressure is necessary during testing of the fuel injector nozzle and holder assembly ( para 417). 3. Remove and discard preformed packing (E) from holder body (A). 4. Disassemble fuel injector nozzle assembly (K) by removing nozzle body (K-1). It may be necessary to soak the nozzle assembly in carbon removing solvent to aid in disassembly. It may be necessary to tap nozzle body downward on the edge of a wooden bench or other similarly soft surface to remove valve. Note. The nozzle body and nozzle valve are fitted individually during manufacture to form a mated assembly. Individual parts are not interchangeable. Therefore, extreme care must be taken during the cleaning, inspection, and repair operations to keep these parts mated. Assemble Note. During assembly, the addition or

correct gage pressure reading on the nozzle tester may require various combinations of spacers available in shim set -5365-235-1941. Although each nozzle assembly pressure reading may vary, experience will indicate the approximate spacer thickness or combination of spacer thickness required to make up pressure differences. The nozzle assembly must be completely assembled, torque tightened and checked again on the nozzle tester to assure proper spacer combination and pressure reading. This procedure may have to be repeated several times before achieving a satisfactory reading. 1. Assemble nozzle valve (K-2) in nozzle body (K-1) to form fuel injector nozzle assembly. 2. Install a new preformed packing (E) in holder body (A). 3. Install spring upper seat (D), with spring adjusting upper and lower spacers (D and M) in end of nozzle opening pressure adjusting spring (N). Install spring lower seat (M) in opposite end of spring (N) and install assembled spring and valve stop spacer (L) in holder body (A). 4. Install fuel injector nozzle assembly (K-1 and K-2) in valve stop spacer (L).

removal of spring adjusting spacers to obtain the Figure 4-170. Disassembling or assembling fuel injector nozzle components.

4-85

b. Cleaning. Note. D O not remove carbon from the valve, (K-2, figure 4-170), or inner surface of nozzle body (K-1 )with a sharp tool, abrasive material, or steel wire brush, as these implements and materials will severely damage the highly polished surfaces. (1) Fuel injector nozzle assembly. S o a k nozzle body in carbon removing solvent to remove major carbon deposits. Remaining carbon deposits should be removed using a soft cloth or felt pad and mutton tallow. A piece of soft wood, soaked in oil may also be used as a carbon remover. (2) Nozzle body spray orifices. C l e a n carbon from the orifices of the nozzle body by soaking nozzle body in a carbon removing solvent only. Do not attempt to clean orifices with cleaning wire as this method will distort nozzle orifices and also may block opening due to wire breakage. It is difficult and often impossible to remove broken pieces of wire. (3) Fuel injector holder and associated parts. Clean all parts thoroughly. Be sure hands are kept free from accumulation of grease which will cause collection of dust and grit on parts. Cover or wrap all parts after cleaning to protect them from dirt accumulation. c. Inspection. (1) Nozzle body and valve. Inspect seat of nozzle valve (K-2. fig. 4-170) for evidence of wear, distortion of the valve seat due to pounding, discoloration due to overheating, and pitting. Inspect the valve stem between seal and shoulder for scratches and discoloration. Check fit of valve in nozzle body by lifting the valve about one-third of its length out of the body. The valve should slide back to its seat without aid when the assembly is held at a 45 degree angle. Mark sticking assemblies for repair. Inspect the eight spray orifices in the nozzle body tip and the drilled passage in the body for freedom of obstructions, Inspect lapped sealing surface of valve body for scratches, discoloration, and cracks. Inspect nozzle body valve seat, using a strong light and a magnifying glass (5 to 7 power magnification minimum) for scratches, discoloration, wear, pitting, and evidence of pounding. Note. An otoscope, such as used by physicians for examination of the inner ear, is well suited for this purpose. 4-86

(2) Valve stop spacers. Inspect the lapped sealing surfaces on the ends of the valve stop spacer (L) for scratches, discoloration, and cracks. Inspect the area around the center hole on the nozzle end for evidence of wear and pounding by the nozzle valve. Maximum allowable depth of wear or pounding at this area is 0.003-inch. Inspect drilled passages in spacer for obstructions. (3) Adjusting spring and spring seats. Inspect the nozzle opening pressure adjusting spring (N) and spring upper and lower seats (D and M) for cracks and evidence of wear. (4) Holder spring. Inspect holder spring (P) for cracks, and for evidence of discoloration due to excessive heat. Inspect free length of holder spring. Limit should be from 1.403 to 1.409-inch when the new copper gasket, FSN 5310-8611406, is used. If the old copper-asbestos gasket is used the limit should be 1.407 to 1.409-inch. (5) Holder body. Inspect the holder body (A) for cracks, burs, nicks, and raised metal. Inspect lapped sealing surface for scratches and discoloration. Inspect the threaded area and tapped openings f o r s t r i p p e d o r d a m a g e d threads. (6) Nozzle cap nut. Inspect the nozzle cap nut (J) for nicks, burs, raised metal surfaces, and for cracks due to overheating. Inspect threaded area inside nut for stripped or damaged threads. Inspect the gasket area on end of nut for deep scratches. (7) Nozzle retainer. Inspect the nozzle retainer (F) for cracks, nicks, burs, and raised metal, and for rounding of the hexagon nut area. Inspect threaded area for stripped or damaged threads, (8) Fuel injector tube connector. Inspect the fuel injector tube connector(Q) for cracks and for stripped or damaged threads. d. Repair. (1) Nozzle body and valve. (a) Replace nozzle body (K-1, figure 4170) and nozzle valve (K-2) when body seat or valve seat is badly worn, pounded, or pitted, or when nozzle does not conform to spray pattern limits specified in paragraph 4-17c(3). Minor discoloration or imperfections of body and valve seat can be cleaned up by lapping the valve into the body. Clamp valve by its stem in jaws of rotating chuck. Place a very minute quantity of fine lapping compound on tip of valve. Slide

nozzle body over valve and lap valve to seat with a very light pressure for 15 to 20 seconds at 500 to 600 rpm chuck speed. Wash body and valve very thoroughly in clean fuel before assembly. (b) A sticking valve can, in some instances, be made to slide freely by cleaning the valve stem with tallow and a felt pad with valve clamped in rotating chuck. If the valve cannot be made to slide freely, the fuel injector nozzle assembly must be replaced. (c) Replace nozzle body and valve assembly when any of the spray holes or the drilled fuel passage cannot be cleaned so that they are free from obstructions. (d) Replace nozzle body and valve assembly when lapped sealing surface of body is badly nicked, scratched, or cracked. Remove minor scratches from sealing surface by lapping with fine lapping compound on a smooth lapping plate. The nozzle body must be held flat on the lapping plate during this operation or the sealing surface will become rounded on the edges. (2) Valve stop spacer. (a) Replace valve stop spacer (L) when lapped sealing surfaces on either end are cracked, deeply scratched, pitted, or when the area around the center hole at nozzle end is worn or pounded beyond 0.003-inch depth. (b) Remove minor scratches and imperfections from lapped sealing areas on ends of spacer by lapping with fine lapping compound on a smooth lapping plate. The spacer must be held flat against the lapping plate during this operation or the sealing surface will become rounded on edges. (c) Replace valve stop spacer when drilled fuel passages cannot be cleaned so that they are completely free from obstructions.

(3) Adjusting spring and spring seats. Replace nozzle o p e n i n g p r e s s u r e adjusting spring (N) and spring upper and lower seats (D and M ) when cracked or worn, or when nozzle opening pressure does not meet the limits specified in paragraph 4-17c(2). (4) Holder spring. Replace holder spring (P) when cracked, broken, or when inspection revealed discoloration due to overheating. Replace the holder spring when it does not conform to the dimensions detailed in para. 418c(4). (5) Holder body. (a) Replace holder body (A) when cracked, burred, nicked, or when threads are stripped or damaged. (b) Remove minor scratches and imperfections in lapped sealing surface of holder body by lapping with fine lapping compound on a smooth lapping plate. The holder and plate must be held 90 degrees to each other. There should be no rocking motion during lapping. (6) Nozzle cap nut. Replace nozzle cap nut (J) when badly nicked, burred, or when cracks are evident due to overheating. Replace cap nut when threads are stripped or damaged, and when gasket area is scratched, nicked, or burred. (7) Nozzle retainer. Replace nozzle retainer (F) when cracked, badly nicked or burred or when hexagon nut area is damaged, Replace retainer when threads are stripped or damaged. (8) Fuel injector tube connector. R e p l a c e fuel injector tube connector (Q) when cracked or threads are stripped or damaged. e. Assemble and Test. (1) Assemble. Refer to figures 4-169 and 4170. (2) Test. Refer to paragraph 4-17c. The fuel injector nozzle and holder assembly should be tested whenever nozzle has been disassembled.

4-87

Section IX. REPLACEMENT OF FLY WHEEL AND CRANKSHAFT OIL SEAL

4-19. General
This s e c t i o n c o v e r s t h e r e p l a c e m e n t o f t h e flywheel and crankshaft oil seal. Refer to Table 4-8 for illustrations and instructions for removal

and installation of the flywheel and crankshaft oil seal. Figure references are listed under appropriate headings in the table.

Table 4-8. Flywheel and Crankshaft Oil Seal

Component Removal Installation

Flywheel Crankshaft Oil Seal

4-171 through 4-174 4-171 through 4-180

4-174, 4-183, 4-171 4-181, 4-182, 4-179, 4-178, 4-176 through 4-174, 4-183, 4-171

4-20. Replacement Instructions

1. Install three bolts (A) from transmission drive gearshaft and flywheel into puller screw holes provided. 2. Pull transmission drive gearshaft from crankshaft dowel pins by alternately tightening the three bolts (B). Figure 4-172. Removing transmission drive gearshaft using bolts as puller screws. Remove 1. Using splined wrench - 5120-793-7895, as shown in figure 4-51, position flywheel so that lifting eye bolt hole (A) is located on top of flywheel. 2. Straighten tabs of lock plates (B) securing nine bolts. 3. Remove nine bolts (C) and three lock plates attaching transmission drive gear shaft and flywheel to crankshaft. Discard lock plates. Install 1. Install three lock plates (B) and nine bolts (C) securing transmission drive gear shaft and flywheel to crankshaft. Tighten bolts to 1000 pounds-inch torque. 2. Bend tabs of lock plates (B) securing nine bolts.

Figure 4-171. Removing or installing transmission drive gearshaft and flywheel mounting bolts. 4-88

Figure 4-174.

1. Install three bolts (A) from transmission drive gearshaft and flywheel into puller screw holes provided. Alternately tighten bolts until flywheel is far enough from crankshaft dowel pins to permit installation of lifting eye bolt. 2. Install eye bolt -5306-017-6143 (B).

Figure 4-173. Installing eye bolt 5306-017-6143.

4-89

Remove 1. Cut locking wire and remove three bolts ( A I attaching oil seal retainer to oil seal cap. 2. Cut locking wire and remove three bolts (B) attaching oil seal retainer to oil seal housing. Install 1. Install three bolts (B) securing oil seal retainer to oil seal housing. Install locking wire. 2. Install three bolts (A) securing oil seal retainer to oil seal cap. Install locking wire.
Figure 4-176

Figure 4-175. Removing or installing crankshaft oil seal retainer.

4-90

1. Install two mechanical pullers - 5120-473-7222 (A) into oil seal cap and housing puller screw holes. 2. Pull cap and housing free of dowel pins.

Figure 4-177. Removing oil seal housing using mechanical pullers5120-473-7222.

Remove 1. Remove spring (A) from lip in crankshaft oil seal. 2. Remove the split oil seal (B) from crankshaft. Install 1. Install split oil seal (B) in crankshaft. 2. Install spring (A) in lip in crankshaft seal.

Figure 4-179. Removing or installing crankshaft oil seal.

Figure 4-178. Removing or installing oil seal housing cap and housing.
1. Position oil seal spring (A) (male and female) to facilitate removal. 2. Twist male end clockwise and female end (B) counterclockwise, and remove crankshaft oil seal spring.

Figure 4-180. Removing crankshaft oil seal spring. 4-91

Position oil seal spring (A) around crankshaft and interlock ends (B). 2. Twist female end of spring clockwise and male end counterclock wise to secure spring. Note. Makes sure spring seats around lip of oil seal and that lip is toward crankcase. Apply a coating of lubricant around lip and outer surface of seal.

1.

Note. Crankshaft oil seal must be rotated on crankshaft until ends of oil seal join 30 degrees from centerline of crank shaft looking at the rear of engine as shown. This is important in controlling oil seepage past the split line of oil seal.

Figure 4-182. Correct position for crankshaft oil seal sp!it line before installing seal retainer.

Figure 4-181. Installing crankshaft oil seal spring.

4-92

Note. Draw flywheel to crankshaft by installing three transmission drive shaftgear and flywheel bolts and alternately tighten about one turn at a time to draw flywheel into dowel pins without binding. R e m o v e b o l t s a n d i n s t a l l transmission drive gearshaft following the above procedure until both flywheel and transmission drive gearshaft are properly alined on dowel pins. Figure 4-183. Installing flywheel, using bolts to draw flywheel against crankshaft.

Section X. SERVICE OPERATIONS 4-21. General

This section covers service operations allocated to the Direct Support Maintenance Organization. Procedures outlined in this section are for service operations requiring a minimum of engine disassembly to perform. Refer to Table 4-9 for illustrations and instructions on service operations covered in this section. Figure and paragraph references will be listed under appropriate headings in the table.

4-93

Table 4-9.

Para 4-22 Para 4-23

Para 4-24

4-22. Checking Cylinder Compression

a. General. For instructional purposes in this section all fuel injector nozzle and holder assemblies will be removed and a compression test will be made on a l l c y l i n d e r s . I f troubleshooting indicates that only one cylinder requires a compression check, it may be done by rem oving the nozzle from the questionable cylinder. Warning; When only one cylinder is checked, there is the possibility of the engine firing on the other cylinders when compression check is being made. To prevent engine firing, remove all nozzles then check cylinder compression. Unless all nozzles are removed, the engine motoring rpm will be below desired cylinder checking rpm. b. Starting Engine. C h e c k t h e v e h i c l e batteries to assure full charge and replace if necessary. Refer to the pertinent operators manual for engine starting procedures. Start engine and allow engine t o r e a c h n o r m a l operating temperature and then stop engine. Cut off fuel supply so engine will not deliver fuel while performing compression test. c. Compression Test. R e m o v e t h e f u e l injector nozzle and holder assemblies from each cylinder (para 4-17). Install the compression checking adapter and compression gage (figs. 4184 and 4-185) and motor engine with the starter motor. Crank engine several seconds, or until compression gage reaches maximum reading. Cylinder compression pressure should be between 330 and 480 psi. High cylinder pressures are caused by combustion of lubricating oil in the engine combustion chamber. If this occurs, allow combustion gases to escape prior to taking compression reading.

Install 1. Position new fuel injectc r nozzle gasket (A) on end of compression adapter - 4!10-795-7961. Apply a light coating of grease on gasket so it adheres to adapter when installed in cylinder. Note. Be sure gasket is installed with open face toward adapter. 2. Install adapter (B) into fuel injector nozzle holder opening and tighten securely using fixed open end wrench - 5120-871-7198 Remove 1. Remove adapter (B) frc m fuel injector nozzle holder opening using fixed open end wrench -5120-871-7198 as shown in figure 4-16$. 2. Remove and discard gasket (A).

Figure 4-184. Installing or removing compression adapter4910-795-7961 (cylinder compress:ion test).

4-94

d. Compression Variation. After all 12 cylinders are checked, determine the pressure difference between high and low cylinder readings. This variation should not exceed 70 psi. e. Engine Motoring RPM. If compression d a t a e x c e e d s t h e a b o v e specifications. the engine motoring rpm should be checked to be sure that it is 140 to 180 rpm. Compression should be checked again to confirm the previous readings before submitting an engine for overhaul.

4-23. Adjusting Intake and Exhaust Valve Clearance

When checking and / or adjusting valve clearance, it is necessary to first remov e t h e cooling fan vanes, fans, fan shroud, top covers, and oil coolers to gain access to valve adjusting screw cover plates. Refer to Table 4-9 for instructions pertinent to the removal of the above items, and the procedures involved in the adjustment o f t h e i n t a k e and e x h a u s t v a l v e clearances.

1. Install gage assembly -4910-870-6283 (A) on adapter - 4910-795-7961 and tighten securely. 2. Crank engine using starter motor and check cylinder compression. It must be within 330 to 480 psi at engine cranking speed. 3. Depress gage vent valve (B) to release pressure and reset gage to zero after compression reading is taken. Recheck reading. Test compression on all cylinders in the same manner.

Figure 4-185. Checking cylinder compression using gage assembly-4910-870-6283 and compression adapter-4910-795-7961.

4-95

Remove 1. Remove two nuts (A), bolts, one plate, and two clamps attaching fuel tubes to support. 2. Remove two bolts (B) attaching support to valve adjusting screw cover plate. Remove supports and cover plates. Remove and discard gaskets. 3. Remove two bolts (C) and flat washers attaching each of the remaining valve adjusting screw cover plates and remove the plates. Remove and discard gaskets.

Install 1. Position new gaskets on exhaust valve openings. Install valve adjusting screw cover plates and supports and install two bolts (B) securing supporta and covers to cylinders. 2. Install two clamps, one plate, two bolts, and nuts (A) securing fuel tubes to support.

Figure 4-186. Removing or installing valve adjusting screw cover p l a t e s - right side.

4-96

Remove 1. Remove two nuts (A), bolts, one plate, and two clamps attaching fuel tubes to supports. 2. Remove two bolts (B) attaching support to valve adjusting screw cover plate. Remove supporta and cover plates. Remove and discard gaskets. 3. Remove two bolts (C) and flat washers attaching the remaining valve adjusting screw cover plates, and rem ove the plates. Remove and discard gaskets.

Install 1. PO sition new gaskets on exhaust valve openings. Install valve adjtusting screw cover plates and supports and install two bolts (B) securing supports and covers to cylinders. 2. Position new gaskets on remaining valve openings on cylinders. Install valve adjusting screw cover plates and install two bolts C) and flat washers securing each plate. 3. Install two clamps, one plate, two bolts, and nuts (A) securing fuel tubes to support.

Figure 4-187. Removing or installing valve adjusting screw cover plates-left side.

4-97

4-24. Checking Intake and Exhaust Valve Timing

a. G e n e r a l . V a l v e t i m i n g i s c h e c k e d w i t h cylinder No. 6R and 6L intake valve clearance set at 0.100 inch. The flywheel is stamped (fig. 4-190) with timing marks 6R INT CLOSE 0 . 1 0 0 C L R for timing the right camshaft with the crankshaft, and is also marked with timing marks 6L INT CLOSE 0.100 CLR for timing left. For instructional purposes the timing of the right camshaft is described. Right and left camshaft timing is identical. Refer to Table 4-9 for instructions pertinent to this operation.

Note. Before checking or adjusting exhaust valve clearance (fig. 4-188) and intake valve clearance (fig. 4-189), make sure both valves are closed on cylinder being checked. Turn engine as shown in figure 4-51 until valves are closed and camshaft lobes are in position shown in figure 473.
1. Loosen exhaust valve adjusting screw lock nut (A). 2. Turn valve adjusting screw (B) until clearance between screw pad and valve stem is 0.025 inch. Torque lock nut to 175 pounds inch after correct adjustment is made. Make certain setting has not changed after tightening lock nut.

Figure 4-188. Setting exhaust valve clearance using thickness gage blade-5210-793-7899.

Figure 4-190. Flywheel timing mark locations.

1. Loosen intake valve adjusting screw lock nut (A). 2. Turn valve adjusting screw (B) until clearance between screw pad and valve stem is 0.010 inch. Torque lock nut to 175 pounds inch after correct adjustment is made.

Figure 4-189. Setting intake valve clearance using thickness gage blade-5210-793-7898.

4-98

Note. It is necessary to remove engine oil

cooler before the transmission oil cooler can be removed.

Figure 4-191. Disconnecting or connecting oil cooler inlet and outlet hoses.

Remove 1. Disconnect manifold heater spark plug electrical lead (A) from spark plug. 2. Cut locking wire and remove two cap screws (B), spacers, and flat washer-a attaching manifold heater ignition unit bracket to oil coolers. Remove ignition unit with bracket and lead. 3. Cut locking wire and remove two bolts (C) and fiat washers attaching engine oil cooler to beam. 4. Cut locking wire and remove two bolts (D) and flat washers attaching transmission oil cooler to beam. 5. Cut locking wire and remove four bolts (E) and flat washers attaching oil coolers to top frame and remove coolers. 6. Remove nine fasteners (F) and remove oil cooler retainer and oil coolers. Install 1. Position engine and transmission oil coolers on side of engine and install four bolts (E) and flat washers securing oil coolers to top frame. Install locking wire. 2. Install two bolts (D) and flat washers securing transmission oil cooler to beam. Install locking wire. 3. Install two bolts (C) and flat washers securing engine oil cooler to beam. Install locking wire. 4. Position oil cooler retainer on top of coolers and install nine fasteners (F) securing retainer to upper cover frame. 5. Position manifold heater ignition unit bracket, with ignition unit and lead, between oil coolers and install two cap screws (B), spacers, and flat washers securing brarket to coolers. Install locking wire. 6. Connect manifold heater spark plug electrical lead to spark plug (A).

Figure 4-192. Removing or installing engine and transmission oil coolers. 4-99

Remove 1. Remove two bolts (A) and flat washers attaching intake valve adjusting screw cover plate. 2. Remove cover plate and gasket (B). Discard gasket. Install 1. Position new gasket (B) on cylinder and install intake valve adjusting screw cover plate. 2. Install two bolts (A) and flat washers securing cover plate.

Figure 4-194. Removing or installing intake valve cover plate.

Remove 1. Remove three screws (AI attaching end shroud to top support and to tab on cylinder head. 2. Refer to figure 4-147 for removal of three screws (B) attaching shroud to inner shroud plate. Remove shroud. Iustall 1. Position end shroud with inner shroud plate and refer to figure 4-147 for installation of three screws (B) securing shroud to shroud plate. 2. Install three screws (A) attaching shroud to top support and to tab on cylinder head.

Figure 4-193. Removing or installing oil cooler end shroud.

Figure 4-195. Cross section of cylinder 6R showing position of camshaft lobes for valve timing.

4-100

b. Positioning Camshaft. Turn engine using splined wrench - 5120-793-7895 until valve rocker arm roller is on base circle of camshaft as shown in figure 4-73. Set number 6R and 6L intake valve clearance to 0.100 inch (fig. 4197). c. Checking Valve Timing. Turn flywheel counterclockwise, viewed from rear, until pad on valve adjusting screw is just free of the valve stem (intake valve has just closed) (fig. 4-195). In this position the fly-wheel mark 6R INT CLOSE 0.100 CLR should be alined with pointer (fig. 4-196). If flywheel marks are not alined with pointer within inch at the time the adjusting screw pad becomes free of valve stem it will be necessary to remove camshaft drive shaft and reset valve timing. Valve timing may be reset following the instructions that accompany figures 4-198 through 4-201.

1. Loosen timing adjusting screw lock nut (A). 2. Turn valve adjusting screw (B) and set valve clearance to 0.100 inch. 3. Gage (C) must move through clearance with a slight drag. Tighten lock nut after setting clearance. Check clearance to make certain setting has not changed.

Figure 4-197. Setting intake valve clearance for cylinder 6R using thickness gage blade-5120-793-7897.

Figure 4-196. Flywheel timing marks a lined with pointer for valve timing-right bank of cylinders.

4-101

Remove 1. Remove six bolts (A), lock washers, and flat washers attaching camshaft gear housing cover. 2. Remove cover and gasket (B). Discard gasket. Install 1. Position new gasket (B) on camshaft gear housing. Install camshaft gear housing cover. 2. Install six bolts (A), lock washers, and flat washers securing cover.

Figure 4-198. Removing or installing camshaft gear housing cover.

Figure 4-200. Removing or installing camshaft drive gearshaft plug using mechanical p u l l e r - 5120-678-5282. d. Special Timing Instructions. W i t h cylinder 6R intake valve set at the just closing point (fig. 4-195) turn flywheel approximately 1/8 of a turn (or 45 degrees) clockwise (viewed at flywheel end) to remove backlash in g-ear train ; then turn flywheel counterclockwise until timing mark (fig. 4-196) is alined with the timing pointer. Install camshaft drive shaft (fig. 4-201), mating splines of drive shaft with splines on drive gearshaft and with splines on cam drive bevel gearshaft. When splines of drive shaft will not enter splines of cam drive bevel gearshaft, withdraw drive shaft and turn slightly before again attempting insertion.

Figure 4-199. Removing or installing camshaft drive gearshaft plug retaining ring.

Figure 4-201. Removing or installing camshaft drive shaft using mechanical p u l l e r - 5120-678-5282.

4-102

figure 4-189

4-103

CHAPTER 5 DISASSEMBLY OF ENGINE

Section I. PREPARATION OF ENGINE FOR DISASSEMBLY 5-1. General

This section covers the preparation of the engine for disassembly. Refer to the pertinent TMs covering the removal of powerplant from the vehicle and separation of the transmission from the engine. Prior to disassembly, engines must be thoroughly drained, cleaned, and accessories before s t r i p p e d o f external proceeding with disassembly. Refer to Table 5-1 for illustrations and instructions required for draining engine oil and removing accessories.

Table 5-1. Draining Engine Oil and Removing Engine Accessories

Engine and Sling Oil Pan Drain Plugs Fuel Pump Starter Time Totalizing Meter Generator and Associated Parts Turbosupercharger and Lower Shroud Plates

5-1 5-2, 5-3 4-1 through 4-3 4-4 through 4-8 5-4, 5-5 4-11 through 4-16 4-20 through 4-33

5-2. Drain Engine Oil

The engine oil must be drained from the engine before engine is disassembled. Lift engine using multiple leg sling - 4 9 1 0 - 9 1 9 - 2 8 8 4 ( f i g . 5 1) and place engine on suitable blocks. Drain engine oil following instructions that accompany figures 5-2 and 5-3.

Figure 5-1. Lifting engine using multiple leg sling-4910-919-2884.

5-1

Remove 1. Cut locking wire and remove two plugs (A). Drain oil into a suitable container. 2. Remove pipe plug (B) and drain oil from front compartment. 3. Remove pipe plug (C) and drain oil from rear compartment

Install 1. Install pipe plug (C) in rear compartment of oil pan. 2. Install pipe plug (B) in front compartment of oil pan. 3. Install two plugs (A) in center of oil pan and install locking wire securing plugs.

Figure 5-2. Removing or installing oilpan drain plugs {Model AVDS-1790-2-M).

Remove 1. Cut locking wire and remove two drain plugs (AI. Drain oil into a suitable container. 2. Remove pipe plug (B) and drain oil from front compartment. 3. Remove pipe plug (C) and drain oil from rear compartment.

Install 1. Install pipe plug (C) in rear compartment of oil pan. 2. Install pipe plug (B) in front compartment of oil pan. 3. Install two pipe plugs (A) in center of oil pan and install locking wire securing plugs.

Figure 5-3. Removing or installing oil pan drain plugs (Models AVDS-17902AM and AFDS-1790-2A).

5-2

5-3. Remove Engine Accessories

The starter, cradle, and support, generator cradle support and air intake tube must be removed to allow the engine to be mounted on the overhaul stand. Remove the fuel pump, starter, generator, turbo supercharger, and associated components as outlined in Chapter 4 and remove the time totalizing meter. Appropriate figure references are listed in table 5-1.

Remove 1. Disconnect time totalizing meter electric lead (A). 2. Remove four self-locking nuts (B) and electrical lead ground wire. 3. Remove time totalizing meter (C) from crankshaft damper and oil filter housing. Install 1. Position time totalizing meter (C) on crankshaft damper and oil filter housing. 2. Install four self-locking nuts (B) and electrical lead ground wire. 3. Connect time totalizing meter electrical lead (A). Figure 5-5. Removing or installing time totalizing meter.

Note. Two clamps are used to secure the time totalizing meter electrical lead on the basic engine. The clamps are installed to secure the electrical lead to prevent damage. Figure 5-4. Disconnecting or connecting time totalizing meter electrical lead clamps.

Section ll. Installation OF ENGINE ON OVER HAUL STAND AND DISASSEMBLY INTO SUBASSEMBLIES 5-4. General
This section covers the installation of t h e engine on the overhaul stand and disassembly of the engine into subassemblies. Components are grouped together in proper disassembly order.

5-5. Shrouding, Cooling Fans, Oil Coolers, Beams, and Associated Parts
Refer to Table 5-2 f o r i l l u s t r a t i o n s a n d disassembly instructions. Figure references are listed in the table.

5-3

Table 5-2. Shrouding, Cooling Fans, Oil Coolers, Beams, and Associated Parts
Component Figure Reference

Engine on Overhaul Stand Cooling Fan Vanes and Cooling Fans Cooling Fan Shroud and Upper Covers Oil Coders, Support Beams, Upper Cover Frame, and Frame Support Bracket Turbosupercharger Oil Inlet Hose and Transmission Shrouds

5-6 4-34, 4-35 4-36 through 4-38, 4-126 through 4-134, 5-7 through 5-9,

4-136 through 4-141 5-10 through 5-21 5-17

Note. Secure engine to maintenance and overhaul stand -4910-856-4137 with four 5/8

x 1-1/2 inch hexagon head bolts and 5/8 flat washers furnished with stand.

inch

Figure 5-6. Engine on maintenance and overhaul stand-4910-856-4137.

5-4

Figure 5-7. Removing or installing oil filler and oil level indicator tube shroud plate oil drain hose- engines with oil filler and indicator with splash pan drain.

Note. Be certain drain hose is inserted through grommet and that grommet is securely seated during reinstallation of shroud plate and drain hose. Figure 5-8. Removing or installing oil filler and oil level indicator tube shroud plate and oil drain hose-engines with oil filler and indicator with splash pan drain.

5-5

Remove

Note. With the exception of the early engine oil filler and oil level indicator tube retaining
straps (A and B, fig. 4-131), the oil coolers, support beams, and upper cover frames on each side of the engine are removed in the same manner. For instructional purposes, removal of the right oil coolers, support beams, upper cover frames and frame support brackets are described in the following instructions.

Figure 5-9. Oil filler and oil level indicator tube shroud plate oil drain hose g r o m m e t - installed view-engines with oil filler and indicator with splash pan drain.

1. Disconnect manifold heater spark plug cable (A). 2. Cut locking wire and remove two screws (B), spacers, and flat washers attaching ignition unit bracket to oil coolers. Remove ignition unit, bracket, and cable. 3. Remove grommets (C) from bracket- Replace damaged grommets. Install 1. Position grommets (C) in bracket. 2. Position ignition unit, bracket, and cable on oil coolers. Install two screws (B), spacers, and flat washers securing ignition unit bracket to oil coolers. Lock wire screws securely. 3. Connect manifold heater spark plug cable (A) to spark plug.

Figure 5-10. Removing or installing manifold heater ignition unit-right side.

5-6

Figure 5-11. Removing or installing right oil cooler screens.

5-7

Disconnect N o t e . Oil coolers will retain a certain amount of oil after engine has been drained. Position a suitable container to catch the excess oil prior to disconnecting the oil cooler inlet and outlet hoses. 1. Disconnect oil cooler oil inlet hose (A) and remove hose. 2. Remove screw (B) and nut attaching manifold heater fuel tube clamp to hose clamp and remove clamps. 3. Disconnect oil cooler outlet hose (C). 4. Disconnect primary fuel filter fuel drain tube (D) and drain fuel into suitable container. Connect 1. Connect primary fuel filter fuel drain tube (D) to primary fuel filter. 2. Connect oil cooler oil outlet hose (C). 3. Position manifold heater fuel tube clamp on fuel tube and oil hose clamp on outlet hose. Install screw (B) and nut securing clamps in plate. 4. Connect oil cooler oil inlet hose (A).

Figure 5-12. Disconnecting or connecting right oil cooler hoses and primary fuel filter drain tubes.

Remove 1. Cut locking wire and remove two spacers attaching engine oil cooler 2. Cut locking wire and remove two spacers attaching transmission oil beam.

bolts (A) and four to support beam. bolts (B) and four cooler to support

Install 1. Install two bolts (B) and four spacers securing transmission oil cooler to support beam. Install locking wire securing bolts. 2. Install two bolts (A) and four spacers securing engine oil cooler to support beam. Install locking wire securing bolts.

Figure 5-13. Removing or installing oil cooler to support bolts. 5-8

Remove 1. Cut locking wire and remove two bolts ( A) and four spacers attaching engine oil cooler to upper cover frame. 2. Remove oil cooler (B). 3. Remove four fasteners (C) and remove retainer from upper cover frame. Install 1. Position engine oil cooler (B) against upper cover frame. 2. Install two bolts (A) and four spacers securing oil cooler to frame. 3. Position retainer on upper cover frame and install four fasteners (C). 4. Tighten two bolts securing oil cooler to upper cover frame and lock wire securely.

Remove 1. Cut locking wire and remove two bolts (A) and four spacers attaching transmission oil cooler to upper cover frame. 2. Remove oil cooler (B) and shroud plate. 3. Remove five fasteners (C) and remove retainer frorn upper cover frame. Install 1. Position transmission oil cooler (B) and shroud plate against upper cover frame. 2. Install two, bolts (A) and four spacers securing oil cooler to frame. 3. Position retainer on upper cover frame and install five fasteners (C). 4. Tighten two bolts securing oil cooler to upper cover frame and lock wire securely.

Figure 5-14. Removing or installing right engine oil cooler.

Figure 5-15. Removing or installing right transmission oil cooler.

Figure 5-16. Disconnecting or connecting upper cover frame-right front view.

5-9

Remove 1. Remove two self-locking nuts and bolts (A) attaching oil indicator tube retaining strap and remove strap. Note. Some early engines used weld nuts in Disconnect 1. Remove two machine screws (A) attaching upper cover frame to right oil cooler end shroud. 2. Remove two bolts (B) attaching frame to right rear shroud. 3. Remove right upper cover frame. Connect 1. Position right upper cover frame (C) on right side of engine. 2. Install two bolts (B) securing frame to right rear shroud. 3. Install two machine screws (A) securing upper cover frame to right oil cooler. end shroud.

lieu o f s e l f - l o c k i n g n u t s

<

2. Remove two self-locking nuts and bolts (B) attaching oil filler tube retaining strap and remove strap. 3. Remove left upper cover frame (C). Install Note. On installations that h a v e

been

modified, oil filler tube will be relocated b e h i n d

turbosupercharger and retaining straps will be discarded.

1. Position left upper cover frame (C) on left side of engine. 2. Position oil filler tube retaining strap around oil filler tube and install two self-locking nuts and bolts (B) securing strap. 3. Position oil indicator tube retaining strap around oil indicator tube and install two self-locking nuts and bolts (A) securing strap.

Figure 5-17. Disconnecting or connecting upper cover fra me-right rear view.

Figure 5-18. Removing or installing oil indicator and oil filler tube to upper frame retaining strap-left side engines without relocated oil filler tube.

5-10

Remove 1. Remove self-locking nut (A), washer, and cap screw attaching brace to support beam. 2. Remove self-locking nut (B), two spacers, bolt, and grommet attaching brace to turbosupercharger tie rod. 3. Remove six self-locking nuts (C) and three flat washers attaching support beam to cylinders and rem ove beam.

Figure 5-19. Removing or installing right oil cooler end shroud.

Install

Note. The flat washers are located at cylinder Nos. 3, 4 and 5 on both cylinder banks.
1. Position support beam on engine and install six selflocking nuts (C) and three flat washers securing beam to cylinders. 2. Install self-locking nut (B), two spacers, bolt, and grommet securing brace to turbosupercharger tie rod. 3. Install self-locking nut (A), washer, and cap screw securing brace to support beam.

Figure 5-20. Removing or installing right oil cooler support beam.

5-11

Remove 1. Remove 12 self-locking nuts (A) attaching upper cover frame support brackets. 2. Remove six brackets (B). N o t e . Upper cover frame support brackets on left side of engine are removed or installed in the same manner.

Install 1. Position six upper cover frame support brackets (B) on cylinder studs. 2. Install 12 self-locking nuts (A) securing brackets to cylinders.

Figure 5-21. Removing or installing upper cover frame support b r a c k e t s - right side.

5-12

Remove 1. Disconnect turbosupercbarger oil inlet hose (A) from bulkhead adapter elbow and remove hose. 2. Remove two machine screws (B) attaching right transmission shroud and remove shroud.

Note. Left turbosupercharger oil inlet hose and transmission shroud are removed or installed in the same manner.
Install 1. Position right transmission shroud on rear of engine and install two machine screws (B) securing shroud. 2. Connect oil inlet hose (A) to bulkhead adapter elbow.

Figure 5-22. Removing or installing right turbosupercharger oil inlet hose and transmission shroud.

5-6. Manifold Heater Tubes, Solenoids, and Filter, Cylinder Head Oil Drain Lines, and Intake Manifold Assemblies
Refer to Table 5-3 for illustrations and disassembly instructions. Figure references are listed in the table.

Table 5-3. Manifold Heater Tubes, Solenoids and Filter, Cylinder Head Oil Drain Lines, and Intake Manifold AssemblyComponent Figure Reference

Manifold Heater Tubes, Hoses, Fuel Check Valve, Fuel Filter, Bracket. and Solenoid Valves Cylinder Head Oil Drain Tubes Intake Manifold, Manifold Heater, and Turbosupercharger Air Outlet Elbow

5-23 through 5-27 5-28 through 5-32 5-33

Remove 1. Remove machine screw (A) attaching right manifold beater fuel return tube clamp to right rear shroud. 2. Disconnect fuel return tube (B) from heater and tube tee. Remove tube.

Note. Left manifold heater fuel return tube is removed or installed in the same manner.
Install 1. Position right manifold heater fuel return tube (B) on right rear shroud and connect to heater and tube tee. 2. Install machine screw (A) securing fuel return tube clamp to right rear shroud.

Figure 5-23. Removing or installing right manifold heater fuel return tube.
5-13

Disconnect
1. Remove nut and machine screw (A) from each of the four clamps attaching manifold heater fuel inlet tube to cylinder head oil drain manifold. 2. Disconnect fuel inlet tube (B) from manifold heater.

Connect
1. Connect manifold heater fuel inlet tube (B) to manifold heater. 2. Install nut and machine screw (A) in each of the four clamps securing fuel inlet tube to cylinder head oil drain manifold.

Note. Manifold heater inlet tube on the left side of the engine is disconnected or connected in the same manner. Figure 5-24. Disconnecting or connecting manifold heaterfuel inlet tube at manifold heater and cylinder head oil drain manifolds.

Remove 1. Disconnect fuel inlet line (A) from manifold heater fuel filter. 2. Disconnect fuel inlet hose (B) from check valve and remove check valve with attached fuel tube.

Note. The fuel check valve attaching screws were removed to facilitate removal of the fuel pump (fig. 4-l).
Install 1. Position check valve with attached fuel tube on front of engine and connect fuel inlet hose (B) on check valve. 2. Connect fuel inlet line (A) to manifold heater fuel filter connection.

Figure 5-25. Removing or installing fuel check valve.

5-14

Remove 1. Disconnect manifold heater fuel inlet tubes (A) from tee in manifold heater fuel solenoid valve. Remove both fuel inlet tubes. 2. Remove tube tee and elbow (B). 3. Remove two assembled washer bolts (C J attaching solenoid valve to mounting bracket and two assembled washer bolts (D) and flat washers attaching solenoid mounting bracket to filter mounting bracket. Remove solenoid mounting bracket. 4. Remove two screws (E), lock washers, and flat washers attaching manifold heater fuel filter to mounting bracket. Remove fuel solenoid valve and filter as a unit. 5. Separate filter and solenoid valve. Remove connecting nipple and inlet tube connector. Install 1. Install inlet tube connector in manifold heater fuel filter and install connecting ripple between fuel filter and manifold heater fuel solenoid valve. 2. Position fuel filter with solenoid valve on mounting bracket and install two screws (E), lock washers, and flat washers securing filter to bracket. 3. Position solenoid mounting bracket and install two assembled washer bolts (D) and flat washers securing solenoid bracket to filter mounting bracket. Install two assembled washer bolts (C) securing solenoid valve to mounting bracket. 4. Install elbow and tube tee (B) in solenoid valve. 5. Position both manifold heater fuel inlet tubes (A) and connect tubes to tee in fuel solenoid valve.

Remove 1. Disconnect manifold heater fuel return tube (A) from elbow in heater fuel return solenoid valve and from elbow in tube cross. Remove fuel return tube ( B ) and grommet. 2. Remove elbows (C) and tube tee from solenoid valve. 3. Remove two assembled washer bolts (D) and remove valve from mounting bracket. 4. Remove three self-locking nuts (E) and bolts attaching mounting bracket to left center shroud and remove bracket. Install 1. Position mounting bracket on left center shroud and install three self-locking nuts (E) and bolts securing bracket to shroud. 2. Position heater fuel return solenoid valve on mounting bracket and install two assembled washer bolts (D) securing valve to bracket. 3. Install elbows (C) and tube tee in solenoid valve. 4. Position manifold heater fuel return tube (B) with grommet and connect tube to elbow (A) in tube cross and elbow (A) in solenoid valve.

Figure 5-27. Removing or installing manifold heater fuel return solenoid valve and bracket.

Figure 5-26. Removing or installing manifold heater fuel inlet solenoid valve and fuel filter.

5-15

Disconnect 1. Remove two cap screws (A) and lock washers at

taching right front cylinder head oil drain tube to oil pan. 2. Separate drain tube from pan and remove and discard drain tube gasket (B). Connect 1. Install new drain tube gasket (B) and position right front cylinder head oil drain tube on oil pan. 2. Install two cap screws (A) and lock washers securing drain tube to oil pan.

Remove 1. Loosen hose clamps (A). 2. Loosen hose clamps (B) and remove cylinder head oil drain tube, hoses, and turbosutpercharger oil drain tube. Note. The right rear cylinder head oil drain tube was disconnected from the oil pan to facilitate removal of the generator (fig. 4-13). Install 1. Position turbosupercharger oil drain tube, hoses, and cylinder head oil drain tube and tighten hose clamps (B). 2. Tighten hose clamps (A). Figure 5-28. Removing or installing right rear cylinder head oil drain tube and turbosupercharger oil drain tube.

Figure 5-29. Disconnecting or connecting right front cylinder head oil drain tube.

Disconnect 1. Remove two cap screws (A) and lock washers attaching left front cylinder head oil drain tube to oil pan. 2. Separate drain tube from pin and remove and discard drain tube gasket (B). Connect 1. Install new drain tube gasket (B) and position left front cylinder head oil drain tube on oil pan. 2. Install two cap screws (A) and lock washers securing drain tube to oil pan.

Figure 5-30. Disconnecting or connecting left front cylinder head oil drain tube. 5-16

Disconnect 1. Remove two cap screws (A) and lock washers attaching left rear cylinder head oil drain tube to oil pan. 2. Separate drain tube from pan and remove and discard tube gasket (B). Connect 1. Install new drain tube gasket (B) and position left rear cylinder head oil drain tube on oil pan. 2. Install two cap screws (A) and lock washers securing drain tube to oil pan.

Figure 5-31. Disconnecting or connecting left rear cylinder head oil drain tube.

Remove 1. Cut locking wire and remove six externally relieved body bolts (A) and flat washers attaching six oil drain manifold tubes to cylinders. Remove oil drain manifold tubes, oil drain tube and outlet tube as a unit. 2. Remove and discard the six body bolt flat washers (B). 3. Loosen all hose clamps (C). Separate and remove right oil drain outlet tube, right front cylinder head oil drain tube, front oil drain manifold tube, four intermediate oil drain manifold tubes, rear oil drain manifold tube, and clamps. Remove and discard six manifold tube annular gaskets.

Note. The left cylinder head oil drain manifold tubes are removed or installed in the same manner. Install 1. Install hose clamps (C) and connect rear oil drain manifold tube, four intermediate oil drain manifold tubes, front oil drain manifold tube, right front cylinder head oil drain tube, and right oil drain outlet tube. 2. Install six externally relieved body bolts (A) and flat washers ( B ) in manifold oil drain tubes. Install six new body bolt annular gaskets on ends of bolts. 3. Position outlet tube, oil drain tube, and manifold tubes as a unit on cylinders. Tighten six body bolts (A) securing tubes to cylinders and install locking w i r e securing bolts. Tighten all hose clamps.

Figure 5-32. Removing or installing right cylinder head oil drain manifold tubes.
5-17

Remove 1. Remove 18 nuts (A) and lock washers attaching intake tubes to cylinders. Remove manifold, manifold heater, and turbosupercharger air outlet elbow as a unit. 2. Remove and discard six intake manifold tube gaskets (B). Note. The right and left intake manifolds are removed or installed in the same manner.

Install 1. Install six new intake manifold tube gaskets (B) on

studs.
2. Position manifold, manifold heater, and turbosupercharger air outlet elbow as. a unit on cylinder studs. Install 18 nuts (A) and lock washers securing intake tubes to cylinders.

Figure 5-33. Removing or installing right intake manifold.

5-7. Fuel Filters, Throttle Linkage, Front and Rear Shrouds, and Oil Filler and Indicator Tubes

Refer to Table 5-4 for illustrations and disassembly instructions. Figure references are listed in the table.

Table 5-4. Fuel Filters, Throttle Linkage, Front and Rear Shrouds, and Oil Filler and Indicator Tubes

Fig. 5-51

Fig. 5-42 Fig. 5-48

5-18

Remove 1. Remove one self-locking nut, pan head screw (A), and holder attaching primary and secondary fuel drain tubes together. Remove holder. 2. Remove primary fuel filter drain tube (B). Install 1. Position primary fuel filter drain tube (B) on engine. 2. Position holder on tubes and install one self-locking nut and pan head screw (A) in holder to secure tubes.

Figure 5-34. Removing or installing primary fuel filter drain tube.

Remove 1. Disconnect fuel outlet hose (A) from elbow. 2. Remove elbow and pipe reducer (B) from position fuel filter outlet. 3. Remove four cap screws (C) and lock washers at taching primary fuel filter to mounting bracket and remove primary fuel filter. Install 1. Position primary fuel filter against mounting bracket and install four cap screws (C) and lock washers securing filter to bracket. 2. Install elbow and pipe reducer (B) in filter outlet. 3. Connect fuel outlet hose (A) to elbow.

Figure 5-35. Removing or installing primary fuel filter.

5-19

Disconnect 1. Disconnect fuel outlet hose (A) from bulkhead elbow. 2. Remove nut (B) attaching fuel outlet hose clamp to lifting eye stud. Remove 1. Disconnect fuel outlet hose (A) from elbow in secondary fuel filter and bulkhead elbow in left front shroud and remote hose. 2. Disconnect and remove fuel inlet hose (B). 3. Remove elbows and pipe reducers (C). 4. Disconnect and remove secondary fuel filter fuel drain tube (D). 5. Remove four cap screws (E) and lock washers attaching secondary fuel filter to mounting bracket. Remove filter. Install 1. Position secondary fuel filter against mounting bracket and install four cap screws (E) and lock washers securing filter to bracket. 2. Position secondary fuel filter fuel drain tube (D) under filter and con nect tube to filter. 3. Install elbows and pipe reducers (C) in filter. 4. Connect fuel inlet hose (B) to filter. 5. Connect fuel outlet hose (A) to bulkhead elbow in left front shroud and elbow in filter. Note. Re-install nut on lifting eye stud and tighten. Lifting eye will be used for oil filter and damper housing assembly removal.

Connect
1. Remove nut (B) from lifting eye stud. Install fuel outlet hose clamp on stud and re-install nut (B). 2. Connect fuel outlet hose (A) to bulkhead elbow.

Figure 5-37. Disconnecting or connecting fuel/ water separator fuel outlet hose from bulkhead elbow.

Figure 5-36. Removing or installing secondary fuel filter.

5-20

Remove 1. Disconnect fuel outlet hose (A) from elbow in fuel / water separator filter and remove hose. 2. Disconnect and remove fuel inlet hose (B). 3. Remove fuel inlet and outlet elbows and drain tube elbow (C) from filter. 4. Disconnect and remove fuel/ water separator filter fuel drain tube (D). 5. Remove lower two cap screws (E), lock washers, and plain washers. 6. Remove upper two cap screws (F), lock washers, and plain washers attaching fuel / water separator filter to mounting bracket. Remove filter. Install 1. Position fuel/ water separator filter on mounting bracket and install upper two cap screws (F), lock washers, and plain washers securing filter to bracket. 2. Install lower two cap screws (E), lock washers, and plain washers. 3. Install fuel inlet and outlet elbows and drain tube elbow (C) in filter. 4. Position fuel/ water separator filter fuel drain tube (D) under filter and connect tube to filter. 5. Connect fuel inlet hose (B) to filter. 6. Connect fuel outlet hose (A) to elbow in filter.

Remove 1. Remove cotter pin, slotted nut (A), flat washer, and bolt Separate adjustable control rod from cross shaft lever. 2. Remove two cap screws (B) and lock washers attaching primary fuel filter mounting bracket to cylinder No. 1 R. Remove mounting bracket. 3. Remove cap screw (C) and lock washers attaching camshaft end plate to cylinder No. 1R. 4. Remove two assembled washer bolts (D) attaching cross shaft bracket. Remove bracket, end plate with tachometer drive adapter, and throttle linkage cross shaft as a unit. Separate cross shaft from camshaft end plate. Remove and discard camshaft end plate gasket. Install 1. Install new camshaft end plate gasket. Install throttle linkage cross shaft in camshaft end plate. Position cross shaft bracket, end plate with tachometer drive adapter, and cross shaft as a unit on right front shroud. Install two assembled washer bolts ( D) securing cross shaft bracket. 2. Install cap screw (C) and lock washer securing camshaft end plate to cylinder No. 1 R. 3. Position primary fuel filter mounting bracket on cylinder No. 1 R and install two cap screws (B) and lock washers securing bracket to cylinder. 4. Position cross shaft lever and adjustable control rod and install bolt, flat washer, slotted nut (A) and cotter pin.

Figure 5-39. Removing or installing primary fuel filter bracket, throttle linkage cross shaft, and camshaft end plate.

Figure 5-38. Removing or installing fuel/ water separator filter.

5-21

Remove 1. Remove three cap screws (A) and lock washers attaching secondary fuel filter mounting bracket and camshaft cover plate to cylinder No. 1L. Remove bracket and cover plate. Remove and discard cover plate gasket. 2. Remove four self-locking nuts (B) and flat washers attaching tachometer drive cover and remove cover. 3. Remove and discard tachometer drive cover gasket

Remove 1. Remove three hex head screws (A), flat washers, and lock washers attaching fuel / water separator filter mounting bracket to cylinder No. 1L and remove bracket. 2. Remove and discard mounting bracket gasket (B). Install 1. Install a new mounting bracket gasket (B). 2. Position fuel/ water separator filter mounting bracket on cylinder No. 1L. Install three hex head screws (A), flat washers, and lock washer-a securing bracket to cylinder.

(c),

Install 1. Install a new tachometer drive cover gasket (C). 2. Position tachometer drive cover and install four selflocking nuts (B) and flat washers securing cover. 3. Install new camshaft cover plate gasket. Position camshaft cover plate and secondary fuel filter mounting bracket to cylinder No. 1 L and install three cap screws (A) securing plate and bracket to cylinder.

Figure 5-41. Removing or installing fuel/ water separator filter mounting bracket.

Figure 5-40. Removing or installing secondary fuel filter mounting bracket, camshaft cover plate, and tachometer drive cover.

5-22

Note. Cylinder barrel shrouds for cylinders No. lR and 6L are identical and are removed or installed in the same manner. Figure 5-42. Removing or installing cylinder barrel shroud / cylinder No. lR.

Remove 1. Remove two plate nuts (A). 2. Remove five machine screws (B) attaching right front
shroud to cylinder and to cylinder No. 1R baffle. Remove shroud.

Note. Cylinder No. lR baffle will be disconnected when the five machine screws (B) are removed.
Install 1. Position right front shroud on engine and install five machine screws (B) securing shroud to cylinder and to cylinder No. 1 R baffle. 2. Install two plate nuts (A).

Figure 5-43. Removing or installing right front shroud.

5-23

Remove 1. Remove two plate nuts (A) from cylinder baffle. 2. Remove cylinder baffle (B).

Note. Cylinder baffles for cylinder Nos. lR and 6L are-identical and are removed or installed in the same manner.
Install 1. Position cylinder baffle (B) over cylinder. 2. Install two plate nuts (A) on cylinder baffle.

Figure 5-44. Removing or installing cylinder baffle-cylinder No. l R .

Disconnect 1. Disconnect fire extinguisher tube (A) from adapter. 2. Remove nut (B) attaching adapter to shroud and remove adapter. 3. Disconnect fuel injection pump fuel inlet hose (C) from bulkhead elbow. 4. Remove nut (D) and external teeth lock washer attaching bulkhead elbow to shroud. Remove elbow and flat washer. S. Remove four nuts (E). external teeth lock washers. and machine screws attaching fuel injection pump fuel cutoff lead to shroud. Remove lead from shroud. Connect 1. Position fuel injection pump fuel cutoff lead through shroud. Install four nuts (E), external teeth lock washers, and machine screws securing lead to shroud. 2. Position bulkhead elbow and flat washer in shroud. Install nut (D) and external teeth lock washer securing elbow to shroud. 3. Connect fuel injection pump fuel inlet hose (C) to bulkhead elbow. 4. Position adapter in shroud and install nut (B) securing adapter to shroud. 5. Connect fire extinguisher tube (A) to adapter.

Figure 5-45. Disconnecting or connecting fire extinguisher and fuel inlet tubesfront shroud.

5-24

Remove 1. Remove three machine screws (A) and remove left front shroud. 2. Remove eight plate nuts (B) from shroud. Note. Remove or install cylinder baffle from c y l i n d e r N o . 1L after left front shroud is removed and in the same manner as cylinder baffle No. lR was removed (fig. 5-44). Cylinder baffle for cylinder No. 6R is identical and interchangeable with baffle for cylinder No. 1L and is also removed or installed in the same manner. Install 1. Install eight plate nuts (B) on left front shroud. 2. Position left front shroud on engine and install three machine screws (A).

Figure 5-47. Removing or installing left front shroud.

Remove 1. Remove two machine screws (A). 2. Remove three machine screws (B) and lock washers attaching top filler plate to crankshaft damper and oil filter housing. Remove top filler plate. 3. Remove three machine screws (C) and lock washers attaching side filler plate to housing. 4. Remove three machine screws (D) attaching side filler plate to left front shroud and remove filler plate. Install 1. Position side filler plate on left front shroud and install three machine screws (D) securing plate to shroud. 2. Install three machine screws (C) and lock washers securing side filler plate to crankshaft damper and oil filter housing. 3. Position top filler plate on housing. Install three machine screws (B) and lock washers securing plate to housing. 4. Install two machine screws (A).

Figure 5-46. Removing or installing top and side filler plates-cylinder No. 1L. 5-25

Disconnect 1. Disconnect fuel return hose (A) from tube cross. 2. Disconnect fuel injector nozzle fuel return tubes (B) from tube cross. 3. Remove nut (C) and flat washer attaching tube cross to right rear center shroud and remove cross. 4. Disconnect turbosupercharger oil hose (D) from bulkhead adapter elbow. S . Remove nut (E) and flat washer attaching adapter elbow to left rear center shroud and remove elbow. 6. Remove hose clamp (F) and rear crankcase breather tube tee. Connect 1. Install hose clamp (F) on rear crankcase breather tube tee. Install rear crankcase breather tube hose through right rear center shroud onto breather tube and tighten clamp. 2. Position bulkhead adapter elbow in left rear center shroud and install nut (E) and flat washer securing elbow to shroud. 3. Connect turbosupercharger oil hose (D) to bulkhead adapter elbow. 4. Position tube cross in right rear center shroud and install nut (C) and flat washer securing cross to shroud. 5. Connect fuel injector nozzle fuel return tubes (B) to tube cross. 6. Connect fuel return hose (A) to tube cross.

Figure 5-48. Disconnecting or connecting fuel and oil tubes-rear center shrouds.

Rem ove 1. Remove three machine screws (A) and lock washers. 2. Remove left and right rear center shrouds (B). Install 1. Position left and right rear center shrouds (B) on engine. 2. Install three machine screws (A) and lock washers.

Figure 5-49. Removing or installing exhaust manifold left and right rear center shrouds. 5-26

Figure 5-50. Removing or installing right near shroud.

5-27

Remove 1. Remove 20 hex head screws(A) and lock washers and remove five cylinder head plates. 2. Remove plate nut (B) from front cylinder head end plate. 3. Remove two hex head screws (C) and lock washers and remove front end plate. 4. Remove plate nut (D) from rear cylinder head end plate. 5. Remove two hex head screws (E) and lock washers and remove rear end plate.

Note. The cylinder head plates on the left side of the engine are removed or installed in the same manner, except for the plates surrounding the oil filler and oil level indicator tubes (between cylinders lL, 2L, and 3L).
Install 1. Position rear cylinder head end plate and install two hex head screws (E) and lock washers securing plate. 2. Install plate nut (D) on end plate. 3. Position front cylinder head end plate and install two hex head screws (C) and lock washers securing plate. 4. Install plate nut (B) on end plate. 5. Position five cylinder head plates and install 20 hex head screws (A) and lock washers securing plates.

Figure 5-51. Removing or installing cylinder head plates -right side.

Remove Note. The oil filler and oil level indicator tubes must be removed before cylinder head plates between cylinder Nos. 1L, 2L, and 3L can be removed.
1. Remove two machine screws (A) and lock washers and remove oil filler tube plate. 2. Remove two machine screws (B) and lock washers and remove oil level indicator tube plate. Install 1. Position oil level indicator tube plate and install two machine screws (B) and lock washers securing plate. 2. Position oil filler tube plate and install two machine screws (A) and lock washers securing plate.

Figure 5-52. Removing or installing oil filler and oil level indicator tube plates engines with one piece oil filler tube.

5-28

Remove 1. Remove three assembled washer bolts (A) and seal washers and remove oil filler tube and cap as a unit. Discard seal washers. 2. Remove and discard oil filler tube gasket (B). 3. Remove three self-locking nuts (C) and remove oil level indicator tube and cap as a unit. 4. Remove and discard oil level indicator tube gasket (D). Install 1. Install a new oil level indicator tube gasket (D) on oil pan, 2. Position oil level indicator tube and cap as a unit on oil pan. Install three self-locking nuts (C) securing tube. 3. Install a new oil filler tube gasket (B) on oil pan. 4. Position oil filler tube and cap as a unit on oil pan. Install three assembled washer bolts (A) and new seal washers securing tube.

Remove 1. Remove two machine screws (A) and lock washers and remove cylinder head plate at oil filler tube. 2. Remove two machine screws (B) and lock washers and remove cylinder head plate at oil level indicator tube. Install 1. Position cylinder head plate at oil level indicator tube position. Install two machine screws (B) and lock washers securing plate. 2. Position cylinder head plate at oil filler tube position. Install two machine screws (A) and lock washers securing plate.

Figure 5-54. Removing or installing cylinder head plates at oil filler and oil level indicator tubes- engines without splash pan installation.

Figure 5-53. Removing or installing oil filler and oil level indicator tubes-engines with one piece oil filler tube.

5-29

Remove

Note. The oil filler and oil level indicator tubes must be removed before cylinder head plates between cylinders Nos. 1L, 2L and 3L can be removed.
1. Remove two hex head screws (A) and lock washers and remove oil filler tube plate. 2. Remove two hex head screws (B) and lock washers and remove oil level indicator tube plate. 3. Remove and discard grommet (C). Install 1. Install a new grommet (C) in oil level indicator tube plate. 2. Position indicator tube plate and install two hex head screws (B) and lock washers securing plate. 3. Position oil filler tube plate and install two hex head screws (A) and lock washers securing plate.

Figure 5-55. Removing or installing oil filler and oil level indicator tubes- engines with splash pan installation.

Remove 1. Remove three assembled washer bolts (A) and seal washers and remove oil filler tube. Discard seal washers. 2. Remove and discard oil filler tube gasket (B). 3. Remove pan head screw (C) and self-locking nut and remove two hose clamps from oil level indicator tube. 4. Remove three self-locking nuts (D) and remove oil level indicator tube. 5. Remove and discard oil level indicator tube gasket (E). Install 1. Install a new oil level indicator tube gasket (E) on oil pan. 2. Position oil level indicator tube on oil pan. Install three self-locking nuts (D) securing tube. 3. Position two hose clamps, one on indicator tube, and install pan head screw (C) and self-locking nut securing clamps. 4. Install a new oil filler tube gasket (B) on oil pan. 5. Position oil filler tube on oil pan. Install three assembled washer bolts (A) and new seal washers securing tube.

Figure 5-56. Removing or installing oil filler and oil level indicator tube plates engines with splash pan installation.

5-30

Remove 1. Remove two machine screws (A) and lock washers and remove cylinder head plate at oil filler tube. 2. Remove two machine screws (B) and lock washer-e and remove cylinder head plate at oil level indicator tube. Install 1. Position cylinder head plate at oil level indicator tube position. Install two machine screws (B) and lock washers securing plate. 2. Position cylinder head plate at oil filler tube position. Install two machine screws (A) and lock washers securing plate.

Figure 5-57. Removing or installing cylinder head plates at oil filler and oil level indicator tubes engines with splash pan installation.

Remove 1. Remove two machine screws (A) and lock washers and remove oil level indicator tube plate. 2. Remove two machine screws (B) and lock washers attaching oil level indicator tube cylinder plate. Install 1. Install two machine screws (B) and lock washers securing oil level indicator tube cylinder plate. 2. Position oil level indicator tube plate and install two machine screws (A) and lock washers securing plate.

Figure 5-58. Removing or installing oil level indicator tube plate-engines with relocated oil filler tube installation.

5-31

Remove 1. Remove three assembled washer bolts (A) and remove oil filler tube. 2. Remove and discard filler tube gasket (B). 3. Remove three self-locking nuts (C) and remove oil level indicator tube. 4. Remove and diaeard indicator tube gasket (D).

Install 1. Position new gasket (D) on studs on oil level indicator tube mounting. 2. Position oil level indicator tube on oil pan and install three self-locking nuts (C). 3. Position new gasket (B) on oil filler tube mounting. 4. Position oil filler tube on oil pan and install three assembled washer bolts (A).

Figure 5-59. Removing or installing oil filler and oil level indicator t u b e s - engines with relocated oil filler tube installation.

5-32

5-8.

Fuel

Injector

Tubes,

Supports,

and

Clamps, Exhaust Pipes and Manifolds Fuel Inlet and Return Hoses Crankcase Breather Base, Tubes, and and Turbosupercharger Tie Rods Supports

Refer to Table 5-5 for illustrations and disassembly instructions. Figure references are listed in the table.

Figure 5-60. Removing or installing oil level indicator tube cylinder plate-engines with relocated oil filler tube installation.
Table 5-5. Fuel Injector Tubes, Supports, and Clamps, Exhaust Pipes and Manifold, Fuel Inlet and Return Hoses, Crankcase Breather Tubes, and Turbosupercharger Base, Supports and Tie Rods

Fig. 5-61 Fig. 5-64 Fig. 6-58 Fig. 5-71 Fig. 5-79

5-33

Remove 1. Disconnect and remove ten fuel injector nozzle fuel return tubes (A) from injector nozzle fuel tube connectors and fuel tube elbow connectors. 2. Disconnect and remove right nozzle fuel return tube (B) from fuel tube connector at cylinder No. 6R. 3. Disconnect and remove left nozzle fuel return tube (C) from fuel tube connector at cylinder No. 6L.

Install 1. Install and connect left nozzle fuel return tube (C) to fuel tube connector at cylinder No. 6L. 2. Install and connect right nozzle fuel return tube (B) to fuel tube connector at cylinder No. 6R. 3. Install and connect ten fuel injector nozzle fuel return tubes (A) to injector nozzle fuel tube connectors and fuel tube elbow connectors.

Figure 5-61. Removing or installing fuel injector nozzle fuel return tubes-engines with metallic tubes.

5-34

Remove 1. Disconnect and remove ten fuel injector nozzle fuel return tubes (A) from injector nozzle fuel tube connectors and fuel tube elbow connectors. 2. Disconnect and remove right nozzle fuel return tube (B) from fuel tube connector at cylinder No. 6R. 3. Disconnect and remove left nozzle fuel return tube (C) from fuel tube connector at cylinder No. 6L.

Install 1. Install and connect left nozzle fuel return tube (C) to fuel tube connector at cylinder No. 6L. 2. Install and connect right nozzle fuel return tube (B) to fuel tube connector at cylinder No. 6R. 3. Install and connect ten fuel injector nozzle fuel return tubes (A) to injector nozzle fuel tube connectors and fuel tube elbow connectors.

Figure 5-62. Removing or installing fuel injector nozzle fuel return tubes-engines with flexible tubes.

5-35

Remove 1. Remove special bolts (A) attaching fuel tube elbow connector to nozzle and holder in cylinder No. 1 R. 2. Remove and discard elbow connector gaskets (B) from bolt as bolt and elbow connector are separated. 3. Remove five special bolts (C) attaching fuel tube connectors to nozzle and holder assemblies in cylinder Nos. 2R, 3R, 4R, 5R, and 6R. 4. Remove and discard connector gaskets (D) from bolts as bolt and connector are separated.

Note. Fuel injector nozzle fuel tube connectors and elbow connectors on left side of engine are removed or installed in the same manner.

Install 1. Position a new connector gasket (B) on special bolt (A), insert bolt through fuel tube efbow connector, and position second new connector gasket (B) on bolt. 2. Install assembled special bolt (A), with gaskets and elbow connector in nozzle and holder at cylinder No. 1R. 3. Position a new connector gasket (D) on special bolt (C), insert bolt through fuel tube connector, and position second new connector gasket (D) on bolt. 4. Install five assembled special bolts (C), with gaskets and tube connectors in nozzle and holder assemblies at cylinder Nos. 2R, 3R, 4R, 5R and 6R.

Figure 5-63. Removing or installing fuel injector nozzle fuel tube connectors and elbow connector-right side.

5-36

Remove 1. Remove eight self-locking nuts (A) and bolts. Remove four plates and eight tube clamps from four left tube clamp supports. 2. Remove four self-locking nuts (B) and bolts. Remove two plates and four tube clamps from double tube clamp support. 3. Remove four self-locking nuts (C) and bolts. Remove two plates and four tube clamps from double angle and single angle brackets. 4. Remove four self-locking nuts (D) and bolts. Remove two plates and four tube clamps from two right tube clamp supports.

Install Note. Some engines were provided with four additional clamps to minimize the vibration of

the fuel injection t u b e . W h e n o v e r h a u l i n g engines, install tube clamping to the current clamping arrangement, a s d e s c r i b e d i n i n structions which accompany figure 5-65 and to dimensions shown in figures 4-41 and 4-42.

Figure 5-64. Removing fuel injector clamps-engines without additional clamps.

5-37

Remove 1. Remove eight self-locking nuts (A) and bolts. Remove four plates and eight tube clamps from four left tube clamp supports. 2. Remove four self-locking nuts (B) and bolts. Remove two plates and four tube clamps from double tube clamp support. 3. Remove four self-locking nuts (C) and bolts. Remove four plates and tube clamps. 4. Remove four self-locking nuts (D) and bolts. Remove four plates and tube clamps. 5. Remove four self-locking nuts (E) and bolts. Remove two plates and four tube clamps from angle brackets. 6. Remove six self-locking nuts (F) and bolts. Remove three plates and six tube clamps from three right tube clamp supports. Install 1. Position two tube clamps, one under and one over fuel injector tubes, and plate on top of each clamp at each right tube clamp support. Install six self-locking nuts (F) and bolts securing clamps.

2. Position two tube clamps, one under and one over fuel injector tubes, and plate on top of each clamp at angle brackets. Install four self-locking nuts (E) and bolts securing clamps. 3. Position two clamps, one under and one over fuel injector tubes, and one plate under and one over each clamp at location shown. Install four self-locking nuts (D) and bolts securing clamps. 4. Position two clamps, one under and one over outer two fuel injector tubes at location shown, and one plate under and one over each clamp. Install four self-locking nuts (C) and bolts securing clamps. 5. Position two clamps, one under and one over fuel injector tubes and one plate on top of each clamp at double tube clamp support. Install four self-locking nuts (B) and bolts securing clamps. 6. Position two clamps, one under and one over fuel injector tubes, and plate on top of each clamp at each left tube clamp support. Install eight self-locking nuts (A) and bolts securing clamps.

5-38

Figure 5-65. Removing or installing fuel injector tube clamps-engines with additional clamps.

Disconnect 1. Disconnect fuel injector tubes (A) for cylinder Nos. 1R, 2R and 3R from injector nozzle and holder assemblies 2. Disconnect fuel injector tubes (B) for cylinder Nos. 4R, 5R, and 6R from injector nozzle and holder assemblies. 3. Disconnect fuel injector tubes (C) for cylinder Nos. 1L, 2L, and 3L from injector nozzle and holder assemblies. 4. Disconnect fuel injector tubes (D) for cylinder N O S. 4L, 5L, and 6L from injector nozzle and holder assemblies.

Connect 1. Connect fuel injector tubes (D) for cylinder N O S. 4L, 5L and 6L to injector nozzle and holder assemblies. 2. Connect fuel injector tubes (C) for cylinder N O S. 1L, 2L, and 3L to injector nozzle and holder assemblies. 3. Connect fuel injector tubes (B) for cylinder Nos.. 4R, 5R, and 6R to injector nozzle and holder assemblies. 4. Connect fuel injector tubes (A) for cylinder NOS. 1R, 2R, and 3R to injector nozzle and holder assemblies.

Figure 5-66. Disconnecting or connecting fuel injector tubes-at fuel injector nozzle and holder assemblies.

5-39

Remove
Remove 1. Move 12 dust caps (A) away from tube connections at fuel injection pump. 2. Disconnect six fuel injector tubes (B) from fuel injection pump front hydraulic head. Remove tubes (C) 4R, 5R, and 6R. 3. Remove tubes (D) 1R, 2R, and 3R by pulling tubes, singularly, between exhaust manifold and cylinder. 4. Disconnect six fuel injector tubes (E) 1L through 6L from fuel injection pump rear hydraulic head. Individually remove tubes. Note. After fuel tubes have been removed, plug all fuel injection pump hydraulic head fuel ports to prevent entrance of dirt. Install 1. Individually position six fuel injector tubes (E) from cylinder NOS. 1L through 6L to fuel injection pump rear hydraulic head. Connect tubes to rear hydraulic head. 2. Individually position three fuel injector tubes (D), between exhaust manifold and cylinder, from cylinder Nos. 1R, 2R, and 3R to fuel injection pump front hydraulic head. 3. Individually position three fuel injector tube cylinders (C) from cylinder Nos. 4R, 5R, and 6R to front hydraulic head. Connect six tubes (B) to hydraulic head. 4. Install 12 dust caps (A) to tube connections at hydraulic heads. 1. Remove two setf-locking nuts (A), flat washers, and bolts attaching right and left bank exhaust pipe retaining straps at rear of engine and remove straps. 2. Remove two self-locking nuts (B), flat washers, and bolts attaching right and left bank exhaust manifold retaining straps at center of engine and remove straps. Install

Note. Some engines had only two sets of

retaining straps securing right and left bank exhaust pipes. When rebuilding engine, install the additional pair of clamps (step 1) securing the right and left bank exhaust pipes. 1. Position retaining straps on right and left bank exhaust manifold at center of engine and insta11 two self-locking nuts (B), flat washers, and bolts securing straps. 2. Position retaining straps on right and left bank exhaust pipes at rear of engine and install two selflocking nuts (A), flat wasbers, and bolts securing straps.

Figure 5-68. Removing or installing exhaust manifold and exhaustpipe retaining straps.

Figure 5-67. Removing or installing fuel injector tubes at fuel injection pump.

5-40

Remove 1. Remove four self-locking nuts (A), flat washers, and bolts attaching exhaust pipe to exhaust manifold for cylinder NO s. lR, 2R, and 3R. Remove pipe. Remove and discard exhaust manifold gasket. 2. Remove 12 self-locking nuts (B) and flat washers attaching exhaust manifold to cylinder Nos. lR, 2R, and 3R. Remove manifold. Remove and discard three manifold gaskets. 3. Remove four self-locking nuts (C), flat washers, and bolts attaching exhaust pipe to exhaust manifold for cylinder NOS . 1L, 2L, and 3L. Remove pipe. Remove and discard exhaust manifold gasket. 4. Remove 12 self-locking nuts (D) and flat washers attaching exhaust manifold to cylinder Nos. 1L, 2L, and 3L. Remove manifold. Remove and discard three manifold gaskets.

securing pipe to) manifold.

Figure 5-69. Removing or installing exhaust manifolds and exhaust pipes-cylinder Nos. IR, 2R, and 3R and cylinder Nos. 1L, 2L, and 3L-engines prior to rerouting of crankcase breather tube.
5-41

Remove 1. Remove four self-locking nuts (A), flat washers, and bolts attaching exhaust pipe to exhaust manifold for cylinder Nos. 1R, 2R, and 3R. Remove pipe. Remove and discard exhaust manifold gasket. 2. Remove 12 self-locking nuts (B) and flat washers attaching exhaust manifold to cylinder Nos. 1R, 2R, and 3R. Remove manifold. Remove and discard three manifold gaskets. 3. Remove four self-locking nuts (C), flat washers, and bolts attaching exhaust pipe to exhaust manifold for cylinder Nos. 1L, 2L, and 3L. Remove pipe. Remove and discard exhaust manifold gasket. 4. Remove 12 self-locking nuts (D) and flat washers attaching exhaust manifold to cylinder Nos. 1L, 2L, and 3L. Remove manifold. Remove and discard three manifold gaskets.

Install 1. Position three new manifold gaskets on cylinder Nos. 1L, 2L, and 3L. Position exhaust manifold on cylinders. Install 12 self-locking nuts (D) and flat washers securing exhaust manifold to cylinders. 2. Position a new exhaust manifold gasket on exhaust manifold. Position exhaust pipe to manifold and install four self-locking nuts (C), flat washera, and bolts securing pipe to manifold. 3. Position three new manifold gasketa on cylinder Nos. 1R, 2R, and 3R. Position exhaust manifold on cvlinders. Install 12 self-locking nuts (B) and flat . washers securing exhaust manifold to cylinders. 4. Position a new exhaust manifold gasket on exhaust manifold. Position exhaust pipe on manifold and install four self-locking nuts (A), flat washers, and bolts securing pipe to manifold.

Figure 5-70. Removing or installing exhaust manifolds and exhaust pipes-cylinder Nos. 1R, 2R, and 3R and cylinder Nos. 1L, 2L, and 3L-engines with rerouted crankcase breather tube.

5-42

Remove 1. Remove self-locking nut and machine screw (A) attaching large and small cushioned clamps from intermediate crankcase breather tube and fuel return hose. 2. Disconnect fuel return hose (B) at check valve and remove hose. 3. Loosen breather tube hose clamps (C). 4. Remove two bolts and lock washers (D) attaching crankcase breather tube tee to rear fan drive and accessory drive housing. Remove tube tee and hose from intermediate crankcase breather tube. Remove and discard tube tee gasket. 5. Remove fuel check valve (E). Install 1. Install fuel check valve (E). 2. Install a new hose on tube tee. Connect tube tee to intermediate crankcase breather tube. Position new gasket and install breather tube tee to rear fan and accessory drive housing and secure with two bolts and lock washers (D). 3. Tighten breather tube hose clamps (C). 4. Position fuel return hose (B) and connect to check valve. 5. Position large and small cushioned clamp and install a machine screw and self-locking nut (A) securing large and small cushioned clamps at intermediate crankcas e breather tube and fuel return hose.

Figure 5-71. Removing or installing fuel return hose and crankcase breather tube t e e - engines prior to rerouting of fuel return hose.

Disconnect 1. Remove three self-locking nuts and machine screws (A) attaching three small cushioned clamps on electrical lead to three large cushioned clamps on intermediate crankcase breather tube. 2. Remove three large cushioned clamps (B) from front and rear intermediate crankcase breather tubes and front intermediate crankcase breather tube. 3. Remove self-locking nut and bolt (C) securing breather tube clamp to bracket. 4. Loosen two hose clamps (D) and remove rear intermediate crankcase breather tube. Remove cushioned clamp and hose from tube. 5. Disconnect fuel injection pump electrical lead (E) from injection pump. Connect 1. Connect fuel injection pump electrical lead (E) to fuel injection pump. 2. Install cushioned clamp and hose on rear intermediate crankcase breather tube and position tube. Tighten two hose clamps (D). 3. Install bolt and self-locking nut (C) securing breather tube clamp to bracket. 4. Install one large cushioned clamp (B) on rear intermediate breather tube and two large cushioned clamps (B) on front intermediate breather tube. 5. Install three machine screws and self-locking nuts (A) securing three small cushioned clamps on the electrical lead to the three large cushioned clamps on the crankcase front and rear intermediate breather tubes.

Figure 5-72. Disconnecting or connecting intermediate crankcase breather tubes at fuel injection pump clamp.

5-43

Remove 1. Remove pan head screw (A) and self-locking nut attaching two cushioned clamps to fuel return hose and turbosupercharger oil inlet hose. 2. Disconnect fuel return hose (B) from fuel return check valve (C) and remove hose. 3. Remove fuel return check valve (C) from fuel injection pump. Install 1. Install fuel return check valve (C) in fuel injection pump. 2. Install fuel return hose (B) and connect to fuel return check valve (C). 3. Position one cushioned clamp on fuel return hose and one cushioned clamp on turbosupercharger oil inlet hose at position shown. Install pan head screw (A) and self-locking nut securing clamps.

Remove 1. Loosen two breather tube hose clamps (A). 2. Remove two bolts (B) and lock washers attaching crankcase breather tube tee to rear fan drive housing. 3. Remove tube tee. Remote and discard tube tee gasket (C). Install 1. Position a new tube tee gasket (C) on rear fan drive housing. Position crankcase breather tube tee on housing. 2. Install two bolts (B) and lock washers securing tube tee to drive housing. 3. Tighten two breather tube hose clamps (A).

Figure 5-73. Removing or installing fuel return hose-engines with rerouted fuel return hose.

Figure 5-74. Removing or installing crankcase breather tube tee-engines with rerouted crankcase breather tube.

5-44

Figure 5-75. Removing or installing breather tube cushioned clamp at rear fan drive housing -engines with rerouted crankcase breather tube.

Remove 1. Remove three pan head screws (A) and self-locking nuts. 2. Remove fuel injection pump electrical lead (B). 3. Remove three small cushioned clamps (C) from electrical lead. 4. Remove three large cushioned clamps (D) from crankcase breather tube. 5. Remove remaining two cushioned clamps (E) from fuel inlet hose. 6. Loosen two hose clamps (F) and remove breather tube, clamps, and hose. 7. Remove two self-locking nuts (G) attaching breather tube to crankshaft damper and oil filter housing. Remove breather tube. Remove and discard breather tube gasket. 8. Disconnect and remove fuel inlet hose (H). Install 1. Install and connect fuel inlet hose (H) 10 fuel injection. pump. 2. Position a new breather tube gasket on crankshaft damper and oil filter housing. Position breather tube on housing and install two self-locking nuts (G) securing tube to housing. 3. Install breather tube with clamps and hose. Tigh ten hose clamps (F) securing breather tubes. 4. Position two cushioned clamps (E) on fuel inlet hose at position shown. 5. Position three large cushioned clamps (D) on breather tube at position shown. 6. Position three small cushioned clamps (C) on fuel injection pump electrical lead (B). ?. Install electrical lead (B) and move three clamps to position shown. 8. Install three pan head screws(A) and self-locking nuts securing clamps.

Figure 5-76. Removing or installing fuel inlet hose and crankcase breather tube.

5-45

Remove 1. Cut locking wire and remove three cap screws (A) and flat washers attaching fan drive control valve (C) to rear fan drive housing. Discard cap screws. 2. Loosen cap screw (B) until screw is free of threads. 3. Remove and discard control valve (C) and cap screw (B). 4. Remove brass gasket (D). Remove and discard mounting gasket. Install

valve has since been eliminated and. on those

e n g i n e s s o e q u i p p e d , a cover plate is used to cover the valve oil passages and will be installed

during engine overhaul. The fan tower has been

redesigned to eliminate the valve mounting surface and the need for the cover plate. 1. Install new mounting gasket, brass gasket (D), and cover. Secure cover with four cap screws, flat washers, and locking wire.

Note. A l i m i t e d n u m b e r o f e n g i n e s w e r e equipped with a fan control valve. The need for a

Figure 5-77. Removing fan drive control valve-engines with fan control valve.

5-46

Remove 1. Remove four self-locking nuts (A), flat washers, and cap screws attaching exhaust pipe tu exhaust manifold for cylinder Nos. 4R, 5R, and 6R. Remove pipe. Remove and discard exhaust manifold gasket. 2. Remove 12 self-locking nuts (B) and flat washers attaching exhaust manifold to cylinder Nos. 4R, 5R, and 6R. Remove manifold. Remove and discard three manifold gaskets. 3. Remove four self-locking nuts (C), flat washers, and cap screws attaching exhaust pipe to exhaust manifold for cylinder Nos. 4L, 5L, and 6L. Remove pipe. Remove and discard exhaust manifold gasket. 4. Remove 12 self-locking nuts (D) and flat washers attaching exhaust manifold to cylinder Nos. 4L, 5L, and 6L. Remove manifold. Remove and discard three manifold gaskets.

Install 1. Position three new manifold gaskets on cylinder Nos. 4L, 5 L, and 6 L. Position exhaust manifold on cylinders. Install 12 self-locking nuts (D) and flat washers securing exhaust manifold to cylinders. 2. Position a new exhaust manifold gasket on exhaust manifold. Position exhaust pipe to manifold and install four self-locking nuts (C), flat washers, and bolts securing pipe to manifold. 3. Position three new manifold gaskets on cylinder Nos. 4R, 5R, and 6R. Position exhaust manifold on cylinders. Install 12 self-locking nuts (B) and flat washers securing exhaust manifold to cylinders. 4. Position a new exhaust manifold gasket on exhaust manifold. Position exhaust pipe on manifold and install four self-locking nuts (A), flat washers, and bolts securing pipe to manifold.

Figure 5-78. Removing or installing exhaust manifolds and exhaust pipes-cylinder Nos. 4R, 5R, and 6R and cylinder Nos. 4L, 5L, and 6L.

5-47

Remove 1. Remove two cap screws (A) and lock washers attaching right turbosupercharger mounting base to support. 2. Remove two cap screws ( B ) and lock washers attaching mounting base to tie rod. Remove base.

Install 1. Position right turborsupercharger mounting base on tie rod, Install two cap screws ( B ) securing base to tie rod. 2. Install two cap screws (A) and lock washers securing base to support. ..

Figure 5-79. Removing or installing right turbosupercharger mounting base.

Remove 1. Remove two cap screws (A), lock washers, and one tie rod clamp attaching turbsupercharger tie rod (B). 2. Remove tie rod and tie rod clamp seat. Install 1. Position tie rod clamp seat and turbosupercharger tie rod (B) on transmission adapter. 2. Position tie rod clamp on tie rod and install two cap screws (A) and lock washers securing tie rod.

Figure 5-80. Removing or installing right and left turbosupercharger mounting base tie rod.

5-48

Remove 1. Remove cotter pin, slotted nut (A), and bolt attaching turbosupercharger mounting base support (B) to transmission adapter. 2. Remove support. Note. Left turbosupercharger mounting base

support is removed or installed in the same manner. Install 1. Position turbosupercharger mounting base support (B) on transmission adapter. 2. Install bolt, slotted nut (A) and cotter pin securing support.

Figure 5-81. Removing or installing right turbo supercharger mounting base support.

5-9. Throttle Control Rods and Lever, Fuel Injection P u m p O i l I n l e t H o s e , Turbosupercharger Oil Inlet Hose and Fire Extinguisher Tube, and Fuel lnjection Pump

R e f e r t o T a b l e 5 - 6 for illustrations and disassembly instructions. Figure references are listed in the table.

Table 5-6. Throttle Control Rods and Lever, Fuel Injection Pump Oil Inlet Hose, Turbosupercharger Oil Inlet Hose and Fire Extinguisher Tube, and Fuel Injection Pump
Component Throttle Control Rods and Intermediate Throttle Lever Fuel Injection Pump Oil Inlet Hose Turbosupercharger Oil Inlet Hose and Fire Extinguisher Tube Fuel Injection Pump Figure Reference 5-82 through 5-84 5-85 Through 5-87 5-88 through 5-90 5-91 through 5-96

5-49

Disconnect 1. Remove cotter pin, slotted nut (A), and bolt attaching throttle adjustable rod. Remove adjustable rod. 2. Remove cotter pin, slotted nut (B), and bolt attaching throttle rod to intermediate throttle lever. 3. Remove cotter pin, slotted nut (C), flat washer, and bolt attaching throttle rod to injection pump lever. Remove red. Connect 1. Position throttle rod on injection pump lever. Install bolt, flat washer, slotted nut (C), and cotter pin securing rod. 2. Install bolt, slotted nut (B), and cotter pin securing throttle rod to intermediate throttle lever. 3. Position throttle adjustable rod on intermediate throttle lever. Install bolt, slotted nut (A), and cotter pin securing rod.

Remove 1. Remove three self-locking nuts (A) attaching intermediate throttle lever support to front fan drive housing. 2. Remove lever support (B), shaft, and throttle lever as a unit. Install 1. Position lever support (B), shaft, and throttle lever as a unit on front fan drive housing. 2. Install three self-locking nuts (A) securing lever support to drive housing.

Figure 5-83. Removing or installing intermediate throttle lever support.

Figure 5-82. Disconnecting or connecting throttle rods at intermediate throttle lever.

5-50

--

Remove 1. Remove two cap screws (A) attaching single angle bracket to fuel injection pump. Remove bracket. 2. Remove two self-locking nuts (B) attaching double angle bracket to front fan drive housing. Remove bracket. Install 1. Position double angle bracket on front fan drive housing. Install two self-locking nuts (B) securing bracket to housing. 2. Position single angle bracket on fuel injection pump. Install two cap screws (A) securing bracket to pump.

Disconnect 1. Disconnect fuel injection pump oil inlet hose adapter (A) in fuel injection pump adapter. 2. Disconnect inlet hose from pipe hushing (B) at crankshaft damper and oil filter housing. Remove inlet hose. Connect N o t e . The fuel injection pump oil inlet hose has a swivel nut at only one end. This swivel end must be connected to the adapter (A). 1. Connect inlet hose to pipe bushing (B) at crankshaft damper and oi[ filter housing. 2. Position inlet hose in engine with swivel nut end at adapter (A) and connect hose to adapter.

Figure 5-84. Removing or installing fuel injector tube angle brackets.

Figure 5-85. Disconnecting or connecting fuel injection pump oil inlet hose-engines prior to rerouting of hose and clamps.

1. Remove assembled washer bolt (A) attaching small loop clamp to mounting base. Remove and discard clamp. 2. Disconnect fan clutch oil transfer hose at elbow (B) in front fan drive housing. 3. Disconnect oil transfer hose at elbow (C) in rear fan

drive housing and remove and discard hose. 4. Remove and discard elbows (D). Note. Pipe plugs will be installed in these openings during r e b u i l d o f t h e f a n d r i v e housings.

Figure 5-86. Disconnecting fan clutch oil transfer hose-engines with transfer hose.

5-51

Disconnect 1. Disconnect fuel injection pump oil inlet hose at fuel injection pump adapter (A). 2. Disconnect inlet hose from pipe bushing (B) at crankshaft damper and oil filter housing. Remove inlet hose. Connect N o t e . The fuel injection pump oil inlet hose

has a swivel nut at only one end. This swivel end must be connected to the fuel injection pump adapter (A). 1. Connect inlet hose to pipe bushing (B) at crankshaft damper and oil filter housing. 2. Position inlet hose in engine with swivel nut end at adapter (A) and connect hose to adapter.

Figure 5-87. Disconnecting or connecting fuel injection pump oil inlet hose-engines with relocated hose clamps.

5-52

Disconnect 1. Remove bolt (A) and lock washer attaching turbosupercharger oil inlet hose clamp (B) to fuel injection pump base. 2. Disconnect turbosupercharger oil inlet hose (C) from elbow in crankshaft damper and oil filter housing. Remove clamp (B) from hose.

Connect 1. Position turbosupercharger oil inlet hose clamp (B) on turbosupercharger oil inlet hose. Connect inlet hose (C) to elbow. 2. Install bolt (A) and lock washer securing clamp (B) to fuel injection pump base.

Figure 5-88. Disconnecting or connecting turbosupercharger oil inlet hose-engines prior to rerouting of hoses and clamps.

5-53

Remove 1. Remove self-locking nut (A) attaching loop clamp to front fan drive housing. 2. Remove self-locking nut (B) attaching loop clamp to rear fan drive housing, 3. Remove fire extinguisher tube (C) and clamps, Remove two clamps from tube. 4. Remove two cap screws (D) and lock washers and remove breather tube support bracket from fuel injection pump. Reinstall cap screws and lock washers in pump.

Install 1. Install two loop clamps on fire extinguisher tube (C) and position tube in engine. 2. Position clamps as shown and install self-locking nut (B) securing one clamp to rear fan drive housing. 3. Install self-locking nut (A) Becuring second clamp to front fan drive housing. 4. Remove two cap screws (D) and lock washers from fuel injection pump. Install breather tube support bracket on pump and secure with two cap screws and lock washers.

Figure 5-89. Removing or installing fire extinguisher tube-engines prior to new tube and clamps.

5-54

Remove 1. Remove self-locking nut (A) attaching two cushioned loop clamps securing oil inlet hose and fire extinguisher tube to front fan drive housing. 2. Remove self-locking nut (B) attaching two cushioned loop clamps securing oil inlet hose and fire extinguisher tube to rear fan drive housing. 3. Remove self-locking nut and machine screw (C) attaching turbosupercharger oil inlet hose and fire extinguisher tube clamps. Remove clamps. 4. Disconnect and remove turbosupercharger oil inlet hose (D) from elbow in crankshaft damper and oil filter housing. 5. Remove fire extinguisher tube (E) and clamps. Remove two clamps from tube.

Install 1. Install two cushioned loop clamps on fire extinguisher tube (E) and position tube in engine. 2. Position turbosupercharger oil inlet hose (D) in engine and connect to elbow in crankshaft damper and oil filter housing. 3. Position turbosupercharger oil inlet hose and fire extinguisher tube clamps as shown. Install self-locking nut and machine screw (C) securing clamps. 4. Position two cushioned loop clamps on fire extinguisher tube as shown and aline with clamp on oil inlet hose. Install self-locking nut (B) securing clamp to rear fan drive housing. 5. Install self-locking nut (A) securing clamps to front fan drive housing.

Figure 5-90. Removing or installing turbo supercharger oil inlet hose and fire extinguisher tube-engines with new tube and relocated clamps.

5-55

Note. The fuel injection pump splined coupler

Figure 5-91. Positioning injection pump coupler by turning flywheel using splined wrench-5120-793-7895.

hubs must be identified with identical marks to prevent mismating of parts. The sleeves and hubs are matched for each assembly and must not be interchanged between assemblies. 1. Turn engine using splined wrench -5120-793-7895 as shown in figure 5-91 until fuel injection pump coupling
bolts (C) are accessible. 2. Stamp identification marks (B) on both injection pump coupler sleeves (A). 3. Remove four bolts (C), lock washers, and lock plates attaching coupler sleeves.

sleeves and

Figure 5-92. Removing fuel injection pump splined coupler bolts.

5-56

1. Separate coupler sleeves (A). 2. Remove and discard preformed packing (B) from coupler sleeves. Figure 5-93. Separating fuel injection pump splined coupler sleeves.

Figure 5-95. Separating fuel injection pump diaphragm coupler.

Note. The fuel injection pump diaphragm couplers are not matched and do not require any special markings. 1. Turn engine using splined wrench -5120-793-7895 as shown in figure 5-91 until two fuel injection pump coupler bolts (A) are accessible. Remove bolts and lock washers. 2. Repeat procedure in step 1 and remove remaining two bolts and lock washers. Figure 5-94. Removing fuel injection pump diaphragm coupler bolts.

1. Cut locking wire and remove three bolts (A) and recessed washers. 2. Loosen bolt (B) until threads are free. Bolt cannot be rem oved until fuel injection pump is removed from engine. Remove pump and remove bolt (B) and recessed washer from pump. Figure 5-96. Removing fuel injection pump.

5-57

5-10. Shrouds, Cylinder Deflectors and Nozzle and Holder Assemblies Refer to Table 5-7 for illustrations and disassembly instructions. Figure references are listed in the table.

Note. Removal or installation of shrouds and cylinder deflectors is the same for both left and right banks of the engine. For instructional purposes, the right bank shrouds and cylinder deflectors are shown.

Table 5-7. Shrouds, Cylinder Deflectors, and Nozzle Holder Assemblies Component Shroud Pl ates and Cylinder Deflectors Nozzle and Holder Assemblies Figure Reference 5-97 through 5-102 5-103

Remove 1. Remove two machine screws (A) attaching lower right camshaft drive shroud. 2. Remove lower shroud (B). 3. Remove machine screw (C) attaching upper right camshaft drive shroud. 4. Remove upper shroud (D). Install 1. Position upper right camshaft drive shroud (D) on engine. 2. Install machine screw (C) securing upper shroud. 3. Position lower right camshaft drive shroud (B) on ermine. 4. Install two machine screws (A) securing lower shroud. Figure 5-97. Removing or installing camshaft drive shrouds-right side.

Disconnect 1. Remove four plate nuts (A) from lower right rear engine shroud. 2. Remove machine screw (B) from shroud. Connect 1. Install machine screw (B) in lower right rear engine shroud. 2. Install four plate nuts (A) on shroud. Figure 5-98. Disconnecting or connecting lower right engine shroud-top view.

5-58

Remove plate nuts (A) from lower 1. Remove four right rear engine shroud. 2. Remove two machine screws (B) attaching cylinder base shroud to lower right rear engine shroud. Remove base shroud. 3. Remove lower right rear engine Shroud (C). 4. Remove machine screw (D), lock washer, and spring clip from crankcase. install 1. Position spring clip on lower right rear of crankcase and install machine screw (D) and lock washer. 2. Position lower right rear engine shroud (C) on engine and engage clip. 3. Position cylinder base shroud on engine shroud (C). Install two machine screws (B) securing base shroud to engine shroud. 4. Install four plate nuts (A) on engine shroud.

1. Remove five self-locking nuts (A) and flat washers from hooks. 2. Remove five intercylinder head deflectors (B). Install 1. Position five intercylinder head deflectors (B) between cylinders. 2. Install five self-locking nuts (A) and flat washers on hooks securing deflectors.

Figure 5-100. Removing or installing intercylinder head deflectors-right side.

Figure 5-99. Removing or installing lower right rear engine shroud-side view.

5-59

Disconnect 1. Remove five self-locking nuts (A) and flat washers from right intercylinder deflector hooks. 2. The right lower cylinder deflector straps (B) should not be removed since the remaining attaching parts will be more accessible during removal of the cylinders (para. 5-12). Connect 1. Install five self-locking nuts (A) and flat washers on right intercylinder deflector hooks.

Figure 5-101. Disconnecting or connecting right intercylinder deflector hooks.

Remove 1. Remove five right intercylinder deflector hooks (A). 2. Remove five self-locking nuts, cap screws, and spacers (B). 3. Remove five right intercylinder deflectors (C). Install 1. Position five right intercylinder deflectors (C) between cylinders. 2. Install five spacers (B), cap screws, and self-locking nuts. 3. Install five right intercylinder deflector hooks (A).

Figure 5-102. Removing or installing right intercylinder deflectors.

5-60

Note. Refer to figure 4-152, 4-153, and 4-165 for instructions covering removal and in-

stallation of the fuel injector nozzle and holder assemblies.

Figure 5-103. Removing or installing fuel injector nozzle and holder assembly.

5-11. Camshaft, Fan Drives, Housings, and Bases Refer to Table 5-8 for illustrations and disassembly instructions. Figure references are listed in the table.

Note. Both the left and right camshafts are removed in the same manner. For instructional purposes, the right camshaft has been used for typical procedures.

Table 5-8. Camshafts, Fan Drives, Housings, and Bases Component Camshaft Front Fan Drive Housing with Clutch Assembly and Mounting Base Fuel Injection Pump Mounting Base Rear Fan and Accessory Drive Housing with Clutch Assembly and Mounting Base Figure Reference 5-104 through 5-116 5-117 through 5-126 5-127, 5-128 5-129 through 5-134

5-61

Remove 1. Remove 11 bolts (A) attaching eight injector tube clamp supports to valve adjusting screw cover plates and remove supports. 2. Remove 37 bolts (B) and flat washers attaching 24 valve adjusting screw cover plates to rocker arm covers. Remove plates. 3. Remove and discard 24 cover plate gaskets (C).

Install 1. Position two new cover plate gaskets (C) on each of 12 rocker arm covers. 2. Position 24 valve adjusting screw cover plates on rocker arm covers. Position eight injector tube clamp supports on cover plates at locations shown and install 11 bolts (A) securing supports and plates to covers. 3. Install 37 bolts (B) and flat washers in remaining locations securing cover plates to covers.

Figure 5-104. Removing or installing valve adjusting screw cover plates. 5-62

Disconnect N o t e . The cylinder and valve rocker arm covers are machined as an assembly. Each rocker arm cover must be kept with its mating cylinder to insure camshaft bearing alinement and running clearance. Identifying numbers are used to prevent mismating of parts. Figure 5-105. Location of valve rocker arm cover and cylinder identifying marks.
1. Remove three cap screws (A) attaching right lifting eye to rocker arm cover and cylinder No. 1R. 2. Remove three cap screws (B) attaching each intercylinder hose flange to remaining covers and cylinders on right side of engine. Slide flanges and lifting eye away from rocker arm covers and cylinders. Con nect 1. Slide intercylinder hose flanges and right lifting eye against rocker arm covers and cylinders. Install three cap screws (B) securing each hose flange to rocker arm cover and cylinder on right side of engine. 2. Install three cap screws (A) securing lifting eye to cover and cylinder No. lR.

Figure 5-106. Disconnecting or connecting right front lifting eye and intercylinder hose flanges.

5-63

Disconnect 1. Remove cap screw (A) and flat washer attaching right camshaft gear housing to rocker arm cover. 2. Do not remove two cap screws (B) and flat washers attaching housing to cylinder until camshaft is removed (fig. 5-115). Connect 1. The two cap screws (B) and flat washers securing right camshaft gear housing to cylinder are installed when camshaft is installed (fig. 5-115). 2. Install cap screw(A) and flat washer securing housing to rocker arm cover.

Figure 5-107. Disconnecting or connecting right camshaft gear housing at cylinder 6R rocker arm cover,

Remove 1. Remove bolt (A) attaching transmission oil cooler end shroud retaining tab to cylinder No. 6R rocker arm cover. Remove tab. 2. Remove three bolts (B) and flat washers. 3. Remove seven bolts (C) and flat washers. 4. Remove two cap screws (D) and flat washers. Install 1. Install two cap screws (D) and flat washers. 2. Install seven bolts (C) and flat washers. 3. Install three bolts (B) and flat washers. 4. Position transmission oil cooler end shroud retaining tab on cylinder No. 6R rocker arm cover. Install bolt (A) securing tab and cover.

Figure 5-108. Removing or installing rocker arm cover bolts and cap screws.

5-64

Figure 5-110.

Figure 5-110.

Note. Before removing rocker arm cover bolts (B) the tension on valve rocker arm, caused by valve springs, must be released. Turn engine (fig. 5-91) until valve rocker arm rollers are on camshaft base circle or until both valves are closed to relieve tension before removing any cover.
Remove 1. Check both cylinder No. 1 R valve rocker arms by moving arms (A) up and down. If clearance cannot be felt, turn engine until clearance is evident. When clearance is felt between botb adjusting screw pads and valve stems, the rocker arm rollers are on the camshaft base circle, and valves are completely closed. 2. Remove remaining four bolts (B) and four packings with retainers. Remove rocker arm covers as shown in figure 5-110. Remove remaining 11 covers in tbe same manner. Install 1. Install four new packings with retainers on four bolts (B). 2. Install four bolts (B) securing rocker arm covers.

Remove 1. Remove six drilled hex-head bolts (A) and flat washers. 2. Remove right camshaft gear housing cover (B). Install 1. Position right camshaft gear housing cover (B) on camshaft g-ear housing. 2. Install six drilled hex-head bolts (A) and flat washers securing cover.

Figure 5-109. Checking valve clearance before removing valve rocker arm covers and removing or installing remaining cover bolts.

Figure 5-111. Removing or installing right camshaft gear housing cover.

5-65

1. Install mechanical puller (A) into threaded end of camshaft drive shaft. 2. Remove camshaft drive shaft (B). Remove 1. Remove and discard camshaft gear housing cover gasket (A). 2. Remove camshaft drive gearshaft oil transfer plug retaining ring (B). Install 1. Install camshaft drive gearshaft oil transfer plug retaining ring (B). 2. Install a new camshaft gear housing cover gasket (A).

Figure 5-114. Removing camshaft drive shaft using mechanical puller-5120-678-5282.

Figure 5-112. Removing or installing camshaft drive gearshaft oil transfer plug retaining ring.

1. Install mechanical puller (A) - 5120-678-5282 into threaded end of camshaft drive gearshaft oil transfer plug. 2. Remove oil transfer plug (B).

Figure 5-113. Removing camshaft drive gearshaft oil transferplug using mechanical puller-5120-678-5282.

Disconnect 1. Loosen two hose clamps (A). 2. Remove two cap screws (B) and flat washers attaching camshaft gear housing to cylinder 6R. Connect 1. Install two cap screws (B) and flat washers securing camshaft gear housing to cylinder 6R. 2. Tighten two hose clamps (A).

Figure 5-115. Disconnecting or connecting right camshaft gear housing at cylinder 6R.

5-66

Figure 5-116. Removing or installing right camshaft.

Disconnect 1. Loosen two hose clamps (A). 2. Remove two self-locking nuts (B) and flat washers attaching rear horizontal fan drive shaft cover adapter to rear fan drive housing. 3. Remove two self-locking nuts (C) and flat washers attaching front cover adapter to front fan drive housing. Connect 1. Install two self-locking nuts (C) and flat washers securing front horizontal fan drive shaft cover adapter to front fan drive housing. 2. Install two self-locking nuts (B) and flat washers securing rear cover adapter to rear fan drive housing. 3. Tighten two hose clamps (A).

1. Separate cover adapters (A) from front and rear fan drive housing. 2. Push the front and rear fan drive shaft covers (B) together to expose the preformed packings.

Figure 5-118. Front and rear fan drive shaft covers disconnected showing location of preformed packings.

Figure 5-117. Disconnecting or connecting horizontal fan drive shaft front and rear cover adapters.

5-67

Figure

5-121.

Horizontal for drive removal housing.

fan

drive

shaft fan

positioned

of front

Figure 5-119.

FIGURE 5-121

Figure drive

5-120. shaft

Positioning in rear fan

horizontal drive housing.

fan

Remove 1. Remove seven self-locking nuts (A) and flat washers attaching front fan drive housing to mounting base. 2. Note that one self-locking nut at stud (B) was removed when fire extinguisher tube was removed (figs. 5-89 and 5-90). Install 1. Install seven self-locking nuts (A) and flat washers securing front fan drive housing to mounting base. 2. One self-locking nut will be installed at stud (B) when fire extinguisher tube is installed (figs. 5-89 and 5-90).

Figure 5-122. Removing or installing front fan drive housing attaching parts. 5-68

Remove 1. Cut locking wire and remove two drilled head cap screws (A) and flat washers attaching front fan drive housing to mounting base. 2. Note that two self-locking nuts were removed from studs (B) when the double angle bracket was removed (fig. 5-84).

Install 1. Install two drilled head cap screws (A) and flat washers and install locking wire securing front fan drive housing to mounting base. 2. Two self-locking nuts at studs (B) will be installed when the double angle bracket is installed (fig. 5-84).

Figure 5-123. Removing or installing front fan drive housing attaching parts.

5-69

Note. To facilitate lifting the fan drive housing and clutch assembly, an improvised lifting tool can be made from a piece of 3/8-in. dia. bar stock and a discarded slotted fan nut. Bend bar stock to shape and securely weld ends of bar to nut as illustrated in figure 2-1.
1. Install improvised lifting tool (A) on fan vertical drive shaft. 2. Lift front fan drive housing and clutch assembly with attached horizontal fan drive shaft from the mounting base assembly.

C a u t i o n : Make certain the improvised tool is properly secured before removing housing and that the fan drive housing is being lifted straight Up off the studs. 3. Remove horizontal fan drive shaft, cover and adapters. Remove and discard preformed packings (figs. 5-120 and 5-121 ).

Figure 5-124. Removing front fan drive housing and clutch assembly using improvised lifting tool.

5-70

Remove 1. Remove ten cotter pins, slotted nuts (A), and flat washers. 2. Remove two cap screws (B) and flat washers. 3. Remove and discard preformed packing (C) from oil transfer tube counterbore in mounting base assembly (D) (or from oil transfer tube in fan drive housing). 4. Remove front fan drive housing mounting base assembly (D) from crankcase assembly. Install 1. Position frunt fan drive housing mounting base assembly (D) on crankcase assembly, 2. Install a new preformed packing (C) in oil transfer tube counterbore in mounting base assembly. 3. Install two cap screws (B) and flat washers, 4. Install ten cotter pins, slotted nuts (A), and flat washers.

Remove 1. Remove and discard preformed packing (A) from oil transfer tube in fuel injection pump mounting base. 2. Remove four bolts (B) and lock washers and remove mounting base from crankcase assembly. Install Note. Due to engines use longer washers. Check all 1-7 / 32-inch long. design change the current bolts and the addition of lock bolts and discard any- that are Replace with current 1-3 / 8-

inch bolts FSN 5305-725-0154 and lock washers FSN 5310-584-5272. 1. Position fuel injection pump mounting base on crankcase assembly and install four bolts (B) and lock washers and torque tighten to 750 pounds-inch. 2. Install a new preformed packing (A) in oil transfer tube on mounting base.

Figure 5-125. Removing or installing front fan drive housing mounting base assembly from crankcase assembly.

Figure 5-127. Removing or installing fuel injection pump mounting base.

Figure 5-126. Location of preformed packing at oil transfer boss in crankcase assembly.

Figure 5-128. Location of preformed packing at oil transfer tube for fuel injection pump mounting base.

5-71

Remove 1. Remove nine self-locking nuts (A) and flat washers attaching accessory drive housing to rear fan and accessory drive housing mounting base. 2. Remove five self-locking nuts (B) and flat washers attaching rear fan drive housing to mounting base. Install 1. Install five self-locking nuts (B) and flat washers securing rear fan drive housing to rear fan and accessory drive housing mounting base. 2. Install nine self-locking nuts (A) and flat washers securing rear fan drive housing to mounting base.

Figure 5-129. Removing or installing attaching parts for rear fan and accessory drive housing assemblies-right side.

Remove 1. Remove the remaining 12 self-locking nuts (A) and flat washers attaching rear fan and accessory drive housing assembly to mounting base. 2. Remove two self-locking nuts (B) and lock washers to provide for the attachment of fan and advance unit housing sling - 4910-795-7954. 3. Note that self-locking nut was removed from stud (C) when fire extinguisher tube was removed (figs. 5-89 and 5-90). 4. Remove one self-locking nut (D) and flat washer from each side of the drive housing mounting base flange. Install 1. Install one self-locking nut (D) and flat washer on each side of the drive housing mounting base flange. 2. One self-locking nut will be installed at stud (C) when fire extinguisher tube is installed (figs. 5-89 and 5-90). 3. Install two self-locking nuts (B) and lock washers used for the attachment of fan and advance unit housing sling - 4910-795-7954. 4. Install the remaining 12 self-locking nuts (A) and flat washers securing rear fan and accessory drive housing assembly to mounting base.

Figure 5-130. Removing or installing attaching parts for rear fan and accessory drive housing assemblies-left side.

5-72

Install 1. Position fan and advance unit housing sling (A) 4910-795-7954 on rear fan drive housing and clutch assembly as shown. 2. Secure lifting sling to rear fan and accessory drive housing with two self-locking nuts (B) and lock washers that were removed in figure 5-130. 3. Secure lifting sling to fan vertical drive shaft with fan slotted nut (C). 4. Adjust lifting eye (D) in slot to assure balanced position of the assembly during removal (fig. 5-132). Remove 1. Remove slotted nut (C) attaching fan and advance unit housing sling (A) - 4910-795-7954 to fan vertical drive shaft. 2. Remove two self-locking nuts (B) and lock washers attaching lifting sling to rear fan and accessory drive housing. 3. Remove lifting sling (A).

Figure 5-132. Removing rear fan and accessory drive housing assemblies.

Figure 5-131. Installing or removing rear fan drive housing using fan and advance unit housing sling - 4910-795-7954.

5-73

Figure 5-134. Location of preformed packings at oil transfer tubes in crankcase a s s e m b l y - rear fan and accessory drive housing mounting base.

Remove 1. Remove ten cotter pins, slotted nuts (A), and flat washers. 2. Remove six cap screws (B) and flat washers. 3. Remove rear fan and accessory drive housing mounting base (C) from crankcase assembly. 4. Remove and discard four preformed packings (D) from oil transfer counterbores in mounting base (or from oil transfer tubes in rear fan and accessory drive housing). Install 1. Position mounting base (C) on crankcase assembly. 2. Install six cap screws (B) and flat washers. 3. Install ten co,ter pins, slotted nuts (A), and flat washers. 4. Install four new preformed packings (D) in oil transfer counterbores in rear fan and accessory drive housing mounting base (C).

5-12. Oil Pan, Crankshaft Damper and Oil Filter Housing, Cylinder Air Deflectors, Cylinder Assemblies, and Pistons and Pins
Refer to Table 5-9 for illustrations references and are disassembly instructions. listed in the table. Figure

Note. For instructional purposes the removal of one right bank cylinder assembly, piston, and pin is described. Remove balance of cylinders in a similar manner.

Figure 5-133. Removing or installing rear fan and accessory drive housing mounting base.

Table 5-9. Oil Pan, Crankshaft Damper and Oil Filter Housing, Cylinder Air Deflectors, Cylinder Assemblies, and Pistons and Pins Component Oil Pan Crankshaft Damper and Oil Filter Housing Cylinder Air Deflectors, Cylinder Assemblies, Pistons and Pins Figure Reference 5-135 through 5-137 5-138 through 5-140 5-141 through 5-147

5-74

Remove 1. Cut locking wire (A) securing eight bolts. 2. Remove eight bolts (B) and flat washers attaching oil pan to rear of crankcase assembly.

Install 1. Install eight bolts (B) and flat washers securing oil pan to rear of crankcase assembly. 2. Install locking wire (A) securing bolts.

Figure 5-135. Removing or installing oil pan rear bolts.

Remove 1. Cut locking wire and remove 12 drilled head bolts (A) and flat washers attaching oil pan to crankshaft damper and oil filter housing. Note. One self-locking nut (B) and flat washer must remain on each side of oil pan until oil pan is removed to prevent oil pan from falling and being damaged.

2. Remove 27 of the 28 self-locking nuts (B) and flat washers attaching oil pan to each side of crankcase assembly. install 1. Install 27 self-locking nuts (B) and flat washers securing oil pan to each side of crankcase assembly. 2. Install 12 drilled head bolts (A) and flat washers securing oil pan to crankshaft damper and oil filter housing. Install locking wire securing bolts.

Figure 5-136. Removing or installing oil pan bolts-right front view.

5-75

Remove 1. Rotate engine overhaul stand (A) until engine is in position shown. 2. Position wooden blocks (B) as shown to support oil pan while it is being removed. Note. Remove the two remaining self-locking nuts and flat washers that were left to prevent the oil pan from falling (fig. 5-136). 3. Remove oil pan (C). Remove and discard oil pan sealing thread (fig. 4-125). Install 1. Rotate engine overhaul stand (A) until engine is in position shown. 2. Position wooden blocks (B) as shown to support oil pan while it is being installed. 3. Install new oil pan sealing thread (fig. 4-125) on oil pan and position oil pan (C) on crankcase assembly. Install one self-locking nut and washer on each side of oil pan to prevent pan from falling when engine is rotated to upright position.

Figure 5-137. Removing or installing oil pan.

Remove 1. Remove two self-locking nuts (A) attaching manifold heater fuel solenoid valve and fuel filter mounting bracket. Remove bracket. 2. Remove 12 self-locking nuts (B) and flat washers attaching crankcase damper and oil filter housing. Install 1. Install 12 self-locking nuts (B) and flat washers securing crankcase damper and oil filter housing. 2. Position manifold heater fuel solenoid valve and fuel filter mounting bracket on housing. Install two selflocking nuts (A) securing bracket.

Figure 5-138. Removing or installing crankshaft damper and oil filter housing attach parts.

5-76

..

Remove 1. Hook suitable chain (A) or hoist into crankshaft damper and oil filter housing lifting eyes. 2. Take up housing weight on chain or hoist and separate housing (B) from crankcase assembly.

Install 1. Hook suitable chain (A) or hoist into crankshaft damper and oil filter housing lifting eyes. 2. Take up housing weight on chain or hoist and position housing (B) on crankcase assembly.

Note. Do not allow housing to rest on studs after housing is separated from crankcase and oil transfer tubes. Figure 5-139. Removing or installing crankshaft damper and oil filter housing. 5-77

Figure 5-140. Front end of crankcase assembly showing locations of oil transfer tube preformed packings.

Disconnect 1. Remove 12 self-locking nuts (A), cap screws, and spacers attaching cylinder air deflectors around cylinder assemblies. 2. Remove the four air deflectors (B) located at cylinder Nos. lR, lL, 6R, and 6L. 3. The ten lower cylinder deflector retainer straps (C) are secured by ten bolts. Remove bolts ( fig. 5-142).

Connect 1. The ten cylinder deflector retainer straps (C) are secured by ten bolts. Install bolts (fig. 5-142). 2. Position the four air deflectors (B) located at cylinder Nos. lR, lL, 6R, and 6L. 3. Install 12 self-locking nuts (A), cap screws, and spacers securing cylinder air deflectors around cylinder assemblies.

Figure 5-141. Disconnecting or connecting cylinder deflectors at cylinders. 5-78

Remove 1. Remove five bolts (A) that attach the five lower cylinder deflector straps on each side of engine. Z . Remove ten lower cylinder deflector straps (B). Note. Remove the ten lower cylinder deflector retainer straps (C, fig. 5-141). 3. Remove all cylinder deflectors (C) from cylinder assemblies.

Install 1. Position all cylinder deflectors (C) except deflectors at outside of cylinder Nos. 1R, lL, 6R, and 6L, on cylinder assemblies. z. Install ten lower cylinder deflector straps (B).

Note. Install the ten lower cylinder deflector retainer straps (C, fig. 5-141).
3. Install five bolts (A) that secure the five lower cylinder straps on each side of engine.

Figure 5-142. Removing or installing lower cylinder deflector straps and deflectors-right side.

5-79

Note. Before removing cylinder assemblies, it will be necessary to check the breaking torque of the 14 nuts attaching each cylinder assembly to crankcase assembly. This check is necessary to determine whether base nut stud has stretched. All stretched studs must be replaced.
1. Check breaking torque of the 14 nuts (B) securing cylinder assembly to crankcase assembly using box wrench (A)-5120-678-5287 in combination with torque wrench. When torque required to break a nut loose is less than 600 pound inches, remove nut, apply antiseize compound FSN 9150-663-1770 to stud, install nut and tighten to a torque of 600 to 660 pound inches. When nut does not tighten to the recommended

Note. Before removing each cylinder assembly, the crankshaft must be turned to position the piston of the cylinder being removed to top dead renter. Rotate crankshaft using splined wrench -5120-793-7895 (fig. 5-91) and observe when (connecting rod has raised piston to top dead center. Make certain each piston is properly positioned before attempting cylinder removal.
1. With right bank cylinder assemblies in a vertical (upright) position remove the remaining two nuts (A) from each right cylinder assembly. Make certain each piston is positioned at top dead center before attempting removal. 2. Do not remove the nuts (B) holding the left cylinder assemblies to crankcase until left cylinders have been rotated to an upright position for removal.

torque, stud is stretching and must be replaced, Mark stud for replacement. Refer to paragraph 6-4e for
instructions on replacement of studs. 2. After checking the breaking torque, remove all nuts (B) except one on each side of cylinder. The remaining two nuts are removed after piston has been positioned to top dead center for removal (fig. 5-144).

Figure 5-143. Checking breaking torque of cylinder base nuts, using box wrench-5120-678-5287.

Figure 5-144. Right bank cylinders in vertical position for removing or installing cylinders from crankcase.

5-80

1. Attach a suitable lifting sling to top of cylinder assembly using two 7 / 16 x 1-1 / 4 in. cap screws (A). 2. Carefully lift cylinder assembly until cylinder is just above piston pin bore (B). 3. Install crankcase protector - 4910-795-7951 on cylinder mounting pad studs and secure with two cylinder base nuts (C). 4. Remove cylinder assembly (D).

Note. Crankcase protector - 4910-795-7951 is installed on cylinder pad before removing cylinder assembly from piston. The protector will guard against damage to cylinder pad and mounting studs in the event connecting rod should strike the pad as cylinder is lifted from piston.

Figure 5-145. Removing cylinder No. lR. 5-81

Note. When carbon deposits make removal of piston pin difficult, tap end of piston pin plug with a soft faced hammer. 1. Remove piston, piston pin (A), and piston pin plugs as a unit. 2. Remove piston (B) from connecting rod. Note. Cylinder No. 6R piston is at top center at the same time as cylinder No. lR, and can be

removed in a similar manner without turning crankshaft. Turn crankshaft, using splined wrench - 5 1 2 0 - 7 9 3 - 7 8 9 5 ( f i g . 5 - 9 1 ) , u n t i l p i s t o n in cylinder No. 2R is at top center. The pistons in cylinder Nos. 2R and 5R will be at top center together, as will pistons for cylinder Nos. 3R and 4R. The left bank pairs of pistons will be at top center together and can be removed in a similar manner.

Figure 5-146. Removing piston pin and piston-cylinder No. 1R.

5-82

Note. Do not remove crankcase protectors netting rods have been removed (para 5-15).

4910-795-7951

until

the

crankshaft

and

con-

Figure 5-147. Engine with cylinder assemblies and pistons removed showing crankcase protectors-4910-795-7951 installed.

5-13. Oil Pump, Oil Tubes, Vibration Damper, Starter and Generator Drive Adapters

Refer to Table 5-10 for illustrations and disassembly instructions. Figure references are listed in the table.

Table 5-10. Oil Pump, Oil Tubes, Vibration Damper, Starter and Generator Drive Adapters Figure Reference Component Oil Pump, Oil Tubes and Oil Pressure Sending Unit and Switch Fuel Pump Drive Shaft Coupling and Crankshaft Torsional Vibration Damper Starter Drive Adapter and Starter Driven Gear Generator Drive Adapter and Drive Gearshaft 5-148 through 5-150 5-151 and 5-152 5-153 through 5-155 5-156 through 5-158

5-83

Remove 1. Cut locking wire and remove two drilled head bolts (A) attaching scavenge oil pickup tube support to crankcase assembly. 2. Cut locking wire and remove two drilled head bolts (B) attaching pickup tube brackets to crankcase. 3. Cut locking wire and remove two drilled bead bolts (C) attaching scavenge oil pickup tube to oil pump assembly. 4. Remove the support and oil pickup tube as a unit. Remove and discard scavenge oil pickup tube gasket (8). 5. Cut locking wire and remove two drilled head bolts (E) attaching oil pan pressure relief tube brackets to crankcase assembly. 6. Remove pressure relief tube and spill tube junction outlet housing (F) as a unit. ?. Cut locking wire and remove drilled head bolt (G) attaching spill tube bracket to crankcase assembly. 8. Cut locking wire and remove two drilled head bolts (H) attaching spill tube to oil pump assembly. Remove tube. Remove and discard spill tube gasket.

Install 1. Position a new spill tube gasket on oil pump assembly. Position spill tube on oil pump. Install two drilled head bolts (H) securing tube to oil pump and install locking wire securing bolts. 2. Install drilled head bolt (G) securing spill tube bracket to crankcase assembly and install locking wire securing bolt. 3. Position pressure relief tube and spill tube junction outlet housing (F) in crankcase assembly. 4. Install two drilled head bolts (E) securing oil pan pressure relief tube brackets to crankcase assembly and install locking wire securing bolts. 5. Position a new scavenge oil pickup tube gasket (D) on oil pump. Position the support and scavenge oil pickup tube as a unit in crankcase assembly. 6. Install two drilled head bolts (C) securing oil pickup tube to oil pump and install locking wire securing bolts. 7. Install two drilled head bolts (B) securing pickup tube brackets to crankcase and install locking wire securing bolts. 8. Install two drilled head bolts (A) securing scavenge oil pickup tube support to crankcase and install locking wire securing bolts.

Figure 5-148. Removing or installing scavenge oil pickup, oil pan pressure relief tube, and oil spill tube.

5-84

Remove 1. Cut locking wire and remove three drilled head cap screws (A) and flat washers attaching oil pump assembly to crankcase. 2. Cut locking wire and remove two drilled head cap screws (B) and flat washers. 3. Loosen remaining drilled head cap screw (C) as oil pump assembly is being removed. N o t e . This cap screw (C) cannot be removed until oil pump is disassembled.

4. Remove oil pump assembly (D) from crankcase. Install 1. Position oil pump assembly (D) in crankcase assembly. 2. Tighten drilled head cap screw (C) as oil pump is being installed. 3. Install two drilled head cap screws (B) and flat washers and install locking wire securing screws. 4. Install three drilled head cap screws (A) and flat washers securing oil pump to crankcase and install locking wire securing screws.

Figure 5-149. Removing or installing oil pump assembly.

5-85

Remove 1. Remove oil pressure sending unit (A). 2. Remove low oil pressure warning switch (B). 3. Remove two cap screws (C), lock washers, and flat washers attaching generator air intake tube front support bracket to crankcase and remove bracket. 4. Remove two cap screws (D), lock washers, and flat washers attaching rear support bracket to crankcase and remove bracket. Install 1. Position generator air intake tube rear support bracket on crankcase and install two cap screws (D).

lock washers, and flat washers securing bracket to crankcase. 2. Position front support bracket on crankcase and install two cap screws (C), lock washers, and flat washers securing bracket to crankcase. Note. It may be necessary to adjust the bracket height when the generator air intake tube is installed. 3. Install low oil pressure warning switch (B). 4. Install oil pressure sending unit (A).

Figure 5-150. Removing or installing oil pressure sending unit, oil pressure warning switch and generator air intake tube support brackets.

5-86

Remove 1. Cut locking wire (A). 2. Remove six drilled head bolts (B) attaching fuel pump drive coupling adapter and crankshaft torsional vibration damper to crankshaft. 3. Remove adapter and fuel pump drive coupling (C). Install 1. Position fuel pump drive coupling adapter and fuel pump drive coupling (C) on crankshaft. 2. Install six drilled head bolts (B) securing adapter and crankshaft torsional vibration damper to crankshaft 3. Install locking wire (A) securing bolts.

1. Install three mechanical pullers (A) - 5120-473-7222 into puller screw boles provided in crankshaft torsional vibration damper. 2. Alternately tighten puller screws and pull damper (B) from dowel pine in flange of crankshaft. Remove damper.

Figure 5-152. Removing crankshaft torsional vibration damper using mechanical p u l l e r s - 5120-473-7222.

Figure 5-151. Removing or installing fuel pump drive coupling adapter and coupling.

5-87

Remove 1. Remove two starter mounting bolts (A). 2. Remove four eelf-locking nuts (B) and flat washers attaching starter drive adapter (C) to crankcase assembly. 3. Remove adapter (C) from crankcase. 4. Remove and discard gasket (D). Install 1. Install new starter drive adapter gasket (D). 2. Position starter drive adapter (C) on crankcase assembly. 3. Install four self-locking nuts (B) and flat washers securing adapter (C) to crankcase. 4. Install two starter mounting bolts (A).

Remove 1. Remove cotter pin (A). 2. Remove slotted nut (B) attaching starter driven gear to starter driven gearshaft. Install 1. Install slotted nut (B) securing starter driven gear to starter driven gearshaft. 2. Install cotter pin (A).

Figure 5-154. Removing or installing starter driven gear attaching parts.

Figure 5-153. Removing or installing starter drive adapter.

5-88

1. Install three 5 / 16-24 x 3 in. bolts (A) for use as puller screws into threaded holes provided in starter driven gear (B). 2. Alternately tighten bolts and pull driven gear (B) from driven gearshaft.

Figure 5-155. Removing starter driven gear.

Remove 1. Remove self-locking nut (A) and flat washer from stud. 2. Remove five self-locking nuts (B) and bolts attaching generator drive adapter to crankcase assembly. Install 1. Install five self-locking nuts (B) and bolts securing generator drive adapter to crankcase assembly. 2. Install self-locking nut (A) and flat washer on stud.

Figure 5-156. Removing or installing generator drive adapter attach partsengines with mounting nuts.

5-89

Remove 1. Remove self-locking nut (A) and flat washer from stud. 2. Remove five bolts (B) and lock washers attaching generator drive adapter to crankcase assembly. Install 1. Install five bolts (B) and lock washers securing generator drive adapter to crankcase assembly. 2. Install self-locking nut (A) and flat washer on stud.

Remove 1. Remove generator drive adapter (A) with drive gearshaft and bearings as a unit. 2. Remove and discard generator drive adapter gasket (B). Install 1. Install a new generator drive adapter gasket (B). 2. Install generator drive adapter (A) with drive gearshaft and bearings as a unit.

Figure 5-157. Removing or installing generator drive adapter attaching partsengines with mounting bolts.

Figure 5-158. Removing or installing generator drive adapter and associated parts.

5-90

5-14. Flywheel, Transmission Adapter, Crankshaft Oil Seal, and Accessory Drive Gear

R e f e r t o T a b l e 5 - 1 1 for illustrations and d i s a s s e m b l y i n s t r u c t i o n s . Figure references are listed in the table.

Table 5-11. Flywheel Transmission Adapter, Crankshaft Oil Seal, and Accessory Drive Gear Component Transmission Drive Gearshaft Assembly, Flywheel, and Transmission Adapter Crankshaft Oil Seal Housing and Accessory Drive Gear I Figure Reference 5-159 through 5-164 5-165 through 5-170

Remove 1. Straighten tabs on three lock plates (A) securing nine bolts. 2. Remove nine bolts (B) and three lock plates attaching transmission drive gearshaft assembly and flywheel to crankshaft. Discard lock plates. Install 1. Install three new lock plates (A) and nine bolts (B) securing transmission drive gearshaft assembly and flywheel to crankshaft. 2. Bend taps on three lock plates (A) securing nine bolts (B).

1. Install three 9 / 16 x 1-3/4 in. bolts (A), used for attaching transmission drive gearshaft assembly, as puller screws in puller screw holes provided. 2. Alternately tighten bolts and pull gearshaft from crankshaft dowel pins. Remove the three bolts from the gearshaft.

Figure 5-160. Removing transmission drive gearshaft assembly using mounting bolts as puller screws.

Figure 5-159. Removing or installing transmission drive gearshaft attaching parts.

5-91

Note. Position flywheel to locate eye bolt hole at top center. 1. Install three 9 / 16 x 1-3/4 in. bolts (A), used for attaching transmission drive gearshaft assembly, as puller screws into puller screw holes in flywheel 2. Alternately tighten bolts and pull flywheel (B) from crankshaft dowel pins only far enough to permit installation of lifting eye bolt (C). 3. Install eye bolt - 5306-017-6143 and attach suitable chain hoist. Continue tightening puller bolts to remove flywheel from crankshaft dowel pins (fig. 5-162).

C a u t i o n : Use care in removing the flywheel from the dowel pins so as not to bind the flywheel on the pins. 1. Remove flywheel (A) from the two dowel pins in flange on crankshaft. 2. Remove three puller bolts (B) from flywheel.

Figure 5-161. Preparing flywheel for removal.

Figure.5-162. Removing flywheel using eye bolt-5306-017-6143.

5-92

figure 5-164 figure 5-164.

Figure 5-163.

5-93

Remove 1. Attach suitable chain hoist in transmission adapter lifting eye (A). 2. Separate adapter (B) from studs, dowel pine, and crankcase assembly. Remove adapter. 3. Remove and discard transmission adapter gasket (C). Install 1. Position a new transmission adapter gasket (C) on crankcase assembly. 2. Attach a suitable chain hoist in transmission adapter lifting eye (A). 3. Position transmission adapter (B) on studs and dowel pins in crankcase.

Remove 1. Cut locking wire and remove three drilled head bolts (A) attaching oil seal retainer to oil seal cap. Remove retainer. 2. Cut locking wire and remove three drilled head bolts (B) attaching oil seal retainer to oil seal housing. Remove retainer. Install 1. Position retainer on oil seal housing. Install three drilled head bolts (B) securing retainer to housing and install locking wire securing bolts. 2. Position retainer on oil seal cap. Install three drilled head bolts (A) securing retainer to cap and install locking wire securing bolts.

Figure 5-164. Removing or installing transmission adapter.

Figure 5-165. Removing or installing crankshaft oil seal retainers.

5-94

Remove 1. Cut locking wire and remove four slotted nuts (A) and flat washers attaching oil seal cap to oil seal housing. 2. Cut locking wire and remove 20 drilled head bolts (B) and flat washers attaching oil seal cap and housing to crankcase assembly. Install 1. Install 20 drilled head bolts (B) and flat washers securing oil seal cap and housing to crankcase assembly. Install locking wire securing bolts. 2. Install four slotted nuts (A) and flat washers securing oil seal cap to oil seal housing. Install locking wire securing nuts.

Figure 5-166. Removing or installing crankshaft oil seal cap and housing attaching parts.

Rem ove Note. Free the oil seal cap and housing from dowel pins by tapping edges of the oil seal cap and housing with a soft faced hammer. 1. Separate and remove oil seal cap and housing (A). 2. Remove and discard oil seal cap and housing gasket (B). N o t e . The oil seal housing is machined with the crankcase and is a mating part. Always keep oil seal housing from. with the crankcase it was removed

Install 1. Position a new oil seal cap and housing gasket (B) on crankcase assembly. 2. Position oil seal cap and housing (A) around crankshaft and on locating dowel pins in crankcase assembly and housing.

Figure 5-167. Removing or installing oil seal cap and housing. 5-95

Remove 1. Remove four cap screws (A) and flat washers attaching oil seal housing support (B) to crankcase assembly. 2. Remove support from dowel pins (fig. 5-169) in crankcase. 3. Remove and discard candlewick packing (C). Note. It may be necessary to loosen No. 7

main bearing crankcase tie rod nuts before removing support. Refer to figure 5-171. Install 1. Position oil seal housing support (B) on dowel pins (fig. 5-169) in crankcase. 2. Install four cap screws (A) and flat washers securing support to crankcase assembly. 3. Install new candlewick packing (C).

Figure 5-168. Removing or installing oil seal housing support.

5-96

Remove 1. Cut locking wire (A). 2. Remove 12 bolts (B) attaching accessory drive gear to flange on crankshaft. Install 1. Install 12 bolts (B) securing accessory drive gear to flange on crankshaft. 2. Install locking wire (A) securing bolts.

1. Install three 7/16 x 1-1/8 in. accessory drive gear mounting bolts (A) in tapped holes provided in accessory drive gear. Z . Alternately tighten bolts (B) and pull accesory drive gear from flange on crankshaft. Remove puller bolts from gear.

Figure 5-170. Removing accessory drive gear using mounting bolts as puller screws.

Figure 5-169. Removing or installing accessory drive gear attaching parts.

5-15. Crankshaft and Connecting Rod Assembly, Piston Oiler Nozzles, Generator and Starter Idler Gears, and Starter Driven Gearshaft

Refer to Table 5-12 for illustrations and disassembly instructions. Figure references are listed in the table.

Table 5-12. Crankshaft and Connecting Rod Assembly, Piston Oiler Nozzles, Generator and Starter Idler Gears, and Starter Driven Shaft

Crankshaft and Connecting Rod Assembly and Piston Oiler Nozzles Generator and Starter Idler Gears and Starter Driven Gearshaft

Fig. 5-171

Fig. 5-177

5-97

Remove N o t e . To avoid interference with the starter driven gearshaft (fig. 5-172), it is necessary to remove lower No. 7 main bearing crankcase tie rod from right side of crankcase. 1. Remove 12 cotter pins, slotted nuts (A), and six plate washers from 12 crankcase tie rods (D). Hold tie rod nuts on opposite ends as necessary to keep rods from turning while removing the nuts. 2. Remove cotter pins and slotted nut (B) from upper tie rod. 3. Remove cotter pin and slotted nut from opposite (left) side of lower tie rod (C).

4. Using a suitable brass rod, push the 13 tie rode (D) through crankcase assembly. Install Note. Do not install the 14 cotter pins until tie rod nuts have been torque tightened (para 7-6c). 1. Push the 13 tie rods (D) through crankcase assembly. 2. Install slotted nut on opposite (left) side of lower tie rod (C). 3. Install slotted nut (B) on upper tie rod. 4. Install six plate washers and 12 slotted nuts (A) on 12 crankcase tie rods (D).

Figure 5-171. Removing or installing crankcase tie rod attaching p a r t s - r i ght front view.

5-98

Remove 1. Remove cotter pin, slotted nut (A), and plate washer and remove upper tie rod at No. 7 main bearing, from left side of crankcase assembly. 2. Remove lower No. 7 main bearing tie rod (B) slotted nut and plate washer from opposite (right) side of crankcase and remove tie rod. 3. Remove 12 cotter pins, tie rod slotted nuts (C), and six plate washers from crankcase. Separate parts.

Install 1. Position 12 tie rods through crankcase and install six plate washers, 12 slotted nuts (C), and cotter pins. 2. Position lower No. 7 main bearing tie rod (B) through crankcase from opposite (right) side of crankcase and install plate washer, slotted nut, and cotter pin. 3. Position upper tie rod at No. 7 main bearing through crankcase and install plate washer, slotted nut (A) and cotter pins.

Figure 5-172. Removing or installing tie rods and attaching parts-left side view.

5-99

Remove Note. The main bearing caps are marked 1 through 7 (front to rear) to identify their locations. Identifying numbers also appear on bearing web in crankcase assembly. The caps are not interchangeable with each other and must be returned to their original positions during installation. Note. Do not use a scriber or other sharp instrument for marking bearing halves. It is recommended that a grease pencil be used for mat-king bearing halves. 1. Cut locking wire and remove 24 slotted nuts (A) and 12 plate washers attaching main bearing caps, numbers 1, 2, 3, 5,6, and 7 to crankcase assembly.

2. Cut locking w ire and remove four slotted nuts (B) and two plate washers attaching main thrust bearing cap (No. 4 or center) to crankcase assembly. Install Note. Do not install locking wire until bearing cap nuts have been torque tightened (para 7-5c). 1. Apply antiseize compound (FSN 9150-663-1770) and install two plate washers and four slotted nuts (B) securing main thrust bearing cap (No. 4) to crankcase assembly. 2. Apply antiseize compound (FSN 9150-663-1770) and install 12 plate washers and 24 slotted nuts (A) securing main bearing caps, numbers 1, 2, 3, 5, 6, and 7 to crankcase assembly.

Figure 5-173. Removing or installing main bearing attaching parts.

5-100

Note. Use caution when removing main bearing cap so that lower main sleeve bearing half does not drop out accidentally. Sleeve bearing halves can be easily damaged. 1. Install crankcase spreading tool -5120-575-1767 (A) in crankcase assembly midway between two main bearing caps. Tighten spreading tool just enough to release pressure of crankcase from ends of main bearing caps. 2. Install mechanical puller - 5120-310-4668 (B) in mechanical adapter - 5120-837-5091. Install puller adapter into threaded bole provided in No. 1 main bearing cap (C).

3. Gently tap the main bearing cap free of the crankcase using the slide hammer on puller. Remove main bearing cap and lower main sleeve bearing half and separate tbe bearing half from the cap. Mark sleeve bearing half with its respective location, using a grease pencil, for identification; e, g., 1 cap, 2 cap, etc. 4. Remove remaining bearing caps (D) (Nos. 2 through 7) and tbe lower sleeve bearing halves in similar manner using puller - 5120-310-4668 and positioning the spreading tool - 5120-575-7767 between bearing caps as necessary. Remove sleeve bearings from bearing caps.

Figure 5-174. Removing main bearing cap using crankcase spreading tool-5120-575-7767, mechanical adapter-5120-837-5091, and mechanical puller-5120-310-4668.

5-101

Note. The crankshaft counterweights for connecting rod bearing journals 1R and 1L and 6R and 6L must be in the position shown. The

crankshaft will then clear the sides of the crankcase when it is removed. Rotate crankshaft as necessary to obtain this position.

Figure 5-175. Crankshaft with main bearing caps removed showing correct position of crankshaft counterweights before removal or after installation of crankshaft.

5-102

Install Note. The crankshaft and connecting rod sling 4910-795-7955 consists of a cable and two adapters. The adapter with the dowel pin hole attaches to the crankshaft flywheel flange. The other adapter attaches to the torsional vibration damper mounting flange. 1. Install the sling adapter (A) on flywheel flange dowel pin. 2. Secure adapter to flange with two bolts (B) used to secure flywheel. Remove 1. Remove two f lywheel bolts (B) attaching sling adapter (A) to flywheel. 2. Remove adapter from flywheel flange dowel pin.

Install 1. Install the sling adapter (A) to torsional vibration damper flange (B) and secure with two vibaration damper mounting bolts. Remove 1. Remove two vibration damper mounting bolts attaching sling adapter (A) to torsional vibration damper flange (B).

Figure 5-177. Installing or removing crank shaft and connecting rod sling4910-795-7955 at crankshaft torsional vibration damper flange.

Figure 5-176. Installing or removing crankshaft and connecting rod sling4910-795-7955 at crankshaft flywheel flange.

5-103

Note. Exercise

care

when

removing

or

in-

stalling crankshaft assembly to prevent damage to the main bearing cap studs and crankshaft journals. Remove 1. Remove crankshaft with connecting rod assemblies installed as shown, using a suitable hoist. 2. Place crankshaft assembly on suitable V blocks with crankshaft resting on bearing journals. Install 1. Before installing crankshaft and connecting rod assemblies in crankcase, place cardboard or plastic

tubes over main bearing studs for protection. If such tubes are not available, cover studs with industrial tape. 2. Install crankshaft and connecting rod assemblies in crankcase as shown using a suitable hoist. Guide the connecting rods through the cylinder mounting holes and past the connecting rod protectors. Note. The connecting rods are installed on the crankshaft in pairs. The connecting rod of each pair toward the flywheel end (rear) serves the left bank cylinders; the connecting rod toward the front of the engine serves the right bank.

Figure 5-178. Removing or installing crankshaft and connecting rod assemblies using crankshaft and connecting rod sling- 4 9 1 0 - 7 9 5 - 7 9 5 5 .

5-104

Remove 1. Remove six upper main sleeve bearing halves (A) from bearing bores in crankcase assembly. Mark respective locations of bearings on the back of bearing half using a grease pencil; e.g., l-case, 2-case, etc. 2. Remove upper main thrust sleeve bearing half(B) and mark as 4-case for identification.

Install Note. Numbers 1 through 7 indicate main bearing sleeve locations beginning from the front. 1. Install marked 2. Install bearing marks. upper main thrust sleeve bearing half (B) 4-case in main bearing bore. six upper main sleeve bearing halves (A) in bores in accordance with respective location

Figure 5-179. Removing or installing upper main sleeve bearing halves.

Remove 1. Cut locking wire (A). Remove 12 slotted nuts (B) and remove six piston oiler nozzle assemblies. 2. Refer to figure 5-147 and remove 12 crankcase protectors - 4910-795-7951 (C).

Install 1. Refer to figure 5-147 and install 12 crankcase protectors - 4910-795-7951 (C). 2. Position six piston oiler nozzle assemblies in crankcase and install 12 slotted nuts (B) securing nozzle assemblies to crankcase. Install locking wire (A) securing slotted nuts (B).

Figure 5-180. Removing or installing piston oiler nozzle assemblies.

5-105

Remove 1. Cut locking wires (A). 2. Remove two slotted nuts (B) attaching starter gear shaft to crankcase. 3. Remove two slotted nuts (C) attaching generator gearshaft to crankcase. Install 1. Install two slotted nuts (C) securing generator gearshaft to crankcase. 2. Install two slotted nuts (B) securing starter gearshaft to crankcase. 3. Install locking wire (A) securing slotted nuts.

idler idler

idler idler Remove 1. Cut locking wire (A). 2. Remove six slotted nuts (B) attaching starter driven gearshaft bearing cage to crankcase assembly. Install two 5 / 16-24 jack screws in holes provided in cage. Alternately tighten jack screws until cage separates from crankcase. Install 1. Install six slotted nuts (B) securing starter driven gearshaft bearing cage to crankcase assembly. 2. Install locking wire (A) securing slotted nuts. Figure 5-183. Removing or installing starter driven gearshaft bearing cage attaching parts.

Figure 5-181. Removing or installing starter and generator idler gearshaft flange nuts.

1. Install mechanical adapter - 5120-837-5091 (A) into tapped hole provided in end of starter idler gearshaft. 2. Install mechanical puller - 5120-310-4668 (B) into adapter. Slide hammer on puller against handle to pull starter idler gearshaft from crankcase assembly. 3. Support starter idler gear (C) with wooden block while removing gearshaft and then remove idler gear. 4. Remove and discard preformed packing (D). Note. The generator idler gearshaft and idler gear are removed in the same manner as instructed for starter idler gearshaft and idler gear. Figure 5-106 5-182. Removing starter and/or generator idler gearshaft.

Remove 1. Remove starter driven gearshaft bearing cage from crankcase assembly. 2. Remove and discard preformed packing. Figure 5-184. Removing or installing

Install 1. Install new preformed packing in starter driven gearshaft bearing cage. 2. Position bearing cage in crankcase assembly. starter gearshaft bearing cage.

5-107

CHAPTER OVERHAUL OF ENGINE

6 COMPONENTS

Section

l.

GENERAL CLEANING, INSPECTION, ASSEMBLY PROCEDURES

REPAIR,

AND

6-1. General
a. Procedures. The procedures for cleaning, inspection, repair and assembly of the various parts and components which make up the engine subassemblies will be the same for a great percentage of parts and components. To avoid repetition, the general procedures are detailed in paragraphs referenced 6-2 through 6-6 and will be throughout this chapter. Any repair, and assembly inspection,

(2) Hands should be kept free of any accumulation of grease, which can collect dust and grit. (3) After cleaning, all parts should be covered or wrapped to protect them from dirt and dust b. accumulation. Castings. (1) Remove sludge and gum deposits using a stiff brush. (2) Clean all surfaces with dry-cleaning solvent or mineral spirits paint thinner. Repeat operation if surface is not free of scale or adhering later. (3) Blow out all tapped holes with compressed air. (4) After cleaning, dry casting with compressed air. Warning: Particles blown by compressed air are hazardous. Make certain air stream is directed away from user and that other persons are not exposed. Protect eyes and face with appropriate shields. c. Oil Passages. Particular attention must be given to all oil passages in machined parts. All oil passages must be free of obstructions. (1) Clean passages with wire or probes to break up all sludge or gum deposits. (2) Wash passages by flushing with drycleaning solvent or mineral spirits paint thinner. Be sure passages are free from obstructions and clear any particles which might later become dislodged and contaminate the oil system. (3) After cleaning, dry passages with compressed air. d. Electrical Cables and Flexible Hoses. Clean cables and flexible hoses with soap and water. Note. Do not allow dry-cleaning solvent or mineral spirits pain thinner to be in prolonged contact with the rubber components and flexible hoses. These cleaners cause leather, rubber, and synthetic materials to dry, rot, and lose pliability, making them unserviceable. 6-1 material which might be dislodged

cleaning, procedures which are peculiar to a specific part or component will be covered in the section or paragraph relating to that castings must be realodized cordance with is marred. MIL-C-5541A item. Aluminum or coated in acwhenever coating

b. Tables will be used to list the various operations and components involved in the overhaul of engine sub-assemblies. Paragraph and / or figure references for disassembly, repair, inspection, cleaning, and assembly procedures will be listed in their appropriate heading. c. The Repair Parts these of tables the under

section

manual.

Appendix B, will be used to identify parts and to locate points of measurement for overhaul limits. 6-2. Cleaning Instructions cleaning must maintenance The

a. General. The importance of be thoroughly understood by are required in all cleaning

personnel. Great care and conscientious effort operations. presence of dirt or foreign material is a constant threat to satisfactory engine operation and maintenance. A dirty operation can result in cylinder scuffing or scratching, high oil consumption, bearing destruction, and a variety of component failures directly attributed to the entrance of dirt. Maintain rigid cleaning standards during all phases of the cleaning operation. apply to The all following general instructions cleaning operations.

(1) Clean all parts before inspection, after repair, and before assembly.

e. Ball and Needle Bearings. (1) Bearings require special attention in cleaning and oiling. After removing the surface dirt, oil, or grease, the bearings, except the sealed, permanently lubricated type, should be placed in hot oil (about 150F.) to loosen congealed oil and grease. After cleaning, the bearings should be coated with a film of lubricant and wrapped tightly in oiled or waxed paper until inspection and assembly. Note. Do not immerse sealed type ball bearings in dry-cleaning solvent, mineral spirits paint thinner, or hot oil. Entrance of cleaning agent will destroy lubricants sealed in bearing at time of manufacture. Loss of lubricant will result in premature failure of bearing and possible severe damage to the engine. (2) Clean sealed ball bearings by wiping the exterior surfaces with a clean cloth moistened in dry-cleaning solvent. Compressed air must never be used in cleaning or drying of ball or needle bearings. Damage to bearings will result from spinning of bearing by air blast. (3) Refer to TM 9-214 for information on inspection, care, and maintenance of bearings. The reconditioning of f. Painted Parts. painted parts should be a matter of good judgment. Parts that appear to be in good condition after cleaning, need not be stripped and repainted in their entirety, but should be cleaned and designated for touch-up only. Parts that are rusted, or otherwise devoid of paint, must be stripped to bare metal. Rubber composition shroud seals must be removed and discarded before the parts can be stripped of paint.

(3) Inspect finish of all parts. Mark all parts that require refinishing. b. Overhaul Standards. To identify parts, the Overhaul Standards Tables of this chapter refer to the exploded views in the repair parts section (Appendix B). Key letters are used on the exploded views to locate points of measurement for overhaul limits. E a c h t a b l e c o n t a i n s t h e maximum, minimum, and key clearances of new or overhaul parts. The clearances, listed mainly for reference, will automatically be achieved if the mating parts are within the dimensional tolerances listed in the tables. In some cases, a part that is out of dimensional tolerance may be used, providing the mating part has been carefully selected and, when mated, is within the maximum clearance limits specified in the wear limits column of the tables. The wear limits indicate the point at which parts may be worn before replacement, in order to assure maximum service and minimum replacement. Normally all parts which have not worn beyond dimensions shown in the Wear limits columns or are damaged from corrosion, will be approved for service. (1) Symbols employed in the Overhaul Standards Tables are identified as follows:

6-3.

Inspection

a. General. The engines are precision built, and the overhaul standards tables listed in this chapter have been fixed at extremely close limits. The following general instructions apply to all inspection procedures. (1) Use modern methods and equipment such as magnaflux, zyglo and ultrasonic inspection for inspecting component parts where cracks and other damage cannot be detected visually. (2) Extreme care must be exercised in all phases of inspection. Inspect components following instructions in paragraph b.

*-An asterisk in the Wear limits column indicates that part must be replaced when worn beyond the limits given in the S i z e s a n d f i t s o f n e w p a r t s column. L-The letter L, following the tolerance dimensions given in the Sizes and fits of new parts column and the Wear limits column, indicates a loose fit (clearance). T-The letter T, following the tolerance dimensions given in the Sizes and fits of new parts column and the Wear limits column, indicates a tight fit (interference). (2) The following is a check list of parts to be magnetic-particle or flourescent-penetrant inspected:

6-2

A. M A G N E T I C - P A R T I C L E
Army Part No. Nomenclature

INSPECTION

CHECK

LIST
Qty Reqd Fig. No.

Item No. 7 11 50.1 10.2 7 74.2 50.2 74.1 34 15 13 31 21 10 6 4 3 7 16 50 20 24 25 46 45 16.2 84 53 16.1 39 48 4 79 54 12 77 41 42 49 32 24 99 4 5 12 33 8 10 51 21 7 42

7320430 7320464 7320478 7320496 7341633 8682553 8682684 8682689 8682691 8682729 8682814 8682817 8682820 8724976 8724977 8724978 8724979 8725084 8725087 8725119 8725120 8725121 8725130 8725134 8725225 8725226 8725227 8725229 8725233 8725243 8725248 8725254 8761020 8761022 8761279 8761280 8761281 8761287 8761440 10865184 10865383 10882610 10882613 10898746 10898777 10898778 10898779 10898875 10898888 10898915 10898962

SHAFT, SHOULDERED: camshaft drive GEARSHAFT, SPUR: injection pump driven GEARSHAFT, BEVEL: fan drive PIN, PISTON: BOLT, MACHINE: advance unit (early) GEARSHAFT, BEVEL: fan drive GEARSHAFT, BEVEL: fan drive driven GEAR, SPUR: generator driven drive idler GEAR, SPUR: starter drive GEARSHAFT, SPUR: advance unit GEARSHAFT, SPUR: generator drive COVER, CAMSHAFT: oil retaining GEAR, SPUR: transmission accessory drive ROD, CONNECTING, ENGINE: CAP: connecting rod NUT, EXTENDED WASHER: connecting rod BOLT, EXTERNALLY RELIEVED: connecting rod CRANKSHAFT: engine GEAR, CLUSTER SPUR: IMPELLER: oil pump IMPELLER: oil pump IMPELLER: oil pump IMPELLER: oil pump IMPELLER: oil pump GEAR, BEVEL: camshaft drive SUPPORT, BEARING FAN: SUPPORT, FAN DRIVE SHAFTGEAR: GEARSHAFT, BEVEL: camshaft drive SUPPORT, FAN DRIVE: CLAMP HUB: support injection advance drive GEARSHAFT, BEVEL, SPUR: advance unit ROD, ENGINE, CRANKCASE: thru bolts SHAFT, STRAIGHT: fan drive CAGE, BEARING ENGINE: starter driven bearing NUT, SLOTTED, HEXAGON: thru and main CAMSHAFT, ENGINE: CAMSHAFT: engine SHAFT, FAN DRIVE: (fly end) SHAFT, IDLER GEAR: generator driven drive gear BOLT, MACHINE: crankpin plugs GEARSHAFT, BEVEL: accessory cam drive bevel PLATE, CRANKSHAFT DAMPER: fuel pump coupling GEAR, SPUR: fuel pump drive BOLT, MACHINE: advance unit (late) GEAR, SPUR: starter driven drive idler GEAR, SPUR: accessory drive GEARSHAFT, SPUR: starter driven SHAFT: oil pump drive gear SHAFT: oil pump SHAFT, IDLER GEAR: starter driven drive idler GEAR, SPUR: oil pump B. FLOURESCENT-PENETRANT INSPECTION CHECK

2 1 1 12 6 1 2 1 1 1 1 2 1 12 12 24 24 1 1 1 1 1 1 1 2 1 2 2 1 1 1 14 1 1 56 1 1 1 1 6 1 1 1 6 1 1 1 1 1 1 1 LIST: 2

B-5 B-26 B-26 B-4 B-27 B-26 B-26 B-26 B-14 B-14 B-27 B-14 B-5 B-3 B-4 B-4 B-4 B-4 B-3 B-9 B-9 B-9 B-9 B-9 B-9 B-5 B-26 B-26 B-5 B-26 B-26 B-27 B-2 B-26 B-14 B-2 B-5 B-5 B-26 B-14 B-3 B-26 B-3 B-3 B-27 B-14 B-3 B-14 B-9 B-9 B-14 B-9

8761242

FAN ASSY, ENGINE:

B-25

18

6-3

c. C a s t i n g s . (1) Inspect all ferrous (cast iron, steel, etc.) castings for cracks with magnetic-particle inspection e q u i p m e n t . I n s p e c t a l l n o n f e r r o u s for cracks using castings) (aluminum inspection flourescent-penetrant equipment. Suspected cracks in the nonferrous casting can also be inspected with a spot check dye penetrate or a magnifying glass (five power magnification minimum) studs, sharp pipe and a strong or light or a dye check and in method. Check particularly the areas adjacent to plugs, and threaded inserts corners fillets.

Bushings, h. Bearings.

Liners,

and

Bushing-type

(1) Check all bushings, liners, and bushingtype 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 for wear, burs, nicks or out-ofround condition. (3) Check for dirt in lubrication holes or grooves. Holes and grooves must be clean and free from damage to insure proper lubrication. (4) Inspect thrust faces of bushing-type bearings for wear and by temporarily assembling mating parts and checking end play with a feeler gage inserted between the thrust faces. (5) Check for conformance to the applicable overhaul standards. i. Oil Seals. All oil seals must be replaced at engine overhaul. Generally, metal encased oil seals are long-life parts and do not have to be replaced during field repair if inspection indicates seals are in good condition. (1) Inspect for damage to the thin feather edge of oil seal which contacts rotating part. and (2) Inspect sealing feather edge for softness pliability. questionable seals

(2) Inspect machined surfaces of castings for nicks, burs, or raised metal. Mark damaged areas for repair. mounting plate for mounting indicate (3) Check all mating flanges and pads with a straight edge or surface warpage. Inspect mating flanges and pads for discoloration which may persistent oil leakage. or (4) Inspect all tapped openings for stripped damaged threads.

(5) Check all castings for conformance to the applicable repair and rebuild standards. d. Ball and Needle Bearings. Refer to TM 9214 for inspection of anti friction bearings. Check all bearings for conformance to the applicable overhaul standards. e. Studs. Inspect all studs for damaged or stripped threads, bent or loose condition, or for any signs of stretching. Inspect dowel pins for f. Dowel Pins. looseness or damage. Mark loose pins for repair. g. G e a r s a n d S h a f t s . Note. There are no established wear limits for gear teeth and splines. Good judgment is required to determine need for replacement. (1) Inspect all gears and shafts for cracks using magnaflux equipment. When magnaflux equipment is not available, use a magnifying glass (five power magnification minimum) and a strong light. (2) Inspect all gear teeth and splines for wear, sharp fins, burs, and galled or pitted surfaces. (3) Inspect shaft and gear hub splines for damage, wear, and for fit with splines on mating parts. Mating splines binding or looseness. must match without

(3) Replace damaged or during field engine repair.

j. Helical-coil and Screw Thread Inserts. (1) D e s c r i p t i o n . T o p e r m i t h i g h e r s t r e s s e s on studs and bolts which are set in aluminum castings, it is common practice to install insets of a stronger metal into which the studs or bolts are threaded. Helical-coil and screw thread inserts are designed to perform this function. The inserts are spiral steel coils having a right hand thread-shaped form on the inside and on the outside of the coils. A bar or tang at the bottom end of the coil, which is engaged by an inserting tool, is used for threading the insert into the casting. Some inserts have a serrated tooth section at the top end of the coil to stake them in place in the castings. Other inserts have turns at the center of the coil in the form of a hexagon. This provides a locking effect when the stud or bolt is threaded into the insert. (2) Inspection. Inspect all helical-coil and

screw thread inserts for secure fit in the casting and for galled or stripped threads. k. Painted Parts. Straighten parts as

(4) Check all gears and shafts for conformance to the applicable overhaul standards.

6-4

necessary and check for broken welds, loose rivets or weld nuts. If parts are cracked or torn, they must be repaired or replaced. Check shroud seals for hardness, tears, or other damage. Mark damaged seals for replacement if the part is otherwise serviceable.

material covered in this procedure is Type 355T71 Federal Specification QQ-A-601. (2) E q u i p m e n t . An alternating current arc welding m a c h i n e s h a l l b e u s e d f o r h e l i a r c welding. Class 4043, conforming to Specification QQ-R-566a or MIL-E-16053 welding rod, is compatible with the base material and shall be used for all welding repairs in this material group. All equipment shall be consistent with good standard welding practices, and be acceptable to the Government Inspector. (3) P r o c e s s e s . (a) MIG (Metal Inert Gas) process. T h e process is recommended when welding 1/8 inch aluminum plate greater than MIG thickness. When (b) TIG (Tungsten Inert Gas) process. welding aluminum plate 1/8 inch thick

6-4. Repair
a. General. Most engine parts and components may be repaired as outlined below. After repair, clean all parts thoroughly to prevent metal chips from repair operations, or abrasives used in repair operations, from entering working parts of the engine. b. General Repair of Castings. (1) Replace all castings when cracks have penetrated high stress areas such as fillets or webbing. (2) Replace all castings which do not conform to tolerances specified in the appropriate repair and rebuild standards table. (3) Replace all castings on which machined surfaces are burred or nicked to the point of impairing subsequent assembly or operation. Repair minor damage to machined surfaces with a fine mill file or crocus cloth dipped in drycleaning solvent or mineral spirits paint thinner. (4) Replace all castings having flanges which are severely warped and cannot be repaired to provide a proper seating surface with its mating part. Repair minor warpage of mounting flanges and mounting pads by working surface across a sheet of crocus cloth held tightly on a surface plate or similar flat surface. (5) Repair damaged pipe threads in tapped holes with a used tap. Note. Pipe plug threads in castings must be in good condition to prevent oil leakage. c. W e l d i n g o f A l u m i n u m A l l o y Note. The following procedures Castings. (1) through

and under, the TIG process is recommended. (4) C a s t i n g p r e p a r a t i o n . (a) C l e a n i n g . All foreign material must be removed from the area to be welded prior to repair operations. The area shall be cleaned using a stainless steel wire brush, drill, burring tool, or approved chemical process, whichever is applicable. (b) C r a c k s . Determine flow of cracks by using dye check method. Drill stop holes at crack ends with a 1 / 4-inch drill and mill out cracks to provide a V aperture. (c) Fractures. Check area around the fracture for cracks using dye check. Drill stop holes at the ends of detected cracks with a 1/4inch drill and mill out crack to provide a V aperture. (d) Missing metal. If the size of the damaged area permits, mill out and chamfer that area to 30 degrees to provide a 60 degree included angle. The insert piece required for this area must be identical in composition and may be cut from scrapped castings or suitable sheet stock. Fit insert piece into milled area, so that 1/6and to 1/8-inch wall. is maintained between insert casting

(7) are based on the applicable paragraphs in Specification MIL-W-8604 and MIL-W-45205, and outline the requirements, equipment, and welding process used for the repair of aluminum alloy castings. Specific information relating to the welding of individual castings will be covered in the appropriate section of this chapter. (1) O p e r a t o r . Welding shall be performed by welding operators who have successfully met the requirements of Specification MIL-T-5021, for Material Group IV (Aluminum Alloys). Operational: TM 9-237 (Nov. 1967). The base

Precisely (5) P r e p a r a t i o n f o r w e l d i n g . measure castings at appropriate locations to detect dimensional changes caused by welding repair. Record dimensions for checking after repair has been made to be sure that critical dimensions have been held. (6) Preheat prior to welding. Preheat

6-5

castings as outlined in Specifications QQ-A-601 and MIL-W-8604. Preheat slowly in an oven or by other suitable method for two hours to approximately 350 degrees 35 degrees F. Control preheat process to avoid incipient melting, excessive grain growth or other undesirable structural changes which might reduce the mechanical properties. Caution: Do not attempt to preheat by using welding torch. (7) W e l d i n g . (a) C r a c k s . The inert gas shielded arc welding process shall be used when making repairs on aluminum alloy. After casting has reached the prescribed preheat temperature, position the casting into the most advantageous welding position. Cover casting with asbestos blankets, except for area to be welded. Weld the outside milled groove with a good root weld. Apply fillet welds until groove is closed. Rotate casting and weld inside groove in the same manner if double V is used. Remove asbestos blankets and allow castings to cool progressively to room Temperature. (b) Fracture and missing metal. Following the procedure outlined in (a), above, place insert piece in opening, aline and secure with clamps or tack weld in three or four places with one inch welds. Place a good root weld in groove and apply fillet welds until groove is closed. Rotate casting and weld inside groove in the same manner. Note. The temperature of the casting surrounding the welded area should not exceed 395 degrees. If necessary, stop welding, cover casting with asbestos blanket and allow to cool to a satisfactory temperature then resume welding. (8) Final inspection and clean up. R e p a i r e d cracks and areas where metal has been replaced must be radiographically inspected and be equal to or better than reference standard 3, TACOM STD 113, Apr 69 (available from USTACOM AMSTA-R). All other areas shall be inspected

by dye penetrant. Defects must be re-welded in accordance casting and with above methods. Measure before compare dimensions taken

repair. Dimensional change will not exceed that as specified on applicable engineering drawing, except as noted. Check machined surfaces for warpage or other dimensional changes. Clean seams with a wire brush and remove weld beads and all sharp edges. X-ray entire repaired area. Remove excess flux with suitable material, rinse with clean water, dry and alodize. Pressure test oil passages that have been repaired to 90 psi hydrostatic pressure using engine oil (OE). d. Ball and Needle Bearings. (1) Replace bearings. all galled, pitted, or damaged not ap-

(2) Replace all bearings which do conform to tolerances specified in the

propriate repair and rebuild standards table. (3) Refer to TM 9-214 for information on inspection, care, and maintenance of anti-friction bearings. e. Studs. Replace all bent or loose studs or studs showing evidence of stretching. Repair minor damage with a thread chaser. Replace all studs having stripped or damaged threads. Remove and replace studs as outlined in (1) and (2), below. (1) Stud identification. Stud chapter. Each table contains identification appropriate

tables appear in the overhaul sections of this the inform ation regarding stud setting heights, oversize studs, number required and reference figures of stud identification and location. (2) Removal. studs out slowly Using stud extractor, back 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 with a wrench.

6-6

Figure 6-1. Standard and oversize stud identification. (3) Replacement. MIL-S-22473. In cases where the dowel pin hole is grossly out-of-round, it will be necessary to drill the hole oversize, fashion a bushing, and install a new pin in the bushing. g. Painted Parts. Retouch or paint parts as acceptable part. necessary to produce an Retouch or repaint parts in their original color in accordance with instructions contained in TM 9213. h. Gears and Shafts. (1) Replace all cracked gears and shafts, and shafts that are bent or twisted. not (2) Replace all gears and shafts which do conform to tolerances specified in the

(a) When threads in tapped holes appear to be in good condition, clean threads with a tap. (b) When threads are stripped damaged, or when stud was removed from or an

aluminum casting for loose fit, always replace stud with next larger oversize or in cases of complete thread pullout, drill out threaded holes, tap hole for thread insert, install insert and standard stud for repair. Markings and color code indicates whether stud is standard or oversize. Check marking and color code as shown in figure 6-1 to be sure replacement is of proper size. Note. When the threads on each end of the stud are a different size, the coarse thread end must enter the aluminum casting. (c) Studs available for replacement as shown in figure 6-1 are marked on the coarse thread end of stud. (d) Apply a small amount of mica-base antiseize compound, Military Specification MIL-T-22361, to threads before installing stud. (e) Drive stud into tapped hole slowly to prevent heating. Drive to setting height given in appropriate table. (f) When tapped holes in castings cannot be fitted with oversize studs, the holes in the castings can be fitted with helical-coil inserts (par. 6-5) and studs of the original size can then be installed. f. Dowel Pins. Replace loose dowel pins. If original dowel pin was only slightly loose, install new pin using sealing compound, Specification

overhaul standards tables. (3) Replace all gears and shafts having worn, galled, nicked, burred, or pitted teeth and splines. Remove any sharp fins and burs from splines with crocus cloth dipped in dry-cleaning solvent or mineral spirits paint thinner. (4) Replace all splined gears and shafts that are damaged to the point of impairing assembly or operation. Replace all gears and shafts having splines which do not match properly with mating splines. i. Bushings, Liners, and Bushing-type Bearings. When bushings, litters, and bushingtype bearings are damaged or worn beyond specified limits, generally the associated parts with which they are used must be replaced. Reference to (1) and (2), below, will be made in the rebuild section for the particular part when replacement type bearings of is bushings, required. 6-7 liners, and bushing-

(1) Removal. Drill out bearing retaining pins when used to secure bearings in castings or retaining cages when applicable.
(2) Installation.

(a) Aline bushing, liner, or bushing-type bearing in casting or retaining cage. Press into place with a suitable pressing arbor. (b) Select proper drill size for installation of bearing retaining pins. Drill through bearing and into casting or retaining cage to the proper depth so that the pin will be flush with the bearing surface after installation. Drive retaining pin through bearing and into casting or retaining cage. Cut off any portion of pin that extends above bearing. (c) Ream or burnish bushing liner, or bushing-type bearing to size specified in appropriate overhaul standards table. (d) Clean repaired parts thoroughly before assembly or installation. j. Oil Seals. Replace all oil seals at engine overhaul. During field repair, replace oil seal when thin feather edge is damaged or when seal has become hard or brittle. (1) Removal. Press or pry damaged oil seal from casting or adapter, being careful not to damage bore in casting or adapter. (2) Repair. When oil seal bore in casting or adapter is burred or damaged to a point where an oil-tight seal is impossible, repair or replace casting or adapter. Remove slight nicks, burs, and scratches from oil seal bore in casting or adapter 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.

thread inserts which do not fit securely in the casting or when casting threads have become galled or stripped. b. Replacement. Replace all unserviceable helical-coil and screw thread inserts in the same manner, following instructions which accompany figures 6-2 and 6-3. For instructional purposes helical-coil inserts in the cylinder assembly will be replaced.

1. Use a diamond-shaped punch is the insert (A) is the serrated-teeth type to drive staked, serrated-teeth section of insert from the thread in cylinder casting. 2. Install screw thread extractor - 5120-251-1527 into insert. Remove insert by applying constant pressure while turning extractor (B) counterclockwise until insert is removed.

6-5.

Replacement of Helical-Coil and Threaded Inserts

a. General. Replace all helical-coil and screw

Figure 6-2. Removing helical-coil threaded insert from cylinder assembly using screw thread extractor-5120-251-1527.5

6-8

quantities, are abrasive. Parts must be cleaned as specified and kept clean. Wrap or cover parts and components when assembly procedures are mot immediately completed. (2) Coat all bearings, shafts, and all contact surfaces w i t h e n g i n e oil (OE) to insure lubrication of parts during initial engine starting. (3) Always use new gaskets and preformed packings when assembling engine. (4) Use flat washers under all lockwashers, nuts and bolts to protect aluminum surfaces. (5) Most bolts, cap screws, and nuts must secured with lockwashers, tab washers, locking wire, or cotter pins, depending on be method of locking specified. (6) Whenever a locking method is not specified for bolts and cap screws, the mid-grip helical-coil threaded inserts into which the bolts or screws are threaded serve as the locking device. (7) It is also important that all hardware be Note. The special coil screw lock inserter tools listed in special tool table 2-1 must be used when installing the self-locking thread type inserts. These special inserters are further identified by painted areas marked either with a red handle or a red stripe around the body. 1. Thread new insert (A) into the threaded guide of inserter -5120-797-2407 by slowly turning the pilot until insert is flush with the end of the tool. 2. Insert the pilot of the screw thread inserter (B) - 5120797-2407 into the threaded hole in cylinder, with face of the inserter resting solidly against the casting as shown. 3. Slowly turn handle (C) of pilot clockwise until no further resistance is felt. The insert will then be flush with cylinder casting. Remove inserter. Figure 6-3. Installing helical-coil threaded insert in cylinder assembly using screw thread inserter-5120-797-2407. tightened to the specified torque. Refer to torque specifications, 6-7. Torque paragraph 6-7.

Specifications

a. Standard Torques for Studs and Bolts. Apply a light film of anti-seize thread compound FSN 9150-663-1770 to stud, bolt, cap screw threads, and contact face of nuts, bolt heads, and cap screws. Avoid excessive amounts of compound in blind tapped holes.
Size (dia. in.) Torque (lb-in.)

1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-100 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...150-175 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...275-325 7/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...400-450 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...550-600 9/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...800-850 b. Special Torques for Studs and Bolts. A p p l y a light film of anti-seize thread compound FSN 9150-663-1770 to stud, bolt, cap screw threads, and contact face of nuts, bolt heads, and cap screws (except as noted). Avoid excessive amounts of compound in blind tapped holes. Crankcase Tie-rod Bolts . . . . . . . . . . ...640 Main Bearing Stud . . . . . . . . . . . . ...450 Crankcase Main Bearing Stud Nuts (Procedure): (1) Tighten all nuts to . . . . . . . ..500 (2) Tighten all nuts to . . . . 700-825 (3) Check stud stretch, it must be 0.0190.022 in. 6-9

6-6. Assembly
a. General. Extreme care must be exercised in all assembly operations to insure satisfactory engine performance. General rules for assembly are outlined below. Step-by-step procedures for assembling the various components are covered in the paragraph relating to the specific component. b. Precautionary Rules. (1) Cleanliness is essential in all assembly operations. Dirt and dust, even in minute

(4) Tighten nuts as necessary to obtain proper stretch. Do not exceed 0.024 stretch when alining locking wire holes. (5) All studs which exceed stretch limits at less than 700 pound-inches must be replaced. All studs which exceed the stretch limits above 700 pound-inches must be loosened and resubjected to operations 1, 2, 3, and 4, above. Note. Retorquing any singular stud is not allowable. The adjacent stud nut must also be loosened and retorqued in sequence. Connecting rod bolt nuts . . . . . . . . . . . . . . . 950 Cylinder base nuts . . . . . . . . . . . . . . . . . . . . . . . .640 (use lubriplate 663-1770) 9150-527-1752, 9150-

Fuel return tube to bulkhead tube cross fitting . . . . . . . . . . . . . . . . . . . . . . ...100 Oil pan mounting cap screws . . . . . 175 Oil pan mounting nuts (no lubrication) . . . . . . . . . . . . . . . ...225 Oil pump cluster gear shaft spanner nut . . . . . . . . . . . . . . . . . . . . . . . . . . 5 7 5 - 6 2 5 Oil pump drive gear nut . . . . . . . . . .600 -1500 Oil pump to crankcase . . . . . . . . . . . 275 Piston oiler nozzle to crankcase .. . 125 Starter driven gearshaft nut . . . . . . 1000 Turbosupercharger oil inlet hose nipple . . . . . . . . . . . . . . . . . . . . . ...150 Valve rocker adjusting screw lock nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 5 Valve rocker cover bearing cap screws (4) . . . . . . . . . . . . . . . . . . ...275-325 Valve rocker cover cap screws (except for bearing cap screws) . . . . . . . . . . 100 Note. On assemblies subjected to wire or cotter pin hole alinement, set torque wrench to low limit and torque nut. To facilitate alinement, it is permissible to tighten nut to first hole beyond torque setting. c. Standard Pipe Plug Torques (using thread lubricant). Coat pipe plug threads with antiseize compound FSN 8030-275-8118 or equivalent.
Pipe Thread Size Torque (lb-in.)

Damper housing to crankcase . . . 2 2 5 Damper mounting cap screws . . . . . . . 1000 Fan adapter to fan cap screws . . . . . . . . . 150 Fan adapter to fan housing shaft nut . 600 Fan housing base to crankcase nuts and cap screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 7 5 Fan housing to fan housing base nuts . 275 Flywheel mounting cap screws . . . . . . . . 1000 Fuel adapter fitting bolt to injector nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . ...300 Fuel injector nozzle and holder nut . . . . . 500* Fuel injection pump base cap screws 750 Fuel injection pump cap screws . . . . . . 600 Fuel injection pump drive coupler hub nut 900 Fuel return tube to adapter on injector nozzle holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...100 *(Use special 275-8118) thread compound FSN 8030-

1/8-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80 1/4-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...125-145 3/8-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...185-215 1/2-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .250-280 3/4-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..305-345 1-11-1 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-1000

Section II. OVERHAUL OF CRANKCASE ASSEMBLY, TRANSMISSION ADAPTER, AND STARTER AND GENERATOR DRIVE COMPONENTS 6-8. General
repair, and assembly accompany the overhaul

operations. components This section covers the overhaul of the crankcase assembly, transmission adapter, and starter and generator drive components. Specific instructions on disassembly, cleaning, inspection, Stud

Overhaul standards of individual follow the inspection procedures. tables are included where

identification

applicable. Refer to table 6-1 for applicable illustrations instructions for overhaul and operations.

6-10

Table 6-1.

Para 6-9b Figs. 6-5 through 6-8

Para 6-9c Fig. 6-9

Para 6-9d Table 6-2 Figs. 6-10 through 6-12

Para 6-4 Para 6-9e Table 6-3

Para 6-9f Figs. 6-7 through 6-5

Para 6-10a Fig. 6-18 Para 6-11a Fig. 6-19 and 6-20 Para 6-12a Figs. 6-24 and 6-25 Para 6-13a Fig. 6-28

Para 6-2

Para 6-3

Para 6-4

Para 6-10c Fig. 6-18 Para 6-11c Fig. 6-22 and 6-23

Para 6-2

Para 6-4 and 6-11b Table 6-4

Para 6-4

Para 6-2 Para 6-3c, 6-3e Table 6-5 Para 6-2 Para 6-3 Table 6-7

Para 6-4d Table 6-6

Para 6-12c Figs. 6-26 and 6-27 Para 6-13c Fig. 6-29

Para 6-4h

6-9. Overhaul of Crankcase Assembly

a. General. (1) The crankcase assembly consists of those parts that are machined with the crankcase. They include main bearing caps, oil seal housing, oil seal housing cap, and oil seal housing support. (2) The engine name plate (fig. 6-4), located on the left side of the crankcase, contains the engine serial No., timing data, and valve settings. Any modifications to this information or addition of overhaul and modification kit data must be incorporated either on the engine name plate or on a modification tag mounted on a designated location elsewhere on the engine.

Figure 6-4. Engine name plate.

6-11

b. Disassembly. Disassemble the crankcase and remove the crankcase from the overhaul stand following instructions figures 6-5 through 6-8. which accompany

Remove 1. Remove two pipe plugs (A). 2. Remove four pipe plugs (B). 3. Remove pipe plug (C). 4. Cut locking wire and remove two drilled head bolts (D) attaching fuel pump drive gearshaft replacement cover. 5. Remove cover (E) and discard gasket. Note. Instructions and cover cover. Install 1. Position a new gasket and fuel pump driven gearshaft replacement cover (E) on crankcase. 2. Install two drilled head bolts (D) securing cover to crankcase and install locking wire securing bolts. 3. Install pipe plug (C). 4. Install four pipe plugs (B). 5. Install two pipe plugs (A). Figure 6-5. Removing or installing pipe plugs and fuel pump driven gearshaft replacement cover. fuel (E) pump are covering to pipe plugs (A) a driven gearshaft replacement having

Remove 1. Remove 2. Remove 3. Remove attaching (D). 4. Remove

pipe plug (A). pipe plug (B). three self-locking nuts (C) and flat washers fuel supply pump adapter replacement cover cover (D) and discard gasket.

Note. Instructions covering fuel supply pump adapter replacement cover (D) are applicable to engines having a cover. Install 1. Position a new gasket and fuel supply pump adapter replacement cover (D) on crankcase. 2. Install three self-locking nuts (C) and flat washers securing cover to crankcase. 3. Install pipe plug (B). 4. Install pipe plug (A). Figure 6-6. Removing or installing pipe plugs and fuel supply pump replacement cover. adapter

applicable

engines

6-12

Remove 1. Remove six pipe plugs (A) from crankcase oil gallery. 2. Remove pipe plug (B). 3. Remove pipe plug (C). Note. Instruction covering pipe plug (C) is

Install 1. Install pipe plug (C). 2. Install pipe plug (B). 3. Install pipe plugs (A) in crankcase oil gallery. to engines having a plug.

applicable

Figure

6-7.

Removing

or

installing

crankcase

oil

gallery

pipe

plugs.

6-13

Remove 1. Remove crankcase 2. Attach a balanced,

four bolts (A) and flat washers attaching to engine overhaul stand. rope sling (B) as shown, with weight equally and remove crankcase from stand.

Install 1. Attach a rope sling (B) as shown, with weight equally balanced, and position crankcase on engine overhaul stand. 2. Install four bolts (A) and flat washers securing crankcase to stand.

Figure 6-8. Removing or installing crankcase from engine overhaul stand using improvised rope sling. c. Cleaning. Thoroughly clean crankcase oil passages (fig. 69) using compressed air and brass wire probes.

(1) Refer to paragraph 6-2b for general instructions on cleaning the crankcase.

6-14

Figure

6-9.

Crankcase

oil

passages-schematic

diagram.

(2) Clean the main sleeve bearing halves with dry-cleaning solvent or mineral spirits paint thinner. Use a wooden scraper to remove sludge or gum deposits from bearing grooves and oil holes. Do not remove the bearing location markings made during engine disassembly. d. Inspection. (1) Castings. inspect the crankcase and related parts according to instructions covering castings in paragraph 6-3b and c. (2) M i s c e l a n e o u s m e t a l c o m p o n e n t s . R e f e r to figure B-2 in Appendix B for parts identification. Inspect crankcase tie rods (79) and oil

seal retainer (44) for damaged threads and other unserviceable conditions. (3) Inspection of main sleeve bearings. (a) Inspection of main sleeve bearing surfaces (7.1, 7.2, 7.3, and 7.4, fig. B-3) is largely a matter of judgment and experience. The following instructions will assist in determining whether a bearing is serviceable or whether it should be replaced. Replace any questionable bearings. (b) Separation of bearing metal, or signs of possible separation, requires that the bearing be replaced.

6-15

(c) Fine scratches on sleeve bearing are not cause for rejection. Pitting or any other form of destruction to the bearing surface is cause for rejection. Replace bearings showing raised metal at edges of scratches. (d) Minute pieces of metal and dirt particles embedded in bearing surfaces are not cause for rejection. Note. Do not attempt to remove such particles. However, if a concentration of embedded particles affects five percent of the surface, replace the bearing. (4) Stud (tie rod) torque and main bearing bore inspection. Note. Main sleeve bearing halves should be installed in their original location when they are to be re-used. Use new bearings when a visual inspection indicates bearings are unserviceable. Use only new or serviceable bearings for main bearing-bore check. install (a) Refer to figure 6-8 for instructions to crankcase on engine overhaul stand.

their

original

location

in

crankcase

and

main

bearing caps. (d) Check clearance between upper bearing flange and crankcase as shown in figure 6-11. (e) Check clearance between the lower main thrust bearing flange and thrust bearing cap in the same manner as shown in figure 6-11.

(b) Check main bearing cap stud torque using a torque wrench as shown in figure 6-10. Torque on studs must be 450 pound-inches. Studs that do not tighten to specified torque must be removed for further inspection. Refer to table above 6-3 when replacing studs. Note. Never tighten main bearing studs recommended torque. 1. Install upper main thrust sleeve bearing (A) into No. 4 main bearing seat of crankcase. 2. Measure clearance between bearing flange and crankcase using feeler gage (B). Clearance should be 0.0040 to 0.0080-inch. Figure 6-11. Checking clearance between

upper main thrust bearing flange and crankcase. (f) Apply a light coating of engine oil, Military Specification MIL-L-45199, to the ends of the seven main bearing caps with sleeve bearing Figure 6-10. Checking torque of main bearing cap studs. (c) Spread a thin coat of Prussian blue, FSN 8010-247-8706, over steel backs of upper and lower main sleeve bearing halves to show the sleeve bearing contact surface with the main bearing bore in crankcase. Install bearings in installed. Using crankcase spreading tool - 5120-575-7767 as shown in figure 5-174 install the bearing caps with bearing halves in their proper locations in the crankcase. according to the location number stamped on the crankcase and cap. The side of the bearing cap marked FLY END must face the rear of the crankcase. (g) Apply a small amount of antiseize halves

6-16

compound, FSN 9150-663-1770, to the threaded area of each main bearing cap stud. Install a plate washer on each pair of main bearing studs. Install a slotted nut on each main bearing stud but do not tighten nuts at this time. (h) Place a surface plate and dial indicator gage on crankcase flange with gage indicator resting on end of stud. Measure and record height of each stud. Torque tighten main bearing stud nuts to 500 pound-inches. Alternately tighten all four nuts on each main bearing to a torque of 700-825 pound-inches. Measure the height of each stud after final torque. The difference between the stud height before and after torque tightening, indicates stud stretch. Normal stud stretch is 0.010 to 0.022-in. If any stud has stretched more than 0.024-in. at 700 pound-inches torque, it must be replaced. Refer to table 6-3 when replacing studs. (i) Install the 14 crankcase tie rods in the holes provided through the crankcase and main bearing caps. Equalize the extension of the threaded portions of the tie rods on each side of the crankcase. Apply a small amount of antiseize compound, FSN 9150-663-1770, to the threaded portions of each tie rod. Install a plate washer and a 9 / 16 slotted nut on each end of the tie rods. (j) Starting at the main thrust bearing cap, with aid of an assistant to hold the nuts on the opposite s i d e o f c r a n k c a s e , alternately tighten all main bearing cap tie rod nuts to 640 pound-inches torque. (k) Check the inside diameter of the main bearings with a dial bore indicator as shown in

figure 6-12 against the limits specified in overhaul standards (table 6-2). Replace bearings which do not meet these requirements. New bearings must also be dial bore checked. Remove the main bearing caps and bearing halves from the crankcase and check contact surface as indicated by Prussian blue, FSN 8010-8478706 transfer. Replace bearings that do not make 75 percent contact with crankcase bearing bores. Repeat dial bore check of new bearings installed.

Figure 6-12. Checking main

inside

diameter

of

bearings.

6-17

Table 6-2. Crankcase Assembly Overhaul Standards

Component Ref. letter Point of measurement Sizes and fits of new parts Wear limits

Crankcase

B-2 B-2 B-3 B-3

A B E V

B-3

B-3 B-3 B-2 B-3 B-3 B-3 B-14 B-14 B-3

F F B C-D T U H Q T-G

Inside diameter of bearing bore in crankcase Outside width of main thrust bearing cap and thrust bearing surface in crankcase Thickness of main bearing half at center (refer to B-3, D-C, below) Thickness of main bearing half 1 / 2 inch from ends (to be 0.0005 to 0.0010 less than at center E) Inside diameter of main bearing at proper torque tightness (90 degrees to split line) (STD) 0.003 undersize 0.010 undersize Inside width of main thrust bearing face Fit of main thrust bearing over bearing cap and thrust bearing surface in crankcase Fit (oil clearance) of bearings on journals (refer to table 6-9) Outside width of main thrust bearing Thickness of main thrust bearing flange (refer to B-3, D-C, above) Inside diameter of bearing bore in crankcase liner (starter) Inside diameter of bearing bore in crankcase liner (generator) Fit (crankshaft end play) of thrust bearing in journal (refer to table 6-9)

4.7538 4.7553 2.0240 2.0260 0.2492 0.2499

** **

4.2545

4.2575

4.2585

4.2515 4.2545 4.2445 4.2475 2.0300 2.0320 0.0040L 0.0080L 0.0040L 2.4860 0.2270 2.8346 2.8346 0.0110 0.0080L 2.4880 0.2290 2.8353 2.8353 0.0150L

4.2555 4.2485 * * 0.0100L 2.4840

2.8356 2.8356 0.0190L

Note. Refer to paragraph 6-3b for explanation of symbols.

6-18

e. Repair. Repair or replace damaged parts. Refer to paragraph 6-4e, table 6-3, and figure 615 through 6-17 when replacing crankcase studs. Repair of crankcases by welding is permissible except in areas of high stress such as radii, webbing, and bosses. Refer to paragraph 6-4c for general welding instructions and (1) through (3) below for specific information on welding repair of the crankcase. (1) Repair by blending, of nicks, grooves, or impact damage on the inside of crankcase on

the underside of the cylinder deck machined surface is permitted providing damage does not progress into restricted area indicated in figure 613. Damaged cylinder stud holes may be repaired, but entire missing sections may not be replaced. It is permissible to repair machined surface mounting bosses on pads which have been damaged by fretting, scoring or impact except in those areas indicated in figure 6-13. Weld surfaces must be restored to specified dimensions by machining.

Figure

6-13.

Crankcase

restricted

welding

areas.

6-19

(2) To detect dimensional changes caused by welding repair, precisely measure crankcase at several key positions depending upon the location of the repair. For repair to side walls, measure through the (d). positions outlined in steps (a)

(d) From cylinder mounting deck to crankshaft bearing support bore centerline using a suitable plug or bore in the crankcase bearing bore (A). This measurement shall be within 8.377-8.369 inch. (e) Oil pan rail shall be flat within 0.010inch when all four corners are on the same plane. (3) For repair in other locations, measure in the appropriate locations to insure that critical dimensions future use. are held. Record dimensions for

(a) Across the main bearing cap support web machined surfaces (B, fig. 6-14). (b) Across the inside of the crankcase at the junction of the side wall and the oil pan rail (D). (c) From oil pan rail face to main bearing cap support face (C).

Figure 6-14. Points of measurement for checking crankcase.

6-20

Figure

6-15.

Crankcase

studding-

right

rear

exploded

view.

Figure

6-16.

Crankcase

studding-

left

rear

view.

6-21

Figure 6-17. Crankcase studding-bottom view.

Table 6-3. Crankcase Standard and Oversize Stud Identification
Fig. No.

6-15

6-15

6-15

Fig. 6-15 6-15

6-15

6-15

6-22

Table 6-3. Crankcase Standard and Oversize Stud Identification- Continued

Fig. No.

6-15

6-15

6-15

6-15

6-16

6-16

6-16

6-16

6-16

6-16

6-16

6-16

6-16

6-16

6-17

6-23

Table 6-3. Crankcase Standard and Oversize Stud Identification - Continued

Fig. No.

6-17

6-17

f.

Assembly. to

(1) Preliminary instructions. Refer general assembly procedures (para 6-6).

(2) Position crankcase. Rotate the engine overhaul stand so the crankcase is in the upright position. (3) Install pipe plugs. Refer to figures 6-5 through 6-7.

6-10. Overhaul of Transmission Adapter

a. Disassembly. Disassemble transmission adapter following the sequence of instructions which accompany figure 6-18.

Remove 1. Cut locking wire and remove four bolts (A) attaching lifting eye to transmission adapter. Remove lifting eye. 2. Cut locking wire and remove two bolts (B) attaching timing pointer to adapter. Remove timing pointer. 3. Do not remove the two dowel pins (C) or the two resilient mounts (D) unless inspection (para 6-3f) shows replacement is necessary. To remove dowel pins or resilient mounts, press from adapter using an arbor press. Install 1. If dowel pins (C) or resilient mounts (D) were removed from transmission adapter, install new parts using an arbor press. 2. Position timing pointer on adapter and install two bolts (B) securing pointer on adapter. Install locking wire securing bolts. 3. Position lifting eye on adapter and install four bolts (A) securing eye on adapter. Install locking wire securing bolts. Figure 6-18. Removing or installing transmission adapter lifting eye and timing pointer.

b. Cleaning, Inspection, and Repair. Refer to paragraphs 6-2 through 6-4. c. A s s e m b l y . Refer to figure 6-18.

6-24

6-11. a.

Rebuild

of

Starter

Drive

Disassembly. Disassemble starter driven

gearshaft following the sequence of instructions in figures 6-19 and 6-20.

Note. If the engine is equipped with a bearing cage that does not have a groove on the pilot diameter for the installation of a preformed packing, discard this bearing cage. Although both the old and new bearing cages maintain the same part number 8761022, only the late bearing cage is carried through normal replacement part channels and must be used when rebuilding packing Preformed starter driven MS 28775-236 gearshaft. cannot be

used on a bearing cage unless there is a groove in the cage pilot to accommodate it. 1. Press starter driven gearshaft (A) from upper ball bearing. 2. Press gearshaft from the lower ball bearing (B) in a similar manner. Figure 6-20. Pressing starter driven gearshaft from ball bearings.

1. Press the starter driven gearshaft from bearing cage. 2. To remove oil seal (A), press it from the bearing cage using a suitable arbor press. Discard oil seal. Figure 6-19. Pressing starter driven gear-

shaft and bearings from bearing cage.

6-25

b. Cleaning, Inspection, and Repair. (1) Refer to paragraphs 6-2 through 6-4. (2) Inspect starter driven gearshaft, oil seal, and bearings against limits specified in overhaul standards (table 6-4). Replace parts not meeting hese requirements.

(3) Minor damage incurred to the leading edge of the starter drive gear may be repaired by regrinding the leading surface to dimensions shown in figure 6-21. Regrind gear tooth chamfer to original configuration after rework of

starter drive leading face.

Figure

6-21.

Starter

drive

gear-rework.

6-26

Table 6-4 Fig. No.

B-14

B-14 B-14 B-14 B-14 B-14 B-14 B-14 B-14 B-14 B-14

Note.

Refer to paragraph 6-3b for explanation of symbols.

c. Assembly. Assemble starter driven gearshaft following instructions which accompany figures 6-22 and 6-23.

1. Coat ball bearing with engine oil, Military Specification MIL-L-45199, and position bearing on bearing flange of gearshaft. Press bearing on gearshaft using a suitable pressing sleeve (A). 2. Coat ball bearing (B) with engine oil, Military Specification MIL-L-45199, and press bearing on opposite end of gearshaft in the same manner. Figure 6-22. Pressing ball bearings on starter driven gearshaft.

6-27

6-12. Overhaul of Generator Drive

a. Disassembly. Disassemble generator drive gearshaft and adapter following instructions accompanying figures 6-24 and 6-25.

1. Coat new oil seal with engine oil, Military Specification MIL-L-45199. Position seal on bore of bearing cage with lip of seal toward ball bearing seat. 2. Carefully press oil seal into cage until seal is tight against seal seat flange. 3. Press starter driven gearshaft in the bearing cage. Figure 6-23. Pressing oil seal into bearing cage.

Figure

6-24.

Removing oil seal.

generator

adapter

6-28

b. Cleaning, Inspection, and Repair. Refer to paragraphs 6-2 through 6-4. (1) Inspect generator drive gearshaft, oil seal, and bearings against limits specified in the overhaul standards (table 6-5). Replace parts not meeting these requirements. (2) Refer to paragraphs 6-3c and 6-3e for inspection of generator adapter and studs. Refer to paragraph 6-4e and table 6-6 when replacing adapter studs.

1. Remove generator adapter oil seal from the adapter using a suitable arbor press. Note. It is not necessary to remove generator drive gearshaft ball bearings unless inspection (para 6-3d) indicates replacement is needed. 2. Press generator drive gearshaft from upper ball bearings (A). 3. Press the gearshaft from lower ball bearing (B) in the same manner. Figure 6-25. Pressing generator drive gearshaft from ball bearings.

Table 6-5. Generator Drive Overhaul Standards

Fig. No.

B-14 B-14 B-14 B-14 B-14 B-14 B-14 B-14 B-14 B-14 B-14 Fig. B-14

Note.

Refer

to

paragraph

6-3b

for

explanation

of

symbols.

6-29

Table 6-6. Generator Adapter Standard and Oversize Stud Identification

Fig. B-14

Note. Refer to figure 6-1 for oversize stud identification. c. Assembly. Assemble generator drive gearshaft and adapter following instructions which accompany figures 6-26 and 6-27.

1. If ball bearings were removed from generator drive gearshift, coat ball bearing (A) with engine oil, Military Specification MIL-L-45199, and position bearing on flange of gearshaft. Press bearing on gearshaft. 2. Coat ball bearing (B) with engine oil, Military Specification MIL-L-45199, and press the bearing on the other end of the gearshaft in the same manner. Figure 6-26. Pressing ball bearings on generator drive gearshaft. 6-30

1. If generator adapter oil seal (A) was removed from generator adapter, position oil seal on seal bore. The side of the seal with the trade mark and part number must be toward the stud side of the adapter. The lip of the seal must be directed toward the side opposite the studs. 2. Carefully press oil seal into adapter until seal is tight against seal seating flange in adapter. Figure 6-27. Pressing oil seal into generator drive gearshaft adapter.

1. Remove retaining ring (A) securing ball bearing (B) in generator idler gear. 2. Press bearing from gear. Figure 6-28. Removing generator idler gear retaining ring and ball bearing. b. Cleaning, Inspection, and Repair. Refer to paragraphs 6-2 through 6-4. (1) Inspect starter idler gear and bearing against limits specified in overhaul standards (table 6-7). Replace parts not meeting these requirements. (2) Inspect generator idler gear and bearing against limits specified in overhaul standards (table 6-7). Replace parts not meeting these requirements.

6-13. Overhaul of Generator and Starter Idler Gears

a. Disassembly. Disassemble generator idler gear following instructions which accompany figure 6-28. The starter idler gear is similar and may be disassembled in the same manner.

6-31

Table 6-7. Generator and Starter Idler Gears Overhaul Standards

Fig. No.

B-14 B-14 B-14 B-14 B-14 B-14 B-14 Fig. B-14

B-14 B-14 B-14 B-14 B-14

Note. Refer

to

paragraph

6-3b

for

explanation

of

symbols.

c. Assembly. Assemble generator idler gear following instructions which accompany figure 6-29. The starter idler gear is similar and may be assembled in the same manner.

1. Coat ball bearing (A) with engine oil Military Specification MIL-L-45199, and position bearing in bearing bore of generator idler gear. 2. Carefully press bearing into gear untill bearing seats against flange in gear. Secure bearing in gear with retaining ring (A) as shown in figure 6-28. Figure 6-29. Pressing ball bearing into

generator

idler

gear.

6-32

Section Ill. O V E R H A U L O F C O N N E C T I N G R O D , C R A N K S H A F T , AND ASSOCIATED PARTS 6-14. General

This section covers the overhaul of the connetting rods, crankshaft, and crankshaft oil seal and oil retaining plugs. Specific instructions on disassembly, cleaning, inspection, repair and assembly accompany the overhaul operations. Overhaul standards of individual components follow the inspection procedures. Refer to the following structions operations. table and (table 6-8) for applicable for inillustrations overhaul

Table 6-8. Connecting Rods, Crankshaft, and Associated Parts

Para 6-15a Figs. 6-30 and 6-31

Para 6-2

Para 6-16c Table 6-9 Fig. 6-34 Para 6-16b Table 6-9

Para 6-17b Figs. 6-35 and 6-36

Para 6-18c Figs. 6-37, 6-31, and 6-30

Para 6-16b Para 6-15b Fig. 6-32 Para 6-15c Fig. 6-33 Para 6-2 Para 6-2

Para 6-17a Para 6-18b Fig. 6-32

Para 6-3 Para 6-3

Para 6-4 Para 6-4

Para 6-18a Fig. 6-33

6-15

figures 6-30 and 6-31

6-33

Note. Do not use a scriber or other sharp instrument for marking connecting rod bearing halves. After bearings are removed, reassemble connecting rods and caps since they are matched units and must be kept together for inspection and installation. 1. Remove 24 cotter pins (A).

of

Note. Care must be exercised in the handling the connecting rods to avoid nicks and

scratches which act as stress risers and can lead to premature failure. 2. Remove 24 connecting rod cap bolt nuts attaching rod caps to connecting rods (B). Remove rod caps, bearings, and connecting rods from crankshaft.

Figure 6-30. Removing or installing connecting rod assemblies.

6-34

b. Crankshaft Oil Seal. R e m o v e

crankshaft

oil seal following instructions which accompany figure 6-32.

Note. For

location

identification

connecting

rods and caps are stamped with a location number on the side of one of the bosses. For example, 1R would identify connecting rod and cap for No. 1 cylinder on the right bank. Bearings are also marked to indicate their locations; for example, t h e c o n n e c t i n g r o d bearing half for cylinder 1R is marked 1RR and the bearing cap half for the same cylinder is m a r k e d "1RC". If the connecting rod, cap, or bearing obliterated, markings are restamp connecting rods, caps, or bearings, so that they can be installed in their original positions. In addition, the connecting rod and cap, which are a matched assembly, are marked with identifying serial numbers. These identifying serial numbers are located on the side opposite the cylinder location numbers. The rod and cap must be kept as a matched assembly, as parts are not interchangeable.

Remove 1. Separate the retaining spring (A) from spring retaining lip of the oil seal. 2. Disengage the ends of the spring I (B) at its parting line with half turn as shown. 3. Separate seal (C) at split line and remove from the crankshaft. Discard seal and spring. Install 1. Apply a light coating of automotive and artillery grease (GAA), FSN 9150-190-0905, to new crankshaft oil seal (C). Install oil seal on crankshaft with closed, or flat, side toward flywheel flange. 2. Place a new seal spring (A) around crankshaft as shown. Turn one end of spring one half turn clockwise and the other end one half turn counterclockwise. Insert male end into female end and release spring ends. Spring ends must be properly engaged. 3. Insert the spring in the retaining groove in the oil seal. Figure 6-32. Removing or installing crankshaft oil seal.

Figure 6-31. Connecting rod and bearing identification marks.

6-35

c. Crankshaft. Remove crankshaft oil retaining plugs following instructions which accompany figure 6-33.

dye check method. Pay particular attention to areas around crankshaft oil holes and fillets adjacent to the crank cheeks. (2) Inspect connecting rod journal radii of crankshaft for evidence of specific points of wear or damages that would indicate a bent or twisted connecting rod. (3) Check diameters of main bearing and connecting rod journals against limits specified in overhaul standards (table 6-9). Check run-out of crankshaft by supporting end journals in V blocks and measuring the run-out at the center journals with a dial indicator. Maximum allowable run-out is 0.025 inch at No. 4 journal. (4) Inspect journals for nicks, burs, grooves. scratches, galling, scuffing, or discoloration. Mark minor defect areas for future repair. (5) Check dowel pins and straight pins for tightness in the crankshaft flanges. Check pins against limits specified in the overhaul standards

Remove 1. Remove six cotter pins (A). 2. Remove six bolts (B), slotted nuts, and flat washers. 3. Remove 12 retaining plugs (C) from each end of the bore through the six crankshaft connecting rod journals. Install 1. position 12 retaining plugs (C) in each end of the bore through the six crankshaft connecting rod journals. 2. Install six bolts (B), slotted nuts, and flat washers securing plugs. 3. Install six cotter pins (A) securing slotted nuts. Figure 6-33. Removing or installing crankshaft oil retaining plugs. Note. Do not remove dowel pins (18, fig. B-3) and straight pins (25) from crankshaft unless inspection (para 6-16) indicates replacement is necessary. secured Dowel pins in flywheel end are with setscrews.

(table 6-9). c. Inspection Bearings. (1) of Connecting rod Rods and

Connecting

bearings. I n s p e c t

connecting rod bearing halves (fig. 6-31) in the same manner as described for main sleeve bearings. Apply a thin coating of Prussian blue, FSN 8010-247-8706, to the backs of the coninstall in their necting r o d b e a r i n g s a n d respective connecting rods and caps according to the location markings (fig. 6-31). Assemble rod and cap, and torque tighten nuts to 950-poundinches. Check bearing inside diameter, using a dial indicator as shown in figure 6-34, against the limits specified in the overhaul standards (table 6-9) for contact as shown by Prussian blue, FSN 8010-247-8706, transfer in the same manner in which the main sleeve bearings were checked (para 6-9d). Replace any bearing that does not make at least 75 percent contact. (2) C o n n e c t i n g r o d a s s e m b l y . (a) Check connecting rod bearing bore with dial indicator against limits specified in

6-16. Cleaning and Inspection

a. Cleaning. Refer to paragraph 6-2. Clean crankshaft oil passages with compressed air and brass wire probes. Note. Care must be taken not to destroy or rod bearing remove main and connecting location markings. b. Inspection of Crankshaft. with (1) Inspect crankshaft for cracks magnetic particle inspection equipment or When when available. similar equipment magnetic particle inspection equipment is not available use a magnifying glass (five power magnification minimum) and a strong light or

overhaul standards (table 6-9). (b) Check rods for cracks and for twisted or bent condition. Bent or twisted connecting rods must be replaced. Under no circumstances should connecting rods be straightened. Destroy any rod found damaged to insure it will not be reused in an engine. (c) Inspect for sharp corners at rod bolt counterbore and contour areas (fig. 6-35). Mark rods having sharp corners for repair.

6-36

(d) Check dimension between centerline of small and large end bores (fig. 6-36). This dimension must be 10.998 to 11.002 inches. If rods do not meet this limit, destroy to insure rods are not reused in an engine. (e) Inspect piston pin sleeve bearing bore (fig. 6-34) for pitting, galling, scoring, or discoloration. Mark damaged bearings for replacement. (f) Connecting rods should be matched by weight. Weight variations between connecting rods in an engine should not exceed 0.5 ounce.

Figure 6-34. Checking connecting rod bearing bore using dial bore indicator. Table 6-9. Connecting Rods, Crankshaft and Associated Parts Overhaul Standards
Component Fig No. Ref. letter

Crankshaft

B-3 B-3 B-3 B-3

K M M-K P

B-3

B-3

S-P

B-3 B-3 B-3 B-3 B-3 B-3

R N N-R A B A-B

Note. Refer to paragraph 6-3b for explanation of symbols.

6-37

Table 6-9. Connecting Rods, Cranksahft and Associated Parts Overhaul Standards-Continued
Fig. Component No. Ref. letter

B-3

B-3 B-3

C-D W

refer to table 6-2

B-3 B-3 B-3 B-3 B-3 B-3

L J L-J G T-G
(refer to table 6-2)

Crankshaft

Connecting rod, B-4 bearings, and B-4 bolts B-4

C TT VV

B-3 B-4 B-4 B-3

W VV UU H

B-4 B-4 B-4 B-4 B-4

A E B D B-D

Note. Refer to paragraph 6-3b for explanation of symbols.

6-38

Table 6-9. Connecting Rods, Crankshaft and Associated Parts Overhaul Standards - Continued
Component Fig. No. Ref. letter Point of measurement Sizes and fits of new parts Wear limits

B-4

RR

B-4 B-4 B-4

SS H SS-H

Outside diameter of split sleeve bearing must be press fit in bore. Burnish to seat sleeve bearing prior to finish diameter Inside diameter of bushing-type sleeve bearing Outside diameter of piston pin Fit of pin in bearing

2.0027 2.0025 2.0002 2.0000 0.0023L 0.0027L

2.0040 1.9998 0.0042L

Note. Refer to paragraph 6-3b for explanation of symbols.

6-17. Repair
a. Crankshafts. (1) Replace crankshafts that are deeply scratched, nicked, burred, scuffed or galled. Minor imperfections in the journals may be repaired by polishing with a crocus cloth dipped in dry-cleaning solvent or mineral spirits paint thinner. (2) Crankshafts that are worn beyond standard wear limits specified in the overhaul standards (table 6-9) or with journal or crankcase damage may be ground undersize to the limits established for crankshaft rework (table 69). (3) In the event any of the crankpins or journals are found unserviceable, it will be necessary to polish or grind all crankpins or journals uniformly undersize to maintain the balance of the crankshaft. Extreme care must be taken when regrinding, to maintain the concentricity of the entire crankshaft and not to exceed a surface roughness of 12 micro inches. All radii on the crankpins and journals, effected by grinding undersize, must be re-established to original configuration. The crankshaft nitride finish of crankpins and journals must be inspected by magnaflux or similar method for fractures and surface cracks after finishing. (4) Replace dowel pins (18 fig. B-3) and straight pins (25) in crankshaft flange if pins do not fit securely in flange, are out-of-round or if pins do not conform to limits specified in the overhaul standards (table 6-9). Note. The headless grooved dowel pins in the flywheel end flanges are available in 0.005 and 0.010 in. oversize. Ream crankshaft flywheel mounting flange to necessary oversize dimen-

sions and install new pins. Whenever oversize pins are used, it will be necessary to ream the flywheel and transmission drive gearshaft accordingly. (5) Replace a cracked crankshaft or a crankshaft showing evidence of wear due to bent or twisted connecting rods. b. Connecting Rods and Bearings. (1) Connecting rod bolts. (a) Replace bolts that do not fit snugly in rod and cap. (b) Replace bolts that have damaged threads, galled pilot diameters, or diameters that are not standards within (table limits 6-9). specified in overhaul

(c) Replace bolts that are cracked or evidence of that any show scratched, or stretching. (2) Connecting rod bearings. R e p l a c e a l l bearings that do not check within limits specified in overhaul standards (table 6-9) or when bearings do not show 75 percent contact by Prussian blue transfer after bore check. (3) Connecting rod assembly. Discard connecting rods that are bent or distorted. Straightening of connecting rods is not permitted. Break and polish sharp edges at connecting rod counterbore and rod contour (fig. 635). Replace connecting rod assemblies which are not within limits specified in overhaul standards (table 6-9). Connecting rods with worn or damaged piston pin bearing may be repaired. Replace worn or damaged piston pin bushing-type bearing using an arbor press. Bearing split line must be 90 degrees from longitudinal center line. Line-ream new bearing to size shown in overhaul standards (table 6-9). 6-39

Take half of the connecting rod base dimension of 4.0941 to 4.0946 in. to achieve 10.998 to 11.002 between centers (fig. 6-36).

Figure 6-35. Break and polish sharp edges of connecting rod counterbore and rod contour.

6-40

crankshaft.

Right

bank

rods

(marked

R)

are

installed on the damper flange side of journal. Note. All location numbers must be visable from the oil pan side when crankshaft and rods are installed in the crankcase. (3) Position connecting rod cap, with bearing installed, on journal and mate it with the corresponding rod. Secure rod and cap to crankshaft with two slotted nuts. (4) Tighten nuts to 950 pound-inches torque, plus sufficient additional torque to aline
NOTE. BEFORE REAMING, LUBRICATE THREADS ON CONNECTING ROD BOLTS AND NUTS WITH THREAD LUBRICANT, 9150-663-1770 OR 9150-527-1752, (OR EQUIVALENT) AND TIGHTEN NUTS TO A TORQUE OF 950 LB-INS.

slots in nuts with cotter pin holes in bolts. (5) Check the side clearance of each pair of connecting rods against limits specified in overhaul standards (table 6-9), using a feeler gage as shown in figure 6-37. Disassemble and and bearings as rods replace connecting necessary to obtain the proper clearance. (6) Secure slotted nuts to connecting rod bolts with cotter pins as shown in figure 6-30.

Figure 6-36. Connecting rod bore center dimensions.

6-18. Assembly
a. Crankshaft. Refer to figure 6-33. b. Crankshaft Oil Seal. Refer to figure 6-32. c. C o n n e c t i n g Rod Assemblies. Note. Total weight variation between individual connecting rods on any one engine shall not exceed 0.5 ounce. (1) Position connecting rod bearing halves in their respective rods and caps (fig. 6-31). Install two connecting rod bolts in each connecting rod making certain each bolt is properly seated in the recess provided. (2) Position rods on crankshaft in proper location according to their identifying number. Connecting rod Nos. 1R and 1L are assembled on the journal at the damper flange end of the Figure 6-37. Checking connecting rod side clearance.

6-41

Section IV. OVERHAUL OF TORSIONAL VIBRATION DAMPER, FLYWHEEL, ACCESSORY DRIVE GEAR, AND TRANSMISSION DRIVE GEAR SHAFT 6-19. General
This section covers the cleaning, inspection, and repair of the torsional vibration damper, flywheel, accessory drive gear, and transmission drive gearshaft. Overhaul standards of the inTable 6-10. Torsional Vibration Damper, Flywheel, Accessory Drive Gear, and Transmission Drive Gearshaft
Cleaning Inspection Repair

dividual 10) for for

components applicable

follow

the and

inspection instructions

procedures. Refer to the following table (table 6illustrations individual operations.

Torsional Vibration Damper

Para 6-2

Flywheel

Para 6-2

Accessory Drive Gear Transmission Drive Gearshaft

Para 6-2 Para 6-2

Para 6-20b Table 6-11 Fig. 6-38 and 6-39 Para 6-20b Table 6-11 Figs. 6-40 and 6-41 Para 6-20b Table 6-11 Para 6-20b Table 6-11

Para 6-21b

Para 6-21c

Para 6-4h Para 6-21c Figs. 6-42 and 6-43

6-20. Cleaning and Inspection

a. Cleaning. Refer to paragraph 6-2.

Inspection. Refer to paragraph 6-3. (1) Torsional vibration damper. I n s p e c t torsional vibration damper (6, fig. B-3) for dents or distortion of the outer surfaces. Name and warning plates must be intact (figs. 6-38 and 639). Check vibration damper against limits specified in overhaul standards (table 6-11). Replace damper that is questionable or unserviceable.

b.

Figure

6-39.

Torsional

vibration

damper

nameplate.

Figure 6-38. Torsional vibration damper warning plate.

6-42

(2) Flywheel. Inspect flywheel (9, fig. B-3) for elongated dowel pin holes. Mark oversize or out-of-round dowel pin holes for repair. Check flywheel fuel injection pump timing mark (IR INJ PORT CLOSE) location to be certain flywheel has been marked properly. Original production engine flywheel marks were set at 26 degrees BTC. Improved design engine flywheel marks were set at 30 degrees BTC at production and were later remarked with a dotted line to a 26 degree setting. All flywheels must be marked to the 26 degree setting with a dotted line as shown in figures 6-40 and 6-41. In the event of a flywheel having original markings only and without a dotted line to indicate the proper 26 degree BTC setting, carefully measure to determine correct degree s e t t i n g a n d m a r k flywheel with a dotted line as shown in figures 640 and 6-41.

Figure 6-40. Original production engine flywheel fuel injection pump timing mark location.

6-43

(3) Transmission drive gearshaft, I n s p e c t gearshaft (10, figure B-3) for oversize or out-ofround dowel pin holes. Mark dowel pin holes for repair. C h e c k b u s h i n g - t y p e b e a r i n g a g a i n s t limits specified in overhaul standards (table 611). (4) Accessory drive gear. C h e c k a c c e s s o r y drive gear (8, figure B-3) against limits specified in overhaul standards (table 6-11).

Figure 6-41. Improved design engine flywheel fuel injection pump timing mark location.

6-44

Table 6-11. Torsional Vibration Damper, Flywheel, Accessory Drive Gear, and Transmission Drive Gearshaft Overhaul Standards Component Torsional damper Fig. No. Ref. letter A Point of measurement Sizes and fits of new parts 4.2515 4.2490 0.0005L 7.9980 8.0000 0.0010L 0.0000 0.6245 0.6295 0.6345 0.6255 0.6305 0.6355 0.0000 0.0000 0.0000 9.7480 9.7500 0.0000 2.8320 2.8338 0.0008L 4.2525 4.2510 0.0035L 7.9990 8.0010 0.0030L 0.0150 0.6255 0.6305 0.6355 0.6257 0.6307 0.6357 0.0012T 0.0012T 0.0012T 9.7500 9.7520 0.0040L 2.8330 2.8346 0.0026L Wear limits 4.2535 4.2475 0.0060L 7.9970 8.0020 0.0050L 0.01.50 * *

vibration B-3 B-3 B-3 B-3 B-3 B-3 B-3 B-3

Flywheel

B-3

B-3

Accessory drive gear B-3 B-3 B-3 drive B-3 B-3 B-3 B-3

Transmission gearshaft

B-3

B-3

Inside diameter of crankshaft pilot bore in damper B Outside diameter of damper hub on crankshaft A-B Fit of damper on crankshaft K Outside diameter of flywheel hub on crankshaft M Inside diameter of crankshaft pilot bore in flywheel K - M Fit of flywheel on crankshaft Flywheel runout Q P Inside diameter of dowel pin holes in flywheel STD 0.005 oversize 0.010 oversize S Outside diameter of dowel pin in crankshaft STD 0.005 oversize 0.010 oversize S-P Fit of dowel pin in flywheel STD 0.005 oversize 0.010 oversize Outside diameter of accessory drive gear J mounting flange on crankshaft L Inside diameter of crankshaft pilot bore in accessory drive gear L-J Fit of accessory drive gear in crankshaft N Outside diameter of hub on transmission accessory drive gearshaft R Inside diameter of transmission accessory drive gearshaft pilot bore in crankshaft N - R Fit of transmission accessory drive gearshaft in crankshaft P Inside diameter of dowel pin hole in transmission drive gearshaft STD 0.005 oversize 0.010 oversize S Outside diameter of dowel pin in crankshaft STD 0.005 oversize 0.010 oversize S-P Fit of dowel pin in transmission drive gearshaft STD 0.005 oversize 0.010 oversize 6-3b for explanation of symbols.

* * * * * * 9.7470 9.7530 0.0060L 2.8315 2.8350 0.0035L

0.6245 0.6295 0.6345 0.6255 0.6305 0.6355 0.0000 0.0000 0.0000

0.6255 0.6305 0.6355 0.6257 0.6307 0.6357 0.0012T 0.0012T 0.0012T

* * * * * * * * *

Note.

Refer

to

paragraph

6-45

6-21.

Repair

a. General. Refer to paragraph 6-4. b. Torsional Vibration Damper. R e p l a c e torsional vibration damper when it does not conform to limits specified in overhaul standards (table 6-11). Replace damper when dented or distorted. Remove minor imperfections with crocus cloth. c. Flywheel and Transmission Drive Gearshaft. Repair elongated dowel pin holes in flywheel and gearshaft by reaming to either 0.005 or 0.010 inch oversize. Install the appropriate o v e r s i z e d o w e l p i n s . I t w i l l b e necessary to line ream the crankshaft flange, flywheel, and transmission drive gearshaft to install the replacement oversize pins. d. Transmission Drive Gearshaft Bushingtype Bearing. W h e n t h e g e a r s h a f t b u s h i n g - t y p e bearing needs replacement, use a suitable arbor and an arbor press to remove bushing-type bearing as shown in figure 6-42. Press new bushing-type bearing into gearshaft using arbor press as shown in figure 6-43. Ream the bushing-type bearing from 1.3775 to 1.3780 inch after installation. When oversize dowel pins have been installed in the crankshaft, transmission drive gearshaft dowel pin holes must be reamed to the proper oversize dimension.

Figure 6-43. Pressing bushing-type bearing into transmission drive gearshaft. e. Accessory Drive Gear. Refer to paragraph 6-4h for repair of accessory drive gear.

Figure 6-42. Pressing bushing-type bearing from transmission drive gearshaft.

6-46

Section V. OVERHAUL OF PISTONS, RINGS, AND PISTON PINS 6-22. General

This section covers the overhaul of the pistons, rings, and piston pins. Specific instructions on disassembly, cleaning, inspection, repair, and assembly accompany the overhaul operations. Overhaul standards of individual components follow the inspection components. Refer to the following table (table 6-12) for applicable illustrations and instructions for overhaul operations.

Table 6-12. Pistons, Rings, and Piston Pins Component Piston Disassembly Para 6-23 Figs. 6-44 and 6-45 Cleaning Para 6-24 Inspection Para 6-25a Table 6-13 Para 6-25b Table 6-13 Para 6-25c Table 6-13 Repair Para 6-26a Assembly Para 6-27 Figs. 6-46 through 6-44

Piston Rings Piston Pins Para 6-24

Para 6-26b Para 6-26c

6-23.

Disassembly

a. Pistons. Disassemble pistons following instructions which accompany figures 6-44 and 6-45.

Note. Before removing compression rings and oil control ring, check to see if they are free in piston grooves. Mark ring grooves of sticking rings for further detailed inspection. 1. Place jaws of remover and replacer - 5120-795-0177 in the end gap of upper piston ring (A). Spread ring, lift out of groove, and remove from piston. Discard piston ring. 2. Remove and discard two intermediate compression rings (B) and oil control ring in the same manner. Figure 6-44. Removing or installing piston compression rings using remover and replacer-5120-795-0177.

Remove 1. Remove oil control piston ring expander spring (A) by separating at parting line as shown. Discard spring. Install 1. Install new oil control ring expander spring (A) in oil control groove of piston and join ends of spring together as shown. Figure 6-45. Removing or installing oil control piston ring expander spring.

6-47

6-24. Cleaning
a. Pistons. (1) Clean pistons (9.3, fig. B-4) and piston pins (9.2) by soaking in carbon removing compound, Specification MIL-S-12382 (Ord Type 1). Use goggles, rubber gloves, and Warning: rubber apron when cleaning parts in carbon removing compound. Provide adequate ventilation. Avoid inhalation of fumes and skin contact. If compound is splashed on skin, flush with fresh water and wash with alcohol. Alcohol containing 2 to 3 percent camphor is preferable. (2) Optional cleaning of the piston can be accomplished with a vapor blast using glass heads to provide the cleaning action and surface roughness. A surface roughness of 50 to 100 RMS is exceptable with a RMS of 80 preferred. If vapor blast equipment is not available, scrape off remaining carbon deposits from piston ring grooves with a scraper or broken piston ring. Be careful not to scratch or gouge ring lands on piston. Clean oil drain holes and oil ring grooves

in piston. Remove carbon from oil holes in ring grooves. Clean carbon from piston pins with crocus cloth dipped in dry-cleaning solvent or mineral spirits paint thinner.

6-25. Inspection
a. Pistons. Inspect piston for cracks, flaws or distortion. Use a magnifying glass and a strong light. Small cracks will show under the light as irregular or dark streaks. Check piston ring grooves against limits specified in overhaul s t a n d a r d s ( t a b l e 6 - 1 3 ) . I n s p e c t p i s t o n for dam age or broken ring lands, nicks, burrs, or scratches. Inspect piston pin bores for wear, cracks, or abrasions. Replace piston if found unserviceable. b. P i s t o n R i n g s . I n s p e c t i o n o f p i s t o n r i n g s rem oved from piston is not required. New rings will be installed during piston assembly. c. Piston Pins and Plugs. I n s p e c t p i s t o n p i n and plugs for cracks, nicks, or wear. Inspect end plugs for large wear pattern and replace if found unserviceable. Check diameter of pins against limits specified in overhaul standards (table 613).

6-48

Table 6-13. Pistons, Piston Rings and Piston Pins overhaul Standards Component Piston Fig. No. B-4 B-4 B-4 B-4 B-4 B-4 Piston Pins B-4 B-4 B-4 B-4 B-4 Piston Rings B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 Piston Rings B-4 B-4 B-4 Ref. letter QQ KK LL M M NN J J-H G F-G CC EE LLEE DD GG MMGG FF JJ NNJJ HH L Point of measurement Diameter at bottom of skirt 90 degrees to piston pin Diameter of top groove in piston (measured over 0.11547 dia. pins) Inside width of top intermediate groove in piston Inside width of lower intermediate groove in piston Inside width of oil control ring groove in piston Inside diameter of piston pin bore in piston Outside diameter of piston pin Fit of piston pin in Piston Outside diameter of piston pin plugs Inside diameter of bore in piston pin Fit of piston pin plug in piston pin Gap clearance of top compression ring when fitted in gage Outside width of top intermediate compression ring Clearance between ring and piston Gap clearance of ring when fitted in gage Outaide width of lower compression ring Clearance between ring and piston Gap clearance of ring when fitted in gage Outaide width of oil control ring Clearance between ring and piston Sizes and fits of new parts 5.7415 5.7380 0.0990 0.0980 0.1880 2.0018 2.0000 0.0016L 0.9975 0.9995 0.0010L 0.0500 0.0925 0.0055L 5.7425 5.7480 0.1000 0.0990 0.1890 2.0020 2.0002 0.0020L 0.9985 1.0005 0.0030L 0.0600 0.0935 0.00075L Wear limits 5.7385 to 5.7435 5.7280 0.1035 0.1025 0.1910 2.0012 to 2.0030 1.9998 0.0006L: to 0.0032L * * * * * 0.0110L * * 0.0100L * * 0.0060L * 5.7600 0.0215L

0.0500 0.0600 0.0925 0.0935 0.0045L 0.0065L 0.0500 0.1850 0.0015L 0.0600 0.1865 0.0040L 0.0500 5.7530 0.0115L

0.0300 Gap clearance of ring when fitted in gage Cylinder bore diameter measured up 2.250 5.7510 inches from bottom of cylinder skirt 0 0 - L Fit of piston in cylinder bore, measured up 0.0075L 2.250 inches from bottom of cylinder skirt, 90 degrees to piston pin

Note.

Refer to paragraph 6-3b for explanation of symbols.

6-49

6-26. Repair
a. Pistons. (1) Replace pistons which are not within limits specified in overhaul standards (table 613). (2) Replace pistons which are distorted, cracked, worn, or abraded. (3) Replace piston if oil holes in the ring lands cannot be cleared or if lands are damaged or broken. (4) Replace pistons that are badly burred, nicked, or scratched. Remove minor burs, nicks, o r s c r a t c h e s f r o m p i s t o n s w i t h c r o c u s cloth dipped in dry-cleaning solvent or mineral spirits paint thinner. b. Piston Rings. Piston rings cannot be repaired. All piston rings must be replaced with new rings at engine overhaul. c. Piston Pins and Plugs. R e p l a c e p i s t o n p i n s and plugs which are cracked, or have deep nicks or scratches. Remove minor nicks or scratches with crocus cloth dipped in dry-cleaning solvent or mineral spirits paint thinner. Replace piston pin plugs which have a large wear pattern on the end. Replace piston pins and plugs not within limits specified in overhaul standards (table 613).

6-27. Assembly
a. Check marking on new rings and install the upper (tapered) compression ring and the two intermediate compression rings with the marking UP toward the piston dome. Install all rings using remover and replacer - 5120-795-0177 as shown in figures 6-44 and 6-45. Use care in installing rings to avoid damaging ring lands or distorting rings. b. Measure side clearance of all new ring (fig. 6-46). Replace rings when side clearance does not conform to limits specified in overhaul standards (table 6-13).

Figure 6-46. Checking piston ring side clearance. c. Install piston in bore of piston and install a piston pin plug at each end of piston pin. d. Select pistons according to weight. Variations in the weight of pistons in an engine should not exceed 0.5 ounce.

6-50

Section VI. OVERHAUL OF CYLINDER ASSEMBLY 6-28. General

This section covers the overhaul of the cylinder assembly. Specific instructions on disassembly, cleaning, inspection, repair, and assembly accompany the overhaul operations. Overhaul standards of individual components follow the inspection procedures. Stud identification information is included in the repair procedures. Refer to tbe following table (table 6-14) for applicable illustrations and instructions for overhaul operations.

Table 6-14. CylinderAssembly Component Cylinder Disassembly Para 6-29 Figs. 6-47 through 6-49 Cleaning Para 6-30 Fig. 6-50 Inspection Para 6-31 and 6-32 Table 6-15 Figs. 6-52 through 6-57 Repair Pam 6-33 Table 6Figs. 68 through 6-64 Assembly Para 6-34 Fig. 6-65

6-51

6-29. Disassembly
a. Cylinder. Disassemble cylinder assembly following instructions which accompany figures 6-47 through 6-49. Note. The 12 rocker arm cover assemblies are machined with cylinder assemblies as matched units. The covers are stamped with matching numbers (fig. 5-105) to correspond with the number stamped on the cylinder. Keep covers with their respective cylinders.

W a r n i n g : The valves and locks are under heavy spring tension. Exercise extreme care when removing locks, retainers and springs. 1. Compress exhaust valve spring and upper retainer. 2. Remove two valve locks (A) from the groove in valve stem. Tap valve spring retainers to free locks. Carefully loosen lifter screw to release valve springs. 3. Remove intake valve spring upper retainer locks (B) in the same manner. 4. Remove lifter assembly (C). Figure 6-48. Compressing exhaust valve springs to remove or install upper valve spring retainer and locks.

1. Place cylinder with valves, springs, and retainers on removing and inserting valve stand - 4910-554-1317 (A). 2. Secure valve lifter assembly - 5120-678-5285 to the cylinder head with four bolts (B) and flat washers. Figure 6-47. Cylinder showing position of valve lifter assembly - 5120-678-5285 and removing and inserting valve stand 4910-554-1317.

6-52

1. Remove exhaust valve inner, intermediate, and outer valve springs, upper retainer and exhaust valve rotor (A) from valve stem. 2. Remove intake valve springs (B), retainer, and seat in the same manner. 3. Hold the valve stems in position in the cylinder head and remove the cylinder from removing and inserting valve stand - 4910-554-1317 (C).

4. Place cylinder on side and remove the intake and exhaust valves (D) through the cylinder bore. Note. Temporarily install valve rocker arm covers on cylinders with two bolts to prevent damage arid mismating of parts. Refer to figure 5-105 for cover and cylinder identification.

Figure 6-49. Removing or installing valve springs, upper retainers, and exhaust valve rotor.

6-53

b. Value Rocker Arm Covers. Refer to paragraph 4-14.

6-30. Cleaning.
a. C l e a n c y l i n d e r a n d a s s o c i a t e d p a r t s , a n d remove heavy carbon deposits from combustion chamber with a scraper or blunt tool which will not nick or scratch the surface, Remove only the heavy carbon deposits. Surface need not be cleaned to a mirror finish. b. Clean carbon from fuel injector nozzle seat using nozzle carbon cutter - 4910-795-7958 as shown in figure 6-50.

c. S o a k c y l i n d e r i n c a r b o n r e m o v i n g c o m pound to remove carbon and other foreign material from dome, valve ports, and the area between the top of the barrel and the head casting.

6-31. Inspection
a. Valve Guides. Inspect valve guides (14 and 37, fig. B-4), for cracks, galling, erosion, or scuffing. Check guides for secure fit in cylinder. Check guides against limits specified in the overhaul standards (table 6-15). Note. Do not remove valve guides unless replacement is necessary. b. Valve Seat Inserts. Check valve seat inserts for secure fit in the cylinder (41, fig. B-4). Inserts must have tight fit. Inspect inserts for burned or pitted surfaces. Check valve seat contact by lightly bluing face of insert with Prussian blue - 8010-247-8706 and placing a new valve into position on valve insert. Rotate valve one-half turn on insert and check valve seat for Prussian blue contact. Valve seat must show perfect contact, as indicated by Prussian blue transfer, to qualify as a serviceable insert. Inserts that do not show perfect contact must be marked for repair. If inserts are cracked, loose, or damaged beyond repair, the cylinder must be replaced. If valve seat inserts can be made serviceable by grinding; repair as outlined inparagraph 6-33a(2). Check the inserts against limits specified in overhaul standards (table 615). c. Cylinder. Two types of cylinders have been used on the ADVS-1790 series engines. The latest type cylinder has a wall thickness increased by 0.030 inch to provide greater strength. These cylinders can be identified by a machined groove on the cylinder mounting flange periphery, refer to figure 6-51.

Figure 6-50. Clean ing carbon deposits from fuel injector nozzle seal using nozzle carbon cutter - 4910-795-7958.

6-54

Figure 6-51. Cylinder identifying groove. (1) C y l i n d e r b a r r e l . R e f e r t o p a r a g r a p h 6 32. Ultrasonic Inspection of Cylinder Barrel, for inspection procedures of the cylinder barrel. (2) Cylinder bore. Inspect cylinder bore for deep scratches, scoring, or metal pickup. Inspect joint between cylinder head and cylinder barrel for pitting or erosion. Carefully run finger over cylinder wall to check for ring ridge. (3) C y l i n d e r b o r e d i m e n s i o n s . C y l i n d e r bores taper slightly at the head end (a room temperature). The tapered section expands, and is essentially straight at operating temperature. Check bore dimensions, as described in (a) through (d), below, against limits specified in overhaul standards (table 6-15). (a) With cylinder at room temperature, take two cylinder bore measurements at top of ring travel. Measure diameter approximately parallel to line of valves, and then take cross

6-55

measurement (90 degrees) to first measurement. Average the two measurements. (b) Take two measurements of diameter bore at bottom of ring travel. Measure diameter of bore approximately parallel to line of valves, and then take cross measurement (90 degrees) to first measurement. Average the two measurements. (c) Head-end average must not exceed flange-end average. (d) Compare the measurements taken 90 degrees apart. Each two measurements (top or bottom) must be within 0.003 inches of each other. If the difference exceed 0.003 inches, the cylinder is out-of-round and must be marked for repair. (4) C a m s h a f t b e a r i n g s u r f a c e . I n s p e c t cam shaft bearing surface for pitting, galling, burs, and nicks. Check bearing diameter, with rocker a r m cover installed, against limits specified in overhaul standards (table 6-15). (5) Cylinder exterior. I n s p e c t c y l i n d e r h e a d and barrel cooling fins for possible repair (para 6-33 f). d. Valve Rocker Arm Covers and Associated P a r t s . (Refer to fig. B-4) (1) V a l v e r o c k e r a r m c o v e r . I n s p e c t v a l v e r o c k e r a r m c o v e r ( 3 9 ) f o r c r a c k s . Inspect cam shaft bearing surface in cover for galling, pitting, burs, and nicks. Check cover against limits specified in overhaul standards (table 615). Check valve adjusting cover plate (29) for cracks and for warpage. Replace cylinder assembly when cover is unserviceable. (2) Valve rocker arms. I n s p e c t v a l v e r o c k e r arms (33 and 34) for cracks, using a magnifying glass and a strong light. Inspect the bushing-type bearings in the rocker arms for scoring and secure fit. Check bearings against limits specified in overhaul standards (table 6-15). Inspect valve rocker arm rollers for scuff or score marks and for looseness on hub. Rotate roller and check clearance between roller and hub by mounting rocker arm securely in a soft-jawed vise. Set a dial indicator against contact surface of roller

and move roller through the extremes of its travel. Check reading on the dial indicator. Limits should be 0.006L in. maximum. Mark worn or damaged rollers and hubs for repair. Inspect adjusting screws (36) for stripped or dam aged threads. Check screw by turing screw in and out of rocker arms. Screw must turn freely. Check swivel pad on adjusting screw for free rotation, Mark damaged parts for replacement. (3) V a l v e r o c k e r a r m s h a f t s . C h e c k v a l v e rocker arm shafts (22 and 35) for cracks, nicks, scoring, or plugged oil passages. Check shafts against limits specified in overhaul standards (table 6-15). Replace unserviceable shafts. (4) Valves. (a) Valve head. C h e c k i n t a k e a n d e x h a u s t valve (11 and 12) for evidence of pitting, imperfect seating, or warping on valve head. Heavy discoloration, burning, erosion, or a heavy carbon deposit on valve face indicates a warped valve. A l i g h t f r o s t e d a p p e a r a n c e o r m i n o r discoloration on valve face does not indicate a warped or unserviceable valve. (b) V a l u e s t e m . I n s p e c t t h e v a l v e s t e m s and the locking groove in the stems for pitting, scoring cracks, or damaged tips. Checks valves against limits specified in overhaul standards (table 6-15). Replace valves that are warped, cracked, or unserviceable. (5) V a l v e springs. Inspect inner spring (18), intermediate spring (17), and outer spring (16) for wear, cracks, set, or other evidence of failure. Check all springs against limits specified in the overhaul standards (table 6-15). (6) Valve spring retainers, valve rotors, and locks. Inspect valve spring retainers (19 and 38) and intake valve spring seat (15) for wear and cracks. Check exhaust valve rotor (40) by rotating inner section. Inner section must rotate freely. Inspect rotor for wear or cracks. Inspect spring retainer locks for wear or cracks. Worn locks will have ridges on top face. Replace any unserviceable parts.

6-56

Table 6-15

Paragraph 6-3b

6-57

Table 6-15

Paragraph 6-3b

6-58

Table 6-15

Paragraph 6-3b

6-59

6-32. Ultrasonic Inspection of Cylinder Barrel (Part No. 10865297, FSN 2815-765-9711)
a. General. The following paragraphs, b

through e, contain the procedure for using cylinder barrel tester on part No. 10865297 (2815-765-9711) cylinder only.

Figure 6-52. Cylinder barrel tester - 4910-937-4261. b. Description of Test Equipment. (1) R e f l e c t o s c o p e . A n e l e c t r o n i c i n s t r u m e n t to provide means of transmitting and receiving pulsed ultrasonic energy, and interpretation for detection of flaws in the cylinder. (2) Search unit fixture. An adapter that directs ultrasonic energy into the proper area of the cylinder assembly, and is oriented to receive energy reflected back from defective areas. (3) M a s t e r c h e c k i n g c y l i n d e r . A p o r t i o n o f the cylinder, properly prepared with a specific defect, to act as a comparator tool. This cylinder compares to a no-go gage relative to cracks in the cylinder.
6-60

c. Functional Description of Equipment. (1) G e n e r a l . This inspection technique utilizes ultrasonic wave propagation for a nondestructive method of finding incipient cracks in the cylinder. The principle of ultrasonic flaw detection employs short bursts of high frequency sound vibrations, generated by a piezoelectric probe, transmitted into the cylinder barrel being inspected. Should a crack or discontinuity exist in the barrel, some of the sound wave energy will be reflected back to the source. A return sound wave, or echo, is converted into electrical energy which is displayed on the screen as a vertical indication on the horizontal (time) base line.

(2) Specific application 10865297 cylinder (thick

to part wall cylinder

No. with

(b) Plug the reflectoscope into a 115 volt 10 volt, 50 / 60 cycle single phase power source. Turn the POWER (SCALE ILLUM) knob clockwise and 10-15 allow sweep time for warm-up left knob knob (approximately hand minutes). delay (upper

groove in periphery of mounting flange). T h e reflectoscope, search unit fixture, and master combination provides a checking cylinder specific functional detection method. The pulser of the reflectoscope transmits short bursts, or pulses, of electrical energy through a cable to the search unit fixture at which point these pulses are routed to the piezoelectric probe. The probe changes the electrical pulses into ultrasonic energy and transmits them through the transmitting medium (water) into and through the cylinder barrel wall, toward the outside diameter of the aluminum muff or crack, and back by the same route to the probe. The probe then changes the ultrasonic energy into electrical pulses which are transmitted by cable back to the reflectoscope where a characteristic wave form is in the screen. Additionally, the displayed reflectoscope embodies an alarm system which may be set to a specific level, to signal when the crack or flaw is detected in the cylinder. d. Detailer Calibration of the Cylinder Barrel Tester. (1) G e n e r a l . T h e f o l l o w i n g a d j u s t m e n t s apply to a new tester. Once these adjustments have been made, they will seldom require readjustment under normal conditions. Should the inspection procedure reveal an abnormally high cylinder reject rate, the tester adjustments should be checked to be certain the readings are correct. However, it is good practice to check all adjustments periodically to insure against accidental tampering. The reflectoscope cover and search fixture probe protector should be in place whenever the tester is not in use. Note. The cylinder barrel tester should not be operated in close proximity to electrical appliances, or false alarming may result. (2) Establish the wave form on the reflectoscope display screen and set the alarm. (a) toscope. Remove the cover from the reflec-

(c) Adjust the control panel). (1) T u r n (2) A d j u s t the

SWEEP SWEEP

DELAY DELAY

(red) clockwise to 1. the (inner black) to adjust the initial pulse wave over the left hand vertical division marker on the display screen. (3) Place the SWEEP toggle switch to PRESET". ES / (4) P l a c e DIV lever to the left hand INCH2, and, place the right

hand lever to 1. (5) T u r n t h e M A R K E R S k n o b ( r e d ) counterclockwise to OFF. (6) Turn theALT. VERT screw fully DISPLAY SHIFT

counterclockwise. to to

(d) Pulser / receiver unit adjustment. (1) P l a c e the TEST switch NORMAL. (2) T u r n 5.0. the FREQUENCY knob

(3) P l a c e t h e S E N S I T I V I T Y s w i t c h t o X1 and turn the SENSITIVITY control knob to 1. (4) Turn the REJECT knob counterclockwise to OFF. (5) T u r n t h e P U L S E LENGTH knob

so that the dot is at the 12:00 oclock position. (e) Display screen adjustment. ILLUM) OFF. GATE (2) Place OFF. the GATE OFF switch to (1) T u r n the POWER (SCALE knob counterclockwise, but not

(3) Adjust the VERT screw to place the horizontal wave form line on the zero horizontal scale line (view A, fig. 53).

6-61

Figure

6-53.

Reflectoscope

wave

forms.

6-62

(4) A d j u s t t h e I N T E N S I T Y s c r e w clockwise to brighten the wave form, but not to the point where a bright spot occurs at the beginning of the wave form. C a u t i o n : Too much intensity can damage display screen phosphor coating. (5) Adjust the ASTIG screw to the sharpest wave form. (6) Adjust the FOCUS screw to the sharpest wave form. (3) Adjust the reflectoscope using the master checking gage. (a) Pour water into the master checking gage, part No. 10935515, to the FILL level (five inches from top). Place the marked defect portion of the gage facing the operator. Note. Fresh water should not be used for test. Allow the water to stand twenty-four hours before use. Add approximately one fluid ounce of anti-coalescent agent, such as Jet Dry, to each ten gallons (37.85 liters) of water. The water, master gage, and test cylinders should be at room temperature during test. Note. Wipe all air bubbles from the cylinder wall. Bubbles may cause a false alarm signal. (b) Remove the protector from search fixture probe. Place the search fixture on the master checking gage (fig. 6-54), with the UPPER-LOWER switch facing the operator. Place t h e s e a r c h f i x t u r e U P P E R - L O W E R switch to UPPER.

Figure 6-54. Ultrasonic search fixture installed on master checking cylinder. (c) Connect the cable to the search fixture, and to the reflectoscope at connector R. (d) Rotate the search fixture handle counterclockwise to move the probe to the uppermost position. The wave form on the display screen will be similar to view B, fig. 6-53. (e) Rotate the search fixture handle clockwise to move the probe downward. Rotate the search fixture handle until the echo pulse, or spike (view C, fig. 6-53), is shown on the display screen when the fixture pointer alines with the master checking gage defect. (f) Move the search fixture probe upward and downward until a maximum pulse is obtained on the display screen (view C, fig. 6-53). (g) Adjust the PULSE TUNING knob (on pulser / receiver unit) to obtain the maximum pulse height on the display screen. (h) Adjust the SENSITIVITY control knob (on pulser / receiver unit) to provide an echo pulse height of 2-1 / 2 inches (view C, fig. 6-53). (i) Place the search fixture UPPERLOWER switch to LOWER.
6-63

(j) Turn the SYNC switch (on transigate) to MAIN PULSE, and the GATE OFF switch on. (k) Turn the START knob (on transigate) to 2. A d j u s t t h e S T A R T V E R N I E R knob so that a downward jog is in line with the 7th from the left vertical scale line on the display screen. Place the search fixture UPPERLOWER switch to UPPER. (l) Turn the LENGTH knob (on transigate) to 1. A d j u s t t h e L E N G T H V E R N I E R knob to end the gate at the right hand edge of the flaw signal (approximately 9-1 / 2 vertical scale lines from the left of display screen). (m) Adjust the VERT screw to place the lower gate line over the zero horizontal scale line on display screen. (n) Adjust the FOCUS and ASTIG knobs for the sharpest wave form. (0) Adjust the SENSITIVITY control knob (Pulser / receiver unit) until the echo pulse measures 2-1 / 2 inches high on the display screen (view D, fig. 6-53). Turn the REJECT knob (p) (pulser / receiver unit) clockwise to the reduce the echo pulse height to 1 inch (view E, fig. 653). (q) Turn the ALARM LEVEL knob (on transigate) to + AUTO RESET. Rotate the ALARM LEVEL vernier knob clockwise, then counterclockwise until the light just appears on RESET button. Place the AUDIO switch to ON and the alarm will sound (buzz). (r) Turn the R E J E C T k n o b ( o n pulser / receiver unit) counterclockwise to OFF. The echo pulse height will then return to 2-1 / 2 inches (view D, fig. 6-53). (S) Continue clockwise rotation of the search until handle until a heavy echo reflection enters the gate (view F, fig. 6-53). The heavy reflection indicates that the search fixture probe has reached the maximum downward travel. The cylinder barrel tester is now adjusted to establish the wave form. (t) Turn the POWER KNOB to OFF. Disconnect cable and remove the search fixture from the master checking gage. Install probe protector and reflectoscope cover. Pour water from checking gage. e. Establish the Wave From on the Reflec-. toscope Display Screen for Daily Operation. (1) Preliminary calitiration.

(a) Remove the reflectoscope cover. (b) Plug the reflectoscope into a 115 volt 10 volt, 50 / 60 cycle single phase power source. Turn the POWER (SCALE ILLUM) knob clockwise and allow time for warm-up. (c) Turn the POWER (SCALE ILLUM) knob counterclockwise, but not to OFF. (d) Turn the SENSITIVITY control knob to l, an d the REJECT knob to OFF. (e) The wave form on the display screen should be similar to view G, fig. 6-53. Note. Should the wave form not appear, or is markedly different than that shown in view G, figure 6-53, recalibrate the tester in accordance with the instructions in paragraph d, above. (f) Pour water into the master checking gage to the FILL level (five inches from top), refer to paragraph d (3) (a). Place the marked defect portion of the gage facing the operator. Note. Wipe all air bubbles from the cylinder wall. Bubbles may cause a false alarm signal. (g) Remove the protector from the search fixture probe. Place the search fixture in the master checking gage with the fixture flange resting on the cylinder mounting flange. Move the probe to the top of its travel and place the fixture UPPER-LOWER switch to UPPER. (h) Connect the cable to the search fixture and the reflectoscope at connector R. The wave form on the display screen will be similar to view H, fig. 6-53. (i) Rotate the search fixture handle clockwise to move the probe downward. Rotate the search fixture handle until the echo pulse, or spike (view D, fig. 6-53) is shown on the display screen when the fixture pointer alines with the defect on the master checking gage. (j) Rotate the search fixture handle to move probe slightly upward and downward until a maximum pulse is seen on the display screen. (k) Adjust the SENSITIVITY control knob to probe an echo pulse height of 2-1 / 2 inches (view I, fig. 6-53). (l) Turn the REJECT knob clockwise to reduce the echo pulse height to 1 inch. (m) Turn the ALARM LEVEL knob (on transigate) to + AUTO RESET. Rotate the ALARM LEVEL vernier knob until the light just appears on RESET button. The alarm will sound (buzz) when the AUDIO switch is ON.

6-64

(n) Turn the REJECT knob (on pulser / receiver unit) counterclockwise to OFF. The echo pulse height will then return to 2-1 / 2 inches high. (o) Remove the search fixture from the master checking gage. The cylinder barrel tester is now calibrated in preparation for cylinder inspection. Note. Steps (f) through (o) above, should be preformed twice each eight hour shift to assure accuracy of the tester. (2) C y l i n d e r i n s p e c t i o n . (a) Clean and degrease the cylinder bore. Remove rust if present. (b) Position the cylinder with the bore facing upward using suitable protection for the cylinder head. Insert plug, part No. 10935522 (fig. 6-55) in the cylinder bore until it bottoms. Pour water into the cylinder and fill to about five inches from the top. Refer to paragraph d (3) (a).

N o t e . Wipe all air bubbles from cylinder walls. Bubbles may cause false alarm signal. ( C ) Place the search fixture in the cylinder with the fixture flange resting on the cylinder mounting flange (figs. 6-56 and 6-57).

Figure 6-56. Positioning ultrasonic search fixture in cylinder bore.

Figure 6-55. Installing plug - 10935522 in cylinder bore.

6-65

6-33. Repair
a. Cylinder Interior. (1) V a l v e g u i d e r e p l a c e m e n t . (a) Replace any cracked, galled, eroded, or scuffed intake and exhaust valve guides (14 and 37, fig. B-4) or guides which do not conform to limits specified in overhaul standards (table 615). Replace and ream valve guides following i n s t r u c t i o n s w h i c h a c c o m p a n y f i g u r e s 6-58 through 6-62.

Figure 6-57. Ultrasonic search fixture installed in cylinder barrel mounting flange. (d) With the search fixture UPPERLOWER switch in the UPPER position, move the search fixture probe through the full upward and downward travel. Note. When a heavy pulse echo enters the right hand edge of the gate (view F, fig. 6-53), the detector has reached the maximum downward travel. Any alarm indicates a crack or defect in the cylinder. Re-inspect the defect suspect area. If the alarm sounds again, the cylinder must be scrapped. Note. Should the inspection reveal an abnormally high cylinder reject rate, the tester adjustments should be checked to be certain the readings are correct. (e) A signal appearing immediately to the left of the gate indicates cylinder bore roughness. The gate start may require minute adjustment to the right to exclude this extraneous signal. (f) Remove the search fixture from the cylinder, empty the water, and remove the plug from the bottom of the cylinder bore. If the cylinder has no defects, treat it to prevent rust.
6-66

Note. The intake and exhaust valve guides are removed from the cylinder in the same manner. Mechanical puller - 5120-448-0400 is used for intake valve guide removal and mechanical puller - 5120-448-0401 is used for exhaust valve guide reinoval. 1. Insert through 2. Install remove screw of mechanical puller - 5120-448-0400 the valve guide and puller (A). nut (B) on end of puller screw and tighten to valve guide from cylinder.

Figure 6-58. Removing intake valve guide using mechanical puller - 5120-448-0400.

Note. The intake and exhaust valve guides are installed in the same manner. Valve guide replacer - 5120-448-0402 is used for replacing intake valve guide, and valve guide replacer5120-448-7993 is used for replacing exhaust valve guide. 1. Remove ferrule (A) from end of valve guide replacer (B). 2. Place new valve guide over replacer (B) with short end of guide entering hollow replacer handle. Replace ferrule to retain guide or replacer. Figure 6-59. Positioning intake valve guide on valve guide replacer - 5120-448-0402.

1. Place assembled intake valve guide (A) and valve guide replacer - 5120-448-0402 into valve guide bore in cylinder. 2. Carefully drive valve guide into cylinder until flange on guide is positioned against top face of guide bore. 3. Remove ferrule (B) from replacer and withdraw replacer from valve guide. 4. Install exhaust valve guide (C) in the same manner using valve guide replacer - 5120-448-7993. Figure 6-60. Installing intake valve guide using valve guide replacer - 5120-448-0402.

6-67

Note. After new valve guides are installed, they must be reamed to specified size to assure proper clearance between valve guide and valve stem. (b) Install the reamer bushing - 4910795-7950 into intake valve seat as shown in figure 6-61. Use hand reamer - 5110-708-3698

to rough ream and hand reamer - 5 1 1 0 - 7 0 8 3699 to finish ream intake valve guides as shown in figures 6-61 and 6-62. The exhaust valve guides may be reamed in a similar manner using reamer bushing - 4910-795-7957, rough hand reamer - 5110-708-3696, and finish hand reamer 5110-708-3697.

Figure 6-61. Intake valve guide hand reamer - 5110-708-3698 or 5110-708-3699 and reamer bushing - 910-795-7950 positioned in cylinder head-sectional view.

6-68

Figure 6-62. Reaming intake valve guide, using hand reamer - 5110-708-3598 or 5110-708-3699 and reamer bushing 4910-795-7950.

6-69

(2) Valve seats. R e p l a c e c y l i n d e r a s s e m b l y (41, fig. B-4) when inserts do not fit securely in the cylinder. Grind seats which do not show perfect contact with valve face. Grind seats

which do not show perfect contact with valve face. Grind inserts (fig. 6-63) as described in (a) through (e), below.

Figure 6-63.

(a) A 45 degree angle grinding stone must be used to grind valve seat inserts. (b) Dress seat on the insert with stone, using valve seat grinding machine. (c) After dressing seat of insert, check valve contact as described in paragraph 6-31b. (d) When perfect contact is obtained, narrow seat on insert to width specified in figure 6-63 by grinding inner wall and exposed face of insert to the angles specified. (e) Keep valve seat area as near as possible to center of valve face. Valves should never seat at the top or bottom of the valve face area. b. Cylinder Bore. R e p l a c e c y l i n d e r a s s e m b l y when joint between cylinder head and cylinder barrel is pitted or eroded. Replace cylinder assembly when cylinder bore dimensions are not within limits specified in the overhaul standards (table 6-15), or when average dome end measurement is larger than average flange end measurement. Reanodize head if required. Hone cylinder to remove scratches, scoring or ring ridge. Hone cylinder when out-of-round more than 0.003 in. Hone cylinders as described in c and d, below.

c. Honing Specifications. (Part No. 10865297, FSN 2815-765-9711 cylinder only) (1) Cross hatch angle to be 35 degrees off the horizontal. (2) Cross hatch to be cut uniformly in both directions. (3) Cross hatch to be clean-cut, but not sharp, and free from torn or folded metal. (4) The micro-finish roughness should average between 35 and 45 micro-inches, rms (root mean square deviation from the mean), as measured on the profilometer machine (Micrometrical Mfg. Company, Ann Arbor, Michigan, Type QA, Type V Moto-Trace or equivalent). (5) The plateau area should be 1 / 2 to 2 / 3 of the surface area. (6) The plateau should be free from burnished or glazed surface. (7) The surface is to be free of imbedded particles. d. Honing Recommendations. (Part No. 10865297, FSN 2815-765-9711 cylinder only) (1) Honing stones should be Army Nos. 11662775-1 and 11662775-2 used alternately around the honing head. The stones are ap-

6-70

proximately 4 inches long and slotted at 0.80 inch intervals 15 degrees to the horizontal to a depth of 0.12 inch from the bottom of the stone. The stones are mounted to 1 / 16 inch thick cork backing before mounting in the shell. This design allows the stone to conform to the tapered section of the bore. The stones should be mounted as per Micromatic Design No. 47415 SA or equivalent. This number represents size 7 / 16 x 1 / 2 x 4 stones mounted with cork backing and slotted. This design will fit Micromatic stone holder No. 33960-5 and Micromatic Model 5R-SFE-8 Blind End Tool. (2) The surface finish should be developed in two stages. Rough hone the entire length of the bore, using moderately heavy stone pressure, until the ring ridge is removed and entire bore has a cross hatch pattern. Finish hone using the same stones, with a very light pressure, for approximately 5 to 8 strokes. This operation will remove rough edges and fragmented metal left from the rough hone operation. Note. The ring ridge may be removed using short stones and a short stroking action prior to the full rough and finish hone cycle. Under no circumstances are short cycle strokes to be performed after the full length strokes have been completed. (3) Honing oil should be principally kerosene with a sulphurized base oil. Adequate filtration should be provided with both magnetic and paper filters recommended. A suggested oil is twenty-seven and one half (27-1 / 2) parts kerosene to twenty-two and one half (22-1 / 2 parts Stuarts Superkool base oil. This may be purchased from the D. A. Stuart Oil Company, 8350 Military Avenue, Detroit, Michigan 48204.) (4) The hone angle should be 35 degrees to horizontal (70 degrees included angle). Spindle speed should be 77 rpm, with a vertical reciprocating rate of 43 cycles per minute.

(5) When diameter of bore at top of ring travel is more than 5.7610 inches after honing, replace cylinder. (6) Clean cylinder with a power brush and hot (160F) soapy water. Dry thoroughly. Lubricate cylinder bore to prevent rust. e. Camshaft Bearings. Remove minor nicks, burs, or scratches from camshaft bearing surfaces with crocus cloth dipped in dry-cleaning solvent or mineral spirits paint thinner. Replace cylinder assembly when camshaft bearing surfaces are scored, galled, or deeply pitted, or when they do not conform to limits specified in overhaul standards (table 6-15). f. Cylinder Exterior. (1) Cooling fins. Straighten bent fins as near as possible to their original spacing. Replace cylinder assembly when more than one percent of barrel cooling fin area is broken. Replace cylinder assembly if head finis broken more than half the depth of the fin or more than two inches long. A cylinder assembly can be used if it has not more than three acceptable defects, or if no two of the defects are on adjacent fins. Repair damaged cylinder head fins as described in (a) through (c), below, and in TB 9-2800-207-50. (a) Use a fine mill file to remove sharp corners of broken head fins. (b) Do not remove more metal than necessary to produce a smoothly blended edge on the damaged fin. (c) Depth of any blended fin must not be less than 50 percent of its original depth, when blended fin is less than 50 percent of original depth, replace cylinder assembly. (2) Studs and inserts. R e p l a c e d a m a g e d , bent, or stripped studs as described in paragraph 6-4e and table 6-16. Replace defective helicalcoil inserts as described in paragraph 6-5.

6-71

Table 6-16. Cylinder Standard and Oversize Stud Idenfication Fig. No. Ref. letter
Setting height

No. reqd.

Stud size and length

B-4

43

31/32

36

B-4

45

3 / 4

12

B-4

51

21/32

24

B-4

52

31/32

48

5/ 16-18(13/ 16) x5/ 16-24(19/32) x 1-11/ 16 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. Os) 7/ 16-14(3/4) x7/16-20(5/8) X 1-1/2 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) 5/ 16-18(11/ 16) x5/ 16.24(9/ 16) x 1.5/16 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) 3/8-16(53/64)x3/8-24(7/8) x 1-3/4 (STD)

Note. Refer to figure 6-1 for oversize stud identification.

6-72

g. V a l v e R o c k e r A r m C o v e r s . (1) Repair or replace damaged parts. Welding is permissible on the two valve rocker arm shaft plug bosses on the outside of the cover. Welding in other areas of the cover is n o t p e r missible. Refer to paragraph 6-4c for general welding instructions, and paragraph (e), below. (a) Replace cylinder assembly when valve rocker arm cover is cracked (except at the rocket arm shaft plug boss which can be welded), or has deep scratches or nicks on the mating surface or camshaft bearing bore surface. Replace cylinder when cover damage cannot be removed by polishing with crocus cloth dipped in dry-cleaning solvent or mineral spirits paint thinner.

(b) Replace cylinder assembly when valve rocker cover does not conform to limits specified in the overhaul standards (table 6-15). (c) Replace damaged screw thread inserts as instructed in paragraph 6-5. (d) Replace cracked adjusting cover plates. Remove minor nicks, burs, or scratches from mating surface with crocus cloth dipped in dry-cleaning solvent or mineral spirits paint thinner. (e) Covers that have been repaired by welding must meet the requirements specified in figure 6-64.

Figure 6-64. Valve rocker arm cover welding standards. h. Valve Rocker Arm. (Refer to fig. B-4) (1) Replace valve rocker arms (33 and 34) when cracked or worn or if the bushing-type bearings are damaged. (2) Replace damaged valve rocker arm roller and bushing. (3) Replace adjusting screw (36) when threads are stripped or damaged or when screw binds in rocker arm. Replace adjusting screw when swivel pad does not rotate freely on screw. i. Valve Rocker Arm Shaft Assemblies. (Refer to fig. B-4)

AT 311 77

(1) Replace cracked or deeply scored rocker arm shaft assemblies (22 and 35). (2) Replace rocker arm shafts that do not conform to limits specified in the overhaul standards (table 6-15). Valve, Springs, Spring Retainers and Rotors. (Refer to fig. B-4) (1) Valves. (a) Discard warped valves (11 and 12) or valves which do not conform to limits specified in repair and, rebuild standards (table 6-1 5). Discard valves having badly pitted or burned

6-73

faces. Discard valves having badly pitted, scored, scratched stems or locking grooves. (b) Reface slightly pitted or burned valves that do not seat perfectly to limits specified in figure 6-63. Discard valves that cannot be refaced to these limits. (c) Check valve length from seat contact to tip of stem after grinding, as shown in figure 663. Discard valve if length is not within limits specified (fig. 6-63). (2) V a l v e s p r i n g s . R e p l a c e s p r i n g s ( 1 6 , 1 7 , and 18) when worn, cracked, or otherwise dam aged. Replace springs that do not conform to limits specified in overhaul standards (table 615). (3) Valve spring retainers, valve rotors, and valve locks. (Refer to fig. B-4) (a) Replace upper intake and exhaust valve spring retainers (19 and 38) and valve spring seat (15) when cracked or worn. (b) Replace valve rotors (40) when inner section does not rotate freely or when assembly is worn or cracked. (c) Replace valve locks (20) when worn or cracked. 1. Position the valve lifter assembly - 5120-678-5285 over the valve springs and retainers (A) and secure in position with four 5 / 16 x 1-3/8 bolts and 5 / 16-in. flat washers. 2. Compress valve springs and retainers with screws (B) and install two valve locks (20) in the groove of each valve stem. Release valve spring compression. Remove valve lifter assembly - 5120-678-5285 from cylinder and remove cylinder from stand. Figure 6-65. Co repressing valve springs using valve lifter assembly-5120-678-5285. (2) Install the exhaust valve rotor (40), outer, intermediate, and inner springs (16, 17, and 18), and upper exhaust valve spring retainer (38) over the exhaust valve stem as shown in figure 6-49. Install the lower intake valve spring seat (15), outer, intermediate, and inner springs (16, 17, and 18), and upper intake valve spring retainer (19) over the intake valve stem in the same manner. Compress valve springs and install valve locks following instructions which accompany figure 6-65. b. Valve Rocker Arm Covers. Refer to paragraph 4-14.

6-34. Assembly
a. Cylinders. (Refer to fig. B-4) (1) Install intake valve (12) and exhaust valve (11) in their respective guides in cylinder (41). Hold valves in position and place the cylinder on valve removing and inserting stand 4910-554-1317 following instructions which accompany figure 6-65.

6-74

Section VIl. OVERHAUL OF OIL PUMP, OIL PAN, DAMPER AND OIL FILTER HOUSING AND ASSOCIATED PARTS 6-35. General
This section covers the overhaul of the pump, oil pan, damper and oil filter housing, associated parts. Specific instructions disassembly, cleaning, inspection, repair oil and on and assembly accompany the overhaul operations. Stud identification information is included in the overhaul procedures. Refer to the following table (table 6-17) for applicable illustrations and instructions for overhaul operations.

Table 6-17. Oil Pump, Oil Pan, Damper and Oil Filter Housing and Associated Parts Component Oil Pump Disassembly Para 6-36b Figs. 6-67 through 6-86 Para 6-37a Figs. 6-88 through 6-97 Para 6-38a Figs 6-99, 6-100, 4-89, 6-101 through 6111 Cleaning Para 6-2 Inspection Para 6-36d Table 6-19 Para 6-3 Repair Para 6-36e Table 6-20 Para 6-4 Para 6-37d Table 6-21 Para 6-38d Table 6-23 Fig. 6-113 Assembly Para 6-36f Figs. 6-87 through 6-67 Figs. 6-97 through 6-88 Figs. 6-111 through 6-101,4-92 through 4-89,6-100,6-99

Oil Pan and Associated Parts Damper and Oil Filter Housing and Associated Parts

Para 6-2

Para 6-38 b, Fig. 6-112

Para 6-38c Table 6-22

6-36. Rebuild of Oil Pump

a. General. Two different oil pump assemblies. have been used in production. It is important to recognize the difference between the oil pumps before attempting disassembly. Throughout this

paragraph the oil pumps will be referred part numbers FSN 2815-679-4965 or 2815-895-6430 where differences occur. to table 6-18 for the different oil characteristics.

to by FSN Refer pump

Table 6-18. Visual Oil Pump Identification Characteristics Item FSN 2315-679-4965 Oil pump Integral part of scavenge oil pump inlet scoop (riveted) None FSN 2815- 895-6430 Oil Pump Separate part, mounted under inlet scoop Dual purpose lock plate for oil pump drive shaft and driven impeller shaft. See figure 6-71. 10898878

Scavenge oil pump inlet screen Oil pump drive shaft lock plate

Casting part number of oil pump housing

8725174

6-75

b. Disassembly. Disassemble oil pump (fig. 666) following instructions which accompany figures 6-67 through 6-86.

Figure 6-66. FSN 2 8 1 5 - 8 9 5 - 6 4 3 0 oil pump assembly as removed from engine.

Remove 1. Remove oil pump pressure relief valve body (A). 2. Separate pressure relief valve (B), outer valve spring. and inner valve spring from valve body. 3. Remove cap screw (C) and flat washer. Install 1. Install cap screw (C) and flat washer. 2. Position inner valve spring, outer valve spring, and pressure relief valve (B) in oil pump pressure relief valve body (A). 3. Install assembled valve body (A) in pump housing. Figure 6-68. Removing or installing oil pump pressure relief valve.

Figure 6-67. Removing or installing locking wire securing oil pump pressure relief valve and piston cooling control valve bodies.

Figure 6-69. Removing or installing piston cooling control valve.

6-76

Remove 1. Remove cotter pin (A). 2. Remove slotted nut (B). 3. Remove and discard two preformed packings (C). 4. Remove and discard preformed packing (D). Install 1. Install new -in. preformed packing (D) in pump housing. 2. Install two new 1-in. preformed packings (C) in pump housing. 3. Install slotted nut (B) securing oil pump driven gear. 4. Install cotter pin (A) securing nnt (B). Figure 6-70. Removing or installing oil pump driven gear attaching parts and preformed packing.

Remove 1. Cut locking wire (A). 2. Remove two bolts (B). 3. Remove lock plate (C). Install 1. Position lock plate (C) on scavenge housing cover. 2. Install two bolts (B) securing plate to cover. 3. Install locking wire (A). Figure 6-71. Removing or installing oil pump drive shaft lock plate (FSN 2815-895-6430 oil pump).

6-77

Remove 1. Straighten tabs on lockwasher (A) securing lock nut. 2. Hold oil pump drive shaft with wrench (B). 3. Remove lock nut from drive shaft using a spanner wrench (C). Remove lock washer from drive shaft. Install 1. Install lock washer (A) on oil pump drive shaft. Install lock nut on drive shaft. 2. Hold drive shaft with wrench (B) and tighten lock nut using a spanner wrench (C). 3. Bend tabs on lock washer(A) securing lock nut. Figure 6-72. Removing or installing oil pump drive shaft lock nut.

Remove 1. Remove oil pump drive shaft (A) with assembled cluster gear. 2. Remove thrust washer (B) from drive shaft. Install 1. Position thrust washer (B) on oil pump drive shaft. 2. Install drive shaft (A) with assembled cluster gear in pump housing. Figure 6-73. Removing or installing oil pump drive shaft and cluster gear (FSN 2815-895-6430 oil pump).

Figure 6-74. Removing oil pump driven gear from impeller drive shaft using suitable puller.

6-78

Remove 1. Cut locking wire (A). 2. Remove two dotted nuts (B) and flat washers attaching oil pickup elbow to pump housing. 3. Remove pickup elbow (C) from housing. 4. Remove bolt (D) and lock plate. 5. Remove five slotted nuts (E) and flat washers attaching scavenge housing cover. 6. Remove housing cover (F) from scavenge housing.

Install 1. Position scavenge housing cover (F) on scavenge housing. 2. Install five slotted nuts (E) and flat washers securing housing cover (F) to housing. 3. Position lock plate on cover and install bolt (D) securing plate. 4. Position pickup elbow (C) on pump housing. 5. Install two slotted nuts (B) and flat washers securing elbow (C) to housing 6. Install locking wire (A) securing nuts.

Figure 6-75. Removing or installing scavenge housing cover and oil pickup elbow (FSN 2815-679-4965 oil pump).

6-79

Remove 1. Cut locking wire (A). 2. Remove two slotted nuts (B) and flat washers attaching oil pickup elbow to pump housing. 3. Remove pickup elbow (C) from housing. 4. Remove five slotted nuts (D) and flat washers attaching scavenge housing cover. 5. Remove housing cover (E) by tapping cover gently to loosen cover from locating dowel pins. Install 1. Position scavenge housing cover (E) on scavenge housing dowel pins. 2. Install five slotted nuts (D) and flat washers securing housing cover (E) to housing. 3. Position pickup elbow (C) on pump housing. 4. Install two slotted nuts (B) and flat washers securing elbow (C) to housing 5. Install locking wire (A) securing nuts. Figure 6-76. Removing or installing scavenge housing cover and oil pickup elbow (FSN 2815-895-6430 oil pump).

Remove 1. Slide two scavenge driven impellers (A) from impeller shafts. 2. Remove driven impeller shaft (B) from scavenge housing. 3. Slide scavenge drive impeller (C) from impeller drive shaft. 4. Remove two slotted nuts (D) and flat washers. Separate and remove scavenge housing from pressure housing. Install 1. Position scavenge housing on pressure housing. Install two slotted nuts (D) securing scavenge housing on pressure housing. 2. Slide scavenge drive impeller (C) on impeller drive shaft. 3. Install driven impeller shaft (B) in scavenge housing. 4. Slide two scavenge driven impellers (A) on impeller shafts. Figure 6-77. Removing or installing oil pump scavenge driven impellers, driven impeller shaft, and scavenge housing.

6-80

Remove 1 . Slide pressure driven impeller (A) from oil pump driven impeller shaft. 2. Remove driven impeller shaft (B) from pressure housing. Install 1. Install driven impeller shaft (B) in pressure housing. 2. Slide pressure driven impeller (A) on oil pump driven impeller shaft. Figure 6-78. Removing or installing oil pump driven impeller and shaft.

Remove 1. Remove Woodruff key (A) from impeller drive shaft. 2. Remove drilled head bolt (B) and lock plate. 3. Cut locking wire and remove five slotted nuts (C) and flat washers attaching pressure housing cover to pressure housing. 4. Separate and remove cover (D) from housing. Install 1. Position pressure housing cover (D) on pressure housing. 2. Install five slotted nuts (C) and flat washers securing cover on housing and install locking wire securing nuts. 3. Position lock plate on cover and install drilled head bolt (B). 4. Install Woodruff key (A) in impeller drive shaft. Figure 6-79. Removing or installing pressure housing cover (FSN 2815-679-4965 oil pump).

6-81

Remove 1. Cut locking wire (A). 2. Remove drilled head bolt (B) and lock plate. 3. Remove five slotted nuts (C) and flat washers attaching pressure housing cover to pressure housing. 4. Separate and remove cover (D) from housing. Install 1. Position pressure housing cover (D) on pressure housing. 2. Install five slotted nuts (C) and flat washers securing cover on housing. 3. Position lock plate on cover and install drilled head bolt (B). 4. Install locking wire (A) securing nuts. Figure 6-80. Removing or installing pressure housing cover (FSN 2815-895-6430 oil pump).

Remove 1. Remove impeller drive shaft (A) from pressure housing. 2. Cut locking wire and remove four slotted nuts (B) and flat washers attaching scavenge oil pump inlet scoop on housing. 3. Remove inlet scoop (C). Do not remove screens. Install 1. Position scavenge oil pump inlet scoop(C) on pressure housing. 2. Install four slotted nuts (B) and flat washers securing inlet scoop on housing and install locking wire securing nuts. 3. Install impeller drive shaft (A) in pressure housing. Figure 6-82. Removing or installing scavenge oil pump inlet scoop (FSN 2815-679-4965 oil pump).

Remove 1. Remove driven impeller (A) from pressure housing. 2. Remove drive impeller (B) from impeller drive shaft. Install 1. Install drive impeller (B) on impeller drive shaft. 2. Install driven impeller (A) in pressure housing. Figure 6-81. Removing or installing oil pump piston cooling drive and driven impellers.

6-82

Remove 1. Remove impeller drive shaft (A) from pressure housing. 2. Cut locking wire and remove four slotted nuts (B) and flat washers attaching scavenge oil pump inlet scoop on housing. 3. Remove inlet scoop (C) from housing. 4. Remove scavenge oil pump inlet screen (D) from housing. Install 1. Position scavenge oil pump inlet screen (D) in housing. 2. Position scavenge oil pump inlet scoop (C) on housing. 3. Install four slotted nuts(B) and flat washers securing inlet scoop on housing and install locking wire securing nuts. 4. Install impeller drive shaft (A) in pressure housing. Figure 6-83. Removing or installing scavenge oil pump oil inlet scoop (FSN 2815-895-6430 oil pump).

1. Mount impeller drive shaft with assembled cluster gear (A) in arbor press. 2. Press drive shaft(B) from ball bearing in gear. Figure 6-84. Pressing impeller drive shaft from ball bearings in drive cluster gear.

6-83

C a u t i o n : Do not use an arbor press to remove ball bearings from drive cluster gear. The gear is designed with a shoulder between the two bearings. 1. Remove ball bearings (A) from drive cluster gear using a brass drift. 2. Remove thrust washer (B). Figure 6-85. Drive cluster gear - exploded view. Disassemble C a u t i o n : The piston oil cooling valve is a spring loaded assembly. Exercise care when disassembling. 1. Compress valve spring and remove retaining ring (A) from valve stem. 2. Gradually release spring compression and remove valve and spring (B) from body. Assemble 1. Position valve and spring (B) in body. 2. Compress spring until valve stem protrudes from body and install retaining ring (A). Figure 6-86. Disassembling or assembling piston oil cooling v a l v e a s s e m b l y . cluster gear. c. Cleaning. Refer to paragraph 6-2. d. Inspection. Refer to paragraph 6-3. Inspect parts to the limits specified in overhaul standards (table 6-19).

6-84

Table 6-19. Oil Pump Overhaul Standards Component D e p t h o f Impeller bore L e n g t h impeller o f Fig. No. B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 Impellers and shafts Impellers and shafts B-9 B-9 B-9 B-9 Ref. letter A B F L L-A Z Z-B DD DD-F E M E-M AA Point of measurement Piston sprayer pump Pressure pump Scavenge pump Pieton sprayer pump End play between impellers and impeller housings with housings correctly assembled Pressure pump End play between impellers and impeller housings with housings correctly assembled Scavenge pump End play between impellers and impeller housings with housings correctly assembled Outside diameter of piston sprayer pump cover end of oil pump impeller drive shaft Inside diameter of bearing bore in cover Fit of shaft in cover bore Outside diameter of pressure pump and scavenge pump bearing surfaces on oil pump impeller drive shaft Inside diameter of bearing in oil pressure pump housing Fit of impeller drive shaft in housing bore Inside diameter of bearing bore in scavenge pump housing Fit of impeller drive shaft in housing bore Outside diameter of scavenge pump cover bearing surface end of impeller drive shaft Inside diameter of bearing bore in scavenge pump cover Fit of impeller drive shaft in scavenge pump cover Outside diameter of pressure and scavenge pump drive and driven impellers Inside diameter of pressure and scavenge pump impeller bores Fit (radial clearance) of impellers in housing Outside diameter of piston sprayer pump impellers Inside diameter of piston sprayer pump impeller bores Fit (radial clearance) of impellers in housing Inside diameter of pressure oil pump driven impeller Outside diameter of oil pump driven impeller shaft Fit of impeller on shaft Inside diameter of scavenge oil pump driven impeller Fit of impeller on shaft Inside diameter of scavenge oil pump driven impeller Outside diameter of oil pump driven impeller shaft Fit of impeller on shaft Sizes and fits of new parts 0.8750 2.0000 2.3500 0.8720 0.0020L 0.8770 2.0020 2.3520 0.8730 0.0050L Wear limits 0.8775 2.0025 2.3525 0.8710 0.0065L 1.9960 0.0065L 2.3455 0.0070L 0.9827 0.9870 0.0043L 1.1307

1.9965 1.9975 0.0025L 0.0055L 2.3460 2.3470 0.0030L 0.0060L 0.9830 0.9835

0.9860 0.9850 0.0015L 0.0030L 1.1315 1.1310

B-9 B-9 B-9 B-9 B-9 B-9 Impellers and shafts B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9

W AA-W CC AACC BB J BB-J D-EE Y-G D-EE G-Y K X K-X C H C-H LL H-LL FF GG FFGG

1.1330

1.1340

1.1350 0.0043L 1.1350 0.0043L 0.9827 0.9870 0.0043L 2.4810 2.4875 0.0065L 2.2485 2.2550 0.0065L 0.9870 0.9829 0.0041L 0.9870 0.0041L 0.9870 0.9829 0.0041L

0.0015L 0.0030L 1.1330 1.1340 0.0015L 0.0030L 0.9830 0.9835 0.9850 0.9860 0.0015L 2.4814 2.4850 0.0032L 2.2490 2.2530 0.0030L 2.4818 2.4862 0.0048L 2.2500 2.2542

0.0030L 0.0052L 0.9865 0.9860 0.9834 0.9839

0.0021L 0.0031L 0.9865 0.9860 0.0021L 0.0031L 0.9860 0.9865 0.9834 0.9839

0.0021L 0.0031L

Note. Refer to paragraph 6-3b for explanation of symbols.

6-85

Table 6-19. Oil Pump Overhaul Standards Component Impellers and shafts - Cont d Oil pump drive and gear bearings Fig. No. B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 Ref. letter HH H-HH KK JJ JJ P KK-P Q N-Q s Point of measurement Inside diameter of pieton sprayer pump impellers Fit of impellers on shaft Outside diameter of bearings Inside diameter of small gear end of drive gear Fit of bearing in drive gear Inside diameter of large gear end of drive gear Fit of bearing in drive gear Inside diameter of bearings Outside diameter of oil pump drive shaft Fit of bearings on shaft Spring helical compression (small) Approximate free length Load at 3.22 inch Maximum solid height Spring helical compression (large) Approximate free length Load at 3.22 inch Maximum solid height Outside diameter of valve stem Inside diameter of pressure relief valve body Fit of valve stem in valve body Spring, helical compression: Approximate free length Load at 1.38 inch Maximum solid height

Continued Sizes and fits of new parts 0.9860 0.0021L 2.0467 2.0463 0.0003L 2.0463 0.0003L 0.9839 0.9835 0.0008L 0.9865 0.0031L 2.0472 2.0470 0.0009T 2.0470 0.0009T 0.9843 0.9840 0.0001T

Wear limits 0.9870 0.0041L * 2.0473 0.0006L 2.0473 0.0006L * 0.9833 O.OO1OL

pump Oil pressure relief valve

4.27 inch 95 lb to 105 1b 2.94 inch 4.96 inch 141.5 lb to 156.5 lb 2.90 inch 0.3110 0.3115 0.3140 0.3160 0.0025L 0.0050L 2.69 inch 63.4 lb to 75.4 lb 1.31 inch

B-9

Piston oil cooling valve

B-9 B-9 B-9 B-9

V T V-T U

0.3105 0.3170 0.0065L

Note. Refer to paragraph

6-3b for explanation of symbols.

e. Repair. R e p l a c e d e f e c t i v e p a r t s . R e f e r t o paragraph 6-4e and table 6-20 when replacing studs. Note. Pump parts are not interchangeable. Do

not attempt to replace individual parts; replace entire pump assembly with FSN 2815-895-6430 oil pump assembly when service of FSN 2815679-4965 pump stock is exhausted. Refer to Appendix B.

Table 6-20. Oil Pump Standard and Oversize Stud Identification Fig. No. B-9 Ref. No. 13-59 Setting height 13/16 No. reqd. 11(FSN 2815-6794965 pump) 7 (FSN 2815-8956430 pump) 2 stud size and length 5/ 16-18(3/4) x5/ 16-24(17/32) x 1-3/8 (STD) (0.003 in. OS) (0.007 in. OS)

B-9

13

B-9

14

3-7 /8

B-9

15

5-3/16

B-9

34

29/ 32

B-9

35

3-7/ 16

B-9

59

7 / 8

5/ 16-18(23/32) x5/ 16-24(29/64)x4-1/2 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) 5/ 16-18(3/4) x5/ 16-24(7/8) x 5-51/64 (STD) (0.003 in. OS) (0.007 in. OS) 5/ 16-18(3/4) x5/ 16-24(19/ 32) x 1-7/16 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) 5/ 16-18(23/32) x5/ 16-24(39/64) x 4-1/8 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) 5/ 16-18(3/4) x5/ 16-24(19/32) x 1-1/2 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS)

Note. Refer to figure 6-1 for oversize stud identification.

6-87

f. Assembly. Refer to figures 6-87 through 667. Torque tighten the drive shaft lock nut (fig. 6-72) and driven gear nut (fig. 6-70) as specified. N o t e . The drive shaft (B, fig. 6-84) must be pressed into the bearings from the large gear end of the cluster gear.

1. Position ball bearing (A) in bore of drive cluster gear. 2. Press bearing into gear until bearing is seated against the gear. Note. Turn gear over and install thrust washer (B, fig. 6-85). Aline thrust washer with installed bearing and press second bearing in gear, as outlined above, until seated against thrust washer. Figure 6-87. Pressing ball bearing into drive cluster gear.

6-88

6-37. Overhaul of Oil Pan Assembly

a. Disassembly. Disassemble oil pan following

instructions w h i c h a c c o m p a n y f i g u r e s 6 - 8 8 through 6-97.

Remove 1. Cut locking wire and remove 13 cap screws (A). 2. Remove left oil pan baffle (B). 3. Cut locking wire and remove 12 cap screws (C). 4. Remove right oil pan baffle (D). 5. Remove pipe plug (E). Install 1. Install pipe plug (E).

2. Position right oil pan baffle (D) in oil pan. 3. Install 12 cap screws (C) and install locking wire securing screws. 4. Position left oil pan baffle (B) in oil pan. 5. Install 13 cap screws (A) and install locking wire securing screws.

Figure 6-88. Removing or installing oil pan baffles.

6-89

Remove 1. Remove two self-locking nuts (A). 2. Remove oil separator drain replacement cover (B). Remove and discard gasket. 3. Remove three self-locking nuts (C). 4. Remove oil level indicator replacement cover (D). Remove and discard gasket. 5. Remove pipe plug (E). Install 1. Install pipe plug (E).

2. Position a new oil level indicator gasket on oil pan. Position oil replacement cover (D) on oil pan. 3. Install three self-locking nuts (C). 4. Position a new oil separator drain gasket on oil pan. Position oil replacement cover (B) on oil pan. 5. Install two self-locking nuts (A).

replacement cover level indicator replacement cover separator drain

Figure 6-89. Removing or installing oil separator drain and oil level replacement covers.

6-90

Remove 1. Remove six bolts (A) and lock washers. 2. Remove two pipe plugs (B). 3. Cut locking wire and remove four slotted nuts (C). Install 1. Install four slotted nuts (C).

N o t e . Do not tighten nuts (C) or install locking wire until oil pan is in position on engine. This allows adapter to aline with oil spill tube. 2. Install two pipe plugs (B). 3. Install six bolts (A) and lock washers.

Figure 6-90. Removing or installing pressure oil pump elbow adapter and oil pickup screen assembly attaching parts (M60 series vehicle application engines).

6-91

Remove 1. Remove pressure oil pickup screen assembly (A). 2. Remove and discard gasket (B).

Install 1. Position a new pressure oil pickup screen assembly gasket (B) on oil pan. 2. Position pressure oil pickup screen assembly (A) on oil pan.

Figure 6-91. Removing or installing pressure oil pickup screen assembly (M60 series vehicle application engines).

6-92

Remove 1. Remove six bolts (A) and lock washers. 2. Remove two pipe plugs (B). 3. Cut locking wire and remove four slotted nuts (C). Install 1. Install four slotted nuts (C).

N o t e . Do not tighten nuts (C) or install locking wire until oil pan is in position on engine. This allows adapter to aline with oil spill tube. 2. Install two pipe plugs (B). 3. Install six bolts (A) and lock washers.

Figure 6-92. Removing or installing pressure oil pump elbow adapter and oil pickup screen assembly attaching parts (universal vehicle application engines).

6-93

Remove 1. Remove pressure oil pickup screen assembly (A). 2. Remove and discard gasket (B). Install 1. Position a new pressure oil pickup screen assembly gasket (B) on oil pan. 2. Position pressure oil pickup screen assembly (A) on oil pan. Figure 6-93. Removing or installing pressure oil pickup screen assembly (universal vehicle application engines).

Remove 1. Remove oil pump elbow adapter (A). 2. Remove and discard gasket (B). 3. Remove and discard two preformed packings (C). Install 1. Position two new preformed packings (C) in oil pump elbow adapter (A). 2. Position a new adapter gasket (B) on oil pan. 3. Position elbow adapter (A) on oil pan. Figure 6-94. Removing or installing oil pump elbow adapter.

6-94

Remove 1. Straighten tabs on two tab washers (A). 2. Remove two bolts (B) and tab washers. Discard tab washers. 3. Remove pressure oil pickup funnel assembly (C). 4. Remove two magnetic drain plugs (D) and discard plug gaskets. Install 1. Position a new drain plug gasket on each magnetic drain plug (D) and install plugs in oil pan. 2. Position pressure oil pick up funnel assembly (C) in oil pan. 3. Install two bolts (B) and new tab washers (A). 4. Bend tabs on tab washers (A) securing bolts (B). Figure 6-95. Removing or installing oil pickup funnel assembly and magnetic drain plugs, (M60 series vehicle application engines).

Remove 1. Straighter tabs on two tab washers (A). 2. Remove two bolts (B) and tab washers. Discard tab washers. 3. Remove pressure oil pickup funnel assembly (C). 4. Remove two magnetic drain plugs (D) and discard plug gaskets. Install 1. Position a new drain plug gasket on each drain plug (D) and install plugs in oil pan. 2. Position pressure oil pickup funnel assembly (C). 3. Install two bolts (B) and new tab washers (A). 4. Bend tabs on tab washers(A) securing bolts(B). Figure 6-96. Removing or installing oil pickup funnel assembly and drain plugs (universal vehicle application engines).

6-95

b . Cleaning. Refer to paragraph 6-2. c. I n s p e c t i o n . Refer to paragraph 6-3. The oil pan gasket flange must not be out-of flat by more than 0.004-inch per foot. d. Repair. Refer to paragraph 6-4e and table 6-21 when replacing studs. Refer to paragraph 64 C for general welding instructions and (1) and (2), below, for specific information on welding repair of the oil pan. (1) Oil pan bottom surfaces. T h e w e l d i n g repair of chips, cracks, and the replacement of metal is permissible in the oil pan to prevent oil leakage between compartments or from cast passages. Repair cracks that do not extend over 12 inches lengthwise and when there are not more than three cracks running crosswise within a six inch area. (2) Oil pan baffles. Sections of missing metal in oil baffles may be replaced, but care must be exercised when replacing baffles immediately adjacent to and attaching to the oil pan outer walls at the engine mounting bosses. Mount bosses may also be repaired if chipped or cracked. After welding repair of the oil pan, leak test compartments and cast passages. Pressure test is not necessary.

Remove 1. Remove pressure oil pickup cover (A). 2. Remove oil pan pipe plug (B). Install 1. Install oil pan pipe plug (B). 2. Install pressure oil pickup cover (A). Figure 6-97. Removing or installing pressure oil pickup cover.

Table 6-21. Oil Pan Standard and Oversize Stud Identification Fig. No. B-7 Ref No. 21 Set ting height 2-13 / 16 No. reqd 2 5/16-18(3/4) x5/ Stud size and length 16(23/32) x 3-9/32 (STD) (0.003 in. OS) (0.007 in. OS) 5/16-18(15/16) x5/ 16-24(25/32) x 2-1/8 (STD) (0.003 in. OS) (0.007 in. OS) (0.012in. OS) 5/ 16-18(3/4) x5/ 16-24(19/32) x 1-7/16 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) 3/8-16(15/16) x3/ 8-24(13/16) x 2-3/32 (STD) (0.003 in. OS) (0.007 in. OS)

B-7

24

1-21 / 32

B-8

17

25 / 32

B-8

14

1-11 / 32

56

N o t e . Refer to figure 6-1 for oversize stud identification.

6-96

e . A s s e m b l y . Refer to figures 6-97 through 688.

6-38. Overhaul of Crankshaft Damper and Oil Filter Housing, Oil Filters, Switches, and Transmitters
a. Disassembly. Disassemble crankshaft

damper and oil filter housing and oil filters following instructions which accompany figures 6-99, 6-100, 4-89 through 4-92, and 6-101 through 6-111.

Figure 6-98. Crankshaft damper and oil filter housing as removed from engine.

6-97

Remove 1. Remove main oil cooler bypass valve plug (A) and gasket (B). 2. Remove and discard gasket (B). 3. Remove bypass valve spring (C). Install 1. Install bypass valve spring (C) in damper and oil filter housing. 2. Position a new bypass valve plug gasket (B) on bypass valve plug (A). 3. Install plug (A) in housing. Figure 6-99. Removing or installing main oil cooler bypass valve plug, gasket, and spring.

Figure 6-100. Removing or installing main oil cooler bypass valve.

6-98

Remove 1. Remove six self-locking nuts (A) and flat washers attaching main oil filter assembly to damper and oil filter housing. 2. Loosen main oil filter stop bolt (B) several turns and pull filter from housing until it engages stop bolt. Collect oil in a suitable container. Note. It may be necessary to use two 5 / 1624 x 1-inch jack screws in the puller screw holes to break the gasket seal between the filter flange and the housing. 3. Remove eight self-locking nuts (C) and flat washers attaching auxiliary oil filter to housing. 4. Loosen auxiliary oil filter stop bolt (D) and drain filter as described in step 2, above. 5. Remove six self-locking nuts (E) and flat washers attaching two oil drain covers to housing. Remove covers and discard drain cover gaskets. 6. Remove four oil cooler tube nipples (F) from housing.

7. Remove core hole plug (G) and gasket from housing. Discard gasket. Install 1. Position a new gasket on core hole plug (G) and install plug in damper and oil filter housing. 2. Install four oil cooler tube nipples (F) in housing. 3. Position new drain cover gaskets and two oil drain covers on housing. Install six self-locking nuts (E) and flat washers securing drain covers to housing. 4. With auxiliary oil filter positioned in housing, tighten auxiliary oil filter stop bolt (D) to 125 inch-pounds torque. 5. Install eight self-locking nuts (C) and flat washers securing filter in housing. 6. With main oil filter assembly positioned in housing tighten main oil filter stop bolt (B) to 125 inch-pounds torque. 7. Install six self-locking nuts (A) and flat washers securing filter in housing.

Figure 6-101. Removing or installing auxiliary and main oil filter attaching parts.
6-99

Remove 1. Remove the main oil filter stop bolt, sealing washer, and main oil filter assembly (A). 2. Remove the auxiliary oil filter stop bolt, sealing washer, and auxiliary oil filter assembly (B). 3. Remove and discard oil filter gaskets (C). 4. Remove eight self-locking nuts (D) and remove two lifting eyes. Remove and discard lifting eye gasket. Install N o t e . The lifting eye gasket is used under the left lifting eye only. 1. Position lifting eye gasket on left side of damper and oil filter housing. Position one lifting eye on each side of housing and install four self-locking nuts (D) securing each lifting eye. 2. Position a new oil filter gasket (C) on main and auxiliary oil filter openings in housing. 3. Position the auxiliary oil filter assembly (B), sealing washer, and auxiliary oil filter stop bolt in housing. 4. Position the main oil filter assembly (A), sealing washer, and main oil filter stop bolt in housing. Figure 6-102. Removing or installing main and auxiliary oil filters.

Remove W a r n i n g : The oil pressure regulator cover is spring loaded. Exercise care when removing cover. 1. Remove two self-locking nuts (A) and flat washers attaching oil pressure regulator valve cover. Remove and discard gasket. 2. Remove oil pressure regulator valve assembly parts in the sequence shown in figure 6-104. Note number of flat washers (A) removed for reference during assembly. Install 1. Install oil pressure regulator valve assembly parts in the sequence shown in figure 6-104. Install the same number of flat washers (A) as removed. 2. Position a new valve cover gasket on housing. Position valve cover on housing and install two self-locking nuts (A) and flat washers securing cover on housing. Figure 6-103. Removing or installing oil pressure regulator valve cover and gasket.

6-100

Figure 6-104. Disassembling or assembling oil pressure regulator valve.

Remove 1. Remove two self-locking nuts (A) and flat washers, attaching fuel check valve bracket and remove bracket. 2. Remove six self-locking nuts (B) and fiat washers attaching fuel pump adapter 3. Remove adapter using two mechanical pullers 5120-473-7222 (C). Install 1. Position fuel pump adapter on housing and install six self-locking nuts (B) securing adapter. 2. Position fuel check valve bracket on adapter and install two self-locking nuts (A) securing bracket. Figure 6-105. Removing or installing fuel pump adapter using mechanical pullers - 5120-473-7222.

6-101

Remove 1. Remove oil temperature transmitter (A). 2. Remove oil temperature switch (B). 3. Remove two reducer bushings (C). 4. Remove pipe plug (D). 5. Remove three pipe plugs (E). Install 1. Install three pipe plugs (E). 2. Install pipe plug (D). 3. Install two reducer bushings (C). 4. Install oil temperature switch (B). 5. Install oil temperature transmitter (A). Figure 6-106. Removing or installing damper and oil filter housing switches, bushings, and pipe plugs - front view.

Remove 1. Remove pipe plug (A). 2. Remove pipe plug (B) (if used on engine). 3. Remove three pipe plugs (C). 4. Remove pipe plug (D) (if used on engine). 5. Remove two pipe plugs (E). 6. Remove two pipe plugs (F). 7. Remove nipple (G) or elbow (whichever is used on engine). 8. Remove bushing (H). 9. Remove pipe plug (J) (if used on engine). Install 1. Install pipe plug(J) (if used on engine). 2. Install bushing (H). 3. Install nipple (G) or elbow (whichever is used on engine). 4. Install two pipe plugs (F). 5. Install two pipe plugs (E). 6. Install pipe plug(D) (if used on engine). 7. Install three pipe plugs (C). 8. Install pipe plug(B) (if used on engine). 9. Install pipe plug (A). Figure 6-107. Removing or installing damper and oil filter housing pipe plugs - rear view.

6-102

Figure 6-109

Figure 6-108.

6-103

Remove 1. Remove bushing (A), spring, and retainer from support. 2. Remove and discard oil filter element (B). Disconnect 1. Position auxiliary oil filter in arbor press and press retainer as shown using suitable blocks (A). 2. Remove cotter pin (B) and remove filter from press. Connect 1. Position auxiliary oil filter in arbor press and press retainer as shown using suitable blocks (A). 2. Install cotter pin (B) and remove filter from press. comarbor comarbor Note. Do not remove support or handle from filter cover unless inspection (para 6-38c) indicates replacement is necessary. Install 1. Position a new auxiliary oil filter element (B) on cover. 2. Position retainer, spring, and bushing (A) on support. Figure 6-111. Removing or installing auxiliary oil filter element. b. Cleaning. Refer to paragraph 6-2. Make certain all oil passages (fig. 6-112) are clear and not obstructed.

Figure 6-110. Disconnecting or connecting auxiliary oil filter element retainer and bushing.

6-104

Figure 6-112. Crankshaft damper and oil filter housing oil passages.

6-105

c . I n s p e c t i o n . Refer to paragraph 6-3, and to (1) through (3), below. ( 1 ) I n s p e c t t h e o i l t e m p e r a t u r e gage transmitter and high oil pressure warning light switch for damaged threads or deformity. Check electrical circuit for continuity. (2) Inspect oil presure regulator plunger, spring, and sleeve and bypass valve springs to

the limits specified in overhaul standards (table 6-22). (3) Inspect the main oil filter elements for plugged, coated, cracked, or damaged screens. Inspect main oil filter cover handle and spring for damage. Inspect auxiliary oil filter cover handle and support for damage.

Table 6-22. Crankshaft Damper and Oil Filter Housing Control Valves - Overhaul Standards Component Fig. No. Ref. letter B E B-E F C F-C D Point of measurement Inside diameter of sleeve (small) Outside diameter of plunger (small) Fit of plunger in sleeve (small) Inside diameter of sleeve (large) Outside diameter of plunger (large) Fit of plunger in sleeve (large) Valve spring: Approximate free length of spring Scale reading at 1.825 inch length Maximum solid height Bypass valve spring: Approximate free length of spring Scale reading at 2.81 inch length Maximum solid height Approximate free length of spring Scale reading at 1.75 inch length Maximum solid height Sizes and fits of new parts 0.8125 0.8095 0.0020L 1.1865 1.1840 0.0015L 0.8135 0.8105 0.0040L 1.1885 1.1850 0.0045L Wear limits

pressure B-6 Oil regulator plunger B-6 B-6 B-6 B-6 B-6 B-6

0.8145 0.8085 0.0060L 1.1905 1.1830 0.0075L * * * * * * * * * *

2.83 inch 29.3 lb 3 lb 1.284 inch 4.28 inch 52.3 lb 5 lb 2.261 inch 2.40 inch 9.12 lb 1.0 lb 0.988 inch

Oil filter and oil B-6 cooler pressure relief bypass valve springs B-6 oil Auxiliary filter bypass pressure relief valve spring

Note. Refer to paragraph 6-3b for explanation of symbols. d. Repair. (1) To replace main oil filter cover handle (63, fig. B-6), remove spring (66), spread handle, and remove handle from cover. Spread new handle and install on cover with spring. To replace auxiliary oil filter cover handle (20) or support, spread handle and remove from cover. Remove rivet (22) and remove support from cover. Position new support in cover and install rivet. Spread new handle and install on cover. (2) Refer to paragraph 6-4e, table 6-23, and figure 6-113 when replacing studs. (3) Refer to paragraph 6-4c for general repair and welding instructions and (2) and (b), below, for specific information on welding repair of the crankshaft damper and oil filter housing. (a) Repair of housing is permissible to include replacement of metal cracks, or chips. Repair shall be accomplished to prevent oil leakage between compartments, cast in passages, and drilled passages. Repair shall not impair the normal oil flow pattern (fig. 6-112) or be restrictive to the oil flow and shall not impair the normal functions of control valves and filtering functions. (b) After welding repair of the housing, visually inspect passages and compartments for obstructions and foreign material. Flow test passages to assure proper functioning and oil control. Leak test compartments and drilled passages and pressure check to 20 psi.

6-106

Figure 6-113.

6-107

Table 6-23. Crankshaft Damper and Oil Filter Housing Standard and Oversize Stud Identification Fig. No. B-6 Ref. letter or No. 50 Setting height 7 / 8 No. reqd. 4 5/16-18(3/4) x Stud size and length 5/16-24(19/32) x 1-1/2 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) x 3/8-24(11/16) x 1-5/8 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) x 5/16-24(9/16) x 1-5/16 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) 5/16-24(19/32) x 1-1/2 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) x 3/8-24(7/8) x 1-3/4 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS)

6-113

15 / 16

3/8-16(51/64)

6-113

25/32

5/16-18(11/16)

6-113 6-113

C D

6-113 6-113

E F

6-113

7 / 8 27 / 32 (oil pressure access cover) 1-1 / 16 1-3/ 16 (fuel pump check valve bracket) 1

12 2

5/16-18(3/4)

6 2

3/8-16(27/32)

5/16-18(13/16) x 5/16-24(19/32) x 1-11/16 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS)

Note. Refer to figure 6-1 for oversize stud identification.

e. Assembly. Refer to figures 6-111 through 6101, 4-92 through 4-89, 6-100, and 6-99.

Section VIII. OVERHAUL OF FRONT FAN DRIVE HOUSING AND CLUTCH ASSEMBLY 6-39. General
a. This section covers the overhaul of the front fan drive housing and clutch assembly. Specific disassembly, cleaning, ininstructions on spection, repair and assembly accompany the overhaul operations. O v e r h a u l s t a n d a r d s o f individual components follow the inspection procedures. Stud identification information is included in the repair procedures. Refer to the following table (table 6-24) for applicable illustrations a n d i n s t r u c t i o n s f o r o v e r h a u l operations. b. F a n d r i v e h o u s i n g s o n o r i g i n a l p r o d u c t i o n engines were modified. to include an oil restrictor in the horizontal oil passage, and can be identified by the hex-head on the restrictor (fig. 6127). The housings on improved design engines were redesigned to eliminate the need for restrictors, and can be identified by the hex socket head pipe plug in the horizontal oil passage on the side of the housing. These changes were made without part number change, which necessitates identification as engines having oil restrictors. c. T h e c l u t c h a s s e m b l i e s w e r e r e d e s i g n e d f o r simplification and are identified by different part numbers. Although the clutches are similar, disassembly and assembly procedures differ. Visual identification of piston actuated and mechanical clutches is shown in figure 4-102. The clutches are interchangeable as assemblies only.

6-108

Table 6-24. Front Fan Drive Housing and Clutch Assembly Component Front Fan Drive Housing Para 6-40a Figs. 6-114 through 6-127 Cleaning Para 6-2 Inspection Para 6-40c Table 6-25 Repair Para 6-40c Table 6-28 Fig. 6-148 Assembly Para 6-40d Figs. 6-127, 6-150 through 6-152, 6124, 5-153, 6-122 through 6-119, 6154,6-155, 6-115, 6-114 Para 6-40d Figs. 6-149,/6-146 through 6-137, 6134, 6-132 through 6-130, 6128 Para 6-40d Figs. 6 - 1 4 7 , 6 144,6-138,6-136, 6-135, 6-133, 6131 through 6-129

Piston Actuated Clutch Assembly Mechanical Clutch Assembly

Para 6-40a Figs. 6-128 through 6-130, 6-132, 6-134, 6-137 through 6-146 Para 6-40a Figs. 6-129 through 6-131, 6-133; 6-135, 6-136, 6-138, 6-144, 6-147

Para 6-2

Para 6-40c Table 6-26

Para 6-40c

Para 6-2

Para 6-40c Table 6-27

Para 6-40c

6-40. Overhaul of Front Fan Drive Housing and Clutch Assembly

Disassembly. (1) Front fan drive housing and cover. Disassemble front fan drive housing and cover following instructions which accompany figures 6-114 through 6-127. a.

Remove 1. Cut locking wire (A). 2. Remove six drilled head bolts (B) and flat washers attaching fan drive oil seal housing to fan drive housing cover. 3. Install two mechanical pullers - 5120-473-7222 in puller screw holes (C) in oil seal housing (D). Turn screws alternately to remove housing. Install 1. Position fan drive oil seal housing (D) on fan drive housing cover. 2. Install six drilled head bolts (B) and flat washers securing housing to cover. 3. Install locking wire (A) securing bolts. Figure 6-114. Removing or installing fan drive oil seal housing.
6-109

Figure 6-116. Removing clutch cover and fan drive vertical shaft bearing using puller.

Remove 1. Cut locking wire and remove 12 slotted nuts (A) attaching fan drive housing cover to front fan drive housing assembly. 2. Install three drilled head bolts (B, fig. 6-114), used to secure fan drive oil seal housing, into screw holes (B, fig. 6-115) and using bolts as puller screws, remove fan drive housing cover from front fan drive housing assembly. Install 1. Position fan drive housing cover in front fan drive housing assembly. 2. Install 12 slotted nuts (A) securing fan drive housing cover to front fan drive housing assembly and install locking wire securing nuts. Figure 6-115. Removing or installing fan drive housing cover. Figure 6-117. Remove fan drive clutch upper ball bearing from housing cover.

6-110

Figure 6-118. Removing fan vertical drive shaft oil seal from housing.

Remove 1. Remove four cotter pine and slotted nuts (A). 2. Remove fan drive bevel gearshaft (B), ball bearings, and bearing supports from housing as a unit 3. Remove bearing support (C) from front ball bearing. 4. Remove bearing support (D) from rear ball bearing. Install 1. Position bearing support (D) on rear ball bearing. 2. Position bearing support (C) on front ball bearing. 3. Position fan drive bevel gearshaft (B), ball bearings, and bearing supports in housing as a unit. 4. Install four slotted nuts and cotter pins (A). Figure 6-119. Removing or installing fan drive bevel gearshaft and associated parts.

6-111

Remove 1. Straighten tab on tab washers (A). 2. Remove bolt (B), tab washer, and lock plate holding fan driven gearshaft and bearings in front fan drive housing assembly. Discard tab washer. Install 1. Install bolt (B), new tab washer, and lock plate holding fan driven gearshaft and bearings in front fan drive housing assembly. 2. Bend tab on tab washer (A) over bolt, Figure 6-120. Removing or installing lower driven gearshaft ball bearing lock plate.

Remove 1. Remove fan driven gearshaft (A), lower driven gearshaft ball bearing, gearshaft ball bearing, and bearing spacer as an assembly. 2. Remove and discard elbow (B) from housing on engines having an elbow. Other engines have a pipe plug at this location. Install 1. Install pipe plug in this location (B). 2. Position fan driven gearshaft (A), lower driven gearshaft ball bearing, gearshaft ball bearing, and bearing spacer as an assembly in front fan driving housing assembly. Figure 6-121. Removing or installing fan driven gearshaft and bearings..

6-112

Figure 6-122. Removing or installing fan drive bevel gearshaft bearing retaining ring.

1. Press fan drive bevel gearshaft from front bevel gearshaft ball bearings (A). Remove and retain shim or shims for use during assembly. 2. Press fan drive bevel gearshaft from rear gearshaft ball bearing (B) in the same manner. Figure 6-123. Removing fan drive bevel gearshaft ball bearings.

Figure 6-124. Removing or installing fan driven gearshaft bearing retaining ring.
6-113

Figure 6-125. Pressing fan driven gearshaft from upper gearshaft ball bearing.

Note. The oil restrictor must be identified with, and kept with the housing from which it was removed. If restrictors are installed in housings not requiring them, or conversely, serious clutch damage will result. Figure 6-127. Removing or installing front fan drive housing oil restrictor (engines having oil restrictors). (2) Clutch assembly. D i s a s s e m b l e p i s t o n actuated and mechanical clutch assemblies following instructions which accompany figures 6-130 through 6-147.

Figure 6-126. Pressing fan driven gearshaft from lower driven gearshaft ball bearing.

6-114

Figure 6-128. Piston actuated clutch assembly-sectional view.

6-115

Figure 6-129. Mechanical clutch assembly-sectional view.

6-116

Figure 6-130. Removing or installing fan drive housing cover preformed packing.

Remove 1. Cut locking wire (A). 2. Remove 16 bolts (B) attaching fan drive hub to drive shaft. Install 1. Install 16 bolts (B) securing fan drive hub to drive shaft. 2. Install locking wire (A) securing bolts. Figure 6-131. Removing or installing fan drive hub attach ing parts.

6-117

Figure 6-132.

Figure 6-133.

6-118

Figure 6-135. Figure 6-134.

6-119

Remove 1. Remove fan drive vertical drive shaft (A) from hub. 2. Remove three clutch springs (B). 3. Remove 15 clutch balls (C). Install 1. Position 15 clutch balls (C) in fan drive hub. 2. Position three clutch springs (B) in hub. 3. Position fan drive vertical drive shaft (A) in hub. Figure 6-136. Removing or installing fan drive vertical drive shaft, balls, and springs from fan drive hub (mechanical clutch). Remove 1. Straighten tab on three washers (A). 2. Remove three cap screws (B), tab washers, flat washers, and offset spacers (fig. 6-132). Discard tab washers. 3. Remove fan drive vertical shaft (C) from drive disc. Install 1. Position fan drive vertical shaft(C) in drive disc. 2. Install three cap screws (B), new tab washers, flat washers, and offset spacers (fig. 6-132). 3. Bend tab on three tab washers (A). Figure 6-137. Removing or installing fan drive disc (piston actuated clutch).

6-120

Figure 6-138. Fan drive shaft oil distributor location.

Figure 6-140. Straightening or bending tabs on key washer securing actuating clutch piston spanner nut (piston actuated clutch).

Figure 6-139. Removing or installing fan drive bottom clutch disc (piston actuated clutch), Figure 6-141. Removing or installing actuating clutch piston spanner nut using face wrench socket 5120-793-7896.

6-121

1. Remove actuating clutch piston (A) from pressure plate. 2. Carefully remove outer piston ring (B). 3. Remove inner piston ring (C). Remove 1. Remove clutch pressure plate (A) with assembled clutch piston from drive hub. 2. Remove three clutch springs (B) from hub. 3. Remove 15 clutch balls (C) from hub. Install 1. Position 15 clutch balls (C) in drive hub. 2. Position three clutch springs (B) in hub. 3. Position clutch pressure plate (A) with assembled clutch piston from hub. Figure 6-142. Removing or installing clutch pressure plate, clutch springs, and balls (piston actuated clutch). Figure 6-143. Removing actuating clutch piston and piston rings (piston actuated clutch).

6-122

Remove 1. Support ball bearing in press 2. Press drive hub from ball bearing. Install 1. Support drive hub in press. 2. Press ball bearing on drive hub using a suitable hollow tool the size of the inner race. Figure 6-144. Removing or installing ball bearing from drive hub.

Remove 1. Remove retaining ring (A) from housing assembly. 2. Remove intermediate clutch diet (B) from housing. 3. Remove drive disc (C) from housing. Install 1. Position drive diet (C) in housing assembly. 2. Position intermediate clutch disc (B) in housing. 3. Install retaining ring (A) in housing. Figure 6-145. Removing or installing intermediate clutch and drive discs.

6-123

Remove 1. Separate vertical drive shaft (A) from housing assembly. 2. Separate top clutch disc (B) from housing. Note. Do not remove the two dowel pins from housing unless inspection (para 6-40c) indicates

the need for replacement. Use an arbor press to remove dowel pins from housing.

Install 1. Position top clutch diae (B) in housing assembly. 2. Position vertical drive shaft (A) in housing.

Figure 6-146. Separating or positioning vertical drive shaft, top clutch disc, and housing assembly (piston actuated clutch).

6-124

Note. Do not remove the two dowel pins from disc housing unless inspection (para 6-40c)

indicates replacement is necessary. Use an arbor press to remove dowel pins from housing.

Figure 6-147.

6-125

b. Cleaning. Refer to paragraph 6-2. c. Inspection and Repair. Refer to paragraph 6-3 and 6-4, and (1) through (7), below. (1) Fan driven gearshaft and fan drive bevel gearshaft. Inspect fan driven gearshaft (74.1, fig. B-26) and fan drive bevel gearshaft (74.2, fig. B-26) to limits specified in overhaul standards (table 6-25). N o t e . If either the fan driven gearshaft or the fan drive bevel gearshaft require replacement, both must be replaced as they are a matched gear set and cannot be replaced individually. ( 2 ) O i l s e a l . Replace the oil seal at each overhaul. (3) H o u s i n g a s s e m b l y . I n s p e c t h o u s i n g assembly (50, fig. B-27) or housing assembly (23, fig. B-27) for loose dowel pins. (4) C l u t c h c o m p r e s s i o n s p r i n g s a n d b a l l s . Inspect clutch compression springs ( 39, fig. B27) for weakness, broken coils, and distorted condition. C h e c k b a l l s ( 4 0 , f i g . B - 2 7 ) a n d springs to limits specified in overhaul standards (tables 6-26 or 6-27).

Due to design changes on the Note. mechanical clutch, two different size balls have been used. Carefully inspect all balls and discard any balls of 11 / 16 inch diameter. Overhaul clutch assembly using only the current 5 / 8 inch diameter balls, FSN 3110-462-0392. (5) Drive hub. Inspect drive hub (41, fig. B-27) or (46, fig. B-27) for raised metal surfaces, loose rivets, warpage or pitted surfaces caused by ball wear. Check bearing surfaces against limits specified in overhaul standards (tables 6-26 or 627). Repair metal sufaces by polishing pitted areas smooth. (6) Clutch discs. Inspect clutch discs (48 and 49, fig. B-27) or 21, 22, 24, and 27, fig. B27) for cracks, warpage, wear, or other abrasive dam age. Inspect for excessive heat distortion. Repairs of clutch discs are not recommended. Replace discs if any of the above mentioned dam age is evident. (7) Studs. Refer to paragraph 6-4e, table 628 and figure 6-148 when replacing studs.

Figure 6-148. Front fan drive housing and mounting base - studding assembly.
6-126

Table 6-25. Front Fan Drive Housing Assembly Overhaul Standards

Fig. No.

B-26

B-26 B-26

B-26

B-26 B-26

B-26 B-26

B-26

B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26

B-26

Fig. B-27

B-26 B-26

B-26

B-26 B-26 B-26 B-27 B-27 B-27 B-27 B-26 B-27 B-26 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 Paragraph 6-3b

6-127

Table 6-26. Early Cooling Fan Clutch Overhaul Standards

Fig. B-27

paragraph 6-3b

Table 6-27. Late Cooling Fan Clutch Overhaul Standards

Fig. B-27

paragraph 6-3b

6-128

Table 6-28. Front Fan Drive Housing Standard and Oversize Stud Identification
Fig. No.

6-148

6-148

6-148

Fig. 6-148 6-148

6-148 6-148

6-148

Note. Refer to figure 6-1 for oversize stud identification. d. Assembly. (1) C l u t c h a s s e m b l i e s .

(a) P i s t o n a c t u a t e d c l u t c h a s s e m b l y . Refer to figures 6-149, 6-146 through 6-137, 6134, 6-132 through 6-130, and 6-128.

Figure 6-149. Installing outer piston ring on actuating piston (piston actuated clutch).

6-129

(b) Mechanical clutch assembly. R e f e r to figures 6-148, 6-144, 6-138, 6-136, 6-135, 6133, and 6-131 through 6-129. Note. When positioning balls in fan drive hub, place a dab of grease, (GAA) FSN 9150190-0905, on each ball pocket to facilitate keeping balls in proper location during assembly. (2) Front fan drive housing. R e f e r t o figures 6-127, 6-150 through 6-152, 6-124, 6153, 6-122 through 6-119, and (a) and (b), below. Note. Before assembly of the front fan drive housing it will be necessary to determine the shim thickness required to control the end play of fan driven gearshaft and tbe backlash of fan drive bevel gearshaft. (a) Determine end play for fan drive gears haft. P o s i t i o n o r i g i n a l s h i m s ( f i g . 6 - 1 2 6 )

on end of inner bearing race (side opposite bearing trade mark) of lower driven gearshaft ball bearing. Measure the total thickness of bearing race and shim, from shim on inner race to supper face of outer race, with end play removed. Thickness should be from 1.2635-inch minimum to 1.2655-inch maximum. When total thickness is greater than 1.2655-inch, strip 0.002-inch thick laminations from the shim pack until the correct thickness is obtained. When total thickness is less than 1.2635-inch, add 0.002-inch thick shims (stripped from a new shim pack FSN 2930-678-3271) as necessary. Figure 6-150 illustrates shim location and measuring points.

Figure 6-150. Determining shim thickness for front fan drive gearshaft and drive bevel gearshaft.

6-130

1. Position shim (A) of predetermined thickness (fig. 6150) on inner race of lower driven gearshaft ball bearing. 2. Press fan driven gearshaft (B) into ball bearing. Figure 6-151. Pressing fart driven gearshaft into lower drive gearshaft ball bearing.

1. Position bearing spacer (A) on fan driven gearshaft and start upper driven gearshaft ball bearing on gearshaft 2. Press gearshaft (B) into ball bearing. Figure 6-152. Pressing fan driven gearshaft into upper driven gearshaft ball bearing. (b) D e t e r m i n e b a c k l a s h f o r f a n d r i v e b e v e l gearshaft. Position original shims (fig. 6-123) on end of inner bearing race (side opposite bearing trade mark) of front bevel gearshaft ball bearing. Measure total thickness of bearing face and shim. from shim on inner race to face of outer race, with end play removed. Thickness should be from 0.7891-inch minimum to 0.791 1-inch maximum. When total thickness is more than 0.791 1-inch, strip 0.002-inch thick laminations from the shim pack until the correct thickness is obtained. When total thickness is less than 0.7891-inch, add 0.002-inch thick shims (stripped from a new shim pack FSN 2930-6783271) as necessary. Figure 6-150 illustrates shim location and measuring points.
6-131

figure 6-155

1. Position shim (A) of predetermined thickness (fig. 6150) over bearing hub of front fan drive bevel gearshaft. 2. Position and press front bevel gearshaft ball bearing (B) on gearshaft. 3. Press rear bevel gearshaft ball bearing (C) on gearshaft in the same manner.
Figure 6-154.

Figure 6-153. Pressing front bevel gearshaft ball bearing on gearshaft. (3) Fan drive oil seal housing. Refer to figure 6-154.

6-132

1. Position fan drive housing cover (A) on arbor press using suitable blocks for support. 2. Preen clutch upper ball bearing (B) into cover.

3. Install housing cover and bearing on vertical drive shaft.

Figure 6-155. Pressing clutch upper ball bearing into fan drive housing cover. (5) Front fan drive housing and clutch assembly. Refer to figures 6-115 and 6-114.

6-133

Section IX. OVERHAUL OF REAR FAN DRIVE HOUSING AND CLUTCH ASSEMBLY AND ACCESSORY DRIVE HOUSING 6-41. General
the fan drive housing oil passage. The housing was redesigned to eliminate the need for restrictors on improved design engines. It cannot be determined whether a housing has an oil restrictor unless the housing is completely disassembled, as the exposed end of the restrictor has the appearance of a hexagon socket head pipe plug. c. The clutch assembly used in the rear fan drive housing is the same as that used in the front fan drive housing. Refer to paragraph 6-39c for differences between piston actuated and mechanical clutch assemblies.

a. This section covers the overhaul of the rear fan drive housing and clutch assembly and accessory drive housing. Specific instructions on disassembly, cleaning, inspection, repair, and assembly accompany the overhaul operations. Overhaul standards of individual components follow the inspection procedures. Stud identification information is included in the repair procedures. Refer to the following table (table 629 for applicable illustrations and instructions for overhaul operations. b. T h e r e a r f a n d r i v e h o u s i n g s o n o r i g i n a l production engines required an oil restrictor in

Table 6-29. Rear Fan Drive Housing and Clutch Assembly and Accessory Drive Housing Component Rear Fan and Accessory Drive Housing Assembly Rear Fan and Accessory Drive Housing Para 6-42a Figs. 6-156 through 6-158 Para 6-42a Figs. 6-116 through 6-118, 6159 through 6172, 6-124 through 6-126 Cleaning Para 6-2 Inspection Para 6-42c Table 6-30 Para 6-42c Table 6-30 Repair Para 6-42c Table 6-32 Para 6-42c Table 6-32 Fig. 6-187 Assembly Para 6-42d Figs. 6 - 1 5 8 , 6 157, 6-206, 6-156 Para 6-42d Figs. 6-205 through 6-202, 6190 through 6188, 6-206, 6-170 through 6-168, 6167 or 6-166, 6172, 6-164,6-162, 6-161, 6-159, 6155, 6-154; 6-153 through 6-151, 6157,6-156, 6-115, 6-114 Para 6-40d Figs. 6-149, 6-146 through 6-137, 6134, 6-132 through 6-130, 6128 Para 6-40d Figs. 6 - 1 4 7 , 6 145, 6-144, 6-138, 6-135, 6-133, 61-31 through 6-129 Figs. 6 - 1 9 1 , 6 192, 6-181, 6-193 through 6-198

Para 6-2

Piston Actuated Clutch Assembly

Para 6-40a Figs. 6-128, 6-130 through 6-132, 6134 through 6137, 6-146

Para 6-2

Para 6-40c Table 6-26

Para 6-40c

Mechanical Clutch Assembly

Fuel Injection Pump Advance Assembly

Para 6-40a 6-129 Figs. through 6-131, 6133, 6-135,6-136, 6-138, 6-144, 6147 6-173 Figs. through 6-186

Para 6-2

Para 6-40c Table 6-27

Para 6-40c

Para 6-2

Para 6-40c Table 6-31

Para 6-42c

6-134

6-42.

Overhaul of Rear Fan Drive Housing and Clutch Assembly and Accessory Drive Housing

Disassembly. (1) Rear fan and accessory drive housing a s s e m b l y . Refer to figures 6-156 through 6-158. (2) Clutch cover, bearing and vertical drive shaft oil seal. Refer to figures 6-116 through 6118.

a.

(3) R e a r f a n a n d a c c e s s o r y d r i v e h o u s i n g . Refer to figures 6-116 through 6-118, 6-159 through 6-172, and 6-124 through 6-126. (4) Rear fan drive housing clutch assembly. Refer to table 6-24 for appropriate clutch disassembly sequence. (5) F u e l i n j e c t i o n p u m p a d v a n c e a s s e m bly.Refer to figures 6-172 through 6-186.

Remove 1. Cut locking wire. Remove six drilled head bolts (A) and flat washers. Refer to figure 6-114 and remove oil seal housing from fan drive housing cover. 2. Refer to figure 6-115 and remove fan drive housing cover (B).

Install 1. Refer to figure 6-115 and install fan drive housing cover (B). 2. Refer to figure 6-114 and install oil seal housing on fan drive housing cover. Install six drilled head bolts (A) and flat washers. Install locking wire securing bolts.

Figure 6-156. Removing or installing rear fan drive housing cover.

6-135

Remove 1. Remove and discard four preformed packings (A) from oil transfer tubes. 2. Remove two cotter pins, slotted nuts (B), and flat washers attaching injection advance bearing cap. 3. Remove injection advance bearing cap (C). Note. Bearing cap and accessory drive housing are stamped with corresponding numbers (fig. 6206) to prevent mismating of parts. Cap should be loosely attached on housing after advance assembly is removed.

4. Remove six cotter pins, slotted nuts (D), and flat washers attaching front, intermediate, and rear bearing supports. Install 1. Install six cotter pine, dotted nuts (D), and flat washers securing front, intermediate, and rear bearing supports. 2. Refer to figure 6-206 and install injection advance bearing cap (C) in appropriate position. 3. Install two cotter pins, slotted nuts (B), and flat washers securing injection advance bearing cap. 4. Install four new preformed packings (A) in oil transfer tubes.

Figure 6-157. Removing or installing bearing cap and bearing support attaching parts.

6-136

Figure 6-158. Removing or installing injection pump advance assembly.

Remove 1. Remove three self-locking nuts (A) and flat washers attaching right camshaft drive inner support. 2. Remove three self-locking nuts (B) and flat washers attaching left camshaft drive inner support.

Install 1. Install securing 2. Install securing

three self-locking nuts (B) and flat washers left camshaft drive inner support. three self-locking nuts (A) and flat washers right camshaft drive inner support.

Figure 6-159. Removing or installing left and right camshaft drive inner support attaching parts.
6-137

Remove 1. Separate right camshaft drive inner support (A) from accessory drive housing and remove camshaft drive gearshaft assembly. 2. Remove and discard preformed packing (B) from support. 3. Separate left camshaft drive inner support (C) from accessory drive housing and remove camshaft drive gearshaft assembly. Remove and discard preformed packing (B) from support. Install 1. Position a new preformed packing (B) on left camshaft drive inner support (C). 2. Position camshaft drive gearshaft assembly in accessory drive housing and position support (C) in housing and on gearshaft assembly. 3. Position a new preformed packing (B) on right camshaft drive inner support (A). Position camshaft drive gearshaft assembly in accessory drive housing and position support (A) in housing and on gearshaft assembly. Figure 6-160. Removing or installing right and left camshaft drive inner supports and preformed packing.

Remove 1. Straighten tab on tab washer and remove bolt (A), tab washer, and lock plate. Discard tab washer. 2. Remove fan driven gearshaft (B) and ball bearings as a unit Install 1. Position fan driven gearshaft (B) and ball bearings as a unit in fan drive housing. 2. Install bolt (A), new tab washer, and lock plate and bend tab on washer over bolt. Figure 6-161. Removing or installing fan driven gearshaft and ball bearings as a unit.

6-138

Remove 1. Remove plain nut (A) and lock washer attaching fuel injection pump drive coupler half to fuel injection pump spur gearshaft. Install 1. Install plain nut (A) and lock washer securing fuel injection pump drive coupler half to fuel injection pump spur gearshaft. Torque tighten as specified. Figure 6-162. Removing or installing fuel injection pump splined drive coupler attaching parts.

1. Remove coupler half (A) from spur gear. 2. Remove Woodruff key (B) from spur gear. Note. Keep the splined coupler half with the coupler half that is on (or removed from) the fuel injection pump (fig. 6-252). Coupler halves are mated parts and must be kept together for a correct assembly. Figure 6-163. Removing fuel injection pump splined drive coupler half.

6-139

Remove 1. Remove plain nut (A) and lock washer attaching drive coupler half to fuel injection pump spur gearshaft. Install 1. Install plain nut (A) and lock washer securing drive coupler half to fuel injection pump spur gearshaft. Tighten the nut to a torque of 900 pound-inches. Figure 6-164. Removing or installing fuel injection pump diaphragm drive coupler half.

C a u t i o n ; Do not attempt to remove the diaphragm drive coupler half from the shaft using a standard puller as shown in figure 6-163. This may distort the coupler and render it unserviceable. Use puller as shown. 1. Remove coupler half (A) from spur gearshaft using improvised tool (fig. 2-2). 2. Remove pilot ring (B) from gearshaft. 3. Remove Woodruff key (C) from gearshaft. Note. The diaphragm type drive coupler halves are not matched sets and it is not necessary to maintain them in pairs. The parts are interchangeable between assemblies. Figure 6-165. Removing fuel injection pump diaphragm drive coupler half.

6-140

Separate 1. Remove seven self-locking nuts (A) and flat washers. 2. Separate rear fan drive housing and accessory drive housing. 3. Cut locking wire and remove four bolts (B) and flat washers attaching fan drive control cover to fan drive housing. 4. Remove fan drive control cover (C). Remove and discard cover gasket. 5. Remove four pipe plugs (D), one from accessory drive housing and three from fan drive housing.

Attach 1. Install four pipe plugs (D), one in accessory drive housing and three in fan drive housing. 2. Position a new fan drive control gasket on fan drive housing and position control cover (C) on gasket. 3. Install four bolts (B) and flat washers securing control cover to housing and install locking wire securing bolts. 4. Position accessory drive housing on fan drive housing. 5. Install seven self-locking nuts (A) and flat washers.

Figure 6-166. Separating or attaching rear fan and accessory drive housings (housings equipped with control covers).

6-141

Separate 1. Remove seven self-locking nuts (A) and flat washers. 2. Separate rear fan drive housing and accessory drive housing. 3. Remove two pipe plugs (B), one from accessory drive housing and one from fan drive housing. 4. Remove oil restrictor (C) from vertical oil passage in fan drive housing. 5. Remove oil restrictor (D) from horizontal oil passage in fan drive housing. Note. The installation of oil restrictors in specified engines i s c r i t i c a l . B e c e r t a i n t h e restrictors are kept with their respective

housings. If restrictors are installed in housings not requiring them, or conversely, serious clutch damage will result. Attach 1. Install oil restrictor (D) in horizontal oil passage in fan drive housing. 2. Install oil restrictor (C) in vertical oil passage in fan drive housing. 3. Install two pipe plugs (B), one in fan drive housing and one in accessory drive housing. 4. Position accessory drive housing on fan drive housing. 5. Install seven self-locking nuts (A) and flat washers.

Figure 6-167. Separating or attaching rear fan and accessory drive housing (housings equipped with oil restrictors).

6-142

Figure 6 - 1 6 8 . Removing or installing fuel injection pump spur gearshaft and bearing.

Remove 1. Remove bearing retaining ring (A). 2. Remove needle roller bearing (B) from rear fan drive housing. Install 1. Position needle roller bearing (B) in rear fan drive housing. 2. Install bearing retaining ring (A). Figure 6-170. Removing or installing needle roller bearing retaining ring and bearing.

Figure 6-169. Removing or installing oil seal.

6-143

1. Position fuel injection pump spur gearshaft (A) in arbor press. 2. Press gearshaft from spur gearshaft ball bearing (B) using press plate to support bearing. Figure 6-171. Removing fuel injection pump spur gearshaft ball bearing.

Remove 1. Straighten tab on retaining washer (A) and remove gearshaft plug and washer. 2. Remove oil transfer plug (B) from camshaft drive gearshaft. Install 1. Position oil transfer plug (B) in camshaft drive gearshaft. 2. Install gearshaft plug and retaining washer (A) torque to 1000-1200 lb. in. and bend tab on washer securing plug. Figure 6-172. Removing or installing oil transfer plug from camshaft drive gearshafts.

6-144

Figure 6-174. Removing or installing rear fan drive shaft.

Remove 1. Remove fan drive gearshaft (A), front bevel gearshaft bearing, and front bearing support as a unit. 2. Remove front bearing support (B) from gearshaft bearing. Install 1. Position front bearing support (B) on front bevel gearshaft bearing. 2. Position fan drive gearshaft (A), gearshaft bearing, and support on injection pump advance assembly. Figure 6-173. Removing or installing fan drive gears haft, bearing, and support.

6-145

Note. B e f o r e r e m o v i n g b o l t s a n d s e l f - l o c k i n g nuts securing the components of the advance assembly, check alinement and legibility of scribe marks on adjusting ring boss, flyweight, and drive gearshaft flange. The marks must be alined to insure proper assembly. If the scribe marks are not alined, scribe a new line on the gearshaft flange in alinement with the ring boss scribe line. Identify the new line using a prick punch dot or some other method. The new gear flange mark and ring boss must be in alinement for proper assembly. 1. Remove intermediate bearing support (A). 2. Remove eight cotter pins, slotted nuts (B) and two flat washers. 3. Remove six bolts (C). Figure 6-175. Removing advance flyweight adjusting ring and injection pump drive gearshaft attaching parts (adjusting ring secured with nuts and washers).

1. Remove intermediate bearing support (A). 2. Cut locking wire (B). 3. Remove six bolts (C). 4. Remove two cotter pins, slotted nuts (D), and flat washers. Figure 6-176. Removing advance flyweight adjusting ring and injection pump drive gearshaft attaching parts (adjusting ring secured with bolts).

6-146

Figure 6-177. Removing injection pump drive gearshaft.

1. Remove advance flyweight adjusting ring (A), flyweights, and oil control housing from flyweight housing as an assembly. 2. Disconnect and remove flyweight extension helical springs (B) from flyweight extension. 3. Remove flyweights (C) from adjusting ring. Note. Note position of flyweights as they must be installed in their original position to assure proper operation. 4. Separate adjusting ring (A) and remove from oil control housing. Figure 6-178. Removing advance flyweight adjusting ring and flyweight.

6-147

Note. Observe location of dowel pins in advance vane housing for alinement with holes in flyweight housing during assembly. Figure 6-179. Removing flyweight housing.

Figure 6-180. Removing advance vane housing and vane.

6-148

Figure 6-181. Removing or installing injection pump drive gearshaft ball bearing retaining ring.

Figure 6-182.

6-149

1. Remove bevel gearshaft ball bearing (A) from accessory drive bevel gearshaft. 2. Remove shim (B) located behind bearing and retain for use during assembly. Remove 1. Partially separate advance vane and housing and remove eight seals and springs (A) 2. Remove vane (B) from housing. Install 1. Position advance vane (B) in housing. 2. With vane partially separated from housing, install Figure 6-183. Removing or installing automatic advance vane, housing, seals, and springs. Figure 6-185. Removing accessory drive bevel gearshaft ball bearing using suitable gear puller.

Figure 6-184. Removing rear bearing support using suitable gear puller.

6-150

Figure 6-186. Removing advance vane housing cover, gearshaftplug, and retaining ring.

6-151

(6) Advance vane housing cover and accessory drive gearshaft. Refer to figure 6-186. (a) Cut four pins 7 / 16-inch (approx.) long from 7 / 32-inch diameter brass brazing rod or other soft material. Insert the pins in the four equally spaced holes in bearing portion of advance vane cover. An improvised ring compressing tool of the type shown in figure 2-1 can be fabricated to facilitate removal, of the advance vane cover internal retaining ring. If the improvised tool is used, install it over the pins and tighten bolts sufficiently to compress the advance vane cover internal retaining ring. (b) Install accessory drive gearshaft in a soft-jawed vise and remove advance vane housing cover (A) using a gear puller as shown in figure 6-186. (c) Compress retaining ring and remove plug (B) from accessory drive gearshaft. C a u t i o n ; Use extreme care in this operation to prevent damage to vane cover or gearshaft. b. Cleaning. Refer to paragraph 6-2.

c. Inspection and Repair. R e f e r t o p a r a g r a p h s 6-3 and 6-4, and (1) through (7), below. (1) Fan drive gearshaft and fan drive bevel gearshaft. Inspect fan driven gearshaft (50.1, fig. B-26) and fan drive bevel gearshaft (5C2, fig. B-26) to limits specified in overhaul standards (table 6-30). (2) Oil seal. Replace the oil seal each overhaul. (3) C l u t c h a s s e m b l y . R e f e r t o p a r a g r a p h 6 40c and tables 6-26 or 6-27. (4) Advance unit seals and springs. I n s p e c t seals and springs for cracks, indentations, and wear. Check seals to the limits specified in overhaul standards (table 6-31). (5) Flyweight springs. I n s p e c t f l y w h e e l springs for cracks and damage. Check spring tension to limits specified in overhaul standards (table 6-31). (6) S t u d s . Refer to paragraph 6-4e, table 632, and figure 6-187 when replacing studs.

6-152

Figure 6-187. Rear fan and accessory drive housing and base studding assembly. (7) F u e l i n j e c t i o n p u m p d r i v e c o u p l e r h a l f . (a) D r i v e s p l i n e d c o u p l e r . I n s p e c t t h e front and rear coupler sleeves and hubs for wear and mutilation and for fit with the splines of mating parts. Mating splines must match without binding and with a maximum total backlash of 0.006 inch from the input end through the output end. Check the quad rings for cracked or torn condition and for deterioration or loss of resilience. (b) D r i v e d i a p h r a g m c o u p l e r . I n s p e c t flange coupling for bent or distorted condition and for a mutilated keyway. Inspect pilot ring for distortion or elongated holes. Replace parts found unserviceable.

6-153

Table 6-30. Rear Fan and Accessory Drive Housing Assembly Overhaul Standards
Component Fig. No. Ref. letter Point of measurement Sizes and fits of new parts Wear limits

Rear fan and B-26 B-26 accessory drive B-26 housing B-27 B-27 B-27 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 Rear fan and B-26 accessory drive B-27 B-26 housing B-27 Fuel injection B-26 pump spur shaftgear B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 Fuel injection B-26 spur B-26 pump B-26 shaftgear B-26 B-26 B-26 B-26 B-26 B-26 B-26 fan and B-26 injection B-26 fan and B-26 injection B-26 B-26 B-26 B-27 B-27 B-26

Q R R-Q E F F-E T U U-T W X X-W Y Z Z-Y V AA AA-V B D D-B E F E-F J M M-J C L L-C K N N-K G XX XX-G H ZZ ZZ-H P YY YY-P AB AB-P S B B-S

Inside diameter of bearing support Outside diameter of bearing Fit of bearing in support Outside diameter of bearing surface on gearshaft assembly Inside diameter of bearing Fit of bearing on gearshaft assembly Outside diameter of bearing Inside diameter of bearing support Fit of bearing in support Outside diameter of bearing surface on gearshaft Inside diameter of bearing Fit of bearing on gearshaft Outside diameter of bearing Inside diameter of bearing support Fit of bearing in support Outside diameter of gearshaft Inside diameter of drive gearshaft Fit of gearshaft in drive gearshaft Outside diameter of bearing surface on fuel injection pump driven gearshaft Inside diameter of bearing Fit of bearing on gearshaft Outside diameter of bearing Inside diameter of liner in housing Fit of bearing in housing Inside diameter of liner in housing Outside diameter of needle bearing Fit of needle bearing in housing Outside diameter of needle bearing surface on gearshaft Inside diameter of needle bearing Fit of gearshaft in needle bearing Inside diameter of oil seal bore in housing Outside diameter of oil seal Fit of oil seal in housing Inside diameter of bearing bore (small) in housing Outside diameter of bearing Fit of bearing in housing Inside diameter of bearing bore (large) in housing Outside diameter of bearing Fit of bearing in housing Outside diameter of bearing surface on gearshaft Inside diameter of bearing Fit of bearing on gearshaft Inside diameter of bearing Fit of bearing on gearshaft Inside diameter of injection advance bearing Outside diameter of hub on advance unit cover Fit of cover in bearing

3.5432 3.5427 0.0013L 2.1655 2.1648 0.0001T 3.1491 3.1495 0.0010L 1.5749 1.5743 0.0001T 3.1491 3.1495 0.0010L 1.6244 1.6260 0.0012L 1.1814 1.1807 0.0003T 2.4404 2.4409 0.0000 1.4995 1.4995 0.0007L 0.9995 0.9995 0.0005L 1.7500 1.7540 0.0030T 2.6772

3.5440 3.5433 0.0001T 2.1660 2.1654 0.0012T 3.1496 3.1501 0.0001T 1.5753 1.5748 0.0010L 3.1496 3.1501 0.0001T 1.6248 1.6270 0.0026L 1.1817 1.1811 0.0010T 2.4409 2.4416 0.0012L 1.5002 1.5000 0.0005T 1.0000 1.0000 0.0005T 1.7510 1.7580 0.0080T 2.6779

3.5444 * 0.0017L 2.1653 * 0.0001L * 3.1504 0.0013L 1.5747 * 0.0001L. * 3.1504 0.0013L 1.6250 1.6275 0.0030L 1.1813 * 0.0002T * 2.4419 0.0015L 1.5005 * 0.0010L 0.9993 * 0.0007L 1.7520 * 0.0020T 2.6782 * 0.0015L 3.1506

2.6767 2.6772 0.0000 0.0012L 3.1503 3.1496 3.1491 0.0000 1.5749 1.5743 0.0001T 1.5743 0.0001T 2.3770 2.3735 0.0025L 3.1496 0.0012L 1.5753 1.5748 0.0010T 1.5748 0.0010T 2.3780 2.3745 0.0045L

Rear fuel drive Rear fuel drive

0.0015L 1.5747 * 0.0001L * 0.0001L * 2.3730 0.0050L *

Note. 6-154

Refer

to

paragraph

6-3b

for

explanation

of

symbols.

Table 6-30.

Fig. Component No.

cam- B-26 Lower shaft drive quill B-26 bevel gearshaft B-26 B-26 B-26 Lower cam- B-26 shaft drive quill B-5 bevel gearshaft B-26 B-26 B-5 Table 6-31. Fuel Injection Pump Advance Unit Assembly Overhaul Standards
Ref. letter Fig No.

B-27 B-27 B-27 B-27 B-27 B-27 B-26 B-26 B-26 B-27 B-26 B-26 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27

GG D D-GG E F F-E R Q Q-R B S S-B

A QQ QQ-A C NN NN-C FF EE EEFF CC DD HH HH-C JJ PP PPJJ LL KK

Note.

Refer

to

paragraph

6-3b for explanation of symbols.

6-155

Table 6-31. Fuel lnjection Pump Advance Unit Assembly Overhaul Standards - Continued
Component Fig No. Ref. letter Point of measurement

Fuel injection B-27 pump advance assembly B-27 B-27 B-27 B-27

KKLL BB Z Z-BB MM

Fit of flyweight pin in flyweight Outside diameter of bearing surface on spur gearshaft Inside diameter of bearing Fit of bearing on spur gearshaft Spring, helical extension: Free length Load at 3.17 inch (inside hooks) Maximum extended length without set (inside hooks) Inside diameter of drive gearshaft Outside diameter of drive gearshaft Fit of gearshaft in drive gearshaft

B-27 B-26 B-26 B-27

AA V V-AA

Note.

Refer

to

paragraph

6-3b

for

explanation

of

symbols.

Table 6-32. Rear Fan and Accessory Drive Housings Standard and Oversize Stud Identification
Fig No. Ref. letter Settting Height No. req'd

6-187

5 / 8

6-187

1-11/16

6-187

23/32

12

6-187

1-1/8

6-187

49 / 64

6-187

3-29 / 32

6-187

1-25/32

6-187

Note. Refer 6-156

to

figure

6-1

for

oversize

stud

identification.

Table 6-32. Rear Fan and Accessory Stud Identification

Fig. No. Ref. letter Setting height No. reqd

Drive Housings Standard and Oversize on-Continued

Stud size and length

6-187

3-1/2

6-181

4-5 / 8

6-187 6-187

L M

2-9/16 4-1 / 4

6-187

5-1/4

6-187

Note. Refer to figure 6-1 for oversize stud identification.

d. Assembly. (1) Shimming procedures for rear fan driven gearshaft, rear fan drive bevel gearshaft, and accessory drive bevel gearshaft. Note. Before assembly of the rear fan and accessory drive housings, it is necessary to determine the shim thickness required to control the end play of the rear fan driven gearshaft and

backlash of the fan drive bevel gearshaft. Figure 6-188 illustrates shim location and measuring points. The shim thickness for the accessory drive bevel gearshaft, which determines the backlash and end play of the two camshaft bevel gearshafts, is determined as shown in figure 6189.

6-157

Figure

6-188.

Determining

shim

thickness

for rear fan driven gearshaft and rear fan drive bevel gearshaft.

6-158

1. Measure the total thickness (A) of ball bearing inner race to face of outer race, with end play removed. 2. Measure the total thickness (B) from inner face of bevel gear to outer face of gearshaft. 3. Add thickness of ball bearing race (A) and gearahaft movement (B) and subtract from 2.6605 to 2.6625inch. Add or remove 0.002-inch shim lanimations from shim pack - 2930-678-3271 until required dimension (C) is established.

Note. The shim pack has several 0.002-inch laminations. Shims may be stripped from the pack to obtain correct shim dimensions. If shims must be added, they will have to be stripped from a new shim pack.

Figure 6-189. Determining shim thickness for accessory drive bevel gearshaft bearing.

(a) Rear fan driven gearshaft end play. Determining end play for the rear fan driven gearshaft is identical to the procedure outlined for the front fan driven gearshaft. Refer to paragraph 6-40d (2) (a) and figures 6-151 and 6-152 for pertinent instructions. (b) Rear fan drive bevel gearshaft backlash. Determining backlash for the rear fan

drive bevel gearshaft is identical to the procedure outlined for the front fan drive bevel gearshaft. Refer to paragraph 6-40d (2) (b) and figure 6153. (c) Drive bevel gearshaft plug and retaining ring. Refer to figure 6-186 to install plug and retaining ring.

6-159

( 3 ) F u e l 6-193

i n j e c t i o n 6-198,

p u m p 6-174

a d v a n c e and 6-173.

assembly. Refer to figures 6-191, 6-192, 6-181, through

1. Position shim (A) of predetermined thickness (fig. 6189) on bearing hub of accessory drive gearshaf. 2. Position bevel gearshaft ball bearing (B) on hub, with bearing trademark facing away from gearshaft. 3. Press bearing on gearshaft. Note. Install rear bearing support (fig. 6184) on bearing using a soft faced hammer. Figure 6-190. Pressing bevel gear-shaft bearing on gearshaft. ball 1. Place accessory drive bevel gearshaft (A) in a soft jawed vise. 2. Install vane housing cover (B) on gearshaft until it exposes the retaining ring groove. 3. Install retaining ring (C) in groove. Pull cover (B) forward until retaining ring is seated in the cover retaining ring groove. Figure 6-191. Installing advance vane housing cover on accessory drive bevel gearshaft.

(2) Rear fan drive clutch assembly. R e f e r to table 6-24 for appropriate clutch assembly sequence.

6-160

1. Position drive gearshaft ball bearing (A) on drive gearshaft. 2. Carefully press ball bearing on gearshaft. Figure 6-192. Pressing drive gearshaft ball bearing on drive gearshaft. 1. Position advance vane housing (A), with vane and seals (fig. 6-183), on advance vane housing cover. 2. The alinement dots on gearshaft spline (B) must aline with the dots on the vane spline (C). 3. The vane must have end clearance of 0.00l-inch. If vane splines (C) have a snug fit on the accessory drive gearshaft splines (B), insert a 0.001 inch feeler gage between vane and vane housing cover. Gently tap vane until proper end play is obtained, then remove feeler gage. 4. Mate dowel pin holes (D) in vane housing with dowel pins (E) in cover and housing bolt holes (F) with cover bolt holes (G). Tap housing lightly with a soft hammer to seat dowel pins. Note. Dowel pins and dowel pin holes will aline in two positions. However, the bolt holes in cover and housing will aline in one position only. Make certain that cover and housing are correctly positioned so that bolt holes are alined. Figure 6-193. Installing advance vane housing and vane.

6-161

1. Position flyweight housing on advance vane housing. 2. Mate dowel holes (A) with dowel pins (C) and bolt holes (B) with bolt holes (D). (Refer to note fig. 6-193.) 3. Tap flyweight housing lightly with a soft hammer to seat dowel pins. Figure 6-194. Installing flyweight housing.

1. Install two flyweights on adjusting ring with flyweight pins (A) installed. Flyweights must be installed in their original positions to assure proper operation. 2. Hook flyweight extension helical springs (B) to flyweights. 3. Spread flyweights against springs and install oil control housing in adjusting ring so the slots in control housing are alined with flyweight pins. 4. Install the assembled adjusting ring, oil control housing, and flyweights on accessory drive bevel gearshaft (C). Oil hole (D) in lower groove of oil control housing must aline with dot in gearshaft (C). Figure 6-195. Installing ring and advance flyweight

adjusting

flyweight.

6-162

1. Position the assembled injection pump drive gearshaft on flyweight housing. 2. Mate dowel pins (A) and bolt holes (B) in gearshaft with dowel pin holes (C) and bolt holes (D) in housing. (Refer to note fig. 6-193). Note. The scribe line on gearshaft flange and adjusting ring boss must be alined. (Refer to note 6-175.) 6-196. Installing injection pump

1. Position six bolts (A) through advance vane housing cover, housing, flyweight housing, and drive gearshaft flange and install six slotted nuts (B) and cotter pins. Install locking wire securing bolts. 2. Move the adjusting ring to aline scribe marks on ring, flyweight, and drive gearshaft flange. Install two slotted nuts (C), flat washers, and cotter pins and flyweight pins securing adjusting ring. 3. Install intermediate bearing support (D). Figure 6-197. Installing advance flyweight

adjusting ring and injection pump drive gearshaft attaching parts (adjusting ring secured with nuts).

Figure

drive

gearshaft.

6-163

1. Install six bolts (A) through gearshaft flange, flyweight housing, advance vane housing, and secure in vane housing cover. Install locking wire securing bolts. 2. Move the adjusting ring to aline scribe marks on ring,

flyweight nuts (B), securing 3. Install

and drive gearshaft flange. Install two slotted flat washers, and cotter pins on flyweight pine adjusting ring. intermediate bearing support (C).

Figure 6-198. Installing advance flyweight adjusting ring and injection pump drive gearshaft attaching parts (adjusting ring secured with bolts).

6-164

Figure

6-199a.

Test

stand

assembly-FSN-4910-986-9873.

(4) Testing fuel injection pump advance assembly using test stand - 4910-986-9873. Testing of fuel injection pump advance assembly is required on all units that have been overhauled to insure optimum engine performance. This testing will be accomplished prior to assembly of the engine rear fan and accessory drive housing assembly. The test stand is designed to check and bench test the advance characteristics of the fuel injection pump advance assembly, under conditions simulating engine operation over an operating range of 200 to 2600 RPM. The

advance assembly is mounted in bearing supports which simulate the mounting on the engine, and is loaded by using a basic AVDS1790 series engine fuel injection pump which is coupled to a drive gear. The test stand is instrumented to permit direct observation of the advance assembly operating characteristics and adjustments m a y b e m a d e assembly without removing to the advance it from the test

stand. Procedures for bench testing the advance assembly are as follows and covered in figures 6199a through 6-201:

6-165

A. B. C. D. E. F. G. H. J. K.

Fuel pressure indicator gage Oil pressure indicator gage Electronic counter switch Electronic counter Fuse Reset button Magnetic pickup cable Oil temperature dial thermometer Electronic tachometer Speed regulator control

L. M. N. P. Q. R. S. T. U. V.

Jog run switch (clutch engage) Stop switch (clutch disengage) Power indicator light Drain tank Motor switch Heat indicator light Fuel injector advance assembly Oil heater switch Oil drain push switch Master switch

Figure 6-199b. Test stand with coupling guard and housing cover removed.

6-166

(a) Check fuel level and oil level gages (figure 6-199c). Fill supply tank (s) if either gage indicates less than half full (use oil, specification MIL-L-45199 (Grade 30) or fuel, specification VV-L-800). (b) Check to insure that the master switch, the oil heater switch, the jog run (clutch engage) switch, and the motor switch are all in the OFF position and that the speed regulator control is at zero (0). (c) Turn master switch handle to the figure

(e) Turn the electronic counter switch, 6-199b, ON. The electronic com-

ponents in the counter will reach operating temperature by the time the test is begun. (f) Loosen fasteners and remove fuel injection pump drive housing cover from top of test stand. Remove the two bearing caps and intermediate bearing support fixture, figure 6-201. from the mounting

ON position. Note that power indicator light comes on. If power indicator light does not light, press the reset buttons. If light still does not operate, investigate and correct the deficiency before starting.

(g) Install retaining ring on oil retaining shaft. Install short (stub) end of oil retaining shaft in driven Install (small) support end over of the advance on large assembly. bearing

gear end of advance assembly and install advance assembly in bearing supports of mounting fixture and secure with hardware removed above. Install drive housing cover and secure with fasteners. Caution: The fuel injector pump advance assembly drive housing cover must always be installed and secured before operating test stand. engage (h) Push jog run (clutch engage) switch to eddy current clutch and turn speed

regulator control to obtain advance assembly speed of 300 rpm on tachometer. Turn speed regulator control clockwise to increase rpm. (i) Observe oil and fuel pressure indicator gages, figure 6-199b. These gages should register more than zero (0); however, maximum pressures will not be evident until a speed of 2000 rpm is obtained. Caution: Turn master switch handle OFF if there is no indication of oil or fuel pressure on the gages. Investigate and correct the deficiency before starting the test. (j) Operate test stand at 300 rpm until the oil temperature dial thermometer (H) stabilizes at 250 degrees. It may require several minutes to warm the entire system to operating temperature. Note and record electronic counter (K) reading (illuminated decimal digits on the front of Figure 6-199c. Test stand heater control and supply tanks. the counter panel). (k) Press oil drain push switch, located immediately below the oil pressure indicator gage. The gage should register zero (0) psi with the switch depressed. observe the counter reading. If the counter has changed more than one (1) degree, the advance assembly requires adjustment. Turn (1) speed Release oil pressure drain regulator control clockwise switch. to in-

(d) Turn oil heater (thermostat) control, figure 6-199c, to a setting of 250 degrees and turn oil heater switch, figure 6-199b ON. The oil heater indicator lamp will light when the heater switch is turned on and will go out when the oil has reached the selected oil temperature heater control setting (250 degrees).

crease the speed to 600 rpm. Note and record the 6-167

counter reading at each 200 rprn increment increase, beginning at 600 rpm and continue through to 2600 rpm. (m) Reduce speed to 600 rpm and recheck counter reading. If this reading does not check with the original repeat the test. Check the readings taken at each 200 rpm increase against similar points on the approved advance unit curve, figure 6-200. If the recorded advance readings fall within the prescribed limits on the curve, the test is complete. If the advance readings do not meet the curve limits, proceed with step (p) below. (n) Turn speed regulator control to zero

(0), figure 6-199b, to reduce speed and counter switch, motor switch, and master switch handle to the OFF position. Note. Injector pump advance assembly will be hot following test. Operator should wear gloves when removing unit from test stand. (o) Loosen fasteners and remove cover. Remove bearing caps and remove unit from bench. Remove oil transfer shaft. Place injector advance pump assembly on oil drain tray with small gear end up. Place advance assembly in a clean cooling. dirt-free container, preferably a polyethylene bag, for storage after draining and

Figure

6-200.

Fuel

injector

advance

unit

curve.

check

(p) Repeats steps (h) through (m) to previous readings. If advance assembly

fails to pass the test, it must be adjusted. Note whether advance assembly advances too soon or too late. Either by condition the can normally be corrected rotating advance flyweight

(r) Push speed control stop switch to disengage eddy current clutch. Turn counter, motor, and motor starter off. (s) Loosen fasteners and remove cover. Remove two cotter pins, and loosen the two slotted nuts enough to permit adjusting ring rotation. See figure 6-201. Note. Do not turn the adjusting ring more than 1 / justment. 16 of an inch during any one ad-

adjusting ring. Note. The advance assembly should be retarded slightly if the advance varies more than 2 degrees at 300 rpm when the oil pressure drain button is depressed. This variance indicates the mechanical retard stop is not in phase with the hydraulic valve.

6-168

Figure 6-201

(t) Rotate the adjusting ring (fig. 6-201) 1 / 16-inch toward the rear of the bench (retard position) if the advance assembly advanced too soon. Move the adjusting ring 1 / 16-inch in the opposite direction (advance position) toward operator, if the advance assembly advanced too late. Tighten the slotted nuts, install cover and repeat steps (c) through (h), above. When advance readings are within the prescribed limits. the advance assembly may be removed from the bench as outlined in step (i), above. Secure the adjusting ring slotted nuts with cotter pins.
6-31

(5) Rear 152,

fan

and 6-189,

accessory 6-190,

drive

assembly. 6-170

Refer to figures 6-154, 6-155, 6-188, 6-151, 66-153, 6-172, 6-202 through 6-168, 6-203, 6-153, or 6-152, 6-204 or 6-205, 6-164, or 6-162, 6-161 through 6-159.

6-169

1. Position fuel injection pump spur gearshaft (A) in an arbor press. 2. Position bearing spacer (B) with chamfer up (toward threaded end of shaft}.

3. Press ball bearing (C) on gearshaft using pipe of a suitable size as an improvised pressing arbor.

Figure 6-202. Pressing driven gearshaft ball bearing on spur gearshaft.

6-170

Note. Apply a thin coat of gasket cement, Specification mating surface of the rear fan drive housing.

MIL-C-10523 (ORD), to the

Figure 6-203. Assembling rear fan and accessory drive housing.

6171

Note. The

splined

coupler

halves

are

1. Position Woodruff key (A) in spur gearshaft. 2. Position pilot ring (B) on gearshaft. 3. Position diaphragm coupler half (C) on gearshaft. Figure 6-205. Installing fuel injection pump diaphragm drive coupler half.

matched set. Make certain the coupler half being installed matches the coupler half on the fuel injection pump. 1. Position Woodruff key (A) in spur gearshaft. 2. Position coupler half (B) on spur gearshaft. Figure 6-204. Installing fuel injection pump splined drive coupler half.

6-172

Note. Before

installing

assembled

fuel

in-

and

accessory to

drive their

housing proper

stamped location

numbers before

jection advance assembly and fan drive bevel gearshaft, check gearshaft backlash and re-shim as necessary (fig. 6-189). Be sure bearing cap

correspond assembling.

Figure 6-206. Installing fuel injection advance bearing cap.

Section X. OVERHAUL OF CAMSHAFT AND THROTTLE CONTROL CROSS SHAFT AND FUEL INJECTION PUMP LINKAGE

6-43. General
a. This section covers the overhaul of the cam shafts and throttle control cross shaft and fuel injection pump linkage. Specific instructions on disassembly, cleaning, inspection, repair, and assembly accompany the overhaul operations. Overhaul standards of individual components follow the inspection procedures. Stud identification information is included in the repair

procedures where applicable. R e f e r t o t h e table (table 6-33) for applicable following illustrations instructions for overhaul and operations. b. Overhaul of the right and left camshafts is similar. For instructional purposes, procedures for the right camshaft will be illustrated with references to the left camshaft only where overhaul procedures vary.

6-173

Table 6-33. Camshaft and Throttle Control Cross Shaft and Fuel Injection Pump Linkage
Component Disassembly Cleaning Inspection

Repair Para 6-44c Table 6-35 Fig. 6-214 Para 6-4

Assembly

Camshaft and Associated Parts Throttle Control Cross Shaft and Fuel Injection Pump Linkage

Para 6-44a Figs. 6-207 through 6-213 Para 6-45a Figs. 6-215 through 6-220

Para 6-2

Para 6-44c Table 6-34 Para 6-3 Table 6-36

Para 6-44d Figs. 6-213 through 6-207 Para 6-45d Figs. 6-220 through 6-215

Para 6-2

6-44. Overhaul of Camshaft

a. Disassembly. Disassemble camshaft

following instructions which accompany figures 6-207 through 6-213.

Remove 1. Remove lifting eye (A), preformed hose, and intercylinder hose flange, and separate the liiting eye and flange from hose. 2. Remove the remaing four groups of intercylinder hose flanges (B) and preformed hoses and separate tbe flanges from hoses. 3. Remove and discard the camshaft end cover plate gasket (C). 4. Remove two hose clamps (D) and the rubber hose from camshaft drive shaft flange.

Install 1. Position rubber hose on camshaft drive abaft flange and install two hose clamps (D). 2. Position a new camshaft end cover plate gasket (C) on camshaft. 3. Position two intercylinder hose flanges (B) on each of four preformed hoses and position hose assemblies on camshaft. 4. position lifting eye (A) and remaining intercylinder hose flange on remaining preformed hose and position hoee assembly on camshaft.

Figure 6-207. Removing or installing lifting eye, intercylinder hose flanges, and hoses.

6-174

Remove 1. Remove four self-locking nuts (A) and flat washers. 2. Remove camshaft drive adapter (B) and associated parts as a unit from camshaft drive housing. Install 1. Position camshaft drive adapter (B) and associated parts as a unit on camshaft drive housing. 2. Install four self-locking nuts (A) and flat washers. Figure 6-208. camshaft Removing or installing drive adapter and parts.

associated

Disassemble 1. Remove preformed packing (A) from drive adapter and discard packing. 2. Remove preformed packing (B) from oil transfer tube in drive adapter and discard packing. 3. Remove two bolts (C), lock washers, and flat washers. 4. Remove camshaft drive shaft flange (D). 5. Remove and discard camshaft drive shaft flange gasket (E). Assembly 1. Position a new camshaft drive shaft flange gasket (E) on camshaft drive adapter. 2. Position camshaft drive shaft flange (D) on drive adapter. 3. Install two bolts (C), lock washers, and flat washers. 4. Position a new preformed packing (B) on oil transfer tube in drive adapter. 5. Position a new preformed packing (A) on drive adapter. Figure 6-209. Disassembling drive associated parts. or assembling and

camshaft

adapter

6-175

Remove Note. It will be necessary to move the camshaft drive gear away from the camshaft driven gear to gain clearance for removal of the camshaft assembly. 1. Remove right camshaft assembly (A) from camshaft drive housing. 2. Remove camshaft drive gearshaft (B), Install 1. Position camshaft drive gearshaft (B) in camshaft drive housing. 2. Position right camshaft assembly (A) in camshaft drive housing. Figure 6-210. Removing or installing right camshaft assembly.

Disassemble 1. Place camshaft (A) assembly in a soft-jawed vise. 2. Cut locking wire and remove eight drilled head bolts (B). 3. Remove gear cover (C). 4. Remove camshaft driven gear (D). Assemble 1. Place camshaft (A) in a soft-jawed vise. 2. Position camshaft driven gear (D) on camshaft. 3. Position gear cover (C) on camshaft. 4. Install eight drilled head bolts (B) and install locking wire securing bolts. Figure 6-211. Disassembling or assembling

camshaft

assembly.

6-176

Remove 1. Place throttle shaft (A) in a soft-jawed vise. 2. Remove the right camshaft. end plate (B) from throttle shaft by carefully tapping on end plate with a soft hammer.

Install 1. Place throttle shaft (A) in a soft-jawed vise. 2. Position right camshaft end plate (B) on throttle shaft aud carefully tap end plate on shaft with a soft hammer.

Figure 6-212. Removing or installing right camshaft end plate.

6-177

Disassemble Note. The left camshaft cover plate assembly and associated parts are similar to the right cam shaft cover plate and may be disassembled in a similar manner.

1. Cut locking wire and remove four cap screws (A) and flat washers. 2. Separate and remove tachometer drive adapter (B) from camshaft end plate. 3. Remove and discard preformed packing (C). 4. Remove, and discard camshaft end plate oil seal (D).

5. Remove bushing-type bearing (E) only if inspection (para. 6-44c) indicates the need for replacement. To remove, press bearing from end plate. Assemble 1. If bushing-type bearing (E) was removed, press bearing into camshaft end plate. 2. Position a new camshaft end plate oil seal (D) in end plate. 3. Position a new preformed packing (C) in tachometer drive adapter (B). 4. Position tachometer drive adapter (B) on camshaft end plate. 5. Install four cap screws (A) and flat washers and install locking wire securing screws.

Figure 6-213. Disassembling or assembling right camshaft cover plate.

b. Cleaning. Refer to paragraph 6-2. c. Inspection and Repair. Refer to paragraphs 6-3 and 6-4, and (1) through (3), below. (1) Inspect bushing-type bearing in camshaft end plate to limits specified in overhaul standards (table 6-34).

(2) Refer to paragraph 6-4e and table 6-35 when replacing studs. (3) Inspect and repair camshaft as follows and as shown in figure 6-214.

6-178

(5) Check bearing journal. check must be

runout the

of

each

camshaft in V

Support and

camshaft journal

blocks at the adjacent journals, and using a dial indicator, cam shaft record runout (TIR) dimensions. If runout exceeds 0.002 inch, straightened. (b) S t r a i g h t e n i n g c a m s h a f t . (1) Install camshaft on trueing device bearing journal having the maximum (TIR) positioned under the pressing

with

runout

spindle. (The camshaft journals must be resting on the support blocks when rotating the camshaft to determine the runout.) Set dial on into zero and rotate camshaft to determine location of runout (TIR) and record reading. journal Figure 6-214. Improvised camshaft trueing device. (a) C h e c k i n g c a m s h a f t b e a r i n g j o u r n a l run-out. Camshafts may be straightened if the runout of any one camshaft bearing surface (journal), when using a dial indicator, does not exceed 0.060 inch total indicator reading (TIR) when supported at the two adjacent bearing journals. Camshafts that exceed 0.060 inch runout between any two journals must be discarded. Maximum journal runout of straightened camshafts is 0.002 inch (TIR) when supported at the two adjacent journals. After straightening a camshaft, the maximum acceptable runout of the center bearing journal, when supported at the end journals, is 0.015 inch (TIR). Check runout as follows: camshaft bearing journal (2) Turn camshaft until bearing marked to indicate the maximum runout dicator

(high side) is adjacent to the spindle (do not press on journals). Apply spindle pressure on the camshaft proximately recorded until one (a), dial half above. indicator of the Release reads pressure apon TIR reading

in

cam shaft and recheck runout by turning camshaft several revolutions. Note. Pressing force required to straighten cam shaft is a matter of judgement. It may be necessary to turn camshaft and apply pressing force several times in order to acquire the technique necessary to true the bearing journal. (3) Apply pressure as required until the journal is within the 0.002 maximum TIR. and true (4) R e p o s i t i o n c a m s h a f t o n s u p p o r t s other bearing journals is a similar

manner. (5) After trueing all bearing journals, recheck camshaft as outlined in procedure (a), above. If readings repeat do not of meet dimensions after and specified, trueing operation. camshaft camshaft

(1) Support the camshaft at the two end journals in V blocks on a surface plate or other available centering device, such as a machine lathe. (2) Position a dial indicator at the

(c) Inspection straightening. (1) M a g n a f l u x

center bearing journal and obtain a zero reading on the dial. (3) Rotate the camshaft and determine the maximum travel of the dial indicator needle. If travel (TIR) exceeds 0.015 inch the camshaft must each be straightened. (4) Repeat steps (2) a n d (3), a b o v e f o r bearing journal and mark position and

each

inspect for cracks. Observe transition areas at bearing surfaces and at cam lobe bases. Camshafts with evidence of cracks must be discarded. journals. (2) Inspect for damage to bearing Minor nicks and scratches can be removed using crocus cloth. (3) Check bearing journals for out-ofround to be certain area was not flattened during trueing. 0.002 tolerance Maximum (TIR). is acceptable Replace out-of-round camshaft if is inch this

dimension of maximum dial indicator reading at

exceeded. 6-179

Table 6-34. Camshafts and Drives Overhaul Standards

Component Fig No. Ref. letter Point of measurement

Sizes and fits of new Parts 1.3090 1.3120 1.3100 1.3130

Wear limits

Camshafts

B-5 B-4 B-4 B-5 B-5 B-5

L X X-L

Outside diameter of journal on camshaft Inside diameter of camshaft bearing in cylinder Fit of journal in bearing Maximum out-of-round of camshaft journal (full indicator reading) Maximum runout of center journal when supported on end bearing (full indicator reading) Outside diameter of camshaft pilot bearing at end plate Inside diameter of split bushing-type bearing in camshaft end plate Fit of camshaft pilot in end plate bushing-type bearing Camshaft lobe lift Outside diameter of large journal on end of camshaft Inside diameter of bearing surface in camshaft gear housing Fit of journal in bearing Outside diameter of hub on gearshaft Inside diameter of bore in upper adapter Fit of hub in adapter bore Inside diameter of hub on gearshaft Outside diameter of upper oil transfer plug Fit of plug in hub Inside diameter of quill (both ends) Spherical outside diameter of upper oil transfer plug Fit of upper quill plug in quill bore Spherical outside diameter of lower oil transfer plug Fit of lower quill plug in quill bore Outside diameter of oil seal Inside diameter of camshaft end plate Fit of oil seal in end plate bore

1.3085 1.3135 0.0050L 0.0020 0.0150

0.0020L 0.0040L 0.0010 0.0020

B-5 B-5 B-5 B-5 B-5 B-5 camUpper shaft drive quill bevel gearshafts B-5 B-5 B-5 B-5 B-5 B-5 B-5 B-5 B-5 B-5 B-26 Camshaft drive quills Camshaft end plate B-26 B-5 B-5 B-5 B-5

N Q Q-N M K G G-K B F F-B C E E-C A D D-A UU UU-A J H H-J

1.3090

1.3100

* * * 0.4000 2.4960 2.5020 0.0065L 1.6210 1.6270 * * * * 0.6320 0.6265 0.0060L 0.6265 0.0060L * * *

1.3120 1.3130 0.0020L 0.0040L 0.4030 2.4965 2.5000 0.4090 2.4975 2.5010

Camshafts

Camshaft drive quills

0.0025L 0.0045L 1.6220 1.6230 1.6250 1.6260 0.0020L 0.0040L 1.2710 1.2720 1.2700 1.2705 0.0005L 0.0020L 0.6295 0.6305 0.6275 0.6280 0.0015L 0.0030L 0.6275 0.6280 0.0015L 0.0030L 1.5010 1.5050 1.4990 1.5000 0.0010T 0.0060T

Note. Refer to paragraph 6-3b for explanation of symbols. Table 6-35. Camshaft Drive Housing and Cover Plate Standard and Oversize Stud Identification
Fig. No. Ref. No. Setting height No. reqd Stud size Length

B-5

29

1-5 / 32

B-5

40

3 / 4

3 / 8-16 (15 / 16) x 3 / 8-24 (13 / 16) x 1-15 / 16 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) 1 / 4-20 (19 / 32) x 1 / 4-28 (21 / 32) x 1-5 / 16 (STD) (0.003 in. OS) (0.007 in. OS) (0.012 in. OS) d. Assembly. Refer to figures 6-213 through 6207.

Note. Refer to figure 6-1 for oversize stud identification. 6-180

6-45.

Overhaul Cross Pump

of

Throttle and Fuel

Control Injection

Shaft

Linkage

a. Disassembly. Disassemble throttle control cross shaft and fuel injection pump linkage following instructions which accompany figures 6-215 through 6-220.

Remove 1. Place the throttle control cross shaft and fuel injection pump linkage (A) in a soft-jawed vise. 2. Remove retaining ring (B). 3. Remove ball bearing (C) as shown in figure 6-216. Install 1. Place the throttle control crow shaft and fuel injection pump linkage (A) in a soft-jawed vise. 2. Install ball bearing (C) on cross shaft. 3. Install retaining ring (B). Figure 6-215. Removing and or installing bearing. camshaft end plate ball bearing retaining ring ball

Remove 1. Remove camshaft end plate bearing inner retaining ring (A). 2. Remove cap screw (B) and lock washer (or assembled washer bolt). 3. Remove control lever (C) from cross shaft. 4. Remove cross shaft bracket bearing retaining ring and bracket (D) with bearing as shown in figures 6-215 and 6-216. 5. Remove cross shaft lever bearing retaining ring and lever (E) with two bearings as shown in figures 6-215 and 6-216. Install 1. Install cross shaft lever (E) with bearings, and retaining ring as shown in figure 6-215. 2. Install cross shaft bracket (D), with bearing, and retaining ring as shown in figure 6-215. 3. Install control lever (C) on cross shaft. 4. Install cap screw (B) and lock washer. 5. Install camshaft end plate bearing inner retaining ring (A). Figure 6-217. Removing or installing cross shaft levers and bracket.

Figure

6-216.

Removing camshaft ball bearing.

end

plate

6-181

Remove 1. Remove retaining ring (A). 2. Remove one shock spring spacer (B). 3. Remove shock spring (C). 4. Remove remaining shock spring spacer (D). 5. Remove cap screw (E) and lock washer (or assembled washer bolt). 6. Remove shock spring control lever (F). 7. Remove Woodruff key (G) from cross shaft. Install 1. Position Woodruff key (G) in cross sbaft. 2. Position shock spring control lever (F) on cross shaft. 3. Install cap screw (E) and lock washer. 4. Position one shock spring spacer (D) on shaft. 5. Position shock spring (C) on shaft with both ends of spring engaging straight pin in control lever (F). 6. Position remaining shock spring spacer (B) on shaft 7. Install retaining ring (A). Figure 6-218. Removing or installing cross shaft shock spring and control lever.

Disassemble 1. Remove cap screw (A) and lock washer (or assembled washer bolt). 2. Remove intermediate throttle lever (B) and Woodruff key from intermediate support shaft 3. Remove two retaining rings (C). 4. Remove intermediate throttle lever support (D) from intermediate support shaft. 5. Remove two retaining rings (E) and two ball bearings from lever support. Assemble 1. Position two ball bearings in intermediate throttle lever support (D) and install two retaining rings (E). 2. Position lever support (D) on intermediate support shaft. 3. Install two retaining rings (C). 4. Position Woodruff key and intermediate throttle lever (B) on intermediate support shaft. 5. Install cap screw (A) and lock washer. Figure 6-219. Disassembling throttle or assembling support. intermediate lever

6-182

Disassemble 1. Remove two retaining rings (A) from cross shaft bracket. 2. Remove ball bearing (B) from brakcet. 3. Remove two ball bearings (C) from cross shaft lever. 4. Remove two retaining rings (D) from lever. 5. Loosen two nuts (E) and remove left and right rod end bearings (F) from adjustable control rod. Note. The rod bearings (F) are pinned and are not to be disassembled. Do not attempt to disassemble connecting link. Figure 6-220.

Assemble 1. Install left and right rod end bearings (F) in adjustable control rod and tighten nuts (E). 2. Install two retaining rings (D) in cross shaft lever. 3. Position two ball bearings (C) in lever. 4. Position ball bearing (B) in cross shaft bracket. 5. Install two retaining rings (A) in bracket.

Disassembling

or

assembling

cross shaft lever, bracket, and adjustable control rod. b. Cleaning. Refer to paragraph 6-2. c. Inspection and Repair. Refer to paragraphs 6-3 and 6-4 for procedures and table 6-36 for overhaul standards.

6-183

Table 6-36. Trottle Control Cross Shaft and Fuel Injection Pump Linkage Overhaul Standards
Component Fig. No.

Ref. letter A C P C-A P-A B D

Throttle control linkage

B-18 B-18 B-5 B-18 B-5 B-18 B-18 B-18

B-18 B-18 Throttle control linkage B-18

D-B E F

B-5

B-5 B-5 B-5 B-5 B-5 B-5

Q N N-Q J H H-J

Note. Refer to paragraph 6-3b for explanation of symbols. d. Assembly. Refer to figures 6-220 through 6-

215.

Section

XI.

OVERHAUL ENGINE

OF

ENGINE FAN

AND

TRANSMISSION AND 6-46. General This section covers the overhaul of the engine and transmission oil coolers and cooling fan. Specific instructions on disassembly, cleaning, company inspection, the repair, and overhaul operations. assembly acStud i-

OIL

COOLERS

COOLING

dentification

information

is

included

in

the

repair procedures where applicable. Refer to the following table (table 6-37) for applicable illustrations a n d i n s t r u c t i o n s f o r o v e r h a u l operations.

6-184

Table 6-37. Engine and Transmission Oil Coolers and Engine Cooling Fan
Component Disassembly Cleaning Inspection Repair Assembly

Engine and Transmission Oil Coolers Engine Cooling Fan 6-47. Overhaul mission ated Parts

Para 6-47b Figs. 6-221 through 6-223 Para 6-48a Fig. 6-225 of Oil Engine Cooler

Para 6-47c Fig. 6-224

Para 6-47d

Para 6-47e Table 6-38

Para 6-47f Figs. 6-223 through 6-221 Para 6-48e Fig. 6-225

Para 6-2 and and TransAssoci-

Para 6-48c

Para 6-48d

a. General. The engine oil coolers are identical and so are the transmission oil coolers. Adaptation to either right or left installation is accomplished by the addition of hose connections, elbows, and bypass valves. For instructional purposes, the engine and transmission oil coolers adapted for right bank installation will be disassembled. b. Disassembly. Disassemble engine and transmission oil coolers following instructions which accompany figures 221 through 223.

Remove 1. Remove transmission oil cooler bypass valve (A). Remove and discard valve gasket. 2. Remove two assembled washer bolts (B) and remove oil cooler shroud plate. Install 1. Position oil cooler shroud plate on transmission oil cooler and install two assembled washer bolts (B). 2. Position a new valve gasket on cooler and install transmission oil cooler bypass valve (A). Figure 6-221. Removing or installing transmission valve and oil cooler bypass shroud plate.

6-185

Remove Note. The

right

and

left

engine

oil

cooler

assemblies are similar except for the position of the hose connector elbows. On the right oil cooler assembly the threaded openings on the elbows face away from the engine oil cooler thermostatic bypass valve. On the left oil cooler assembly, the threaded openings on the elbows face toward the engine oil cooler thermostatic bypass valve. 1. Remove six self-locking nuts (A). 2. Remove two hose connector elbows (B). 3. Remove and discard two hose connector elbow gasket (C). Install 1. Position two new connector elbow gaskets (C) on oil cooler assembly. 2. Position two hose connector elbows (B) on oil cooler. 3. Install six self-locking nuts (A). Figure 6-222. Removing or installing engine right oil cooler hose connector elbows.

Remove 1. Remove thermostatic bypass valve (A) from oil cooler. 2. Remove and discard valve gasket (B). Install 1. Position a new valve gasket (B) on oil cooler. 2. Install thermostatic bypass valve (A) in oil cooler. Figure 6-223. Removing or installing engine right oil cooler thermostatic bypass valve.

6-186

c.

Cleaning. (1) External surfaces of coolers may be

rubber

plug

into

bypass

opening

in

the

valve

housing. Reinstall valve into the valve housing so that the valve bears up against the rubber plug. Note. Use only cleaning solutions recommended in these instructions or ones satisfactory for aluminum. Many solutions satisfactory for cleaning copper or copper nickel coolers are highly corrosive to aluminum and if used will result in the destruction of the cooler. If equipment has been previously used with any other cleaning solutions, it should be thoroughly washed out and flushed with the recommended solution. Warning; Cleaning solvents and solvent cleaning compounds are toxic and flammable and must be used only in a well ventilated room. Take adequate safe guards for fire prevention in work area. Use protective clothing and contact of these solutions with the skin. avoid

cleaned using oil cooler cleaning tool - 2940-9273303. Clean thoroughly and blow dry with compressed air at 15 psi pressure. (2) To clean the interior of an oil cooler assembly core, the pump equipment shown in figure 6-224 is required. Four solutions are used for the cleaning procedure. There are several possible arrangements of the equipment depending upon equipment availability and versatility. If provision can be made for flushing pump lines, one set of pump equipment can be used with four storage tanks to provide the required four solutions for rinsing, cleaning, a n d flushing. If such provisions cannot be made conveniently, four sets of pump equipment are required. (3) Remove the thermostatic bypass valve (A) from the valve housing (fig. 6-223). Press a

Figure 6-224. Oil cooler cleaning equipment setup-schematic diagram.

6-187

(4) Preclean core interior to remove oil and loose sludge from the core to reduce contamination operations. of cleaning solution in subsequent so that Connect pump equipment

(10) It is important that the dip tank be continuously stirred, a n d f r e q u e n t checks on the viscosity be made as the JAN-T171 is so volatile that the concentration may change rapidly. After the cooler is dipped in the primer it should immediately be blown out with compressed air from both sides to insure against plugging. The nozzle used to blow air through the core should be a narrow slit 3 to 4 inches long. It is recommended that line air pressure at about 100 psi be used. (11) The tanks may be sprayed with primer after the dip for appearance, if desired. For spray, the proportions should be: 1 part MIL-P8585 to 1 part TT-6-916B. d. Inspection. Refer to paragraph 6-3 and (1) through (4), below. (1) Oil cooler assemblies. Inspect oil cooler assemblies for dented tubing or bent fins. Inspect gasket contact surfaces for burs and raised metal. Seal all oil cooler openings. Pressure check coolers by pumping engine oil (OE) into coolers at 400 psi hydrostatic pressure. Coolers must hold 400 psi for ten minutes without loss of pressure. Release pressure, drain oil, and flush with dry-cleaning solvent or mineral spirits paint thinner. Identify leaking coolers for possible repair. (2) Thermostatic bypass valves. I n s p e c t engine bypass Check perature Gradually and transmission for oil cooler or thermostatic threads. valves stripped damaged covered,

fluid flow will be in the reverse direction of normal flow. Use mineral spirits, Federal Specification TT-T-291, or kerosene, Federal Specification VV-K-211, or dry cleaning solvent, Federal Specification P-S-661. Flush core in reverse direction for 30 minutes or until solution appears Reverse lines and flush approximately 15 minutes in the opposite direction. Drain cooler. (5) Remove carbon deposits, engine oil, gums, lead deposits, and foreign contamination by flushing cooler in opposite direction to normal oil flow for 30-60 minutes. Use solvent cleaning compounds conforming to Specification MIL-C6864. Reverse lines and direction for 15 minutes. above) opening and flush in opposite clean.

(6) Remove plug installed in bypass ((3), section opening. Flush for 15 minutes to clean bypass block cooling

passage. Remove plug from cooling section opening and replace in bypass opening. (7) Rinse cooler for 10 minutes by circulating clear petroleum solvent such as drycleaning or System solvent, shall of be Federal suitably Specification filtered to P-S-661, prevent kerosene, Federal foreign Specification matter. VV-K-211.

circulation

(8) Flush cooler with a preservative oil consisting of three parts MIL-L-6082, Grade 1065, and one part MIL-C-6529, or, for systems employing MIL-L-7808 oil, MIL-C-8188B, or equivalent, shipment or in preservative preparation oil for

operation valve of raise

mersing

of valve assemblies by imin warm water. Check temwith accurate of thermometer. temperature water to temcover. Valves between

water

storage. Connect cooler to pump equipment and flush in each direction for 10 minutes, checking the mesh screen after each flush to insure that no metal particles have appeared. After flushing operations, install plugs in inlet and outlet ports. (9) When the coolers have been cleaned it will be necessary t o r e c o a t t h e m w i t h z i n c chromate primer per MIL-P-8585. In order to insure that the coating covers the entire core, the oil ports should be plugged and the cooler dipped in the zinc chromate. The dip solution should be prepared as follows: 1 part MIL-P-8585 to 1 parts JAN-T-171.

perature i n d i c a t e d o n valve marked 148 F must travel -inch

80 F and valve from 185 F. Remove water and clean with dry-cleaning solvent or mineral spirits paint thinner. Replace valve assembly when travel is less than -inch. (3) O i l c o o l e r h o s e s . I n s p e c t o i l c o o l e r o u t l e t and inlet hoses for breaks and abrasions in woven shielding. R e p l a c e h o s e w h e n w o v e n shielding is broken or abraided. (4) Oil cooler screens. Inspect oil cooler screens for bent, cracked, or broken mounting brackets. Check for torn or broken screening.

6-188

Replace

screens

that

are

unserviceable.

paragraph 6-4e and table 6-38 when replacing studs. Note. Do not repair leaks by soldering. Soldering is not an acceptable repair because of high operating temperature and pressure.

Straighten bent screens to as near original shape as possible. e. Repair. Refer to paragraph 6-4. Refer to TB 9-228 for repair of oil coolers. Refer to

Table 6-38. Engine Oil Cooler Standard and Oversize Stud Identification
Fig. No. Ref. No. Setting height No. reqd Stud size and length

B-24

55

12

5 / 16-18 (11 / 16) x 5 /16-24(11 / 16) x 2-7 / 16 (STD) (0.003 in. OS) (0.007 in OS) (0.012 in. OS)

Note. Refer to figure 6-1 for oversize stud identification. f. Assembly. Refer to figures 6-223 through 6221.

6-189

6-48. Overhaul of Engine Cooling Fan and Associated Parts a. Dissassembly. The cooling fan vane and

housing were removed during disassembly, Chapter 5. Disassemble cooling fan following instructions which accompany figure 6-225.

Disassemble 1. Remove 16 cotter piss, slotted nuts (A), flat washers, and cap screws attaching cooling fan hub to fan. 2. Separate fan from hub (B). Assemble Note. The machined face of the fan is marked TOP to insure correct assembly.

1. Position cooling fan hub (B) inside of fan marked TOP. 2. Install 16 cap screws, flat washers, slotted nuts (A), and cotter pins securing fan to hub.

Figure 6-225. Disassembling or assembling cooling fan and cooling fan hub. b. Cleaning. Refer to paragraph 6-2. c. Inspection. Inspect cooling fans using a magnifying glass under a strong light. Inspect for nicks, scratches, and cracks. A radial crack in area of a bolt hole is sufficient cause for replacement of the fan. Discard cooling fans that have bent, broken, or warped blades. Replace fan when bolt holes are elongated or show evidence of wear. Replace fan when erosion of the leading edge of the fan blade exceeds 25 or of the total blade width. d. Repair. R e p a i r s c r a t c h e s , n i c k s , a n d r a i s e d metal using a fine mill file. Note. Care must be taken when using a file, not to remove excessive amounts of metal since this will disturb the delicate balance of the fan. e. Assembly. Refer to figure 6-225. The cooling fan vane and housing will be assembled during engine assembly, Chapter 7.

6-190

Section

XII.

O V E R H A U L

O F

E N G I N E PARTS

SHROUDING

A N D

ASSOCIATED 6-49. General This section covers the overhaul of the engine shrouding and associated components. Specific instructions on disassembly, cleaning,

inspection, repair and assembly accompany the overhaul operations. Refer to the following table (table 6-39) for applicable illustrations instructions for overhaul operations. and

Table 6-39. Engine Shrouding and Associated Components

Component Disassembly Cleaning Inspection Repair Assembly

Cooling Fan Vanes Engine and Transmission Shrouds Oil Cooler Frames, Brackets, and Associated Parts Cylinder Air Deflectors 6-50.

Para 6-2 Para 6-50b Figs. 6-226, 6-227 Para 6-2

Para 6-3 Para 6-50d Para 6-50d Para 6-50e Figs. 6-227, 6-226

Para 6-2

Para 6-3

Para 6-3

Para 6-2

Para 6-3

Para 6-3

Overhaul of Engine Shrouding Associated Components

and

b. Disassembly. Disassemble cooling fan housings, shroud rails, and cover plates following instructions which accompany figures 6-226 and 6-227.

a. General. Disassembly of the various shroud components other than the cooling fan housings, shroud rails, and cover plates was accomplished during engine disassembly, Chapter 5.

Remove Note. The four screws (A) and flat washers are an integral part of the cover plate and cannot be removed without destruction of flat washers. 1. Loosen four screws (A). 2. Remove two cap screws (B), self-locking nuts, and flat washers. 3. Remove four cap screws (C), lock washers, and flat washers. 4. Remove front cooling fan housing (D).

5. Remove rear cooling fan housing (E). Install 1. Position rear cooling fan housing (E) in cooling fan shroud. 2. Position front cooling fan housing (D) in shroud. 3. Install four cap screws (C), lock washers, and flat washers. 4. Install two cap screws (B), self-locking nuts, and flat washers. 5. Tighten four screws (A).

Figure 6-226. Removing or installing front and rear cooling fan housings. 6-191

Remove 1. Remove 2. Remove 3. Remove 4. Remove 5. Remove 6. Remove

six-self-locking nuts (A) and bolts. two cover plates (B). eight self-locking nuts (C) and bolts. rear cooling fan shroud rail (D). six self-locking nuts (E) and bolts. front cooling fan shroud rail (F).

Install 1. Position front cooling fan shroud rail (F) on cooling fan shroud. 2. Install six self-locking nuts (E) and bolts. 3. Position rear cooling fan shroud rail (D) on fan shroud. 4. Install eight self-locking nuts (C) and bolts. 5. Position two cover plates (B) on fan shroud. 6. Install six self-locking nuts (A) and bolts.

Figure 6-227. Removing or installing cooling fan shroud rails and cover plates.

c. Cleaning. Refer to paragraph 6-2. d. Inspection and Repair. Refer to paragraphs 6-3 and 6-4, and (1) and (2), below. of (1) In the event of complete reconditioning the engine and transmission shrouds, the

inner shroud (21, fig. B-22). left outer shroud plate (22), turbosupercharger end shroud (24), right outer plate (29), and right inner shroud plate (31) require painting with a high temperature FSN heat resisting or paint MIL-P-14276, 8010-815-2692, equivalent.

rubber seals found on some shrouds must be removed and discarded. All paint must be stripped off to the bare metal before repainting. After painting install new rubber seals on shrouds as required. (2) countered Due near to the high temperatures the enleft the turbosupercharger

e. Assembly. Refer to figures 6-227 and 6-226. Remaining shroud components not assembled at this point will be assembled 7. during engine assembly, Chapter

6-192

Section AND

Xlll.

OVERHAUL OF INTAKE MANIFOLDS, EXHAUST MANIFOLDS CYLINDER FILLER HEAD OIL DRAIN TUBES, OIL AND INDICATOR TUBES the overhaul operations.

TUBES, AND

6-51. General This section covers the overhaul of the intake manifolds, exhaust manifolds and tubes, cylinder head oil drain tubes, and oil filler and indicator tubes. Specific instructions repair, on and disassembly, cleaning, inspection,

assembly

accompany

Stud identification information is included in the repair procedures where applicable. Refer to the following table (table 6-40) for applicable illustrations operations. and instructions for overhaul

Table 6-40. Intake Manifolds. Exhaust Manifolds and Tubes. Cylinder Head Oil Drain Tubes, and Oil Filler and Indicator Tubes
Component Disassembly Cleaning Inspection Repair Assembly

Intake Manifolds and Flame Heater Assembly Exhaust Manifolds and Pipes Cylinder Head Oil Drain Tubes Oil Filler and Indicator Tubes

Para 6-52b Figs. 6-228 through 6-235

Para 6-52c

Para 6-52d

Para 6-52d Table 6-41 Fig. 6-236 Para 6-53c

Para 6-52e Figs. 6-235 through 6-228

Para 6-2

Para 6-53c

Para 6-2

Para 6-53c

Para 6-4

Para 6-53a Figs. 6-237 through 6-239

Para 6-2

Para 6-53c

Para 6-4

Para 6-53d Figs. 6-239 through 6-237

6-193

6-52.

Overhaul of Intake Manifolds Flame Heater Assembly

and

intake manifold is mentioned only where there is difference in disassembly procedures. b. Disassembly. Disassemble intake manifolds and flame heater following instructions which accompany figures 6-228 through 6-235. a

a. General. The right and left intake manifolds are similar and are disassembled in the same manner. For instructional purposes the right intake manifold will be disassembled. The left

Remove 1. Remove attaching 2. Remove 3. Remove

four self-locking nuts (A) an flat washers manifold heater assembly to heater tube. right mainfold heater (B) and fittings. and discard heater gasket (C). Figure 6-228. Removing or

Install 1. position a new heater gasket (C) on heater tube. 2. Position tight manifold heater (B) and fittings on tube. 3. Install four self-locking nuts (A) and flat washers securing manifold heater assembly to tube. manifold heater assembly.

installing

6-194

Disassemble Note. The right and left manifold heater assemblies are similar except for the position of the spark plug and heater housing plug. The two parts are reversed for the left heater assembly. 1. Remove spark plug (A). Remove and discard spark plug gasket. 2. Remove pipe elbow (B). 3. Remove pipe elbow (C). 4. Remove bushing (D). 5. Remove manifold heater spray nozzle and holder assembly (E). 6. Remove two flat head screws (F) and remove baffle. Note. The two screws (F) are staked in place. It may be necessary to remove the stake marks before attempting to remove screws. 7. Remove heater housing plug (G). Remove and discard plug gasket. Note. Instruction covering housing plug (G) is applicable only to engines equipped with a plug. Assemble 1. On engines equipped with a plug, position a new plug gasket on heater housing plug (G) and install plug in manifold heater housing. 2. Position baffle in housing and install two flat head screws (F). Stake screws in place. 3. Install manifold heater spray nozzle and holder assembly (E) 4. Install bushing (D) in holder assembly. 5. Install pipe elbow (C) in bushing. 6. Install pipe elbow (B) in holder assembly. 7. Position a new spark plug gasket on spark plug (A). Install spark plug in housing. Figure 6-229. Disassembling or assembling

Remove 1. Loosen two hose clamps (A). 2. Remove right turbosupercharger air outlet elbow (B). 3. Remove rubber hose (C) and clamps. Separate two clamps from hose. 4. Loosen two hose clamps (D). 5. Remove air outlet tube (E) from hose. 6. Remove rubber hose (F) and clamps. Separate two clamps from hose. Install 1. Position two hose clamps (D) on rubber hose (F). Position hose on heater tube. 2. Position air outlet tube (E) in hose. 3. Tighten two hose clamps (D). 4. Position two hose clamps (A) on rubber hose(C). Position hose on air outlet tube. 5. Position right turbosupercharger air outlet elbow (B) in hose. 6. Tighten two hose clamps (A). Figure 6-230. Removing or installing air outlet tube and associated parts.

manifold heater assembly.

6-195

Remove Note. Scribe a line across flange of heater tube elbow for correct manifold intake and positioning during assembly. 1. Remove six self-locking nuts (A). 2. Remove heater tube (B). 3. Remove and discard heater tube gasket (C). Install 1. Position a new heater tube gasket (C) on intake manifold elbow. 2. Position heater tube (B) on elbow with scribe marks alined. 3. Install six self-locking nuts (A). Figure 6-231. Removing or installing heater tube.

Remove 1. Remove 2. Remove 3. Remove 4. Remove 5. Remove 6. Remove 7. Remove 8. Remove

and discard preformed packing (A). flat washer (B). spring tension washer (C). small flange (D). and discard preformed packing (E). flat washer (F). spring tension washer (G). large flange (H).

Remove 1. Remove four self-locking nuts (A). 2. Remove two self-locking nuts (B) and flat washers. 3. Separate intake manifold tubes (C) for cylinder Nos. 5R and 6R from right intake manifold. 4. Separate intake manifold tubes (D) for cylinder Nos. 1R and 2R in the same manner. Install 1. Position intake manifold tubes (C) for cylinder Nos. 5R and 6R on right intake manifold. 2. Install two self-locking nuts (B) and flat washers. 3. Install four self-locking nuts (A). 4. Install intake manifold tubes (D) for cylinder Nos. 1R and 2R in the same manner. Figure 6-232. Removing or installing intake manifold 6-196 tube attaching parts.

9. Remove flanges (J) from intake manifold tubes. 10. Remove flanges and associated parts from intake manifold tubes for cylinder Nos. 1R and 2R in the same manner. Install 1. Install flanges (J) on intake manifold tubes for cylinder Nos. 5R and 6R. 2. Position large flange (H) on intake manifold tube for cylinder No. 6R. 3. Position spring tension washer (G) on intake manifold tube for cylinder No. 6R. 4. Position flat washer (F) on intake manifold tube for cylinder No. 6R. 5. Position a new preformed packing (E) on intake manifold tube for cylinder No. 6R. 6. Position small flange (D) on intake manifold tube for cylinder No. 5R. 7. Position spring tension washer (C) on intake manifold tube for cylinder No. 5R. 8. Position flat washer (B) on intake manifold tube for cylinder No. 5R. 9. Position a new preformed packing (A) on intake manifold tube for cylinder No. 5R. 10. Install flanges and associated parta on intake manifold tubes for cylinder Nos. 1R and 2R in the same manner. Figure 6-233. Removing or installing flanges and associated parts from cylinder Nos. 5R and 6R intake manifold tubes.

Remove 1. Remove eight self-locking nuts (A) attaching intake manifold tubes for cylinder Nos. 3R and 4R to right intake manifold. 2. Remove intake manifold tubes (B). 3. Remove and discard two intake manifold tube gaskets (C). Install 1. Position two new intake manifold tube gaskets (C) on right intake manifold. 2. Position intake manifold tubes (B) for cylinder Nos. 3R and 4R on right intake manifold. 3. Install eight self-locking nuts (A) securing tubes to manifold. Figure 6-234. Removing or installing intake manifold tubes for cylinder Nos. 3R and 4R.

Remove Note. The right and left intake manifold elbows are identical. The position of the left intake manifold elbow is 180 degrees opposite from the position of the right elbow. 1. Remove six seff-locking nuts (A) and flat washers. 2. Remove right intake manifold elbow (B) from right intake manifold. 3. Remove and discard intake manifold elbow gasket (c). Install 1. Position a new intake manifold elbow gasket (C) on right intake manifold. 2. Position right intake manifold elbow (B) on right intake manifold. 3. Install six self-locking nuts (A) and flat washers. Figure 6-235. Removing or installing right intake manifold elbow.

6-197

c. Cleaning. Refer to paragraph 6-2. Clean intake manifold rubber hoses using a dry cloth only. d. Inspection and Repair. Refer to paragraphs 6-3 and 6-4, and (1) through (3), below. (1) Manifold heater assembly. I n s p e c t heater assembly (15, fig. B-21) for damaged

threads or plugged heater assembly. (2) Spark

orifices. to

Replace TM

damaged for

plug. Refer

9-8638

care and maintenance of spark plugs. Set plug gap from 0.094 to 0.114 inches. (3) Studs. Refer to paragraph 6-4e, table 6-41, and figure 6-236 when replacing studs.

Figure

6-236.

Right

and

left

intake

manifold-stud

identification.

Table 6-41. Manifold Heater Induction and Intake Manifold Standard and Oversize Stud Identification
Fig. No. Ref. No. Setting height No. req'd

B-13 B-13

9 15

1-3 / 8 13 / 16

4 8

6-236

13 / 16

16

6-236

A, E

12

6-236

B C

25 / 32 23 / 32

12 24

Note. Refer to figure 6-1 for oversize stud identification. 6-198

e. Assembly. Refer to figures 6-235 through 6228.

6-53.

Exhaust Oil Drain Filler

Manifolds, Tubes, Oil and

Cylinder Oil

Head

complished during engine disassembly, Chapter 5. (2) Oil filler and oil level indicator tubes. Refer to figures 6-237 through 6-239. Note. Due to design changes, two different oil level indicator tubes and three different oil filler tubes have been used on the engine. Basic disassembly procedures are the same for each tube design.

and

Level

Indicator

a.

Tubes Disassembly.

(1) Exhaust manifolds and cylinder head oil drain tubes. Disassembly of exhaust manifolds and cylinder head oil drain tubes was ac-

Disassemble 1. Remove cap spring (A). 2. Do not remove cap shoulder bolts (B) unless inspection (para 6-53c) indicates replacement is necessary. Bolts are staked in place. 3. Remove and discard seal (C). Oil filler tube only.

Assemble 1. Position seal (C) on oil filler tube only. 2. If necessary, install new cap shoulder bolts (B) and stake in place. 3. Install cap spring (A).

Figure 6-237. Disassembling or assembling oil filler and oil level indicator tubes (one piece oil filler and indicator tubes without splash pan drain).

6-199

Disassemble 1. Remove two machine bolts (A) and lock washers attaching cap assembly to left front upper cover and remove cap. 2. Remove and discard cap gasket (B). 3. Remove and discard two preformed packings (C) from cap. 4. Remove and discard preformed packing (D). 5. Remove cap spring (E). 6. Remove machine bolt (F) and remove cap (G). Assemble 1. Position cap (G) on cap assembly and install machine bolt (F). 2. Install cap spring (E). 3. Install a new preformed packing (D). 4. Position two preformed packings (C) on cap assembly. 5. Position a new cap gasket (B) on left front upper cover. 6. Install two machine bolts (A) and lock washers, securing cap assembly to upper cover. Figure 6-238. Disassembling or assembling

Disassemble 1. Remove two machine bolts (A) and lock washers attaching cap assembly to left front upper cover and remove cap. 2. Remove and discard cap gasket (B). 3. Remove and discard two preformed packings (C) from cap. 4. Remove and discard preformed packing (D). 5. Remove cap spring (E). 6. Remove machine bolt (F) and remove cap (G). Assemble 1. Position cap (G) on cap assembly and install machine bolt (F). 2. Install cap spring (E). 3. Install a new preformed packing (D). 4. Position two preformed packings (C) on cap assembly. 5. Position a new cap gasket (B) on left front upper cover. 6. Install two machine bolts (A) and lock washers, securing cap assembly to upper cover. Figure oil 6-239. level Disassembling tube cap oil filler tube). or assembling

oil filler and oil level indicator tubes (improved oil filler indicator tubes with splash pan drain). Note. Refer to figure 6-238 for disassembly or assembly procedures of the relocated oil filler tube. b. Cleaning. Refer to paragraph 6-2. c. I n s p e c t i o n a n d R e p a i r . R e f e r t o p a r a g r a p h s 6-3 and 6-4, and (1) and (2), below. (1) Inspect exhaust manifolds for cracks, broken welds, damaged bellows, and bent flanges. 6-200 237)

indicator

(relocated

(2) Inspect cap shoulder bolts (B, fig. 6for looseness or damaged shoulder area. d. Assembly. Refer to figures 6-237 through 6239 for assembly of oil filler and oil level indicator tubes and caps. Exhaust manifolds and cylinder head oil drain tubes will be assembled during engine assembly, Chapter 7.

Section XIV. OVERHAUL OF GENERATOR SUPPORTS, FUEL CHECK VALVE, PRIMARY FUEL 6-54. General FILTERS, AND FUEL / WATER

AND AND

STARTER SECONDARY

SEPARATOR the overhaul operations.

assembly

accompany

This section covers the overhaul of the generator and starter supports, fuel check valve, primary fuel / and secondary separator. cleaning, fuel filters, instructions repair, and on and water Specific

Stud identification information is included in the overhaul procedures where applicable. Refer to illustrations operations. the following table (table 6-42) for applicable instructions for overhaul and

disassembly,

inspection,

Table 6-42. Generator and Starter Supports, Fuel Check Valve, Primary and Secondary Fuel Filters, and Fuel / Water Separator
Disassembly Cleaning Inspection Repair Assembly

Generator and Starter Supports Fuel Check Valve Primary and Secondary Fuel Filters Fuel / Water Separator and Fuel Drain Tubes 6-55. a. Overhaul Supports

Para 6-55a Fig. 6-240 Para 6-56a Figs. 6-241, 6-242 Para 6-57a Figs. 6-244, 6-245 Para 6-58a Figs. 6-246, 6-247

Para 6-2

Para 6-3

Para 6-4 Table 6-43 Para 6-4

Para 6-55d Fig. 6-240 Para 6-56c and Figs. 6-242, 6-241,6-243 Para 6-57c Figs. 6-245, 6-244 Para 6-58c Figs. 6-247, 6-246

Para 6-2

Para 6-3

Para 6-57b

Para 6-57b

Para 6-57b

Para 6-58b

Para 6-58b

Para 6-58b

of

Generator

and

Starter

Disassembly. Disassemble following 6-240. instructions The which starter

generator accompany was

support figure

support

disassembled during starter removal, Chapter 4.

1. Remove 2. Remove 3. Remove attaching

self-locking nut (A). clamping bar (B) and U bolt. two self-locking nuts (C) and flat washers cradle to support.

Figure

6-240.

Disassembling

generator

cradle, support, and U bolt. 6-201

b. Cleaning. Refer to paragraph 6-2. c. Inspection and Repair. Refer to paragraphs 6-3 and 6-4. Refer to paragraph 6-4e and table 643 when replacing studs.

Table 6-43. Generator and Starter Support Standard and Oversize Stud Identification
Fig. No. Ref. No Setting height No. req'd Stud size and length

B-7

27

B-7

17

1-5/16 (generator) 1-11/32 (starter)

Note. Refer to figure 6-1 for oversize stud identification. d. Assembly. The starter support is assembled during starter installation Chapter 4. The

generator support is assembled assembly, Chapter 7.

during

engine

6-202

6-56. Overhaul of Fuel Check Valve

a. Disassembly. Disassemble fuel check valve following instructions which accompany figure 6-241.

Remove 1. Remove 2. Remove 3. Remove 4. Remove 5. Remove 6. Remove

fuel pump inlet tube (A). pipe adapter (B). manifold heater fuel inlet tube (C). pipe adapter (D). pipe tee (E). 15 degree pipe adapter (F).

Install 1. Install 2. Install 3. Install 4. Install 5. Install 6. Install

15 degree pipe adapter (F). pipe tee (E). pipe adapter (D). manifold heater fuel inlet tube (C). pipe adapter (B). fuel pump inlet tube (A).

Figure 6-241. Removing or installing fuel check valve tubes and fittings.

6-203

Note. Components of the fuel check valve are not available as replacement parts. Therefore, no further disassembly is required.

Figure 6-242. Deleted.

b. Cleaning, Inspection and Repair. Refer to paragraphs 6-2, 6-3, and 6-4. c. A s s e m b l y . R e f e r t o f i g u r e 6 - 2 4 1 . d. Test and Adjustment (fig. 6-243). (1) Fill valve with test fluid, MIL-F-7024A Type II, and apply a pressure of psi to port FREE FLOW (fuel inlet from marked primary fuel filter). The check valve must open at this pressure. Valve operation can be determined when outlet port. fluid flows from the fuel pump

(2) Apply a pressure of 85 to 95 psi to the heater pump inlet port. The check ball must bypass fluid at this pressure. Adjust socket head adjusting screw (F, fig. 6-242) to obtain this opening pressure. (3) Plug the fuel pump outlet port, and the heater pump outlet port, and apply a pressure of 100 psi at heater pump inlet port. There should be no fuel leakage from the FREE FLOW port. (4) If the valve fails to pass either test, replace entire valve assembly.

Figure 6-243. Fuel check valve flow diaphragm.

6-204

6-57.

Overhaul ary Fuel Parts

of Primary and SecondFilters and Associated

a. Disassembly. Disassemble primary and secondary fuel filters following instructions which accompany figures 6-244 and 6-245. The mounting brackets, fuel hoses, and fittings were removed during engine disassembly, Chapter 5.

Disassemble 1. Remove retaining nut (A) and gasket (B). Discard gasket. 2. Remove filter head (C). 3. Remove and discard preformed packing (D). 4. Remove and discard filter element (E). 5. Remove disc (F), gasket (G), washer (H), spring (J), washer (K), and retaining ring (L) from filter body stem. Assemble 1. Install retaining ring (L), washer (K), spring (J), washer (H), gasket (G), and disc (F) on filter body stem. 2. Install a new filter element (E). 3. Position a new preformed packing (D) in filter head (C). 4. Install filter head (C). 5. Position a new gasket (B) on retaining nut (A) and install nut.

Figure

6-244.

Disassembling fuel

or

assembling

primary

filter.

6-205

Disassemble 1. Remove two body retaining screws (A) and gaskets (B). Discard gaskets. 2. Separate two fuel filter bodies (C) from fuel filter head. 3. Remove and discard filter elements (D) from each filter body. 4. Remove and discard two head gaskets (E). 5. Remove plug (F) from head. Assemble 1. Install plug (F) in fuel filter head. 2. Position two new bead gaskets (E) in filter head. 3. Position a new filter element (D) in each filter body (C). 4. Position two filter bodies in filter head. 5. Position a new gasket (B) on each body retaining screw (A) and install screws.

Figure

6-245. Disassembling or assembling secondary fuel filter.

6-206

b. Cleaning, Inspection, and Repair. Refer to paragraphs 6-2 through 6-4. Pressure check primary filter outlet hose and secondary filter inlet and outlet hoses to a proof pressure of 150 psi. Pressure check the fuel injection pump fuel inlet hose to a proof pressure of 200 psi. Replace hoses that do not withstand pressure check. c. Assembly. Refer to figures 6-245 and 6-244. The mounting brackets, fuel hoses, and fittings are installed during engine assembly, Chapter 7.

6-58.

Overhaul rator, and

of

Fuel

Water Fuel

SepaFilter

Secondary Fuel / Water

Separator Associa-

Valves, Drain ted Parts

and

a. Disassembly. Disassemble fuel / water separator and secondary fuel filter and fuel / water separator drain valves following instructions which accompany figures 6-246 and 6-247. The mounting brackets, fuel hoses, and fittings were removed during engine disassembly, Chapter 5.

Disassemble 1. Remove eight screws (A), lock washers (B), and flat washers (C). 2. Remove cover (D) and remove and discard preformed packing (E). 3. Remove and discard enter two coalescer elements (F) and final filter element (G) from separator body. 4. Remove two pipe plugs (H) from body and one pipe plug (J) from cover.

Assemble 1. Install two pipe plugs (H) in body and one pipe plug (J) in cover. 2. Install new outer two coalescer elements (F) and a new final filter element (G) in separator body. 3. Install a new preformed packing (E) in cover (D) and position cover on body. 4. Install eight screws (A), lock washers (B), and flat washers (C).

Figure 6-246. Disassembling or assembling fuel / water separator.

6-207

b. Cleaning, Inspection, and Repair. Refer to paragraphs 6-2 through 6-4. (1) Pressure check fuel / water separator inlet and outlet hoses to a proof pressure of 500 psi. Replace hoses that do not withstand pressure check. (2) Flush drain valve tubes thoroughly with a high pressure cleaning device to assure tubes are cleaned and free of obstructions. Check tubes for cracks, dents, or signs of corrosive deterioration. Inspect tube fittings for burrs or mutilated sealing surfaces. Check drain valves for leakage. Valves that leak must be replaced. c. Assembly. Refer to figures 6-247 and 6-242. The mounting brackets, fuel hoses, and fittings are installed during engine assembly, Chapter 7.

Disassemble 1. Remove two hose clamps (A) and two hoses. 2. Remove two nuts (B) with sleeves and remove long tube (C) and short tube (D) from drain valves. 3. Place the toggle type valve handles in the open position. Remove two nuts (E) and remove two valves from bracket. Assemble 1. Place the toggle type valve handles in the open position. Position two drain valves on bracket and install two nuts (E). 2. Position short tube (D) and long tube (C) in drain valves and install two nuts (B) with sleeves. 3. Install two hoses and hose clamps (A). Figure 6-247. Disassembling or assembling

secondary fuel filter and fuel / water separator drain valves.

6-208

Section XV. OVERHAUL OF FUEL FUEL TUBES, FUEL INJECTOR RETURN TUBES, INJECTION PUMP AND OIL HOSES, AND EXHAUST 6-59. General This section covers the overhaul of the fuel injection pump fuel tubes, fuel injector nozzle fuel return tubes, injection pump and turbosupercharger oil hoses, and generator air intake and exhaust tubes and associated parts.

INJECTION PUMP NOZZLE FUEL TURBOSUPERCHARGER

AND GENERATOR AIR INTAKE TUBES AND ASSOCIATED PARTS Specific instructions on disassembly, cleaning, inspection, repair, and assembly accompany the overhaul operations. Refer to the following table (table 6-44) for applicable illustrations instructions for overhaul operations. and

Table 6-44. Fuel Injection Pump Fuel Tubes, Fuel Injector Nozzle Fuel Return Tubes, Injection Pump and Turbosupercharger Oil Hoses, and Generator Air Intake and Exhaust Tubes and Associated Parts
Component Disassembly Cleaning Repair Assembly

Fuel Injection Pump Fuel Tubes Fuel Injector Nozzle Fuel Return Tubes Injection Pump and Turbosupercharger Oil Hoses Generator Air Intake and Exhaust Tubes

Para 6-60a

Para 6-60b

Para 6-60a

Para 6-60b

Para 6-60b Figs. 6-248 and 6-249 Para 6-60b

Para 6-60b

Para 6-60c

Para 6-60b

Para 6-60c

Para 6-61a

Para 6-2

Para 6-61b

Para 6-61b

Para 6-61 c

Para 6-62a Fig. 6-250

Para 6-2

Para 6-3

Para 6-4

Para 6-62c Fig. 6-250

6-209

6-60.

Overhaul of Fuel Tubes,

Fuel Injection Pump Fuel Return Hoses,

and Nozzle Fuel Return Tubes a. Disassembly. The fuel injection pump fuel tubes and nozzle return fuel return tubes were disassembled during disassembly of engine, Chapter 5 . b. Cleaning, Inspection, and Repair. Refer to paragraphs 6-2 through 6-4. (1) Fuel Injection Pump Fuel Tubes. F l u s h the fuel tube assemblies with a high pressure flushing device. After flushing, blow dry with compressed air and plug tube ends with plugs or caps to assure cleanliness. Inspect tubes for correct inside diameter hole dimension. The correct inside dimension is 0.084-inch. Tubes with larger or smaller hole diameter are to be discarded. On original production engines, fuel tubes were hand formed from straight tubes. Carefully inspect all tubes for proper configuration using a current preformed tube of like function for comparison. Excessive bending or hand forming creates high stress points and Figure original design 6-248. Comparison and of serviceable improvised production greatly reduces tube life. Discard any tube that deviates from preformed comparison tube Inspect tube assemblies for configuration. cracks, splits or kinks and for defective safety sleeve nut and sleeves. Refer to figures 6-248 and 6-249 for comparison of original production and improvised design sleeve fittings shown in serviceable and unserviceable condition. Straighten minor bends in tubing when possible. Discard entire tube assembly if fittings are damaged or tubing has been kinked.

sleeves-fuel injection pump tube ends.

6-210

(2) Nozzle fuel return tubes and hoses. Clean nozzle fuel return tubes and hoses thoroughly. Inspect tube and hose connections for cracks, or mutilated sealing surfaces. Inspect hoses for pliability or signs of deterioration. Note. Due to design change, there are two types of fuel returns used on engines. Original production engines had a rigid preformed metal tube, while improved hose. design engines have a flexible rubber

(3) Fuel injection pump fuel return hose. Pressure check fuel injection pump fuel return hose to a proof pressure of 200 psi. Replace tubes that are unserviceable. c. Assembly. Fuel injection pump fuel tubes and nozzle fuel return tubes will be assembled during engine assembly, Chapter 7. 6-61. Injection charger Oil Pump and TurbosuperHoses

a. Disassembly. The injection pump and turbosupercharger oil hoses were disassembled during disassembly of engine, Chapter 5. b. Cleaning, Inspection, and Repair. Refer to paragraph 6-2 through 6-4. Inspect fuel injection pump and turbosupercharger oil hoses for cracks, frayed or chafing check of the the woven metal sheathing. Figure 6-249. Comparison nozzle of serviceable ends. Pressure turbosupercharger

oil inlet hose to a proof pressure of 300 psi. sleeves-injector tube Pressure check the turbosupercharger oil inlet hose to a proof pressure of 200 psi and oil supply hose to 160 psi. Check hose connections for cracks damage c. or is damage. apparent. pump be and turoil hoses will assembled Replace hose connections when pressure check indicates a leak or hose Assembly. Injection

bosupercharger during engine assembly, Chapter 7.

6-211

6-62.

Overhaul of Generator Air Intake and Exhaust Tubes and Associated Parts

b. Cleaning, Inspection, and Repair. Refer to paragraphs 6-2 through 6-4. c. A s s e m b l y . R e f e r t o f i g u r e 6-250. The

a. Disassembly. Disassemble generator air intake tube assembly following instructions which accompany figure 6-250. The generator boot exhaust tube, and associated parts were disassembled during disassembly of engine, Chapter 5.

generator boot, exhaust tube, and associated parts are assembled during engine assembly, Chapter 7.

Disassemble 1. Remove six cap screws (A) and lock washers attaching screen to hose elbow. 2. Remove screen (B). 3. Remove and discard screen gasket (C). 4. Loosen two hose clamps (D) and remove hose from generator air intake tube and elbow. Remove clamps from hose. Assemble 1. Position two hose clamps (D) on hose. Position hose on elbow and generator air intake tube and tighten hose clamps. 2. Position a new screen gasket (C) on elbow. 3. Position screen (B) on elbow. 4. Install six cap screws (A) and lock washers securing screen to elbow. Figure 6-250. Disassembling or assembling generator air intake tube assembly.

6-212

Section

XVI.

OVERHAUL TUBE, MANIFOLD

OF

CRANKCASE FUEL

BREATHER FILTER

TUBES, AND

FIRE

EXTINGUISHER AND

INJECTION

PUMP TUBES,

ELECTRICAL

LEAD,

HEATER

ELECTRICAL 6-63. General This section covers the overhaul of the crankcase breather tubes, fire extinguisher tube, injection pump electrical lead, and manfiold heater fuel tubes, filter, and electrical components.

COMPONENTS Specific instructions on disassembly, cleaning, inspection, repair, and assembly accompany the overhaul operations. Refer to the following table (table 6-45) for applicable illustrations instructions for overhaul operations. and

Table 6-45. Crankcase Breather Tubes, Fire Extinguisher -Tube, Injection Pump Electrical Lead, and Manifold Heater Fuel Tubes, Filter, and Electrical Components
Component Disassembly Cleaning Inspection Repair Assembly

Crankcase Breather Tubes, Fire Extinguisher Tube, and Pump Eletrical Lead Manifold Heater Fuel Tubes, Filter, and Electrical Components 6-64. Overhaul Tubes, and of

Para 6-64a

Para 6-2

Para 6-64b

Para 6-64b

Para 6-64c

Para 6-65a Fig. 6-251

Para 6-65b

Para 6-65b

Para 6-65b

Para 6-65c Fig. 6-251

Crankcase Lead

Breather Tube,

bent, or dented condition. Check spray holes in tube for obstructions and corrosion. Inspect tube fittings (25 and 26) for cracks and for stripped or damaged a threads. maximum Pressure working check tube of to 25 withstand pressure

Fire

Extinguisher

EIectrical

a. Disassembly. The crankcase breather tubes, fire extinguisher tube, and electrical lead were disassembled during engine disassembly, Chapter 5. Repair. R e f e r b. Cleaning, Inspection, and to paragraphs 6-2 through 6-4.

psi. Replace tube when cracked, badly bent, or when spray holes cannot be cleaned. Replace fittings damaged. (3) Pump electrical lead. Inspect pump electrical lead (51, fig. B-11) for cracked, frayed, or deteriorated continuity with Inspect insulation. Inspect lead for a low voltage circuit tester. connectors or for stripped or when cracked or when threads are

(1) Breather tubes and tee. Inspect breather tubes (10, 11, 30, 36, and 43, fig. B-11) and breather tube tee (16) for cracked, bent, or dented condition and for warping of tube mounting surface. Replace when cracked or badly dented or bent, or when mounting surfaces are badly warped. Straighten bent tubes to as near original shape as possible. Remove minor warpage of mounting surfaces by rubbing across abrasive cloth held tightly on a surface plate or similar flat surface. (2) Fire extinguisher tube. Inspect fire extinguisher tube (24, fig. B-11) for cracked,

electrical is

damaged threads. Replace electrical lead when insulation indicates a cracked broken, connector threads are damaged, or when low voltage tester failure, c. Assembly. The crankcase breather tubes, fire extinguisher tube, and electrical lead are assembled during engine assembly, Chapter 7.

6-213

6-65.

Overhaul of Manifold Heater Tubes, Filter, and Electrical Components

b. Cleaning, Inspection, and Repair. Refer to paragraphs 6-2 through 6-4. (1) Heater tubes. Flush rigid heater tubes (19, fig. B-21) thoroughly and dry with compressed air. Clean plastic tubes (50) with a clean dry cloth and blow tubes out with compressed air. Inspect tube fittings for stripped or damaged threads. Replace tubes that are split or kinked or when fittings are damaged. (2) Heater fuel filter. Replace filter element if deformed or if foreign material is embedded. (3) E l e c t r i c a l c o m p o n e n t s . I n s p e c t h e a t e r electrical leads (9, fig. B-21) and ignition units (8) for cracks, continuity, and other damage. Replace leads and ignition units that fail to pass continuity test. c. Assembly. Refer to figure 6-251. The manifold heater tubes and electrical components are assembled during engine assembly, Chapter 7.

a. Disassembly. Disassemble the manifold heater filter following instructions which accompany figure 6-251. The heater tubes and electrical components were disassembled during engine disassembly.

Disassemble 1. Unscrew and separate filter head (A) and filter bowl. 2. Remove and discard filter element (B). 3. Remove and discard preformed packing (C). Assemble 1. Position a new preformed packing (C) on filter bowl. 2. Position new filter element (B) in bowl 3. Install head (A) on bowl. Figure 6-251. Disassembling or assembling

manifold heater fuel filter. Section INJECTOR XVIl. PUMP OVERHAUL DRIVE OF FUEL INJECTION FUEL AND

COUPLERS,

NOZZLES, TIME

PISTON OILER NOZZLES, TOTALIZING METER cleaning, inspection,

6-66. General This section covers the overhaul of the fuel injection pump drive couplers, fuel injector nozzles, piston oiler nozzles, and time totalizing meter. Specific instructions on disassembly,

repair,

and

assembly

ac-

company the overhaul instructions. Refer to the following table (table 6-46) for applicable instructions for overhaul illustrations and operations.

6-214

Table 6-46. Fuel Injection Pump Drive Couplers, Fuel Injector Nozzles, Piston Oiler Nozzles and Time Totalizing Meter
Component Disassembly Cleaning Repair Assembly

Fuel Injection Pump Drive Splined Coupler Diaphragm Coupler Fuel Injector Nozzles

Para 6-67a Fig. 6-252 Para Fig. Para Fig. 6-67a 6-253 4-23 4-169

Para 6-2

Para 6-67b

Para 6-67b

Para 6-67c Fig. 6-252 Para 6-67c Fig. 6-253 Para 4-26, 4-27, Figs. 4-169, 4-168 4-167 Para 6-69c Fig. 6-254

Para 6-2 Para 4-23

Para 6-67b Para 4-23

Para 6-67b Para 4-23

Piston Oiler Nozzle Time Totalizing Meter 6-67. Overhaul Couplers

Para 6-69a Fig. 6-254

Para 6-69b

Para 6-69b Para 6-70a Figs. 6-255, 6-256

Para 6-69b

of

Fuel

Injection

Drive

a. Disassembly. Disassemble the drive splined coupler following instructions which accompany figure coupler 6-252. Disassemble instructions drive which diaphragm accompany following

figure 6-253.

Disassemble 1. Refer to figure 4-59 and 4-61 to remove front coupler sleeve and hub from injection pump. 2. Separate front coupler sleeve (A) and injection pump hub (B). 3. Remove quad ring (C) from coupler sleeve. 4. Remove Woodruff key (D) from pump shaft. Note. Keep front coupler sleeve and hub together. Place them with the rear coupler sleeve and drive shaft hub on rear fan drive housing. Check identification marks made during engine disassembly (fig. 4-52) to make sure these parts match. These parts are mated and must be kept together. Assemble 1. Position Woodruff key (D) in pump shaft. 2. position quad ring (C) in internal groove of front coupler sleeve (A). 3. Install injection pump hub (b) in coupler sleeve. 4. Refer to figure 4-63 to install hub and sleeve on pump shaft and install preformed packing.

Figure

6-252. fuel

Disassembling injection splined pump coupler.

or

assembling

drive

6-215

6-68.

Rebuild of Fuel Injector Holder Assembly to paragraphs nozzle and 4-22

Nozzle 4-24

and and

Refer fuel 6-69.

through

figures 4-163 through 4-165 for rebuild of the injector holder Piston assembly. Oiler Nozzle

Overhaul of Assembly

a. Disassembly. Do not remove nozzles (fig. 6-254) unless the nozzle or holder cannot be cleaned without disassembly. To remove nozzles, position holder in a soft-jawed vise and remove nozzles. b. Cleaning, Inspection, and Repair. Refer to paragraphs 6-2 through 6-4. Make sure oil passages in holder and oil holes in nozzles are clean and free of obstruction. Replace nozzles and holders as necessary, when oil passages and Disassemble 1. Refer to figure 4-60 and 4-62 to remove diaphragm coupler (A) from injection pump. 2. Remove Woodruff key (B) from pump shaft. Assemble 1. Position Woodruff key (B) in pump shaft. 2. Refer to figure 4-64 to install diaphragm coupler (A) on fuel injection pump. Figure 6-253. Disassembling fuel injection pump diaphragm paragraphs below. (1) paragraph 6-2 through splined (7). or assembling drive holes cannot be cleaned of obstructions. c. Assembly. Refer to figure 6-254 to install the nozzle in the holder if removed. Stake nozzles on three flats, 120 degrees apart.

coupler. 6-4, and (1) and (2), to

b. Cleaning, Inspection, and Repair. Refer to

Drive 6-42c

coupler.

Refer

(2) Drive diaphragm coupler. W h e n cleaning, Diaphragm must not be immersed in fluids or cleaners. Inspect diaphragm (10, fig. B16) for cracks, scratches, or mars on rims or diaphragms. Inspect diaphragm pack and flange coupler (12) keyways for wear or mutilation. If diaphragm pack is cracked, do not attempt to repair by welding. Replace unserviceable parts by salvage or replace coupler assembly. c. Assembly. Refer to figures 6-253 and 6-252. Figure 6-254. Piston oiler nozzle and holder assembly.

6-216

6-70.

Time

Totalizing

Meter

a. Inspection and Test. Inspect the time totalizing meter for dents or other deformities which would impair its function. Test the totalizing meter to be sure it is functioning properly by connecting the meter electrical connection (fig. 6-255) to a 24 volt electrical system. The time totalizing meter is calibrated to record the electrical impulse in tenths of an hour and will numerically record every six minutes. Allow sufficient passage of time to be certain hour counter is performing properly.

Figure 6-255

6-217

b. Resetting Time Totalizing Meter. C o n n e c t lead from time totalizing meter electric reset device - 6645-179-2712 to connection on meter and plug reset device into a 110 volt electrical circuit. The time totalizing meter and the time totalizing meter reset device both have a four digit, accumulative time, recording system. To determine the number of hours required to reset the time totalizing meter to a zero reading, add the number of hours registered on the time totalizing meter to the number of hours required to equal 10,000. Example: a time totalizing meter registration of 0500 and a reset device setting of 9500 will advance the time totalizing meter until a reading of 0000 is achieved. Refer to figure 6-256 and follow the instructions to establish the correct procedure to calibrate the time totalizing meter electric reset device.

1. Plug reset device into 110 volt electrical circuit being sure power switch (A) is in the off position. 2. Depress reset knob (B) and lock by turning turn clockwise until tbe white line on knob is in a horizontal position. 3. Open preset cover (C) and dial in the desired numbers, when added to the reading on the time totalizing meter equal a 10,000 hour meter reading. 4. Close preset cover (C) and unlock reset knob (B) by turning turn counterclockwise. 5. Turn power switch (A) on the depress start switch (C) to begin resetting. Unit will complete resetting and stop automatically. 6. Should unit stop slightly short of zero, introduce additional counts by momentarily depressing start switch (D). Figure 6-256. Time totalizing meter electric reset device-6645-179-2712.

6-218

CHAPTER ASSEMBLY OF

7 ENGINE

Section 7-1. Cleanliness

I.

GENERAL pound FSN friction. 9150-663-1770 to reduce the

The engine is a precision product and extreme care and cleanliness must be exercised in all phases of assembly operations to insure satisfactory engine performance. Dirt and dust, even in minute quantities, are abrasive. After cleaning and just before assembly, coat all bearings, shafts, a n d c o n t a c t s u r f a c e s w i t h engine oil (OE). This will insure s u f f i c i e n t lubrication of moving parts when first put into operation. 7-2. General Assembly Instructions

Note. When using a torque wrench, the final reading must be taken while the nut, cap screw, or bolt is turning. When torque reading is close to that specified when wrench is at the end of its swing, back off the nut slightly and change wrench position; then pull to the desired reading while the nut is turning. To start a partially tightened nut will require a much higher torque than that required to keep a nut turning. The ratio of pounds-torque to pounds-pull on a bolt is not an even ratio and excess torque may easily overstress the bolt. Under-torquing bolts and studs subject to cyclic loads such as cylinder base studs and connecting rod bolts will result in fatigue failures. It is therefore important that the torque values specified in this manual followed to avoid failures of fasteners. be

a. Gaskets. Always use new gaskets when assembling the engine. Use new preformed packings and annular copper gaskets throughout engine assembly. An engine overhaul parts kit 2815-678-4245, consisting of all necessary gaskets and preformed packings, is available for use during engine overhaul. b. Kits and Sets. S e v e r a l o f t h e c o m p o n e n t s o f the engine are available in kits or sets. Whenever a kit or set is used for parts replacement, all components of the kit or set should be installed, except for the auxiliary oil filter parts kit, FSN 2940-884-4801. This kit is the universal type. Refer to Appendix for specific information. c. Attaching Parts. W h e n t o r q u e t i g h t e n i n g nuts, bolts, and screws, and a torque specification is n o t noted in the text or illustration covering the installation, it is understood that the standard torque values in paragraph 6-7 prevail. Whenever a nut, bolt, or screw requires that special attention be given, the torque value will be noted in the text or illustration pertaining to that operation. Torque wrench readings are of no value, unless properly used. It must be understood that it is not the force necessary to turn the nut, bolt, or screw that is important, but the resultant pull on the part that completes the union. Therefore, resistance of the nut to turning must be kept to a Threads must be clean and undamaged, and lubricated with antiseize comminimum.

Note. Do not exceed torque specified. d. Lock Nuts, Tab Washers, Locking Wire, Lock Washers, and Cotter Pins. All bolts and nuts should be secured with lock nuts, tab washers, locking wire, lockwashers, or cotter pins, as specified. Many engine failures have been traced to neglect of this simple precaution. 7-3. Installation Instructions

Note. References to figures in this Chapter are listed in the reverse order of disassembly both in text and tables, which is the sequence required to accomplish reassembly of the engine; i.e., 524 through 5-11. Usually the step-by-step procedure to be followed for installing subassemblies on the engine are given immediately following the removal procedure in Chapter 5. This method of installation will be used throughout this chapter unless otherwise indicated in the contents table immediately following each paragraph. Each contents table lists engine components, grouped in proper assembly order, and the appropriate paragraph reference and / or figure reference for installation procedures.

7-1

Section 7-4. General

Il.

ASSEMBLY

OF

ENGINE

FROM

SUBASSEMBLIES

maintenance and overhaul stand - 4910-8564137 (fig. 6-8) and rotate stand so that oil pan flanges are up. 7-5. Starter Drive Gearshaft, Generator

This section covers the assembly of the engine from subassemblies. Components are grouped together in proper assembly order. The crankcase assembly was partially assembled during rebuild of engine components (Chapter 6). Normally the crankcase assembly will be on the overhaul stand after it has been inspected and the main bearing bosses have been checked. In case crankcase is not on stand, install on

and Idler Gears, Piston Oiler Nozzles, and Crankshaft and Connecting Rod Assembly

Refer to Table 7-1 for illustrations and assembly instructions. References are listed in the table.

Table 7-1. Starter Drive Gearshaft, Generator and Idler Gears, Piston Oiler Nozzles, and Crankshaft and Connecting Rod Assembly
Component Reference

Starter Drive Gearshaft and Generator and Starter Idler Gears Piston Oiler Nozzles and Crankshaft and Connecting Rod Assembly a. Starter Drive Gearshaft and Generator and Starter Idler Gears. Refer to figures 5-184, 5183, and 5-181 and to the instructions given in (1) and (2), below. (1) Starter drive gearshaft bearing cage. There are two types of bearing cages being used on the engine. Early bearing cages have a flush mounting face and require the use of a sealent. Late bearing cages have a machined recess to accommodate a preformed packing. When overhauling an engine, do not attempt to use a preformed packing on a bearing cage that does not have a machined groove to accommodate the packing. (2) Generator and starter idler gears. I n s t a l l generator idler gear and assembled ball bearing retaining ring toward rear of crankcase in the same manner as the starter idler gear. Note. Retaining ring securing ball bearing in starter idler gear must be toward rear of crankcase when idler gear is positioned in crankcase.

Para 7-5a, Figs. 5-184, 5-183, 7-1, 5-181 Fig. 5-180, Para 7-5c, Figs. 5-179 through 5-175, 7-2, 7-3, 5-173, 7-4, 5-172, 5-171

1. Install new preformed packing (A) on idler gearshaft (C). 2. Position starter idler gear (B) and a line with idler gearshaft bore in crankcase. Figure 7-1. Installing starter idler gear.

7-2

b. Piston Oiler Nozzles. Refer to figure 5180. c. Crankshaft and Connecting Rod Assembly. Refer to figures 5-179 through 5-175 and to the instructions given in (1) through (3), below. (1) Main bearing caps. Coat outer edges of the bearing cap and machined surfaces of the crankcase webs with installation of caps. engine oil to facilitate

Note. End play should be from 0.00740 to 0.019-inch. When end play exceeds 0.019-inch, remove bearing caps and crankshaft. Install bearing cap and recheck thrust bearing bore (para 6-9d). Then install crankshaft and recheck end play to make sure it is within limits.

1. Install number 4 (center) thrust bearing cap (A) and bearing half in position on crankcase studs (tie rods). Use crankcase spreading tool (B)-5120-575-7767 to spread crankcase so bearing caps will slide over studs and into position in the crankcase. Note. Be sure main bearing caps and main bearing halves are installed in their original positions according to location number identification on the cap and bearing half. 2. Install the remaining six bearing halves in caps (C) and similarly install caps and bearings in crankcase. Note. The side of each main bearing cap identified as fly end must be installed toward flywheel end or rear of engine. Figure 7-2. Installing main bearing caps using crankcase spreading tool5120-575-7767. (2) Crankshaft end play. C h e c k c r a n k s h a f t end play following the instructions which accompany figure 7-3.

1. Mount a dial indicator (A) on crankcase so indicator point contacts drive gear flange on crankshaft. 2. Using a heavy duty screwdriver, wedged between main bearing cap and crankshaft counterweight, push crankshaft toward front end (B) of crankcase. 3. Set indicator (C) on zero reading (0). 4. Using heavy duty screwdriver, push crankshaft toward the rear (D) of crankcase and check indicator end play reading. Figure 7-3. Checking crankshaft end play. (3) Main bearing attaching parts.

(a) Refer to figure 5-173 and install all main bearing cap plate washers and nuts. Do not torque tighten nuts at this time. Check and record the height of each stud using a flat surface plate and dial indicator as shown in figure 7-4.

7-3

(b) Refer to figures 5-172 and 5-171 and install crankcase tie rods but do not torque tighten at this time. Refer to paragraph 7-6c. (c) Starting at number 4 main thrust bearing, and alternating right and left, successively torque tighten all main bearing stud nuts to 500 pound-inches, then, following the same procedure and sequence, torque tighten all nuts to inches a final torque of 700 to 825 pound-

(d) Following the same procedure as (a), above, recheck stud height and apply sufficient additional torque to each nut, as in (c), above, to aline nut slot with drilled hole in stud, and to obtain a stud stretch of 0.019 to 0.022-in. Do not exceed 0.024-in. Stud stretch is defined as the difference between the original height recorded in (a) above, and height observed after nuts have torque been refer to torque tightened, specifications 7-6. (para 6-7). Drive Gear, Crankshaft Adapter,

Accessory

Oil Seal, Transmission and Flywheel Figure 7-4. Measuring main bearing stud stretch using dial indicator.

Refer to Table 7-2 for illustrations and assembly instructions. References are listed in the table.

Table 7-2. Accessory Drive Gear, Crankshaft Oil Seal, Transmission Adapter, and Flywheel
Component Reference

Accessory Drive Gear Crankshaft Oil Seal Housing Transmission Adapter, Flywheel, and Transmission Drive Gearshaft Assembly a. Accessory Drive Gear.

Para 7-6a and b, Figs. 5-169, 7-5, 5-168, 7-6, 7-7, 5-167 through 5-165 Para 7-6e through g, Figs. 5-182, 5-163, 7-8, 5-159, 7-9

(1) Install accessory drive gear. R e f e r t o figure 5-169 and alternately tighten 12 bolts to draw drive gear on to crankshaft flange. Note. Always use accessory drive gear, FSN 2815-861-3829 (part number - 10898778) during engine assembly. This gear can be identified by measuring the length of the gear teeth, which are approximately 1-15 / 32-inch.

(2) Checking accessory drive gear backlash. Check backlash between accessory drive gear teeth and starter drive idler gear teeth as shown in figure 7-5. Backlash should be from 0.004 to 0.009-inch. Check backlash between accessory drive gear teeth and generator drive idler gear in the same manner.

7-4

c. Torque Tighten Crankcase Tie Rod Nuts. Refer to figures 5-172 and 5-171 and, with the aid of an assistant holding the slotted nuts on opposite side of crankcase, tighten crankcase tie rod nuts to 640 pound-inches. Install 14 cotter pins to secure nuts. Care should be taken so that the tie rod extends equally on both sides of crankcase. d. Crankshaft Oil Seal. The crankshaft oil seal is installed during overhaul of the crankshaft (fig. 6-32). Refer to figure position of oil seal split line. 7-7 for correct

Figure 7-5. Checking accessory drive gear and starter idler gear backlash. b. Crankshaft Oil Seal Housing and Support. Refer to figure 5-168 and install new candlewick packing in four openings, at the crankcase and oil seal housing support parting line as shown in figure 7-6. Refer to figures 5-167 through 5-165 and install oil seal cap and housing attaching parts and retainers. Figure 7-7. Correct position of crankshaft oil seal split line before installing seal retainer. e. Transmission Adapter. Refer to figures 5164 and 5-163. f. Flywheel. Note. The dowel pins (fig. 7-8) are so located that the flywheel can be installed on the flange on the crankshaft in only one position. g. Transmission Drive Gearshaft Assembly. (1) Position transmission drive gearshaft assembly on dowel pins (fig. 7-8) which protrude through flywheel. (2) Refer to figure 5-159 and alternately tighten bolts to 1000 pound-inches. (3) Check flywheel runout as shown in figure 7-9 using dial indicator. Runout should not exceed 0.015-inch. Replace flywheel if runout exceeds this limit. Figure 7-6. Installing candlewick packing between crankcase and oil seal housing support.

7-5

Figure 7-9

Install eye bolt-5306-017-6143 in threaded hole provided in flywheel (A). 2. Attach suitable chain hoist eye bolt and aline dowel pin holes in flywheel with dowel pins in crankshaft flange. Position alined flywheel against flange on crankshaft. 3. Install three 9 / 16 x 1 in. bolts and alternately tighten bolts to draw flywheel toward flange on crankshaft. Bolts are used to secure transmission drive gearshaft. Note. Eye bolt 5306-017-6143 must be removed from flywheel, before flywheel is drawn tight against flange on crankshaft, to permit flywheel to clear transmission adapter lifting eye. 4. Remove lifting eye bolt and continue to tighten three bolts until flywheel is tight against flange, then remove bolts. Figure 7-8. Installing flywheel using eye

1.

bolt-5306-017-6143.

7-6

7-7.

Starter and Generator Drive Oil Pump, and Oil Tubes Table 7-3 for

Adapters,

Vibration

Damper,

Sending

Units,

the

Refer to table.

illustrations

and assembly instructions. References are listed in

Table 7-3. Starter and Generator Drive Adapters, Vibration Damper, Sending Units, Oil Pump, and Oil Tubes
Component References

Generator Drive Adapter and Drive Gearshaft Starter Drive Adapter and Starter Driven Gear Crankshaft Torsional Vibration Damper and Fuel Pump Drive Shaft Coupling Sending Units, Oil Pump, and Oil Tubes a. 156. b. Starter Drive Adapter and Starter Driven Gear. Refer to figures 5-155 through 5-153. c. Crankshaft Torsional Vibration Damper and Fuel Pump Drive Shaft Coupling. Refer to figure 5-151 and position crankshaft torsional vibration pump damper damper on crankshaft. adapter to 1000 Tighten fuel drive coupling bolts and vibration Generator Drive Adapter and Drive

Para 7-7a, Figs. 5-158 through 5-156 Para 7-7b, Figs. 5-155 through 5-153 Para 7-7c, Fig. 5-151 Para 7-7 and e, Figs. 5-156, 7-10, 5-149, 5-148

Gearshaft. Refer to figures 5-158 through 5-

mounting

pound-inches. Brackets.

d. Oil Pressure Sending Unit, Switch, and Generator Air Intake Refer to figure 5-150. Tube Support

e. Oil Pump and Oil Tubes. Refer to figures 5-149 and 5-148. Always use new preformed packings on oil transfer tubes when installing the oil pump assembly. Make certain oil transfer tubes aline with openings in crankcase and mesh oil pump drive gear with accessory drive gear (fig. 7-10). Check oil pump drive gear to be certain there is 0.008 to 0.012 inch backlash between teeth of pump drive gear and accessory drive gear.

Figure 7-10. Oil pump mounting flange oil discharge locations.

7-7

7-8.

Pistons and Pins, Cylinder A s s e m b l i e s , C y l i n d e r A i r Crankshaft Damper and Oil Filter Housing, and Oil Pan

Deflectors,

Refer to Table 7-4 for illustrations and assembly instructions. References are listed in the table. Table 7-4. Pistons and Pins, Cylinder Assemblies, Cylinder Air Deflectors, Crankshaft Damper and Oil Filter Housing, and Oil Pan
Component References

Pistons and Pins and Cylinder Assemblies Cylinder Air Deflectors Crankshaft Damper and Oil Filter Housing Oil Pan

Para Para Para Para

7-8a, 7-8b, 7-8c, 7-8d,

Figs. Figs. Figs. Figs.

7-11 through 7-13, 5-144, 5-143 5-142, 5-141 5-139, 5-138 4-125, 5-137 through 5-135, 6-78, 6-80

a. Pistons and Pins and Cylinder Assemblies. Refer to the instructions given in (1) and (2), below. (1) Pistons. (a) The pistons are marked for identification as shown in figure 7-11 to aid in installing the pistons in their proper position. The piston boss is stamped with an arrow and the cylinder location (1R) to identify the cylinder from which the piston was removed and to assure piston will be returned to its original cylinder. The arrows on the piston pin bosses are pointed up, or to the exhaust outlet port. Cylinders are stamped with piston markings at the intake valve side (bottom) of valve rocker arm cover flange. Markings of any piston or cylinders must be renewed if position marks and / or arrows are not entirely legible. Replacement piston must be marked to the corresponding cylinder it is to be used with. At engine overhaul, all 12 pistons and pins are matched according to weight and cannot vary more than 5 oz. Always keep piston pin with its respective pin.
Figure 7-11

7-8

(b) Coat pistons with lubriplate or engine oil and stagger the four piston ring gaps 90 degrees apart. (2) C y l i n d e r assemblies.

Note. For instructional purposes, the installation of only one cylinder assembly is described. The remaining cylinder assemblies should be installed in the same manner. Note. Wash cylinder bores thoroughly just prior to engine assembly, using a power brush with hot (160 F) soap water. Cylinder bores should then be oiled to prevent rust. (a) Rotate engine overhaul stand until right bank cylinder holes, with connecting rod protectors, are positioned Nos. 1R through 6R. to receive cylinder

(b) Install piston with rings in cylinder and cylinder assemblies on crankcase following instructions which accompany figures 7-12 and 7-13.

1. Install piston and rings (A) in cylinder assembly using compressor and gage-4910-795-7956. The piston position number (fig. 7-11) must always correspond to the cylinder number marked on intake valve side of valve rocker arm cover flange. The arrow on the piston boss must he directed toward the exhaust port outlet. Guide piston and rings into cylinder until all piston rings have entered the cylinder bore. Slide the compressor f r o m p i s t o n a n d r i n g a s s e m b l y . I n s t a l l remaining pistons in cylinders in the same manner. 2. Install new preformed packing (B) on each cylinder base making sure that packing is not twisted or otherwise improperly seated. Figure 7-12. Installing piston in cylinder assembly using compressor and gage-4910-795-7956.

7-9

(c) When all cylinder assemblies are installed as described and illustrated in figure 713, install remaining cylinder extended washer nuts and torque tighten the nuts alternately to 640 pound-inches. Use box wrench - 5120-6785287 in combination with a torque wrench as shown in figure 5-143. b. Cylinder Air Deflectors. Refer to figures 5142 and 5-141. c. Crankshaft Damper and Oil Filter Housing. Refer to figures 5-139 and 5-138. d. Oil Pan. Refer to figures 4-125, 5-137 through 5-135 and torque tighten oil pan bolts to 175 pound-inches and self-locking nuts to 225 pound-inches. Tighten four slotted nuts (C, fig. 6-90 or C, fig. 6-92) and install locking wire. Note. During overhaul operations, consideration must be given to engine model, when assembling oil pan to engine. Engine Model AVDS-1790-2-M had an oil pan (10865039, fig. 7-14) with oil drain plugs located specifically C a u t i o n : If lubricant is extended to face of washer nut, reliable retaining torque cannot be obtained. 2. Rotate engine crankshaft using engine turning splined wrench-5120-793-7895 (fig. 5-91) until the No. 1R connecting rod (B) is at the top of its stroke. 3. Remove crankcase protector-4910-795-7951 from cylinder No. 1R mounting studs (C) being careful not to allow connecting rod to forceably drop against the crankcase cylinder mounting surface or mounting studs. 4. Remove piston pin from piston of No. 1R cylinder assembly and place piston and cylinder over No. 1R connecting rod. Insert piston pin (D) with plugs through connecting rod and piston and center pin in position. Center piston pin plugs in piston. 5. Slide cylinder (E) over piston on crankcase studs and temporarily secure with two extended washer nuts (fig. 5-144) positioned approximately 180 degrees apart. Figure 7-13. Installing cylinder assemblies on crankcase. designed for a certain vehicle and the engine model was not interchangeable with other vehicles. The oil pan (10912162, fig. 7-15) on engine Models AVDS-1790-2-AM and AVDS1790-2A provides an oil drain plug location that is accessible in all vehicles. Although limited numbers of early oil pans are in current use, care must be taken in Depot overhaul to identify the early oil pans and properly designate engine model.

1. Sparingly coat cylinder stud threads (A) on crankcase with antiseize thread lubricant FSN 9150-527-1752 or 9150-663-1770.

7-10

Figure 7-14. Oilpan (10865039) drain plug location-limited to M60 series vehicles.

Figure

7-15.

Oil

pan

(10912162) drain plug application.

location

for

universal

vehicle

e. Protective Coverings. Rotate

engine

stand,

as shown in figure 7-16 and cover all cylinder and engine openings with plastic covers, or suitable improvised covers following instructions which accompany figure 7-16.

Note. All openings must be covered to prevent foreign material, dirt, loose metal parts, etc. from accidentally falling into openings, cylinder exhaust port openings. especially

7-11

1. Cover 12 cylinder exhaust ports (A). 2. Cover 12 fuel injector nozzle holder assembly ports (B). 3. Cover starter adapter opening (C) :

4. Cover oil filler and oil level indicator openings (D) and cylinder head oil drain tube openings (E). 5. Cover oil cooler inlet and outlet hose openings (F) on each side of crankcase damper and oil filter housing. to prevent entrance of dust and

Figure

7-16.

Protecting

openings

foreign objects. 7-9. Fan Drives, Housings, and Bases to Table 7-5 for illustrations and assembly instructions. References are listed in the table.

Refer

Table 7-5. Fan Drives, Housings, and Bases

Component Reference

Rear Fan and Accessory Drive Housing with Clutch Assembly and Mounting Base Fuel Injection Pump Mounting Base Front Fan Drive Housing with Clutch Assembly and Mounting Base a. Rear Fan and Accessory Drive Housing with Clutch Assembly and Mounting Base. (1) Install three new preformed packings on oil transfer tubes in crankcase (fig. 5-134). Apply a thin coat of gasket cement (MIL-C10523 Ord) to mounting base lower mounting surface 7-12 before assembly to crankcase.

Para 7-9a, Fig. 5-134, 5-133, 5-131, 7-17, 5-130, 5-129 Para 7-9b, Fig. 5-128, 5-127 Para 7-9c, Fig. 5-126, 5-125, B120 through 5-117, 7-19

, 7-18, 5-123, 5-122, 5-

(2) Refer to figure 5-133 and torque tighten screws and nuts to 275 pound-inches. Apply a thin coat of gasket cement (MIL-C-10523 Ord.) on the mounting surface of the base prior to assembling rear fan and accessory drive housing.

(3) Refer to figure 5-131 and install fan and advance unit housing sling - 4910-795-7954. and (4) Refer to figure 7-17 and install rear fan accessory drive housing with clutch

(5) Refer to figure 5-130 and torque tighten the 12 self-locking nuts (A) to 275 pound-inches. Refer to figure 5-129 and torque tighten 14 selflocking nuts to 275 pound-inches. b. Fuel Injection Pump Mounting Base. (1) Install new preformed packing on oil transfer tube in crankcase (fig. 5-128). four (2) Refer to figure 5-127 and torque tighten bolts to 750 pound-inches. with Clutch

assembly.

Front Fan Drive Housing c. Assembly and Mounting Base.

(1) Install new preformed packing at oil transfer tube in crankcase assembly (fig. 5-126). (2) Apply a thin coat of (MIL-C-10523 Ord.) on the lower mounting surface. ten gasket cement mounting base

(3) Refer to figure 5-125 and torque tighten slotted nuts and two cap screws to 275 (4) Position cover adapter (58, fig. B-26) on fan drive shaft cover (57). Similarly, (58) on rear fan drive shaft

pound-inches. front

position adapter cover (62).

(5) Join the two shaft covers (58 and 621 using rubber hose (61) and two hose clamps (60). Tighten hose clamps just enough to hold the covers together as a unit. Install a preformed packing (56) on adapter end of each shaft cover drive 1. Lower the rear fan and accessory drive housing assembly (A) until holes in housing aline with studs in mounting base. 2. Continue lowering housing until accessory drive bevel gearshaft gear teeth (B) engage with the gear teeth of the accessory drive gear. 3. Refer to figure 5-131 and remove lifting sling (C) after rear fan and accessory drive housing are positioned. Figure 7-17. Installing rear fan and a c c e s s o r y drive housing using fan and advance unit housing sling-4910-795-7954. (6) Install retaining ring (55) on front far shaft (54).

Note. Do not install retaining ring in groove located on the front spline. Ring must be located beyond the spline at this time. (7) Install front fan drive shaft with retaining ring, in front fan drive bevel gearshaft (50.1) of front fan drive housing and clutch assembly. Long spline must enter gearshaft. I n s t a l l t h e a s s e m b l e d d r i v e s h a f t c o v e r s i), above) over the front fan drive shaft, with Irt housing toward front fan drive housing as shown in figure 7-18.

7-13

(8) Refer to figure 5-123 and torque tighten two drilled head cap screws to 275 pound-inches. Refer to figure 5-121 and torque tighten seven self-locking nuts to 275 pound-inches. (9) Refer to figures 5-120 through 5-117 and install the fan horizontal drive shaft. Center hose on drive shaft housing and tighten hose clamps securely. (10) Refer to figure 7-19 for the view of the engine as it appears at this stage of assembly.

Note. To facilitate lifting the front fan drive housing assembly, an improvised lifting tool can be made from a piece of 3 / 8-in. dia bar stock and a discarded slotted fan nut. Bend bar stock to shape and securely weld ends of bar to nut as illustrated in figure 2-1. 1. Install improvised lifting tool (A) on fan vertical drive shaft. 2. Apply light coat of gasket cement (MIL-C-10523 Ord.) on mounting base (B). 3. Lower front fan drive housing assembly and associated parts on mounting base. Figure 7-18. Installing front fan drive housing assembly using improvised lifting tool.

7-14

Figure 7-19

7-15

7-10. the

Camshafts to Table

and 7-6

Fuel for

Injection

Pump and assembly instructions. References are listed in

Refer

illustrations

table. Table 7-6. Camshafts, Fuel Injection Pump, and Rocker Arm Covers
Component References

Camshafts and Valve Timing

Fuel Injection Pump and Timing Rocker Arm Covers Note. Both the left and right camshafts are installed in the same manner. For instructional purposes, the right camshaft has been used for typical procedures. a. Camshafts and Valve Timing. (1) Refer to figure 5-116 and position camshaft on bearings in cylinder heads. Attach camshaft gear housing to cylinder (5-115) but do not tighten screws at this time. Note. Valve rocker arm covers for cylinder Nos. 2R through 5R are not installed until the engine is timed. (2) Set cylinder No. 6R valve clearance and engine timing following instructions which accompany figures 7-20 through 7-22.

Para 7-10a, Figs. 5-116, 5-115, 7-20 through 7-22, 5-106, 5-109, 5-105, 5-108, 7-22, 7-23 through 7-26, 5-112, 5111 Para 7-10b, Figs. 4-71, 4-72, 7-27, 7-28, 4-65 through 468, 4-75 through 4-81, 7-29 Para 7-10C, Figs. 5-109, 5-108, 7-22, 7-23, 7-27, 7-28, 7-30

Figure 7-20. Flywheel timing mark locations.

7-16

Figure

7-21.

Positioning

engine

flywheel

using

splined

wrench-

5120-793-7895.

7-17

Note. The valve timing procedure must be followed in detail to prevent the valves from striking the head of the piston. 1. Rotate the right camshaft (A) until the two lobes (cams) for intake and exhaust valves for No. 6R cylinder are pointed towards the crankshaft. Remove cover from fuel injector nozzle holder assembly opening in cylinder. 2. Apply a light film of sealing compound (MIL-C-10523 Ord.) on valve rocker arm cover and position cover (B) on cylinder. Identifying numbers on cover and cylinder must correspond (fig. 5-105). Valve rocker arm rollers must contact base circle of camshaft and lip of preformed intercylinder hoses must not be folded under cover. Tap cover gently to position cover over dowel pins. 3. Refer to figure 5-109 and torque tighten four bolts (C) to 275 to J25 pound-inches. Refer to figure 5-108 and torque tighten all bolts and cap screws to 100 poundinches. 4. Refer to figure 5-107 and secure camshaft gear housing to valve rocker arm cover and cylinder with bolts (D). 5. Using thickness gage blade-5210-793-7897 (E) set intake valve clearance to 0.100-inch by turning the adjusting screw clockwise to decrease the clearance or counterclockwise to increase the clearance. Note. Check position of valve adjusting screw pad. Pad must seat flat on valve stem. Figure 7-22. Installing valve rocker arm cover and adjusting intake valve clearance (cylinder No. 6R).

The exhaust valve clearance is Note. decreased by turning the adjusting screw clockwise or increased by turning the screw counterclockwise. T o r q u e t i g h t e n a d j u s t i n g s c r e w lock nut to 175 pound-inches after adjustment.

Figure 7-23. Adjusting exhaust valve clearance.

7-18

1. Slowly turn camshaft (A) clockwise, as viewed from flywheel end, until No. 6R intake valve has just closed. 2. Closing point is determined by trying to rotate the swivel pad (B) on the intake valve adjusting screw while the camshaft is being rotated. The valve is closed the instant the swivel pad is free to move. Figure 7-24. Determining closing point of No. 6 intake valve.

Note. Do not force camshaft drive shaft. The shaft is machined with a 24-tooth spline on inner end, and a 28-tooth spline on outer end. This difference in number of teeth provides a vernier effect which makes it possible to index the drive shaft so it will engage the splines of the camshaft drive gearshaft and camshaft drive bevel gearshaft at some point within 360 degrees. An setting is then provided without accurate changing the relationship of the camshaft and crankshaft. 1. Maintain the position of camshaft as set in figure 7-24 and the crankshaft position set in figure 7-21. 2. Insert camshaft drive shaft (A), using mechanical puller-5120-678-5282, and mate splines on drive shaft with splines in camshaft drive bevel gearshaft. When splines of drive shaft do not mate with splines of camshaft gearshaft, withdraw drive shaft and turn slightly before again attempting insertion. It may be necessary to repeat this Note. operation a number of times before splines will mate and allow drive shaft to be inserted into position. Figure 7-25. Installing camshaft drive shaft.

7-19

timing by rotating (3) Check valve crankshaft clockwise as viewed from rear, approximately 1 / 8 turn to remove gear backlash, then turn counterclockwise until the valve is just closed. Stop rotating the crankshaft the instant the swivel pad becomes free. Observe position of flywheel timing mark. When timing mark on flywheel is alined within 1 / 8-inch of the timing pointer, the valve timing is correct. When timing mark is not alined, withdraw camshaft drive shaft, and repeat timing procedure ((2) above) and again check valve timing. When correct valve timing is obtained, install right oil transfer plug following instructions in figure 7-26. Note. When correct timing cannot be obtained as described in (3), above, it may be necessary to set timing mark 1 / 8 to 1 / 4-inch out of alinement before installing drive shaft. by (4) Set cylinder No. 6 intake valve clearance rotating crankshaft counterclockwise ap-

(5) Rotate the crankshaft counterclockwise approximately 270 degrees from 6L INT CLOSE .100 CLR until flywheel timing mark 6R INT CLOSE .100 CLR is alined with timing pointer. Install the left camshaft and No. 6L valve rocker cover following same procedure as outlined for right camshaft and No. 6R valve rocker cover. (6) Refer to figure 5-111 and install the camshaft gear housing covers, using new mounting gaskets. b. Fuel Injection Pump and Timing. Refer to figures 4-63 and 4-64 to install coupler half on fuel injection pump. Torque tighten nut to 900 pound-inches. Refer to figures 4-71, 4-72, 4-65 through 4-68, and 4-75 through 4-81. Additional pertinent instructions are listed below.

proximately 1 / 4 turn in order to have No. 6R intake valve rocker arm roller on base circle of camshaft. Set intake valve clearance to final 0.010-inch setting, using thickness gage blade 5120-793-7897 as shown in figure 7-22. Torque tighten adjusting screw lock nut to 175 poundinches after adjustment.

Figure

7-27.

Correct

position

of

cylinder

1R

camshaft lobes (cams) for fuel injection pump installation-installed view.

1. Install right oil transfer plug using mechanical puller5120-678-5282. 2. Refer to figure 5-112 and install retaining ring. Figure 7-26. Installing right camshaft oil transfer plug.

7-20

Figure 7-28. Correct position of camshaft lobes (cams) for fuel injection pump i n s t a l l a t i o n -sectional view.

1. Using two 5 / 16-in. steel rods (A), hold fuel injection pump diaphragm pack stationary. Rotate flange coupling counterclockwise to remove any backlash in injection pump gear train and bring the advance unit to the full retard position. 2. When backlash is removed and timing marks alined, install four lock washers and bolts (B) and tighten securely. Note. When installing bolts in diaphragm coupling, be sure the proper length bolts - FSN 5306-944-7537 are used. Bolts longer than 53 / 64-inch can be threaded completely through the coupling flange and dent the diaphragm pack. This will create a high stress point and possible Figure drive premature 7-29. gear coupling failure. injection and pump setting Removing train fuel

backlash

advance unit retard positiondiaphragm coupling.

7-21

c. Install Rocker Arm Covers. T h e

camshaft

lobes (cams) for cylinder No. 1R must be down towards crankshaft, so valve rocker arm rollers are on base circle of camshaft as shown in figures 7-27 and 7-28 before installing rocker arm cover. The identification number stamped on rocker arm cover must match the number stamped on cylinder assembly (fig. 5-105). Rocker arm covers must always be installed on their mating cylinder assemblies. instructional covers are purposes. in installation the same Note. For Remaining manner. (1) Remove protective cover from fuel injector nozzle and holder opening in cylinder assembly. Apply a light film of sealing compound (MIL-C-10523 Ord.) to valve rocker arm cover and install cover. Refer to figure 5-109 and torque tighten four bolts to 275 to 325 poundinches. Refer to figure 5-108 and torque tighten all bolts and cap screws to 100 pound-inches. (2) Set valve clearance of No. 1R intake valve to 0.010-inch using thickness gage blade 5210-793-7898 as shown in figure 7-22. (3) Set valve clearance of No. 1R exhaust valve to 0.025-inch using thickness gage blade 5210-793-7899 as shown in figure 7-23. (4) Rotate crankshaft as necessary to position camshaft lobes (cams) in downward position (figs. 7-27 and 7-28) as each of the remaining valve rocker arm covers are installed.
Figure 7-30

of rocker arm cover for cylinder No. 1R is used. installed

7-22

7-11.

Nozzle Table

and 7-7

Holder for

Assemblies, and

Cylinder assembly

Deflectors,

and

Shrouds are listed in

Refer to the table.

illustrations

instructions.

References

Table 7-7. Nozzle and Holder Assemblies, Cylinder Deflectors, and Shrouds
Component References

Nozzle and Holder Assemblies Shroud Plates and Cylinder Deflectors a. Fuel Injector Nozzle and Holder

Para 7-11a, Figs. 5-103, 4-165 Para 7-11b, Figs. 5-102 through 5-97 Camshaft Drive Shrouds and Cylinder b. Deflectors. Refer to figures 5-102 through 5-97. Note. Removal or installation of shrouds and cylinder deflectors is the same for both left and right banks of the engine. For instructional purposes, the right bank shrouds and cylinder deflectors are illustrated.

A s s e m b l i e s . Refer to figures 5-103 and 4-165. Note. When installing new gasket on nozzle assembly, apply a thin coating of grease to the gasket to retain gasket in position on nozzle assembly.

7-12.

Turbosupercharger Injection Pump Oil

Oil

Inlet Hose,

Hose and

and

Fire

Extinguisher Rods

Tube,

Fuel

Inlet

Throttle

Control

and

Lever

Refer to Table 7-8 for illustrations and assembly instructions. References are listed in the table. Table 7-8. Turbosupercharger Oil Inlet Hose and Fire Extinguisher Tube, Fuel Injection Pump Oil Inlet Hose, and Throttle Control Rods and Lever
Component References

Turbosupercharger Oil Inlet Hose and Fire Extinguisher Tube Fuel Injection Pump Oil Inlet Hose Throttle Control Rods and Intermediate Lever a. Turbosupercharger Oil Inlet Hose and Fire Extinguisher Tube. Refer to figures 5-90 through 5-88.

Para 7-12a, Figs. 5-90 through 5-88 Para 7-12b, Figs. 5-87 through 5-84 Para 7-12c, Figs. 5-83 and 5-82 b. Fuel Injection Pump Oil Inlet Hose. R e f e r to figures 5-87 through 5-84. c. Throttle Control Rods and Intermediate Throttle Lever. Refer to figures 5-83 and 5-82.

7-13.

Turbosupercharger Return Hoses, Manifolds, and

Base,

Supports, Breather

and

Tie

Rods,

Fuel

Inlet

and and

Crankcase Fuel

Tubes,

Injector

Clamps,

Pipes Exhaust Supports, and Tubes

Refer to Table 7-9 for illustrations the table.

and assembly instructions. References are listed in

Table 7-9. Turbosupercharger Base, Supports, and Tie Rods, Fuel Inlet and Return Hoses, Crankcase Breather Tubes, Exhaust Pipes and Manifolds, and fuel Injector Clamps, Supports, and Tubes
Component References

Turbosupercharger Base, Supports, and Tie Rods Fuel Inlet and Return Hoses and Crankcase Breather Tubes Exhaust Pipes and Manifolds Fuel Injector Clamps, Supports, and Tubes Fuel Injector Nozzle Fuel Return Tubes

Para 7-13a, Figs. 5-81 through 5-79 Para 7-13b, Figs. 5-77 through 5-71 Para 7-13c, Figs. 5-78, 5-70 through 5-68 Para 7-13d, Figs. 5-67 through 5-64, 4-86 Para 7-13e, Figs. 5-63 through 5-61

7-23

Turbosupercharger Base, Supports, and a. Tie Rods. Refer to figures 5-81 through 5-79. b. Fuel Inlet and Return Hoses and Crankcase Breather 5-71. Pipes and Manifolds. Refer to Tubes. Refer to figures 5-77 through

the tube(s) to gain alignment. The tube MUST be aligned in its free state before attempting to engage the fittings, t o m i n i m i z e u n w a n t e d stresses. (4) Start fittings on both ends by hand until the sleeve is seated. If a wrench is required, only low torques are necessary to seat the sleeve. When the sleeve is seated, an increase in torque will be quite evident. When this point is reached, draw the nut (each end) up approximately 1 / 6 of a turn (minimum), but not more than 1 / 3 of a turn (maximum), to complete the tightening operation. Note. Overtightening sleeve and cause fuel leaks. will damage the

c. E x h a u s t

figures 5-78 and 5-70 through 5-68. d. Fuel Injector Clamps, Supports, and Tubes. Refer to figures 5-67 through 5-64 and 4-86, and (1) through (6), below. (1) Fuel tubes should be installed individually and in the sequence listed below to assure adequate wrench clearance. Beginning with the left bank fuel injector tubes (rear pump head) install tubes for cylinders 5, 3, 1, 6, 2, and 4 in that order. Install the right bank tubes for cylinders 2, 4, 1, 6, 5, and 3 in that order. Note. Injector tubes for cylinders 1, 2, and 3 right bank, must be routed under the right exhaust manifold between cylinders 2R and 3R exhaust port manifold connections. (2) Special precautions must be taken to ensure that all tube connections to a given injection pump port, terminates at the proper cylinder (figure 4-86). Current replacement fuel injector tubes have identification tags at each end to assure proper injection pump port connection and cylinder nozzle connection. Incorrect hook up of the injector tubes to a wrong cylinder or injection pump connection would result in damage to the piston rings and cylinder walls and severe damage to the engine if operated under full load. (3) Check the alignment of each tube with its mating fitting. It may be necessary to bend

(5) NEVER OVER TIGHTEN when attempting to remedy a fuel leak. Overtightening will deform the sleeve and eventually lead to tube failure. It is permissible to loosen the nut, or fitting, and re-tighten. This procedure will, in many cases, seal the fuel leak. The loosening and tightening operation tends to re-seat the sleeve, thus providing an effective seal. Replace fittings and / or tubes rather than overtighten to stop leaks. (6) The proper installation and positioning of the tube clamps is essential to ensure tube lift. Install all stationary clamps as shown in figure 731. The floating clamps, i.e., the four clamps located nearest the pump head, must be positioned as specified to ensure maximum vibration dampening. The two floating clamps on the right bank each support three tubes. Similar clamps on the left bank support only two tubes, i.e., tube Nos. 1 and 2, and 5 and 6.

7-24

Figure

7-31.

Fuel

injector

clamps,

supports,

and

tubes-installed

view.

e. Fuel Injector Nozzle Fuel Return Tubes. Refer to figures 5-63 through 5-61. Note. Install rigid fuel drain tubes only if they are in a like new condition, otherwise install current flexible rubber hose as shown in figure 731. The drain tube on hose between cylinder numbers 6L and 5L (fig. 7-32 or 7-33) will be noticeably longer than the other drain tubes or hoses due to the position of the fuel injector nozzle and holder assembly drain connector.

F i g u r e 7-32. Fuel injector nozzle fuel return tube between cylinder numbers 6L 7-25 and 5L-engines with tubes.

F i g u r e 7-33. Fuel

injector 6L

nozzle and

fuel

return

hose

between

cylinder

numbers 7-14. Oil Filler and Indicator

5L-engines and

with Front

hoses. Shrouds, Throttle Linkage,

Tubes,

Rear

and Fuel Filters Refer to Table 7-10 for illustrations and assembly instructions. Table 7-10. Oil Filler and Indicator Tubes, Rear and Front Shrouds, Throttle Linkage, and Fuel Filters
Component References

Cylinder Head Plates, Oil Filler Tube, and Oil Level Indicator Tube Rear Shroud Front Shroud Throttle Linkage, F u e l D r a i n T u b e s , F u e l / W a t e r Separator, Secondary Fuel Filter, and Primary Fuel Filter

Para 7-14a, Figs. 5-60 through 5-51 Para 7-14b, Figs. 5-50 through 5-48 Para 7-14c, Figs, 5-47 through 5-42 Para 7-14d, Figs. 5-41 through 5-39, 4-84, 4-85, 5-38 through 5-34

7-26

a. Cylinder Head Plates, Oil Filler Tube, and Oil Level Indicator Tube. Refer to figures 5-60 through 5-51. Rear Shrouds. Refer to figures 5-50 b. through 5-48.

c. Front Shrouds. Refer to figures 5-47 through 5-42. d. Throttle Linkage, F u e l D r a i n T u b e s , Fuel / Water Separator, Secondary Fuel Filter, and Primary Fuel Filter. Refer to figures 5-41 through 5-39, 4-84, 4-85, 5-38 through 5-34.

7-15.

Intake Manifold Assemblies, Cylinder Head Oil Drain Lines, and Manifold Heater Tubes, Solenoids, and Filter

Refer to Table 7-11 for illustrations and assembly instructions. References are listed in the table,
Table 7-11. Intake Manifold Assemblies, Cylinder Head Oil Drain Lines, and Manifold Heater Tubes, Solenoids, and Filter
Component References

Intake Manifold, Manifold Heater, and Turbosupercharger Air Outlet Elbow Cylinder Head Oil Drain Tubes Manifold Heater Tubes, Hoses, Fuel Check Valve, Fuel Filter, Filter Bracket, and Solenoid Valves

Para 7-15a, Fig. 5-33 Para 7-15b, Figs. 5-32 through 5-28 Para 7-15c, Figs. 5-27 through 5-23

a. Intake Manifold, Manifold Heater, and T u r b o s u p e r c h a r g e r . Refer to figure 5-28 and (1) and (2), below. (1) After tubes for cylinder Nos. 3R and 4R are secured, tighten tube flange nuts at cylinder Nos. lR, 2R, 5R, and 6R at intake manifold. (2) Cover turbosupercharger air outlet

elbow opening to prevent entrance of foreign objects. b. Cylinder Head Oil Drain Tubes. Refer to figures 5-32 through 5-28. c. M a n i f o l d H e a t e r T u b e s , H o s e s , F u e l C h e c k Valve, Fuel Filter, Filter Bracket and Solenoid Valves. Refer to figures 5-27 through 5-23.

7-16. Oil Coolers, Beams, Cooling Fans, Shrouding, and Associated Parts
Refer to Table 7-12 for illustrations and assembly instructions. References are listed in the table.
Table 7-12. Oil Coolers, Beams, Cooling Fans, Shrouding and Associated Parts
Component References

Turbosupercharger Oil Inlet Hoee and Transmission Shrouds Oil Coolers, Support Beams, Upper Cover Frame, and Frame Support Bracket Cooling Fan Shroud and Upper Covers Cooling Fan Vanes and Cooling Fane

Para 7-16a, Fig. 5-22 Para 7-16b, Figs. 5-21 through 5-7 Para 7-16c, Figs. 4-141 through 4-136, 5-9 through 5-7, 4132 through 4-128 Para 7-16d, Fige. 4-35, 4-34, 4-88

a. Turbosupercharger Oil Inlet Hose and Transmission Shrouds. Refer to figure 5-22. b. Oil Coolers, Support Beams, Upper Cover Frame, and Frame Support Bracket. Refer to figures 5-21 through 5-7 and figure 7-34.

c. Cooling Fan Shroud and Upper Covers. Refer to figures 4-141 through 4-136, figures 5-9 through 5-7, and figures 4-132 through 4-128.

7-27

Figure 7-34. Overall view of engine showing progress of engine assembly at this point. d. Cooling Fan Vanes and Cooling Fans. Refer to figures 4-35, 4-34, and 4-88.

7-17.

Engine Accessories

Refer to Table 7-13 for illustrations and assembly instructions. References are listed in the table.
Table 7-13. Installing Engine Accessories Component Fuel Pump Turbosupercharger and Lower Shroud Plates Starter Time Totalizing Meter Generator Para Para Para Para Para 7-17a, 7-17b, 7-17c, 7-17d, 7-17e, Figs. Figs. Figs. Figs. Figs. References 4-3 through 4-1 4-33 through 4-18 4-8, 4-7, 5-1, 4-9, 4-4 5-5, 5-4, 4-10 7-31, 4-17 through 4-13, 4-11

a. Fuel Pump. Refer to figures 4-3 through 41. b. Turbosupercharger and Lower Shroud Plates. Refer to figures 4-33 through 4-18. c. Starter. Refer to figures 4-8, 4-7, 5-1, 4-9, and 4-4 and (1) through (3), below. (1) Install starter while engine is still mounted on overhaul stand (figs. 4-8 and 4-7). (2) Install multiple leg sling - 4910-9192884 (fig. 5-1) on suitable chain hoist. Install
7-28

hooks of sling in engine lifting eyes and take up the slack. Remove four bolts and flat washers securing engine to overhaul stand bracket. Lift engine and move overhaul stand. Lower engine on suitable blocks or moveable dolly maintaining lifting sling hook-up as a precaution against engine tipping during remaining assembly operations. (3) Install starter cradle and support on engine (fig. 4-9 and 4-4).

d. Time Totalizing Meter. Refer to figures 55 , 5-4, and 4-10. Note. After installing time totalizing meter on engine, the engine name plate must be stamped with an X after the engine serial number. This will show engine has a time totalizing meter installed. The time totalizing meter must be set back to zero (para 6-70b) before being installed. e . G e n e r a t o r a n d A s s o c i a t e d P a r t s . Refer to figures 7-35, 4-17 through 4-13, and figure 4-11.

1. Position cradle (A) on generator support, 2. Install two self-locking nuts (B) and flat washers but do not tighten. 3. Install clamping bar (C) on U bolt. 4. Install self-locking nut (D). Tighten nut until approximately ~8 -inch of bolt is exposed through the nut. This is the approximate position of nut after U bolt has been positioned over the generator, prior to installing the outside bar and nut.

N o t e . The preformed packing (fig. 4-12) is a generator part and must be in place before installing generator air intake tube. Figure 7-35. Assembling generator cradle, support, and U bolt. f. Test and Adjustments. After the egine has been completely assembled it s h o u l d b e t e s t e d and the necessary adjustments made as directed in Chapter 8 of this manual.

7-29

CHAPTER 8 ENGINE TEST AND ENGINE CONTAINER

Section I. ENGINE TEST AND ADJUSTMENTS 8-1. Engine Specifications

a. Speed Range. The engine must operate satisfactorily under all loads through a speed range of 1400 to 2400 rpm and must idle satisfactorily at 675 to 725 rpm. b. Gross Horsepower (Without Accessories). Under full throttle setting, engine will develop 750, plug or minus 15, gross horsepower at 2400 rpm, using fuel conforming to specification VV F-800 (DF-2) and the correction factors provided in tables 8-2 through 8-5. c. Gross Torque (Without Accessories). Under full throttle setting, engine will develop the following gross torque using fuel conforming to Specification VV-F-800, DF-2. (1) 1720 lbs/ft. - plus or minus 2.0% @ 1800 rpm. (2) 1635 lbs/ft. - plus or minus 2.0% @ 2400 rpm. d. Oil Consumption. Engine shall not consume more than 0.0075 pounds per brake horsepower hour (lbs / bhp / hr) of lubricating oil when operating under full load and using engine oil conforming to Military Specification MIL-L-45199 Grade 2 (SAE 30). e. F u e l C o n s u m p t i o n ( W i t h o u t A c c e s s o r i e s ) . When operating at full throttle under full load, on a dynamometer, at a speed of 2400 rpm, engine shall consume not more than 0.420 pounds per brake horsepower hour (lbs / bhp / hr) fuel conforming to Specification VV-F-800 (DF-2). f. Exhaust Gas Temperature. E x h a u s t g a s temperatures, measured at individual cylinder ports, shall not exceed 1250 F. Temperature variation between cylinders shall not exceed 150F. g . B l o w - b y P r e s s u r e . With engine under full throttle and full load, blow-by shall not exceed 18 cfm. h. Lubricating Oil Temperature. Temperature of oil in the engine pan sump shall not exceed 230 F. Temperature of oil entering the engine through the oil pump shall be maintained between 160F and 22F. i. Oil Pressure. (1) Engine oil pressure shall not be more than 70 psi or less than 40 psi when engine is operating at 2400 rpm, and shall not be less than 15 psi when engine is idling at 675 to 725 rpm, measured at and / or adjacent to the oil pressure sending unit, with the oil temperature of 160F to 180F, using engine oil specified in paragraph d, above. (2) Piston oiler nozzle oil pressure shall be 35 psi minimum at 2400 rpm measured at plug on left side of crankcase, at rear, above starter. j. Temperatures. T h e p r e f e r r e d i n d u c t i o n a i r inlet temperature is 85F plus or minus 10 F. k. Fuel Pressure. The fuel pressure at the injection pump inlet shall be 30-40 psi at engine speeds of 1800 to 2400 rpm. Manifold Pressure. l. Intake manifold pressure rise above atmospheric after the turbosupercharger with boost, shall not exceed 35 inches Hg.; without boost 28 to 32 inches Hg. Variation between left and right banks shall not exceed 4 inches Hg. m. Exhaust Smoke Density Test. The maximum exhaust smoke density at full power position, when measured within one foot of the exhaust outlet, shall not exceed the following conditions when using fuel in accordance with grade DF-2 of Specification VV-F-800.

8-1

Speed

RPM Engine 1800 2000 2200 2400

No. 3 3 2 1

Visual Light Gray Light Gray Haze Clear

Robert Bosch Meter No. 3.5 3.2 2.6 2.4

Note. T h e m e t e r readings shall precedence over the visual reading.

have

8-2.

Crankcase and Induction System Leakage Test

a. General. The engine crankcase and induction systems should be pressure tested to determine whether or not all connections are water-tight and airtight. The complete assembled engine is air-pressure tested for leaks. Leaks that are present will be indicated by the presence of air bubbles when using a soap solution on the joints as outlined below. Seal all openings as b. Seal Openings. directed in (1) through (3), below. (1) Seal exhaust outlet openings on left and right turbosuperchargers (fig. 8-2). (2) Seal air inlet openings in left and right turbosuperchargers (fig. 8-1). (3) Seal oil filler and indicator tube caps (fig. 1-2 or 1-7). c. Remove Engine Cooling Fans. R e m o v e engine cooling vanes and cooling fans (fig. 4-34 and 4-35). The fans are removed in order to gain access to several of the points of application of the soap solution (f, below). d. Install Sleeve Spacer. Install two fan rotor hub sleeve spacers - 4 9 1 0 - 7 9 5 - 7 9 5 2 , t o p r e v e n t oil seepage (fig. 4-87 ). e. A p p l y A i r P r e s s u r e . I n s t a l l a t e e - t y p e connection in crankcase breather tube (fig. 1-7). Connect manometer and air hose connection in tee. Apply air pressure and regulate air pressure to indicate ten inches of mercury (in. Hg.) on manometer. f. Apply Soap Solution. A p p l y s o a p s o l u t i o n to all locations listed in (1) through (10), below. (1) Air indication system and intake manifolds. (2) Exhaust system. (3) Pipe plugs in crankcase, oil pan, intake manifold, exhaust manifold and crankcase damper and oil filter housing. (4) All ventilation and vacuum line fittings. This shall include all hose connections.

(5) Oil level indicator tube flange. (6) Oil filler tube flange. (7) Intercylinder preformed hoses. (8) Injector nozzle and holder (at rocker arm cover). (9) Cylinder head oil drain system. (10) Fan drive housings. g. Minor Pressure Leakage. Minor leaks should be repaired (h, below) during this test procedure and rechecked. However, some minor leaks are acceptable providing the engine passes the final acceptance test outlined below. Mark any area where leaks are evident so that the leak may be repaired. (1) Reduce air pressure to zero. (2) Remove seal (tape) from oil filler and indicator tube caps and close caps securely. (3) Pressurize system six inches of mercury (in. Hg.). (4) Test pressure loss after a five-minute (exposure) time interval must not exceed 3-1 / 2 inches mercury (in. Hg.). h. Repair of Minor Pressure Leakage. Examine marked areas (g, above) for loose hose clamps, loose attaching parts at mounting flanges, defective gaskets, or defective hoses, whichever may exist. Repair leak by replacing defective hoses or gaskets or by tightening loose hose clamps or loose mounting flange attaching parts. i. Remove Sleeve Spacer. R e m o v e t w o f a n rotor hub sleeve spacers - 4910-795-7952 (fig. 487). j. Installation of Cooling Fans. I n s t a l l e n g i n e cooling fans (fig. 4-35). k. Check Cooling Fan Clearance. C h e c k f a n blade clearance following instructions which accompany figure 4-88. l. Install Cooling Fan Vanes. Install cooling fan vanes (fig. 4-34).

8-3. Fuel and Oil System Leakage Test

a . G e n e r a l . This test is made to determine if an oil or fuel leak exists within the engine V prior to and in conjunction with engine run-in

8-2

(para 8-4) and cannot be found through visual inspection. Perform test as directed in b through d, below. b. Remove Cooling Fan Vanes and Cooling F a n s . Remove cooling fan vanes and cooling fans (figs. 4-34 and 4-35). c. Install Sleeve Spacers. Install two fan rotor hub sleeve spacers - 4910-795-7952 (fig. 4-87). d. Test for oil and Fuel Leakage. (1) Start engine and check for oil and fuel leaks at hoses, tubes, and all connections inside engine V and around engine. Tighten hose connections or replace leaking hoses, elbows, tee, and nipples as necessary to correct oil or fuel leaks. Note. Slide fuel injection tube, dust caps (C, fig. 4-87) away from tube connections at fuel injection pump to check for fuel leaks. Note. DO NOT run engine above idle speed, and DO NOT apply load to engine. (2) Refer to troubleshooting (paras 3-1 through causes and probable 3-11) for corrections for other possible leakage points around engine. (3) When all points for oil and fuel leaks have been inspected and / or corrected, remove fan rotor hub sleeve spacers - 4910-795-7952 (fig. 4-87). e. Install Cooling Fans. Install engine cooling fans (fig. 4-35). f. Check Cooling Fan Blade Clearance. Check fan blade clearance following instructions accompanying figure 4-88. g. Install Cooling Fan Vanes. Install cooling fan vanes (fig. 4-34).

(4) Remove pipe plug from secondary fuel filter or pipe plug from fuel/ water separator (fig. 8-1). (5) Remove pipe plug (B, fig. 6-6) and attach piston oil sprayer pressure gage or connection. (6) Install oil fitting in oil pan. (7) Remove main oil gallery pipe plug (fig. 8-1) and install main oil gallery thermocouple. (8) Install main oil gallery pressure connector or attach to oil pressure sending unit (fig. 8-1). (9) Attach oil inlet and outlet lines to crankshaft damper housing if external oil circulating system is to be used. If engine is not to be run on a circulating oil system, lubricate engine by forcing engine oil under pressure into the lubrication system to assure adequate lubrication of engine parts until the engine oil pump has time to circulate oil. Fill engine oil pan with proper grade oil to fill mark on oil level gage. (10) Attach fuel inlet line to primary fuel filter (fig. 8-1). (11) Attach fuel return line, flywheel end (fig. 8-2). (12) Attach turbosupercharger induction air inlet (fig. 8-1) and exhaust outlet tubes (fig. 8-2). Connect same type air cleaners that are used with engine installed in vehicle. (Refer to applicable Vehicle Technical Manual.) Air intake should be located so that only cool, fresh air will be inducated into engine. A means must be provided for conducting exhaust gases and cooling air from engine to avoid recirculation through engine cooling fans. (13) Install thermocouple in intake manifold elbow, both banks (fig. 8-1). (14) Install manifold pressure gages or connections in intake manifold elbows (fig. 8-1), both banks, set manometers to current wet barometer reading. (15) Attach fuel shutoff connection, damper end, and ascertain to be operative (fig. 8-1). (16) Turn on oil circulating pump and fuel supply purge pump. (a) When fuel flows from secondary fuel filter or fuel / water separator pipe plug hole, air has been removed from fuel system. Attach fuel pressure gage or connection at pipe plug hole. (b) Oil circulation is checked by loosening the externally-relieved body bolt (fig. 8-1) on No.

8-4.

Engine Run-in

a. General. This paragraph describes run-in schedules for overhauled engines prior to being placed in service. Engine run-in is performed after overhaul to assist in breaking-in new parts, to detect faulty assembly. to check for oil leaks, and to determine whether an engine will operate satisfactorily when installed in vehicle. b. Preparation for Run-in. (1) Couple engine to suitable load. The load may be a water brake or electric dynamometer. (2) Remove engine right and left rear upper covers (figs. 4-127 and 4-141). Remove pipe plugs from each bank and attach thermocouples to exhaust manifolds. Reinstall upper covers. (3) Attach C0 2 fire extinguisher (fig. 8-1).

8-3

1 cylinder on both banks, when oil flows tighten bolts. (17) Install starter cables (fig. 1-2). (18) Wash all fuel and oil from engine. (19) Check all thermocouple connections. If connected c o r r e c t l y , should read ambient temperature; if connected incorrectly, scale reading will go to top of scale. (20) Start engine at IDLE speed (para c, below). (21) Check engine main oil pressure (para 81i, (1) and (2)).

(22) Piston oiler nozzle pressure should be readable. Note. Pressure will not reach the desired operating level until the engine speed has been increased (para 8-1i. (2)). (23) Exhaust manifold temperatures should register (para 8-1f). (24) Visually inspect engine for fuel and oil leaks. (25) Ready for engine test schedule (table 81).

Figure 8-1. Engine connection pointsright front view.

8 - 4

Figure 8-2. Engine connection points - left rear view. c. Starting Procedures. D u r i n g c o l d w e a t h e r , when ambient temperature is below 30 degrees F, use engine manifold flame heaters to start engine. Note. Do not attempt an engine start until the fuel shutoff solenoid is connected and ascertained to be operative. C a u t i o n : Do not operate the starter motor continuously for more than one minute. Allow a two-minute cool-off period before re-energizing the starter. (1) Remove pipe plug (F, fig. 6 245 or 8-1), purge system and bleed the secondary fuel filter or water separator filter to remove trapped air. Install pipe plug. (2) Crank the engine several revolutions with the fuel shutoff switch in the OFF position to make certain the engine is not hydrostatically locked and is otherwise free. (3) Turn on the master switch. (4) Start engine by operating electric starting motor with throttle in idle position (Refer to Caution, above.) (5) When engine oil pressure does not reach the minimum 15 psi pressure within 20 seconds, STOP THE ENGINE IMMEDIATELY b y holding the fuel shutoff switch in the OFF position. Determine the cause of low pressure. Refer to troubleshooting, paragraph 3-9. Note. After starting engine, run at idle, 675 to 725 rpm, for five minutes to permit the engine to warm up and to circulate the oil. Check oil level and add sufficient oil to bring oil level to FULL mark on oil level gage. Oil level must be determined with engine idling. Check all items vital to safe engine operation, such as fuel lines, oil lines, oil pressure, throttle control, mounting bolts, coupling, thermocouple harness, etc. d. Run-in Schedule. A n o v e r h a u l e d e n g i n e should be started and tested in accordance with the schedule (table 8-1). e . P e r f o r m a n c e C u r v e . Figure 8-3 is a mean 2 is performance curve. A variation of acceptable.

8-5

Note. Do not add more than three shims, When oil pressure still does not fall within limits specified, replace faulty valve. b . F u e l P r e s s u r e . Install a pressure gage in place of the pipe plug (fig. 8-1) in the top, center of the secondary fuel filter and / or water separator to check fuel pressure. Fuel pressure should be adjusted to 40 psi by turning adjusting screw of the fuel pump (fig. 8-1). Turn screw clockwise t o i n c r e a s e p r e s s u r e a n d c o u n terclockwise to decrease pressure. Refer to TM 9-2910-213-34 for further information on the fuel pump. c. Idle Speed. A d j u s t f o r s m o o t h i d l e a t 6 7 5 to 725 rpm by turning idle adjusting screw (D, fig. 4-85). Turn screw clockwise to increase idle speed and counterclockwise to decrease idle speed. d. Throttle Control Linkage. N o r m a l p i n travel on the vehicle control lever is approximately 3 / 16 inch from the stop at both the idle position and the full throttle position. W hen the pin travel is more or less than 3 / 16 inch without spring movement, adjust rod to bring within limits specified (fig. 4-85). Manifold Heater. Pump fuel into the e. engine using a purge pump and press heater button. If heater is operative, heat will be felt at intake manifold turbosupercharger tube (feel intake manifold turbosupercharger tube with hand). When no heat is felt, check harness and heater spark plug for faulty connections. Inspect purge pump and heater nozzle for proper operation. Repair faulty connections or replace purge pump or heater nozzles. f. Oil Consumption Check. (1) Inspect engine for oil leaks. (2) Operate engine until normal operating temperature is reached (180F). (3) Idle engine for five minutes to allow oil level to stabilize. Check oil level with engine idling, When necessary, add oil to bring level in oil pan to full level, as indicated on level gage. (Refer to applicable Lubrication Order.) (4) Operate engine for 1-1 / 2 hours at 2400 rpm and maximum horsepower. (5) Idle engine for five minutes to allow oil level to stabilize. (6) Check oil level, with engine idling, using oil level gage.

Figure 8-3. Mean performance curve. f. Acceptance Test. Repair all fuel and oil leaks at start of test. Check again before engine is removed from stand. At completion of test run, check acceleration, idle, idle oil pressure, and operation of governor. Acceleration should be c h e c k e d with throttle a m o d e r a t e steady movement. If engine power is outside limits, check for cause and make correction. Gross corrected horsepower shall be maintained between 735 and 765 horsepower. The governor shall be adjusted to limit the engine speeds as follows: (1) Low idle - 675 to 725 rpm. (no load) 2640 rpm ( 2 ) H i g h idle maximum. Overhaul/ MWO Engine Data Plate. g. overhauled, After engine is install overhaul/ MWO data plate o n engine as outlined in TB ORD-1030. h . E n g i n e S t o r a g e . After engine has successfully completed the acceptance test the engine is to be stored or shipped in accordance with instructions provided in section II of this Chapter.

8-5.

Engine Test and Adjustments

a. Oil Pressure. Oil pressures shall be measured in accordance with paragraph 8-1i, (1) and (2). The oil pressure regulator valve (D, fig. 6-104) is adjustable, within limits, by the addition or removal of washer-type shims (A) between relief valve cover and spring. Add shims to increase pressure and remove shims to reduce pressure. When oil pressure cannot be adjusted to within the 40-70 psi range, in this manner. replace valve spring (C).

8-6

(7) Add oil as required to bring oil in oil pan to full level as indicated on oil level gage, carefully measuring amount added. (8) Maximum allowable oil consumption at 2400 rpm, with SAE 30 oil, is 0.0075 pounds per brake horsepower hour (lbs / bhp / hr). g. Checking Exhaust Gas Temperature. P i p e plugs (4, fig. B-12) are provided in exhaust manifold elbows for installation of thermocouples to measure exhaust gas temperatures (para 8-1f). Variations of temperatures between cylinders should not exceed 150F. Check fuel injector nozzles of cylinders that exceed this variation.

h. Lubricating Oil Pressure Outlets. Lubricating oil pressure outlets are provided in the main and piston oiler nozzle gallery lines for installation of pressure sensing gages to measure the engines oil pressures (para 8-1i, (1) and (2)). i. Induction Air Temperature. An outlet is provided in the bottom of the intake manifold, on each side of the engine, for installation of thermocouples to measure induction air temperature (para 8-1j). j. Manifold Pressure. An outlet is provided in the intake manifold elbows, on each side of the engine, for installation of a manometer gage and / or connection (para 8-11).

Table 8-1. Overhaul Test Schedule-Beam Length...1.75 Ft. (or 21.008 in.) Run No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Time Min. RPM Scale limits Obs. BHP Torque Lh-Ft.

10 Warm-up 700 16.0 84 15 1000 16.0 438 15 83.5 116.9 1400 20 1800 159.5 287.1 837 429.0 1024 20 2200 195.0 20 208.0 499.2 1092 2400 549.6 1202 30 2400 229.0 F.R. - F.L. F.R. - F.L. 2400 F.R. - F.L. 30 Check for low idle at 675 to 725 rpm. Adjust if necessary. Check oil filter and inspect for oil and fuel leaks. 5 2200 F.R. - F.L. 5 F.R. - F.L. 2000 1800 F.R. - F.L. 5 Check governor high idle speed. This shall not exceed 2640 rpm, (No-Load, water off). If adjustment is required, recheck horsepower at 2400 full load.

16

Borescope cylinders (para 8-6), check for fuel and oil leaks, prepare engine for removal from stand.

Note. Run numbers 1 through 8, and 11 through 14, shall equal three hours. Sequence of operations may be varied.

8-6. Inspection of Cylinders for Scuffing

a. G e n e r a l . (1) As used in this publication, cylinder wall scuffing is defined as a streak or streaks, running the length of the piston ring travel, on the cylinder wall, which are greater than 1 / 4 inch wide and which reveal a high gloss or polish where the cylinder wall honing pattern has been completely worn away. (2) Scuffing is caused by excessive localized heat on the contact face of the piston ring and cylinder bore. The excessive heat is due to a breakdown of the oil lubricating film and is the

result of one or more conditions such as; abrasives in the oil or induction air, lack of or improper honing, defective piston ring, etc. The heat and pressures involved during the scuffing process will flow or smear the cylinder wall metal and destroy the honing pattern. The process in general generates additional heat due to friction and in many cases the scuffing will progress or the width of the afflicted area will grow and may envelope the entire cylinder bore. Scuffing is detrimental to the engine, since oil consumption and blow-by gases can no longer be controlled. b. Borescope Inspection. (1) After completion of dynamometer inspection, all overhauled engines s h a l l h a v e cylinders inspected by borescope as follows:

8-7

(a) F i r s t p r o d u c t i o n i n s p e c t i o n . T h e f i r s t ten engines when completed, and after successful performance of the overhaul engine test schedule, shall have all cylinders, of each engine, inspected by borescope. If no evidence of scuffing is detected, the sampling inspection method may be applied. (b) S a m p l i n g i n s p e c t i o n . U n d e r t h i s method, after successful performance of the overhaul engine test schedule, sample engines shall be selected for borescope inspection at the rate of one in every 25 engines or one per month when monthly production is less than 25. If scuffing of cylinder walls is detected, the five engines produced preceding the sample engine and the five engines produced after the sample engine will have all cylinders borescoped. Should there be evidence of scuffing as a result of this inspection, the inspector shall refuse acceptance of these engines and subsequent production engines, until required corrections have been made and evidence to this effect has been presented to inspector. (2) Refer to figures 4-126 through 4-141 to remove upper cover shroud plates. Remove as many fuel injection pump fuel tube support clamps as are accessible with the cover plates removed. Disconnect fuel injector fuel return hoses or tubes and fuel injection pump fuel tubes from injector nozzles (fig. 4-150) using extreme caution not to bend or kink the fuel tubes. (3) Loosen the fuel injector nozzles using open end fixed wrench - 5120-871-7198 (fig. 4152). Remove fuel injector nozzle and holder assemblies from the 12 cylinder heads (fig. 4153). To facilitate removal of No. 6L nozzle and holder assembly, remove the connector from the nozzle head. This will allow the necessary clearance with the shrouding to remove the nozzle and holder. (4) The relative position of the piston for borescoping the cylinders is in the down position

or at the lowest most point of the downward stroke. This enables the inspection of the longest portion of cylinder bore affected by piston travel. To achieve this, the flywheel must be rotated using splined wrench - 5120-793-7895 (fig. 451) allowing two pistons on each bank of cylinders to be in the down position and enabling the complete inspection of an engine with only three turns of the flywheel. The combinations of cylinders that can be inspected at one time are as follows: (a) Nos. 2 and 5 right bank, - 3 and 4 left bank, (b) Nos. 3 and 4 right bank, - 1 and 6 left bank, (c) Nos. 1 and 6 right bank and 2 and 5 left bank. To determine when the pistons to be checked are at the lowest point of the downward stroke, use a brass rod as a gage and insert it through the fuel injector nozzle opening in the cylinder head (fig. 8-5). When piston stroke is in the maximum down position, mark the gage rod at the point where the rod protrudes from the cylinder head nozzle opening. This will facilitate the proper positioning of the following cylinders to be checked. Note. Do not use borescope as a probe or gage in determining position of the piston in the cylinders. The instrument can easily be damaged when engine flywheel is rotated to position pistons for borescoping. (5) During inspection of the cylinders, it is recommended that a record be made of each cylinder checked and the position o f a n y discrepancies noted. Relative position of a cylinder defect can be determined as though reading a clock with the top of the cylinder in the 12:00 position. A wear pattern beginning at the top of the cylinder and extending on a 30 degree angle clockwise , would be recorded as a wear pattern extending from the 12:00 to 1:00 position.

8-8

Figure 8-6. Borescope instrument in position for cylinder bore inspection. (6) Connect borescope control transformer (fig. 8-4) in 110 volt electrical circuit and insert borescope into cylinder (fig. 8-6), Visually adjust light intensity and mirror angle until a sharp clean image of the cylinder bore is apparent. Inspection of the cylinder bore should be made at three levels, lower, middle, and upper position of the cylinder to assure maximum coverage of the cylinder wall surface. Polish marks the length of the piston pin travel may be evident on the cylinder side walls on a line parallel with the cylinders. These lines normally are not serious and are caused by the movement of the piston pin allowing the pin end plugs to come in contact with the cylinder walls. Other wear lines, surface scratches, and wear patches that are not continuous the full length of the cylinder bore are usually not significant. (7) A normal shiny area will often appear at midbore and usually on the anti-thrust side of the bore (below exhaust valve on left bank and below intake valve on right bank). This shiny area will not extend the full length of ring travel and should not be confused with scuffing of the cylinder wall. (8) Cylinder bores that show evidence of in. or more scuff marks, must be replaced. Rehone cylinders and thoroughly inspect (para 631 and 6-32), dimensionally check and clean thoroughly before reinstalling cylinders on engine. R e p l a c e m e n t c y l i n d e r s w i l l r e q u i r e

Figure 8-4.

Figure 8-5. Checking piston position with brass rod.

8-9

complete re-test and borescoping after test. Always install new piston rings in cylinders that have been re-honed. Pistons must be thoroughly inspected (para 6-25) and cleaned thoroughly before assembly. (9) Install fuel injector nozzle and holder assembly (fig. 4-165), connect fuel injector fuel

return hoses or tubes and fuel injection pump fuel tubes to injector nozzles (fig. 4-150) and install upper shroud plates (fig. 4-141 through 4126). (10) Operate engine at normal temperature and inspect engine for leaks.

Table 8-2. Air Entrance Temperature Correction Temp 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 F Corr +.00000 +.00055 +.00110 +.00165 +.00220 +.00275 +.00330 + .00385 + .00440 +.00495 +.00550 + .00605 + .00660 +.00715 +.00770 +.00825 +.00880 +.00935 + .00990 +.01045 +.01100 +.01155 Temp 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 F Corr +.01210 +.01265 +.01320 +.01375 +.01430 +.01485 +.01540 +.01595 +.01650 +.01705 +.01760 +.01815 +.01870 +.01925 +.01980 +.02035 +.02090 +.02145 +.02200 +.02255 +.02310 +.02365 Temp 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 F Corr +.02420 +.02475 +.02530 +.02585 +.02640 +.02695 +.02750 +.08205 +.02860 +.02915 +.02970 +.03025 +.03080 +.03135 +.03190 +.03245 +.03300 +.03355 +.03410 +.03465 +.03520 +.03575

Table 8-3. Air Entrance Pressure Correction In. HB-Abs 29.92 29.90 29.85 29.80 29.75 29.70 29.65 29.60 29.55 29,50 29.45 29.40 29.35 Corr .0000 +.0003 +.0009 +.0015 +.0021 +.0027 +.0032 +.0038 +.0044 +.0050 +.0056 +.0062 +.0067 In. HG-Abs 29.30 29.25 29.20 29.15 29.10 29.05 29.00 28.95 28.90 28.85 28.80 28.75 28.70 28.65 Corr +.0073 +.0079 +.0085 +.0091 +.0097 +.0102 +.0108 +.0114 +.0120 +.0126 +.0132 +.0137 +.0143 +.0149 In. HG-Abs 28.60 28.55 28.50 28.45 28.40 28.35 28.30 28.25 28.20 28.15 28.10 28.05 28.00 Corr +.0155 +.0161 +.0167 +.0173 +.0178 +.0184 +.0190 +.0196 +.0202 +.0207 +.0213 +.0219 +.0225

8-10

Table 8-4. Fuel Temperature Correction Temp. F 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 Corr .000 +.001 +.002 +.003 + .004 + .005 + .006 +.007 + .008 +.009 +.010 +.011 +.012 +.013 +.014 +.015 +.016 +.017 +.018 +.019 Fuel Flow No. / Hr. Max. 313.0 312.7 312.4 312.1 311.8 311.5 311.2 310.9 310.6 310.3 310.0 309.7 309.4 309.1 308.8 308.5 308.2 307.9 307.6 307.3 Temp. F 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2. Corrected Corr +.020 +.021 +.022 + .023 +.024 + .025 +.025 +.027 +.028 +.029 +.030 +.031 +.032 +.033 +.034 +.035 +.036 +.037 +.038 + .039 net BHP Fuel Flow No. / Hr. Max. 307.0 306.7 306.4 306.1 305.8 305.5 305,2 304.9 304.6 304.3 304.0 303.7 303.4 303.1 302.8 302.5 302.2 301.9 301,6 301.3 -Observed BHP x) 1

Table 8-5. Fan Horsepower to be Used for Correcting Engine Gross Horsepower Engine Speed (rpm) 2520 2400 2200 2000 1800 1600 1400 1200 1000 900 FORMULAE AVDS-1790-2A 125.0 108.0 83.5 62.5 45.6 32.0 21.5 13.5 7.2 5.7

+ air temp. correction + Induction air pressure correction + fuel temperature correction) 3. Gross horsepower = c o r r e c t e d n e t B H P + fan horsepower. 4. Correction factor references a. Induction air temperature correction factor - Table 8-2 b. Induction air pressure correction factor - Table 8-3 c. Fuel temperature correction factor and maximum fuel flow - Table 8-4 5. Specific fuel consumption = Fuel flow lb/ hr. Corrected gross BH P 6. Specific Oil oil consumption lb/ =

Consumption

hr.

Corrected gross BHP = N T L W Z = 3 . 1 4 1 6 RPM of Dynamometer shaft SAMPLE 7. Fuel Air Ratio = Fuel lb/ hr. Air lb/ hr.

= Torque in lb. ft = LWZ = Length of torque arm in feet = Weight of scale reading (lbs) (Beam reading) = Scale reading factor (ratio to actual weight, in units)

CALCULATIONS: = = = = 2400 1339 255 29.64

Example: r p m torque beam wet barometer

If length of torque arm is 21.00 inches or 1.75 feet, and scale reading factor is 3, then OBHP = W N 1000

1. Dry barometer = 29.35 2. Average entrance pressure in inches of water = 0 8-11

3. Average entrance temperature = 88 F 4. Fuel temperature = 70 F 5. Torque arm = 1.75 feet Correction Factors: 1. Dry entrance pressure (1) in inches Hg Absolute 29.35-0 (2) = 29.35 = Correction = .0067 2. Average entrance temperature 88 F (3) Correction = .0154 3. Fuel temperature (4) - Correction = .010 4. Total correction - .0067 + .0154 + .010 = 1.0321 SAMPLE CALCULATIONS:

bhp Observed

defects and subjected to the tests outlined in the technical manual. (2) F i f t y - h o u r q u a l i t y c o n t r o l t e s t s c h e d u l e . Each engine selected in accordance with sub paragraph (1), above, shall be operated, as specified in table 8-6, for 50 hours as nearly continuously as possible (a) Starting with run No. 3, an oil consumption reading shall be taken each one-half () hour when operating at 2400 rpm full load. (b) A blow-by check shall be made at 2400 rpm full load prior to runs No.'s. 3-11-1519 and 22. Normal reading will be 11 to 15 cubic feet per minute (CFM). Maximum permissible blow-by is 18 cfm. The blow-by can be measured with a volumeter or gas meter between the crankcase breather tube and exhaust pipe. (c) Approximately 100 amps load shall be applied to the generator during the complete test. (d) Readings shall be taken every one-half () hour and will include all data taken on the regular test. (3) Corrections. Engine subjected to this test shall be completely disassembled and all interchangeable parts subjected to wear or stress shall be inspected. A complete report including the inspection and testing of the engine shall be submitted to the Government inspector. Should there be evidence of failure of parts requiring correction as a result of this test, the inspector shall refuse acceptance of subsequent production engines until such corrections have been made a n d objective e v i d e n c e p r e s e n t e d t o t h e Government inspector. Engines subjected to this test shall be reassembled with new parts replacing those found unsatisfactory during examination. (4) Disposition of engines. After correction of all defects disclosed by the test, engine shall be reassembled, given a final run in accordance with paragraph 8-4, inspected in accordance with paragraph 8-6, and if found acceptable, shipped as a regular production engine. (5) Control test failure. Failure of a control test engine to pass any specified examination or test shall be cause for rejection of subsequent lots until satisfactory evidence is submitted to the government inspector that the faults revealed by the examination or test have been corrected.

Correction Net bhp 612.0 X 1.0321 = 631.65 Fan hp Fan hp@2400 rpm (Table 8-5) = 108 Corrected Gross b h p Corrected net bhp + Fan hp = 631.65 + 108 = 739.65 Corrected Gross Torque Corrected gross bhp x 5252 =

Brake Specific Fuel Consumption

8-7. Quality Control lest

a. General. A 50-hour quality control test shall be conducted for the purpose of determining the continued quality of the engine. b. Control Test. (1) Selection of test s a m p l e . E n g i n e s s h a l l be selected at the rate of one per month when production is below 100 per month; or one in every 100 engines when production exceeds 100 units per month; or on curtailed production at least one every 60 days. Test engines shall be identified as to production period, examined for

8-12

Table 8-6.50 Hour Quality Control Test Run No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Time 1 hour hour 1 hour hour 2 hours hour 2 hours 1 hour 5 hours 1 hour 5 hours 1 hour 5 hours 1 hour 5 hours 1 hour 5 hours 1 hour 5 hours 1 hour 5 hours 5 min. 5 min. 5 min.

Engine Speed load Idle Full load Idle load Idle Full load Idle Full load Idle Full load Idle Full load Idle Full load Idle Full load Idle Full load Idle Full load Full load Full load Full load

Rack Setting 2000 700 2400 700 2000 700 2400 700 2400 700 2400 700 2400 700 2400 700 2400 700 2400 700 2400 2200 2000 1800 rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm

Section II. ENGINE AND CONTAINER 8-8. General

This section of the manual covers the reusable metal container, Army Part No. 10912269, and procedures for preservation of engines for storage. The container is designed to provide substantial protection against damage for the engine during transit, and also against environmental deterioration over extended periods of storage. The following instructions will cover the removal of the engine from the container, reconditioning and testing of the container, preservation of engines for storage, the installation of the engine in the container, sealing, and periodic inspection. pressure relief valve (fig. 8-7), located in a recessed insert on the end of the container. Remove all nuts, lock washers and bolts securing the upper and lower container sections together. Remove upper section of container and retain sealing gasket (providing it has not been mutilated and is still serviceable). Remove the seven bolts and lock washers securing the engine to the transmission adapter support flange and the four nuts and lock washers securing the engine mounting brackets to the mounting flanges on the engine support cross members. Remove all engine parts previously removed from the engine and secured separately in the container. In cases where the engine has been returned for rebuild, forward these parts to the proper reconditioning area.

8-9.

Disassembling Container and Removing Engine

a. Prior to disassembling the metal container, the pressure must first be released through the

8-13

Figure 8-7. Pressure relief valve, humidity indicator, and pneumatic valve installed view. b. Remove the engine from the container using engine lifting multi-leg sling - 4910-919-2884 and place engine on suitable supports before removing the mounting brackets (fig. 8-8) secured to the oil pan. Remove six nuts, washers, and bolts and remove mounting brackets from the oil pan. Retain engine mounting brackets and all attaching hardware with container to assure availability of all parts when engine container is to be reused. Install all disassembled engine parts, removed from containers, on engines that are to be made operational.

Figure 8-8. Engine mounting bracket installed view. 8-10. Reconditioning Container a. Cleaning. Clean the interior and exterior of container using the process in C-1 of MIL-P116. Remove minor paint scale and rust with a power buffer. If major rust exists, remove by abrasive blasting. b. Inspection. Inspect interior and exterior of upper and lower container sections for dents, cracks, or defective weld. Check mounting flanges for bends. Bents that do not effect proper alinement of the upper and lower sections of container are permissible. Inspect the lower

8-14

section of the container (fig. 8-9) for cracked mounting flanges, bent or stripped studs. Inspect vibration damper mounts for cracks, tears or separation o f b o n d i n g b e t w e e n m e t a l a n d rubber. Inspect container skids for splits or cracks. Minor checks and dents are acceptable if serviceable is not affected. Check the gaskets and

discard if permanently deformed. Check humidity indicator (fig. 8-7) and discard if pink discoloration is evident. Pressure test relief valve to be sure valve functions properly. Apply a soap solution to the valve and replace any valve that does not open with a gage reading of seven to ten psi.

Figure 8-9. Interior of lower section of engine container. c. Repair. (1) Straighten all dents which would interfere w i t h r e q u i r e d clearance, i.e., approximately three to four inches of clearance between component and inside surface of container. Weld all cracks and defective welding. Remove weld splatter. (2) Straighten or repair bends and distortions in flanges that would affect proper alinement. (3) Replace broken mounting brackets or repair cracks by welding. Remove weld splatter. (4) Replace vibration damper mounts if there is evidence of cracks, tears, or separation of bonding between metal and rubber. Do not use mounts over five years old unless a represen-

8-15

tative sample indicates that such mounts will perform in accordance with test requirements of Specification MIL-M-45907. (5) Replace unserviceable skids. Fabricate skids from wood conforming to Class A of MILW-3912. Wood shall be pressure creosoted in accordance with requirements of TT-W-57. (6) If interior or exterior of container required removal of paint or rust by power buffing, apply spot prime and paint, as required. If container required abrasive blasting, remove grit and coat with one coat of primer 8010-1615718 (TT-P-636) or 8010-298-3867 (TT-E529) or 8010-292-3741 (TT-E-485) Type IV) as prescribed by TM 9-213. e. Assembly and Pressure Check. (1) A s s e m b l y . Coat a new or serviceable sealing gasket or O ring with a thin, uniform film of sealing compound conforming to MIL-18660 and install on lower section mounting flange. Install air pressure gage in place of relief valve (fig. 8-7). Assemble upper and lower sections of container and torque tighten bolts to 90-105 lbs. ft. (2) P r e s s u r e test. Pressurize the container to 10 psi using air that has passed through water separator - 4920-242-400 or equivalent. Immerse container in water. Evidence of air bubbles due to air leaks will be cause for rejection and rework. The alternate method of checking i s t o p r e s s u r i z e c o n t a i n e r t o t h e specified 10 psi and allow container to stand for a-minimum of 12 hours. Any appreciable drop in pressure will be sufficient cause for rejection. If the container air pressure is maintained satisfactorily, release p r e s s u r e , r e m o v e a i r pressure gage and install relief valve. f. Container Markings. The container shall be marked in accordance with MIL-STD-129 and as follows: (1) Adjacent to lifting rings, eyes, or lugs, (with arrows 5 inches long pointing thereto), mark in 10 inch letters, LIFT HERE. (2) Adjacent to and above air-filling valve, mark in 1-inch letters, AIR VALVE, and below, FILL TO 5 POUNDS PRESSURE. (3) Adjacent to and below air-filling valve, mark in 1-inch letters, USE DRY AIR ONLY. (4) Adjacent to and above the item-record receptacle, mark in -inch letters, RECORDS. (5) Adjacent to and above the humidity indicator, mark in -inch letters, HUMIDITY INDICATOR.
8-16

(6) Adjacent to and, above the relief valve, mark in -inch letters, RELIEF VALVE, and below, DO NOT DISTURB. (7) Along warning closure flange on both sides of the container, mark in 1-inch letters, WARNING: PRESSURE RELEASE BEFORE OPENING CONTAINER. (8) At loaded center of balance (43-inches from relief valve end) on both sides of the lower section of the container, mark a vertical line 6inches high and 1-inch wide with adjacent 1-inch letters, CENTER OF BALANCE. (9) Each container shall be provided with a name plate conforming to Specification MIL-P13525 and shall be secured to the record receptacle end of container. (10) Each container shall contain a decal (10912360) with instruction for assembling container. Decal will be secured to the inner wall (fig. 8-9) of the lower section at the name plate end of the container. g. Preparation of empty container for Shipment or Storage. After the container has been reconditioned, pressure checked, and has had the proper markings added, remove the upper section of the container. Install and secure the mounting brackets and hardware used to secure the engine in the container. Apply a film of sealing compound conforming to MIL-I-8660 on the container gasket and assemble container. Torque tighten the bolts to 90-105 lbs ft. Add 5 to 7 psi of dry air and allow sufficient time to insure that the air pressure is retained.

8-11. Engine Preservation

a. Preservation Through the Fuel System. Equip an auxiliary fuel container, with a fuel l i n e , a n d- f i l l w i t h a s u f f i c i e n t a m o u n t o f preservative oil, conforming to Specification VVL-800, to operate the engine as prescribed below. Arrange the container to provide adequate of the p r e s s u r e t o a s s u r e p r o p e r supply preservative oil to the fuel system. Disconnect the fuel line at the most convenient point nearest to the engine fuel pump and connect the line from the auxiliary fuel container to the fuel-toengine line at the point of disconnect. Disconnect return line at the quick t h e e n g i n e fuel disconnect coupling and connect a transparent plastic line to the disconnected engine fuel return line with the other end inserted into a recovery container to collect the returned diesel fuel. The fuel valve on the auxiliary fuel container shall be

turned to the ON position, and the engine started and operated not over 1200 revolutions per minute (RPM) until observed fuel return is purged of diesel fuel and the system filled with preservative oil. b. All openings such as exhaust manifolds, air intakes, breathers, etc. shall not be sealed. Note. The engine requires no special depreservation procedures to be made serviceable.

engine mounting bracket hold-down studs and securely tighten engine-to-container engine mounting flange. Tighten the six nuts that secure the transmission adapter support flange. Position parts that have been removed from the engine and tape or strap separately to engine and support cross members. Note. Engines that are being returned for rebuild should be securely mounted in container. The loose parts that have been removed from the engine should also be secured by some means to prevent shifting and causing additional damage to the engine and container during transit.

8-12. Engine Installation

a. T h e t u r b o s u p e r c h a r g e r o u t e r s h r o u d p l a t e assembly and the intermediate shroud plate on both the right and left bank must be removed, in order to provide proper clearance for the engine in the container. On engines which have the oil filler tube installation at the rear of the engine, the upper portion of the two piece tube must be disconnected and removed. Refer to figure 4-18 through 4-21 and 4-23 for removal of the shroud plates and upper portion of the oil filler tube. The parts that have been removed from the engine, must be packaged separately to prevent damage and secured to the engine or container prior to assembling container halves. b. Inspect engine thoroughly for loose or missing parts or components. Check to be sure engine has been properly identified as having been preserved for storage. Install the two engine mounting brackets on the three centrally located oil pan mounting bosses on either side of the engine (fig. 8-8). Install the six bolts from the underside of the oil pan and assemble a washer and a nut on each bolt. Tighten securely. The engine mounting brackets must be installed on the engine prior to installing engine in container. c. L o o s e n b u t d o n o t r e m o v e t h e s i x n u t s securing transmission adapter support flange to the container cross member (fig. 8-10). Using engine lifting multi-leg sling - 4910-919-2884, carefully guide the engine into position on the engine mounting bracket hold-down studs in the container. Aline the rear transmission adapter support flange screw holes with the screw holes in the engine transmission adapter and install six 1 in. screws and lock washers starting with the upper right and left screw holes on the support flange. Install one 1 in. screw and lock washer in the remaining screw hole in the lower center of the support flange. Tighten all screws securely. Install the four nuts and lock washers on the

Figure 8-10. Transmission adapter installed view. d. Fill each of the two desiccant baskets (fig. 89) mounted on the side wall of the container, with eight bags of desiccant (MIL-D-3464, 16 unit bags, Class 1). Apply sealing compound conforming to MIL-I-8660 on the sealing gasket and position the sealing gasket on the container flange. Assemble the upper section of the container to the lower section. Torque tighten assembly bolts to 90-105 lbs ft. e. W h e n a s s e m b l y i s c o m p l e t e , p r e s s u r i z e t h e container 5 to 7 psi of dehydrated air and allow container to stand for a minimum of twelve hours to be sure air pressure is maintained. f. Periodic inspection of containers that are to be stored for extended periods of time should be made to determine if the pressure of moisture is evident in the container. This is determined by the humidity indicator located in the recessed insert on the end of the container (fig. 8-7). Under moisture-free conditions, the indicator will show blue in color. As the presence of

8-17

moisture will turn moisture the first should

in the container increases, the indicator from blue to purple, then pink, if the content of the container is sufficient. At indication of moisture, the container be disassembled and the engine

represerved (para 8-11). Replace all desiccant bags and replace container sealing gasket. Reassemble and test container as indicated in d and e, above.

8-18

INDEX
Paragraph Figure Paragraph Bracket, frame support: Installation . . . . . . . 7-16b Removal . . . . . . . . . . . . . . . . 5-5 Bracket, fuel check valve: Installation . . . . . . . . . . . . . . . . . . . 7-15c Removal . . . . . . . . . . . . . . . . 5-6 Bracket, fuel injection tube: Installation . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Bracket, manifold heater fuel filter: Installation . . . . . . . . . . . 7-15c Removal . . . . . . . . . . . . . . . . 5-6 Bushing: Cleaning . . . . . . . . . . . . . . . . 6-2 Inspection . . . . . . . . . . . . . . .6-3 Repair . . . . . . . . . . . . . . . . . . 6-4 Bushing-type bearing: Cleaning . . . . . . . . . . . . . . . . 6-2 Inspection . . . . . . . . . . . . . . . 6-3 Repair . . . . . . . . . . . . . . . . . . 6-4 C Camshaft drive quill, overhaul standards . . . . . . . . . . Table Camshaft left and right: Assembly . . . . . . . . . . . . . . . . 6-44d Cleaning . . . . . . . . . . . . . . . . . 6-2 Data . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . 1-16 Disassembly . . . . . . . . . . . . . 6-44a Drive ratios and rotations . 1-25 Inspection . . . . . . . . . . . . . . . 6-44c Installation . . . . . . . . 7-10a Figure

A Accessories (see specific item) Adapter, generator drive: 5-158-5-156 Installation. . . . . . . . . . . . . .7-7a 5-156-5-158 Removal . . . . . . . .. . . . .5-13 Adapter, generator drive gearshaft: 6-26 Assembly . . . . . . . . . . . . . . 6-12c Cleaning . . . . . . . . . . .6-2 6-24,6-25 Disassembly . . . . . . . . . . 6-12a Inspection . . . . . . . . . . . . . . .6-3c Repair . . . . . . . . . . . . . . . . . . .6-4d Adapter, starter drive: Installation . . . . . . . . . . . . . .7-7b 5-155-5-153 Removal . . . . . . . . . . . . . . . . 5-13 5-153-5-155 Adapter, transmission: Assembly, . . . . . . . . . . . . . . 6-10c 6-18 Cleaning . . . . . . . . . . . . . . . .6-2 Disassembly . . . . . . . . . . . . . .6-10a 6-18 Inspection . . . . . . . . . . . . . 6-3 Installation. . . . . . . . . . . . . 7-6c-g 5-182, 5-163, 7-8, 5-159, 7-9 Removal. . . . . . . . . . .5-14 5-159 - 5-164 Repair . . . . . . . . . . . . . . . . . . .6-4 Adjustments (see specific item) Advance, fuel injection pump Assembly . . . . . . . . . . . . .6-40d 6-191,6-192, 6-181,6-193,6-198 Cleaning . . . . . . . . . . . . . . .6-2 Disassembly . . . . . . . . . . . . . . 6-40a 6-173-6-186 Inspection . . . . . . . . . . . . .40c Overhaul standards . . . . . Table 6-31 Repair . . . . . . . . . . . . . . . . .6-42c Air intake system troubleshooting . . . . . . . . . . . 3-7 Appendix . . . . . . . . . . . . . . . . . 1-3 Assembly (see specific item) Assembly procedure . . . . . . . 7-2 B Bearing, connecting rod: Cleaning . . . . . . . . . . . . . . . . .6-16a Description . . . . . . . . . . . . . . 1-13 Inspection . . . . . . . . . . . . . . . 6-16b Installation . . . . . . . . . . . . . . . 7-5c

5-21 - 5-10 5-10 - 5-21 5-25 5-25 4-49 4-49 5-26 5-26

6-34 6-213 - 6-207

6-207 - 6-213

Overhaul standards . . . . . . . . Table Removal . . . . . . . . . . . . . . . . . 5-15 Bearing, crankshaft main (see Main bearing, crankshaft) Bearing, fan drive housing outer flange: Installation . . . . . . . . . . . . . . . 4-7 4-105, 4-101 - 4-99, 4-35, 4-34 Removal . . . . . . . . . . . . . . . . . 4-7 4-34, 4-35, 4-99 - 4-101, 4-103, 4-104

5-180 - 5-175, 7-2,7-3, 5-173,7-4, 5-172,5-171 6-9 5-171 - 5-176

Overhaul standards Table Removal . . . . . . . . . . . . . . . . 5-11 Repair . . . . . . . . . . . . . . . . . . 6-44c Castings: Cleaning . . . . . . . . . . . . . . . .6-2 Inspection . . . . . . . . . . . . . . . 6-3 Repair . . . . . . . . . . . . . . . . . . 6-4 Clamps and supports, fuel injection tube: Installation . . . . . . . . . 7-13d Removal . . . Cleaning (see Clutch, front Assembly . . . . . . . . . . . . . 5-8 specific item) fan drive: (mechanical) 6-40d

5-116, 5-115, 7-20 - 7-22, 5-106, 5-109, 5-105, 5-108, 7-22, 7-23, 7-26, 5-112, 5-111 6-34 5-104 - 5-116 6-214

5-67 - 5-64, 4-86 5-64 - 5-67

6-147, 6-138, 6-135, 6-131,

6-144, 6-136, 6-133. 6-129

9-1

INDEX - Continued
Paragraph Figure Paragraph Installation . . . . . . . . . . . . . . . . 7-5c Figure Clutch. front fan d r i v e - C o n t i n u e d Assembly (piston actuated) . . . . 6-40d 6-149, 6-146, 6-137, 6-134, 6-132, 6-130, 6-128 Cleaning . . . . . . . . . . . . . . . . . . . . . . 6-2 Description . . . . . . . . . . . . . . . . . . . 1-21 Differences . . . . . . . . . . . . . . . . . . . . 4-8 Disassembly (mechanical) . . . . 6-40a 6-129, 6-131, 6-133, 6-135, 6-136, 6-138, 6-144, 6-147 Disassembly (piston actuated) . . 6-40a 6-128, 6-130, 6-132, 6-134, 6-137, 6-146 Inspection . . . . . . . . . . . . . . . . . . . . 6-40c Installation . . . . . . . . . . . . . . . . . . . 4-7 4-101 - 4-99, 4-35, 4-34 Overhaul standards (mechanical) Table 6-27 Overhaul standards . . . . . . . . . . . . . Table 6-26 (piston actuated) . . . . . . . . . . 4-34, 4-35, Removal . . . . . . . . . . . . . . . . . . . . . . 4-7 4-99 - 4-101 Repair . . . . . . . . . . . . . . . . . . . . . . 6-40 Clutch, rear fan drive: Assembly (mechanical) . . . . . 6-40d 6-147, 6-144, 6-138, 6-136, 6-135, 6-133, 6-131, 6-129 Assembly (piston actuated) . . 6-40d 6-149, 6-146, 6-137, 6-134, 6-132, 6-130, 6-128 Cleaning . . . . . . . . . . . . . . . . . . . 6-2 Description . . . . . . . . . . . . . . . . . 1-21 Differences . . . . . . . . . . . . . . . . . 4-8 Disassembly . . . . . . . . . . . . . . . . . 6-40a 6-128, 6-130, 6-132, 6-134, 6-137, 6-146 Inspection . . . . . . . . . . . . . . . . . . . 6-40c 4-101 - 4-99, Installation . . . . . . . . . . . . . . . . . . 4-7 4-35, 4-34 Overhaul standards (mechanical Table 6-27 Overhaul standards (piston actuated . . . . . . . . . . . . . . Table 6-26 Removal . . . . . . . . . . . . . . . . . . . . 4-7 4-34, 4-35, 4-99 - 4-101 Repair . . . . . . . . . . . . . . . . . . . . 6-40 Common tools and equipment . . 2-4 Compression test, cylinder . . . 4-22 Connecting rod: Assembly . . . . . . . . . . . . . . . . . . . 6-18c 6-37, 6-31, 6-30 Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Description . . . . . . . . . . . . . . . . . . 1-13 Disassembly . . . . . . . . . . . . . . . . . 6-15a 6-30, 6-31 Inspection . . . . . . . . . . . . . . . . . . 6-16c 6-34

5-180, 5-179, 5-175, 7-2, 7-3, 5-173, 7-4, 5-172, 5-171 Overhaul standards . . . . Table 6-9 Removal . . . . . . . . . . . . . . . . . 5-l5 5-171 - 5-176 Repair . . . . . . . . . . . . . . . . . . 6-178 Cooling fan (see Fan, cooling) Cooling fan shroud (see Shroud, cooling fan) Cooling fan vane (see Vane, cooling fan) Cooling system: Description . . . . . . . . . . . . . 1-21 Troubleshooting . . . . . . . . . . . 3-10 Coupler, fuel injection pump drive, splined and diaphragm: 6-252, 6-253 Assembly . . . . . . . . . . . . . . . . 6-67c Cleaning . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . 6-67a 6-252, 6-253 Inspection . . . . . . . . . . . . . . . . 6-67b Repair . . . . . . . . . . . . . . . . . . . 6-67b Coupling, fuel pump drive shaft: Installation . . . . . . . . . . . . . . 7-7c 5-151 5-151 Removal . . . . . . . . . . . . . . . . . 5-13 Cover, valve rocker arm: Assembly . . . . . . . . . . . . . . . . 4-15 4-163 - 4-156 Cleaning . . . . . . . . . . . . . . . . . 6-30 Disassembly . . . . . . . . . . . . . 4-15 4-156 - 4-163 Inspection . . . . . . . . . . . . . . . 6-31 Repair . . . . . . . . . . . . . . . . . 6-33g Crankcase: Assembly . . . . . . . . . . . . . . . . 6-9f 6-7 - 6-5 Cleaning . . . . . . . . . . . . . . . . 6-9c Description . . . . . . . . . . . . . . 1-10 Disassembly . . . . . . . . . . . . . 6-9b 6-5 - 6-8 Inspection . . . . . . . . . . . . . . . 6-9d 6-10 - 6-12 Overhaul standards . . . . . . . Table 6-2 Repair . . . . . . . . . . . . . . . . . . 6-9e Crankcase breather tube (see Tube, crankcase breather) Crankshaft: Cleaning . . . . . . . . . . . . . . . . 6-16b Description . . . . . . . . . . . . . . 1-12 Inspection . . . . . . . . . . . . . . . 6-16b Installation . . . . . . . . . . . . . . 7-5c 5-180, 5-179 5-175, 7-2, 7-3, 5-173, 7-4, 5-172, 5-171 Overhaul standards . . . . . . .Table 6-9 5-171 - 5-176 Removal . . . . . . . . . . . . . . . . 5-15 Repair . . . . . . . . . . . . . . . . . . 6-17a Crankshaft accessory drive gear (see Gear, accessory drive) Crankshaft flywheel (see Flywheel) Crankshaft torsional vibration damper (see Damper, torsional vibration)

9-2

INDEX - Continued
Paragraph Cylinder: Assembly . . . . . . . . . . . . . . . . . . . . 6-34 Checking compression . . . . . . . . . 4-22 Cleaning . . . . . . . . . . . . . . . . . . . . . 6-30 Data . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . . 1-15 Disassembly . . . . . . . . . . . . . . . . . . 6-29 Inspection . . . . . . . . . . . . . . . . . . . 6-31, 6-32 Installation . . . . . . . . . . . . . . . . . . . 7-8a Figure Paragraph Lubrication system . . . . . . . . . . . . . . . . . 1-17 Main bearings . . . . . . . . . . . . . . . . . . . . .1-11 Manifold air induction and heater system . . . . . . . . . . . . . . . . . . . . . . . 1-19 Pistons, pins and rings . . . . . . . . . . . . . 1-14 Sending units . . . . . . . . . . . . . . . . . . . . . . 1-23 Transmission oil cooler . . . . . . . . . . . . . 1-21 Turbosupercharger . . . . . . . . . . . . . 1-19 Diaphragm coupler: (see Coupler, fuel injection pump drive) Disassembly (see specific item) Disassembly instructions . . . . . . . . . . . . 5-1 Disassembly, preparation for engine: Draining . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Mounting on overhaul stand . . . . . . Removal of accessories . . . . . . . . . . . . . . 5-3 Drive coupler, fuel injection pump (see Coupler, fuel injection pump drive) Drive ratios and rotations data . . . . . . . . 1-25 E Elbow, turbosupercharger air outlet: Installation . . . . . . . . . . . . . . . . . . . . . . . . 7-15a Removal . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Electrical components, manifold heater: Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .6-65c Cleaning . . . . . . . . . . . . . . . . . . . . . . 6-65b Disassembly . . . . . . . . . . . . . . . . . . . . . 6-65a Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6-65b Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65b Electrical lead, fuel injection pump fuel shutoff: Assembly, . . . . . . . . . . . . . . . . . . . . . . . . . 6-64c Cleaning . . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . 6-64a Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6-64b Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64b Engine assembly: Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24c Differences between models . . . . . . . . . . 1-6 Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 General . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-8 Installation instruction . . . . . . . . . . . . . 7-4 Mounting on overhaul stand . . . . . . . 5-3 Specifications . . . . . . . . . . . . . . . . . . . . . 8-1 Tests and adjustments . . . . . . . . . . . . . . 8-5 Troubleshooting . . . . . . . . . . . . . . . . . . . . 3-4 Engine system description (see specific item) Exhaust system and turbosupercharger 1-20 F Fan and accessory drive housing, rear (see Housing, rear fan and accessory drive) Fan control valve (see Valve, fan control) Fan, cooling: Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48e Blade clearance . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Figure

6-65 4-184, 4-185 6-50

6-47 - 6-49

6-52 - 6-57 7-11 - 7-13, 5-144, 5-143 Overhaul standards . . . . . . . . . Table 6-15 5-141 - 5-147 Removal . . . . . . . . . . . . . . . . . . . . . 5-12 Repair . . . . . . . . . . . . . . . . . . . . . . . 6-33 6-58 - 6-63 Cylinder air deflector (see Deflector, cylinder air) Cylinder exhaust valve (see Valve, cylinder exhaust) Cylinder head shroud plates (see Shroud plate, cylinder head) Cylinder intake valve (see Vavle, cylinder intake) D Damper, torsional vibration: Cleaning . . . . . . . . . . . . . . . . . . . . . 6-2 Description . . . . . . . . . . . . . . . . . . . 1-12 Inspection . . . . . . . . . . . . . . . . . . . . 6-20b 6-38, 6-39 Installation . . . . . . . . . . . . . . . . . . 7-7c 5-152 Overhaul standards . . . . . . . . . . . . Table 6-11 Removal . . . . . . . . . . . . . . . . . . . . . 5-13 5-152 Repair . . . . . . . . . . . . . . . . . . . . . . . 6-21b Data (see specific item) Deflector, cylinder air: Cleaning . . . . . . . . . . . . . . . . . . . . . 6-2 Inspection . . . . . . . . . . . . . . . . . . . . 6-3 Installation . . . . . . . . . . . . . . . . . . . 7-8b 5-142, 5-141 Removal . . . . . . . . . . . . . . . . . . . . . 5-12 5-141, 5-142 Repair . . . . . . . . . . . . . . . . . . . . . . . 6-3 Deflector, cylinder head: Installation . . . . . . . . . . . . . . . . . . . 7-11b 5-102 - 5-97 Removal . . . . . . . . . . . . . . . . . . . . . 5-10 5-97 - 5-102 Description: Accessories . . . . . . . . . . . . . . . . . . . 1-9 Camshafts . . . . . . . . . . . . . . . . . . . 1-16 Connecting rods and bearings . 1-13 Cooling system . . . . . . . . . . . . . . . 1-21 Crankcase . . . . . . . . . . . . . . . . . . . 1-10 Crankcase breather . . . . . . . 1-22 Crankshaft, flywheel and 1-12 damper . . . . . . . . . . . . . . . . . Cylinders and valves . . . . . . . . . .1-15 Engine oil cooler . . . . . . . . . . . . . 1-21 Exhaust system and turbosupercharger . . . . . . . . . . . . 1-20 Fire extinguisher system . . . . . . . 1-22 Fuel system . . . . . . . . . . . . . . . . . . 1-18 General . . . . . . . . . . . . . . . . . . . . . . 1-8 Localization of engine components . . . . . . . . . . . . . . . . . 1-7

5-1 - 5-3 5-4

5-33 5-33 6-251 6-251

5-2, 5-3

5-6

6-225 4-88

9-3

INDEX - Continued
Paragraph Fan, cooling - continued Description . . . . . . . . . . . . . . . . . . 1-21 Disassembly . . . . . . . . . . . . . . . . . . 6-48a Drive ratios and rotations . . . . 1-25 Inspection . . . . . . . . . . . . . . . . . . . 6-48c Installation . . . . . . . . . . . . . . . . . . Figure Paragraph Figure Removal . . . . . . . . . . . . . . . . . . . . 5-7 5-34 - 5-36 Repair . . . . . . . . . . . . . . . . . . . . . . 6-57b Fuel injection metering pump (see Metering pump, fuel injection) Fuel injection pump fuel tube (see Tube, fuel injection pump fuel) Fuel purge system . . . . . . . . . . . . . . 1-18 Fuel shutoff adenoid (see solenoid, fuel shutoff) Fuel supply pump (see Pump, fuel supply) Fuel system: Data . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . . 1-18 Troubleshooting . . . . . . . . . . . . . . 3-8 Fuel/Water separator filter and elements: 6-247, 6-246 Assembly . . . . . . . . . . . . . . . . . . . 6-58c Cleaning . . . . . . . . . . . . . . . . . . . . 6-58b Data . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . . 1-18 6-246, 6-247 Disassembly . . . . . . . . . . . . . . . . . 6-58a Inspection . . . . . . . . . . . . . . . . . 6-58b 4-98 - 4-94, Installation . . . . . . . . . . . . . . . . . . 4-6, 7-14d 5-38, 5-37 4-94 - 4-98, Removal . . . . . . . . . . . . . . . . . . . . 4-6, 5-7 5-37, 5-38 Repair . . . . . . . . . . . . . . . . . . . . . . 6-58b G Gear, accessory drive: Cleaning . . . . . . . . . . . . . . . . . . . 6-2 Inspection . . . . . . . . . . . . . . 6-21b 5-169 Installation . . . . . . . . . . . . . . . . . 7-6a Overhaul standards . . . . . . . . . .Table 6-11 5-165 - 5-170 Removal . . . . . . . . . . . . . . . . . . . . 5-14 Repair . . . . . . . . . . . . . . . . . . . . . 6-4h Gear, generator driven idler: 6-29 Assembly . . . . . . . . . . . . . . . . . . . 6-13c Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 6-28 Disassembly . . . . . . . . . . . . . . . . . 6-13a Inspection . . . . . . . . . . . . . . . . . . 6-3 Overhaul standards . . . . . . . . . . Table 6-7 Repair . . . . . . . . . . . . . . . . . . . . . . 6-4h Gear, generator idler: Installation . . . . . . . . . . . . . . . . . . 7-5a 5-184, 5-183, 7-1, 5-181 5-177 - 5-184 Removal . . . . . . . . . . . . . . . . . . . . 5-15 Gear, starter driven: Installation . . . . . . . . . . . . . . . . . . 7-7b 5-155 - 5-153 5-153 - 5-155 Removal . . . . . . . . . . . . . . . . . . . . 5-13 Gear, starter driven idler: Assembly . . . . . . . . . . . . . . . . . . . 7-5a, 5-184, 5-183, 7-1, 5-181, 6-13c 6-29 Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . . 6-13a 6-28 Inspection . . . . . . . . . . . . . . . 6-3 Overhaul standards . . . . . . . .Table 6-7 Repair . . . . . . . . . . . . . . . . . . . . . . 6-4h

6-225

Removal . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . 6-48d Fan drive clutch, front (see Clutch, front fan drive) Fan drive clutch, rear (see Clutch, rear fan drive) Fan drive housing and clutch, front (see Housing with clutch, front fan drive) Filter (see specific item) Flywheel: Cleaning . . . . . . . . . . . . . . . . . . . 6-2 Description . . . . . . . . . . . . . . . . . 1-12 Inspection . . . . . . . . . . . . . . . . . . 6-20b 6-40, 6-41 Installation . . . . . . . . . . . . . . . . . 4-20 4-174, 4-183, 4-171, 5-182, 5-163, 7-8, 5-159, 7-9 Overhaul standards . . . . . . . . Table 6-11 4-171 - 4174, Removal . . . . . . . . . . . . . . . . . . . 6-20, 5-159 - 5-164 5-14 Repair . . . . . . . . . . . . . . . . . . . . . 6-21c Flywheel torsional vibration damper (see Damper, torsional vibration) Forms, records and reports . . . . . 1-5 Frame, upper cover: Installation . . . . . . . . . . . . . . . . . . 7-16b 5-21 - 5-10 Removal . . . . . . . . . . . . . . . . . . . . 5-5 5-10 - 5-21 Fuel check valve (see Valve, fuel check) Frame, oil cooler and associated parts: Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Inspection . . . . . . . . . . . . . . . . . . . 6-3 Repair . . . . . . . . . . . . . . . . . . . . . . 6-3 Fuel check valve bracket (see Bracket, fuel check valve) Fuel check valve tubes (see Tube, fuel check valve) Fuel filter, manifold heater: Assembly . . . . . . . . . . . . . . . . . . . . 6-65a 6-251 Cleaning . . . . . . . . . . . . . . . . . . . . 6-65b Data . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Disassembly . . . . . . . . . . . . . . . . . 6-65a 6-251 Inspection . . . . . . . . . . . . . . . . . . . 6-65b Installation . . . . . . . . . . . . . . . . . . 7-15c 5-26 Removal . . . . . . . . . . . . . . . . . . . . 5-6 5-26 Repair . . . . . . . . . . . . . . . . . . . . . . 6-65b Fuel filter, primary and secondary: Assembly . . . . . . . . . . . . . . . . . . . . 6-57c 6-245, 6-244 Cleaning . . . . . . . . . . . . . . . . . . . . 6-57b Data . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . . 1-18 Disassembly . . . . . . . . . . . . . . . . . 6-57a 6-244, 6-245 Inspection . . . . . . . . . . . . . . . . . . . 6-57b Installation . . . . . . . . . . . . . . 7-14d 5-36 - 5-34

4-88, 4-35, 4-34 4-34, 4-35

9-4

INDEX - Continued
Paragraph Gear, starter idler: Installation . . . . . . . . . . . . . . . . . . 7-5a Removal . . . . . . . . . . . . . . . . . . . . 5-15 Gearshaft, generator drive: Assembly . . . . . . . . . . . . . . . . . . . . 6-12c Cleaning . . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . . 6-12a Inspection. . . . . . . . . . . . . . . . . . . 6-3 Installation . . . . . . . . . . . . . . . . . . 7-7a Removal . . . . . . . . . . . . . . . . . . . . 5-13 Repair . . . . . . . . . . . . . . . . . . . . . . 6-4d Gearshaft, starter driven: Assembly . . . . . . . . . . . . . . . . . . . . 6-11c Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . . 6-11a Inspection . . . . . . . . . . . . . . . . . . . 6-4, 6-11b Installation . . . . . . . . . . . . . . . . . . . 7-5a Figure Paragraph Hose, fuel inlet: Installation . . . . . . . . . . . . . . . . . . 7-13b Removal . . . . . . . . . . . . . . . . . . . . .5-8 Hose, fuel return: Installation . . . . . . . . . . . . . . . . . . . 7-13b Removal . . . . . . . . . . . . . . . . . . . . . 5-8 Hose, fuel injection pump oil inlet: Assembly . . . . . . . . . . . . . . . . . . . . 6-61c Cleaning . . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . . . 6-61a Inspection . . . . . . . . . . . . . . . . . . . . 6-61b Installation . . . . . . . . . . . . . . . . . . . 7-12b Removal . . . . . . . . . . . . . . . . . . . . . 5-9 Repair . . . . . . . . . . . . . . . . . . . . . . . 6-61b Hose, turbosupercharger oil: Assembly . . . . . . . . . . . . . . . . . . . . 6-61c Cleaning . . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . . . 6-61a Inspection . . . . . . . . . . . . . . . . . . . . 6-61b Installation . . . . . . . . . . . . . . . . . . . 7-12a Removal . . . . . . . . . . . . . . . . . . . . 5-5, 5-9, Repair . . . . . . . . . . . . . . . . . . . . . . . . 6-61b Housing, crankshaft damper and oil filter: Assembly . . . . . . . . . . . . . . . . . . . . . 6-38e Figure

5-184, 5-183, 7-1, 5-181 5-177 - 5-184 6-26 6-24, 6-25 5-158 - 5-156 5-156 - 5-158

5-76 5-76 5-71 5-71

5-87 - 5-84 5-85 - 5-87

6-22, 6-23 6-19, 6-20

5-184, 5-183, 7-1, 5-181 Overhaul standards . . . . . . . . . . . Table 6-4 Removal . . . . . . . . . . . . . . . . . . . . . 5-15 5-177 - 5-184 Repair . . . . . . . . . . . . . . . . . . . . . . . 6-4 Gearshaft, transmission drive: Cleaning . . . . . . . . . . . . . . . . . . . . . 6-2 Inspection . . . . . . . . . . . . . . . . . . . 6-21b Installation . . . . . . . . . . . . . . . . . . 7-6e 5-182, 5-163, 7-8, 5-159, - g 7-9 Overhaul standards . . . . . . . . . . .Table 6-11 5-159 - 5-164 Removal . . . . . . . . . . . . . . . . . . . . . 5-14 Repair . . . . . . . . . . . . . . . . . . . . . . 6-12c, e 6-42, 6-43 Generator: Data . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Drive ratios and rotations . . . . . 1-25 4-16 - 4-13 Installation . . . . . . . . . . . . . . . . . . 4-4, 7-17e 4-17, 4-11, 4-10, 7-31 4-10 - 4-16 Removal . . . . . . . . . . . . . . . . . . . . 4-4 Generator drive gearshaft (see Gearshaft, generator drive) Generator driven idler gear (see Gear, generator driven idler) Generator system troubleshooting . 3-6 H Heater, manifold: Assembly . . . . . . . . . . . . . . . . . . . . 6-52e Cleaning . . . . . . . . . . . . . . . . . . . . . 6-52c Data . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Description . . . . . . . . . . . . . . . . . . 1-19 Disassembly . . . . . . . . . . . . . . . . . 6-52b Inspection. . . . . . . . . . . . . . . . . . . 6-52d Installation . . . . . . . . . . . . . . . . . 7-l5a Removal . . . . . . . . . . . . . . . . . . . . . 5 Repair . . . . . . . . . . . . . . . . . . . . . . . 6-52d Troubleshooting . . . . . . . . . . . . . . 3-11

5-90 - 5-88 5-17, 5-88 - 5-90

6-235 - 6-228

6-228 - 6-235 5-33 5-33 6-236

6-111 - 6-101, 4-92, 4-89, 6-100, 6-99 Cleaning . . . . . . . . . . . . . . . . . . . . . . 6-38b 6-112 6-99, 6-100, Disassembly . . . . . . . . . . . . . . . . . . . 6-38a 4-89, 6-101 - 6-111 Inspection . . . . . . . . . . . . . . . . . . . . 6-38c Installation . . . . . . . . . . . . . . . . . . . 7-8c 5-139, 5-138 Overhaul standards . . . . . . . Table 6-22 Removal . . . . . . . . . . . . . . . . . . . . . 5-12 5-138 - 5-140, 6-112 Repair . . . . . . . . . . . . . . . . . . . . . . . 6-38d Housing, crankshaft oil seal: 5-169, 7-5, Installation . . . . . . . . . . . . . . . . . . . 7-6a 5-168, 7-6, 7-7, 5-167 - 5-165 5-165 - 5-170 Removal . . . . . . . . . . . . . . . . . . . . . .5-14 Housing, front fan drive: 6-127, 6-150, Assembly . . . . . . . . . . . . . . . . . . . . . 6-40d 6-152, 6-124, 6-153, 6-122 - 6-119, 6-154, 6-155, 6-115, 6-114 Cleaning . . . . . . . . . . . . . . . . . . . . . . 6-2 6-114 - 6-127 Disassembly . . . . . . . . . . . . . . . . . . . 6-40a Inspection . . . . . . . . . . . . . . . . . . . . 6-40c Installation . . . . . . . . . . . . . . . . . . . . 7-9c 5-126, 5-125, 7-18, 5-123, 5-122, 5-1205-117, 7-19

9-5

INDEX - Continued
Paragraph Figure Paragraph Lever, intermediate throttle: Installation . . . . . . . . . . . . . . . . . 7-12c Removal . . . . . . . . . . . . . . . . . . .5-9 Linkage, fuel injection pump: Assembly . . . . . . . . . . . . . . . . . . . . 6-45d Cleaning . . . . . . . . . . . . . . . . . . . 6-2 Disassemble . . . . . . . . . . . . . . . . 6-45a Inspection . . . . . . . . . . . . . . . . . . . 6-3 Overhaul standards . . . . . . . . . . . Table Repair . . . . . . . . . . . . . . . . . . . . . . 6-4 Linkage, throttle control: Installation . . . . . . . . . . . . . . . . . . 7-14d Overhaul standards . . . . . . . . . . . Table Removal . . . . . . . . . . . . . . . . . . . . 5-7 Localization of engine components 1-7 Lubrication system: Data . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . . 1-17 Troubleshooting . . . . . . . . . . . . . . 3-9 M Main bearing, crankshaft: Cleaning . . . . . . . . . . . . . . . . . . . 6-9c Description . . . . . . . . . . . . . . . . . 1-11 Inspection . . . . . . . . . . . . . . . . . . 6-9d Installation . . . . . . . . . . . . . . . . . . 7-5c Overhaul standards Table Removal . . . . . . . . . . . . . . . . . . . . 5-15 Mandatory replacement parts 2-3 Manifold, exhaust: Cleaning . . . . . . . . . . . . . . . . . . 6-3 Inspection . . . . . . . . . . . . . . . . . .6-53 Installation . . . . . . . . . . . . . . . . . 7-13c Removal . . . . . . . . . . . . . . . . . . . . 5-8 Figure Housing, front fan drive - Continued Overhaul standards . . . . . . . . . . . Table 6-25 5-110 - 5-119 Removal . . . . . . . . . . . . . . . . . . . . 5-11 6-148 Repair . . . . . . . . . . . . . . . . . . . . . . 6-40c Housing, rear fan and accessory drive: Assembly . . . . . . . . . . . . 6-42d 6-205-6-202, 6-19 - 6-188, 6-206, 6-1706-118, 6-167, 6-166, 6-172, 6-164, 6-162, 6-161, 6-159, 6-155, 6-154, 6-153 - 6-151, 6-157, 6-156, 6-115, 6-114 6-116 - 6-118, 6-159 - 6-172, 6-124 - 6-126 5-134, 5-133, 5-131, 7-17, 5-130, 5-129 6-30 5-129 - 5-134, 6-187

5-83, 5-82 5-82 - 5-84 6-220 - 6-215 6-215 - 6-220 6-36

5-39 6-36 5-39

Cleaning . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . 6-42a Inspection . . . . . . . . . . . . . . . . . 6-42c Installation . . . . . . . . . . . . . . . . 7-9a

Overhaul standards . . . . . . . . . Table Removal . . . . . . . . . . . . . . . . . . . 5-11 Repair . . . . . . . . . . . . . . . . . . . . 6-42c Housing with clutch, front fan drive: Installation . . . . . . . . . . . . . . . . 4-7, 7-9C

Removal . . . . . . . . . . . . . . . . . . . 4-7, 5-11

4-101 - 4-99, 4-35, 4-34, 5-126, 5-125, 7-18, 5-123, 5-122 - 5-117, 7-19 4-34, 4-35, 4-99 - 4-101, 5-117 - 5-126

6-10 - 6-12 5-179 - 5-175 6-2 5-173 - 5-175

5 - 7 8 , 5-70 - 5-68 5-68 - 5-70, 5-78

I Improvised tools and 2-6 equipment . . . . . . . . . . . . . . Insert, Helical-coil: Description . . . . . . . . . . . . . . . . 6-3j Inspection . . . . . . . . . . . . . . . . . 6-3j Replacement . . . . . . . . . . . . . . . 6-5 Insert, threaded: Description . . . . . . . . . . . . . . . . 6-3j Inspection . . . . . . . . . . . . . . . . . 6-3j Replacement . . . . . . . . . . . . . . . . 6-3j Inspection (see specific item) Installation (see specific item) Intake manifold (see Manifold, intake) Intake manifold heater (see Heater, manifold) L Leakage test: Crankcase and induction system 8-2 Fuel and oil system . . . . . 8-3

Manifold beater (see Heater, manifold) Manifold heater fuel filter (see Fuel filter, manifold heater) Manifold air induction and heater system . . . . . . . . . . . . 1-19 Manifold heater fuel filter bracket (see Bracket, manifold heater fuel filter) Manifold heater fuel tube (see Tube, manifold heater fuel) Manifold heater solenoid valve (see Solenoid valve, manifold heater) Manifold, intake: 6-235 - 4-228 Assembly . . . . . . . . . . . . . . . . . . . . 6-52e Cleaning . . . . . . . . . . . . . . . . . . . 6-52c 4-118, Disassembly . . . . . . . . . . . . . . . . . 6-52b 6-228 - 6-235 Inspection . . . . . . . . . . . . . . . . . . 6-52d 4-110, Installation . . . . . . . . . . . . . . . . . . 4-11 4-11 - 4-111 4-111 - 4118, Removal . . . . . . . . . . . . . . . . . . . . 4-11, 5-6 5-33

9-6

INDEX - Continued
Paragraph Manifold, intake-Continued Repair . . . . . . . . . . . . . . . . . . . . . . 6-52d Meter, time totalizing Inspection . . . . . . . . . . . . . . . . . 6-70a Installation . . . . . . . . . . . . . . . . . . 7-17d Removal . . . . . . . . . . . . . . . . . . . 5-3 Metering pump, fuel injection (see Pump, fuel injection) Model differences . . . . . . . . . . . . . . 1-6 Mounting base support, turbosupercharger: Installation . . . . . . . . . . . . . . . . . . 7-13a Removal . . . . . . . . . . . . . . . . . . . . . 5-8 Mounting base tie rod, turbosupercharger: Installation . . . . . . . . . . . . . . . . . . 7-13a Removal . . . . . . . . . . . . . . . . . . . . . 5-8 Mounting base, front fan drive housing: Installation . . . . . . . . . . . . . . . . . . 7-9c Figure 6-236 6-255, 6-256 5-5, 5-4, 4-10 5-4, 5-5 Repair . . . . . . . . . . . . . . . . . . . . . . 6-69b O Oil capacity data . . . . . . . . . . . . . . . 1-24 Oil cooler, engine and transmission: Assembly . . . . . . . . . . . . . . . . . . . . 6-47f Cleaning . . . . . . . . . . . . . . . . . . . . 6-47c Description . . . . . . . . . . . . . . . . . . 1-21 Disassembly . . . . . . . . . . . . . . . . . 6-47b Inspection . . . . . . . . . . . . . . . . . . . 6-47d Installation . . . . . . . . . . . . . . . . . . 7-16b Removal . . . . . . . . . . . . . . . . . . . . 5-5 Repair . . . . . . . . . . . . . . . . . . . . . . 6-47e Oil cooler support beams (ace Support beam, oil cooler) oil filler tube (see Tube, oil filler) Oil filter, auxiliary: Assembly . . . . . . . . . . . . . . . . . . . . 6-38e Paragraph Removal . . . . . . . . . . . . . . . . . . . . 5-15 Figure 5-180, 5-179 - 5-175, 7-2, 7-3, 5-173, 7-4, 5-172, 5-171 - 5-176

5-81 5-81 5-80 5-80 5-126, 5-125, 7-18, 5-123, 5-122, 5-120 - 5-117 5-117 - 5-126 5-128, 5-127 5-127, 5-128 5-134, 5-133, 5-131, 7-17, 5-130, 5-129 5-129 - 5-134 5-79 5-79

6-223 - 4-221 6-224 6-221 - 6-223 5-21 - 5-10 5-10 - 5-21

Removal . . . . . . . . . . . . . . . . . . . . . 5-11 Mounting base, fuel injection pump: Installation . . . . . . . . . . . . . . . . . . . .7-9b Removal . . . . . . . . . . . . . . . . . . . . 5-11 Mounting base, rear fan drive housing: Installation . . . . . . . . . . . . . . . . . . 7-9a

6-110, 6-109, 6-108, 6-102, 6-101

Removal . . . . . . . . . . . . . . . . . . . . 5-11 Mounting base, turbosupercharger: Installation . . . . . . . . . . . . . . . . . . . 5-13a Removal . . . . . . . . . . . . . . . . . . . . 5-8

Cleaning . . . . . . . . . . . . . . . . . . . . . 6-38b Description . . . . . . . . . . . . . . . . . . . 1-17 Disassembly . . . . . . . . . . . . . . . . . . 6-38a

6-101, 6-102, 6-108, 6-109, 6-110

N Nozzle and holder, fuel injector: Assembly, . . . . . . . . . . . . . . . . . . . 4-18e 4-166 - 4-168 Cleaning . . . . . . . . . . . . . . . . . . . . . . 4-18b, c Disassembly . . . . . . . . . . . . . . . . . . 4-18a 4-167, 4-168 Inspection . . . . . . . . . . . . . . . . . . . 4-18b, c Installation . . . . . . . . . . . . . . . . . . 4-157 - 4-150, 4-135 - 4-133, Overhaul standards (see specific item) 4-130 - 4-126 Removal . . . . . . . . . . . . . . . . . . . . . 4-17 4-126 - 4-130, 4-133 - 4-135, 4-141, 4-150 - 4-153 Repair . . . . . . . . . . . . . . . . . . . . . . . . 4-18d Testing . . . . . . . . . . . . . . . . . . . . . . 4-17 4-126 - 4130, 4-133 - 4-135, 4-141, 4-150 - 4-153 Nozzle, piston oiler: Assembly . . . . . . . . . . . . . . . . . . . . 6-9c 6-254 Cleaning . . . . . . . . . . . . . . . . . . . . 6-69b Disassembly . . . . . . . . . . . . . . . . . 6-69a 6-254 Inspection . . . . . . . . . . . . . . . . . . . 6-69b Installation . . . . . . . . . . . . . . . . . . 7-5c

Inspection . . . . . . . . . . . . . . . . . . . . 6-38c Repair . . . . . . . . . . . . . . . . . . . . . . . 6-38d Oil filter housing (see Housing, crankshaft damper and oil filter) Oil filter, main: Assembly . . . . . . . . . . . . . . . . . . . . 6-38e Cleaning . . . . . . . . . . . . . . . . . . . . . 6-38b Description . . . . . . . . . . . . . . . . . . . 1-17 Disassembly . . . . . . . . . . . . . . . . . . 6-38a Inspection . . . . . . . . . . . . . . . . . . . . 6-38c Repair . . . . . . . . . . . . . . . . . . . . . . . 6-38d Oil pan: Assembly . . . . . . . . . . . . . . . . . . . . 6-37e Cleaning . . . . . . . . . . . . . . . . . . . . . 6-37b Description . . . . . . . . . . . . . . . . . . 1-17 Disassembly . . . . . . . . . . . . . . . . . . 6-37a Drain plugs . . . . . . . . . . . . . . . . . . 5-2 Inspection . . . . . . . . . . . . . . . . . . . 6-3 Installation . . . . . . . . . . . . . . . . . . . 7-13, 7-8d

6-111, 6-102, 6-101

6-101, 6-102, 6-111

6-97 - 6-88 6-2 6-88 - 6-97 5-2, 5-3 4-125 - 4-119, 4-11, 4-16, 4-13, 4-17, 4-10, 5-137 - 5-135, 6-78, 6-80

9-7

INDEX - Continued
Oil pan - Continued Paragraph Figure Paragraph Cleaning . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . 6-15c Inspection . . . . . . . . . . . . . . . . . . 6-3 Repair . . . . . . . . . . . . . . . . . . . . . . 6-4 Pump, fuel injection: Data . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . 1-18 Drive ratios and rotations . . . . 1-25 Installation . . . . . . . . . . . . . . . . . 4-47, 7-10b Figure

Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-13, 4-5, 4-6, 5-12 4-11 - 4-16, 4-119 - 4-125, 5-135 - 5-137 Repair . . . . . . . . . . . . . . . . . . . . . . 6-37d Oil pressure sending unit (see Sending unit, oil pressure) Oil pressure regulating valve (see Valve, oil pressure regulating) Oil pump: Assembly, . . . . . . . . . . . . . . . . . . 6-36f 6-87 - 6-67 Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Data . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . . 1-17 Differences . . . . . . . . . . . . . . . . . . 6-36a Disassembly . . . . . . . . . . . . . . . . . 6-36b 6-67 - 6 - 86 Drive ratios and rotations . . . . 1-25 Inspection . . . . . . . . . . . . . . . . . . 6-36d Installation . . . . . . . . . . . . . . . . . . 7-7d, 5-156, 7-10, 5-149 Overhaul standards . . . . . . . . . . Table 6-19 Removal . . . . . . . . . . . . . . . . . . . . 5-13 5-148 - 5-150 Repair . . . . . . . . . . . . . . . . . . . . . 6-36e Oil pump pressure relief valve (see Valve, oil pump pressure relief) Oil seal, crankshaft: Assembly . . . . . . . . . . . . . . . . . . . 6-18b 6-32 Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 6-32 Disassembly . . . . . . . . . . . . . . . . . 6-15b Inspection . . . . . . . . . . . . . . . . . . . 6-3 4-181, 4-182, Installation . . . . . . . . . . . . . . . . . . 4-20 4-179, 4-178, 4-176 - 4-174, 4-183, 4-171 4-171 - 4-180 Removal . . . . . . . . . . . . . . . . . . . . 4-20 Repair . . . . . . . . . . . . . . . . . . . . . . 6-4 Oil temperature sending unit (see Sending unit oil temperature) Organizational direct support, general support, and depot maintenance . . . . . . . 1-4 Overhaul standards (see specific item) P Pistons, rings, and piston pins: Assembly . . . . . . . . . . . . . . . . . . . 6-27 Cleaning . . . . . . . . . . . . . . . . . . . 6-24 Data . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . 1-14 Disassembly . . . . . . . . . . . . . . . . 6-23 Inspection . . . . . . . . . . . . . . . . . 6-25a, c Installation . . . . . . . . . . . . . . . . . 7-8a Overhaul standards Table Removal . . . . . . . . . . . . . . . . . . . 5-12 Repair . . . . . . . . . . . . . . . . . . . . . 6-26a, c Plug, crankshaft oil retaining: Assembly. . . . . . . . . . . . . . . . . . 6-18a 9-8

6-33

Removal . . . . . . . . . . . . . . . . . . . 4-4, 5-9 Pump, fuel supply: Data . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . 1-18 Drive ratios and rotations 1-25 Installation . . . . . . . . . . . . . . . . . 4-4 Removal . . . . . . . . . . . . . . . . . . . 4-14 R Reference . . . . . . . . . . . . . . . . . . . . . 1-2 Removal (see specific item) Repair (see specific item) Repair parta (also see Appendix B) . . . . . . . . . . . . . . 2-2 Rocker arm cover, valve (see Cover, valve rocker arm) Rocker arm, shaft and valve: Cleaning . . . . . . . . . . . . . . . . . . . 6-30d Inspection . . . . . . . . . . . . . . . . . . 6-31 Installation . . . . . . . . . . . . . . . . . 4-15, 7-10C

4-63 - 4-77 4-55, 4-56, 4-78, 4-82, 4-50, 4-45, 4-86, 4-87, 4-42, 4-41, - 4-85, 4-40 - 4-36, 4-88, 4-35, 4-34 4-34 - 4-62, 5-91 - 5-96

4-3 - 4-1 4-1 - 4-3

6-45, 6-44 Removal . . . . . . . . . . . . . . . . . . . 4-15 6-44, 6-45 6-46 7-11 - 7-13, 5-144, 5-143 6-13 5-141 - 5-147

4-161 - 4-158, 4-162 - 4-164, 4-157 - 4-153, 4-165, 4151, 4-126, 4-38 - 4-35, 4-88, 4-34, 5-109, 5-108, 7-22, 7-23, 7-27, 7-28, 7-30 4-34 - 4-38, 4-126 - 4-135, 4-141 - 4-160

Repair . . . . . . . . . . . . . . . . . . . . . 6-33g Rod, throttle control: Installation . . . . . . . . . . . . . . . . . 7-12c Removal . . . . . . . . . . . . . . . . . . . 5-9 Run-in, engine . . . . . . . . . . . . . . . . 8-4 Run-in schedule . . . . . . . . . . . . . . . Table S Scope

5-83, 5-82 5-82 - 5-84 8-1

6-33

1-1,

1-3

INDEX - Continued
Paragraph Figure Paragraph Figure Secondary fuel filter (see Fuel filter, secondary) Sending units and switches . . . . . 1-23 Sending unit, oil pressure: Data . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . 1-23 Installation . . . . . . . . . . . . . . . . . . 7-7d 5-156, 7-10, 5-149, 5-148 Removal . . . . . . . . . . . . . . . . . . . . . . 5-13 5-150 Sending unit, oil temperature: Data . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . . 1-23 Installation . . . . . . . . . . . . . . . . . . 7-7d, 5-156, 7-10 5-149, 5-148 Removal . . . . . . . . . . . . . . . . . . . . 5-13 Service operations . . . . . . . . . . . . . . Table 4-9 Shaft, throttle control cross: Assembly . . . . . . . . . . . . . . . . . . . 6-45d 6-220 - 6-215 Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly. . . . . . . . . . . . . . . . . 6-45a 6-215 - 6-220 Inspection . . . . . . . . . . . . . . . . . . . 6-3 Overhaul standards . . . . . . . . . . . Table 6-36 Removal . . . . . . . . . . . . . . . . . . . . 5-7 5-39 Repair . . . . . . . . . . . . . . . . . . . . . . 6-4 Shop layout. . . . . . . . . . . . . . . . . . 2-8 Shroud, camshaft drive: Installation . . . . . . . . . . . . . . . . . .5-l0 5-97 Removal . . . . . . . . . . . . . . . . . .7-llb 5-97 Shroud, cooling fan: Assembly ... . . . . . . . . . . . . . . . . .6-50e 6-226,6227 Cleaning . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . .6-50b 6-226,6-227 Inspection . . . . . . . . . . . . . . . . . 6-50d Installation . . . . . . . . . . . . . . .7-l6b 4-141-4-136, 5-9-5-7, 4-134-4-126, 4-38-4-36 Removal . . . . . . . . . . . . . . . . . . . .5-5 4-36-438, 4-126-4-134, 5-7-5-9, 4-136-4-141 Repair . . . . . . . . . . . . . . . . . . . . . 6-50d Shroud, front: Installation . . . . . . . . . . . . . . . . . . 7-14e 5-47-5-42 Removal . . . . . . . . . . . . . . . . . . . ..5-7 5-42-5-47 Shroud plate, cylinder head: Assembly . . . . . . . . . . . . . . . . . . .6-50e Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . . 6-50b Inspection . . . . . . . . . . . . . . . . . .6-50d Installation . . . . . . . . . . . . . . . . . . 7-14a Removal . . . . . . . . . . . . . . . . . . . . 5-7 Repair . . . . . . . . . . . . . . . . . . . . . .6-50d Shroud, rear: Installation . . . . . . . . . . . . . . . . . 7-14b Removal . . . . . . . . . . . . . . . . . . . . 5.7 Shroud, transmission: Assembly . . . . . . . . . . . . . . . . . . . .6-50e Cleaning . . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . 5-50b 6-226,6-227 Inspection . . . . . . . . . . . . . . . . . . . .6-50d Installation . . . . . . . . . . . . . . . . . . . 7-16a 5-22 Removal . . . . . . . . . . . . . . . . . . . . 5-5 5-17 Repair. . . . . . . . . . . . . . . . . . . . . .6-50d Solenoid, fuel shutoff . . . . . . . . . 1-18 Solenoid valve, manifold heater: Description . . . . . . . . . . . . . . . . . . . . 1-19 Installation . . . . . . . . . . .7-15c 5-27,5-26 Removal . . . . . . . . . . . . . . . . . . . . .5-6 5-26,5-27 Special instructions . . . . . . . . . . . . . . . .4-2e Special tools and equipment (also see Appendix B) . . . . . . . . . .2-5 Specification, engine (see Engine assembly) Starter: Data . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Drive ratios and rotations . . . . . . .1-25 4-8,4-7,5-1, Installation . . . . . . . . . . . . . . . . . . .4-4, 7-17c 4-9,4-4 4-4-4-8 Removal . . . . . . . . . . . . . . . . . . . . . 4-4 Starter driven gear (see Gear, starter driven) Starter driven idler gear (see Gear, starter driven idler) Starting system troubleshooting 3-5 Strap, exhaust manifold and exhaust pipe: 5-68 Removal . . . . . . . . . . . . . . . . . . . . .5-8 Studs: Cleaning . . . . . . . . . . . . . . . . . . . . .6-2 Identification . . . . . . . . . . . . . . . . .6 - 1 Inspection . . . . . . . . . . . . . . . . . . . .6-3e Repair . . . . . . . . . . . . . . . . . . . . . . .6-4 Torque specifications . . . . . . . . . .6-7 Support beam, oil cooler: Installation . . . . . . . . . . . . . . . . . . 7-16b 5-21-5-10 Removal . . . . . . . . . . . . . . . . . . . . ..5-5 5-10-5-21 Support, generator: Assembly . . . . . . . . . . . . . . . . . . . .6-55d 6-240 cleaning. . . . . . . . . . . . . . . . . . . . . . . .6-2 Disassembly . . . . . . . . . . . . . . . . .6-55a 6-240 Inspection . . . . . . . . . . . . . . . . . . .6-3 Installation . . . . . . . . . . . . . . . . . . 4-4 4-12 4-12 Removal . . . . . . . . . . . . . . . . . . . . 4-4 Repair . . . . . . . . . . . . . . . . . . . . . . 6-4 Support, turbosupercharger (see Mounting base support, turbosupercharger) Support, starter: Assembly . . . . . . . . . . . . . . . . . . . .6-55d 6-240 Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . .6-55a 6-240 Inspection. . . . . . . . . . . . . . . . .6-3 Repair . . . . . . . . . . . . . . . . . . . . . .6-4 T Tachometer drive: Drive ratios and rotations . . ...1-25 Test and adjustments (see specific item) Threaded insert (see Insert, threaded) Throttle control cross shaft (see, Shaft, throttle control cross)

5-60-5-51 5-51-5-60

5-50-5-48 5-48-5-50 6-227,6-226

9-9

Paragraph

Figure

Paragraph Installation . . . . . . . . . . . . . . . 7-14d Removal . . . . . . . . . . . . . . . . . 5-7 Repair . . . . . . . . . . . . . . . . . . . . 6-58b Tube, fuel injector nozzle fuel return: Assembly. . . . . . . . . . . . . . . . . . 6-60C Cleaning . . . . . . . . . . . . . . . . . . . . 6-60b Disassembly . . . . . . . . . . . . . . . . . 6-60a Inspection . . . . . . . . . . . . . . . . . . 6-60b Installation . . . . . . . . . . . . . . . . 7-13e Removal . . . . . . . . . . . . . . . . . . . . 5-8 Repair . . . . . . . . . . . . . . . . . . . . . 6-60b Tube, fuel injection pump fuel: Assembly . . . . . . . . . . . . . . . . . . . . 6-60c Cleaning . . . . . . . . . . . . . . . . . . . . 6-60b Disassembly . . . . . . . . . . . . . . . . . 6-60a Inspection . . . . . . . . . . . . . . . . . . 6-60b Installation . . . . . . . . . . . . . . . . . 7-13d Removal . . . . . . . . . . . . . . . . . . . 5-8 Repair . . . . . . . . . . . . . . . . . . . . . . 6-60b Tube, generator air exhaust and intake: Assembly . . . . . . . . . . . . . . . . . . . 6-62c Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . . 6-62a Inspection . . . . . . . . . . . . . . . . . .6-3 Repair . . . . . . . . . . . . . . . . . . . . . . 6-4 Tube, intake manifold: Installation . . . . . . . . . . . . . . . . . . 4-10 Removal . . . . . . . . . . . . . . . . . . . . 4-10 Tube, manifold heater fuel: Assembly . . . . . . . . . . . . . . . . . . . 6-65c Cleaning . . . . . . . . . . . . . . . . . . . . 6-65b Disassembly . . . . . . . . . . . . . . . . . 6-65a Inspection . . . . . . . . . . . . . . . . . . . 6-65b Installation . . . . . . . . . . . . . . . . . 7-15c Removal . . . . . . . . . . . . . . . . . . . .5-6 Repair . . . . . . . . . . . . . . . . . . . . . . 6-65b Tube, oil filler: Assembly . . . . . . . . . . . . . . . . . . . 6-53d Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . . 6-53a Inspection . . . . . . . . . . . . . . . . . . 6-53 Installation . . . . . . . . . . . . . . . . . . 7-14a Removal . . . . . . . . . . . . . . . . . . . . 5-7 Repair . . . . . . . . . . . . . . . . . . . . . 6-4 Tube, oil level indicator: Assembly . . . . . . . . . . . . . . . . . . . 6-53d Cleaning . . . . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . . . . 6-53a Inspection . . . . . . . . . . . . . . . . . . 6-53c Installation . . . . . . . . . . . . . . . . . 7-14a Removal . . . . . . . . . . . . . . . . . . . . 5-7 Repair . . . . . . . . . . . . . . . . . . . . . 6-4 Tube, oil pump: Installation . . . . . . . . . . . . . . . . . . 7-7d, Removal . . . . . . . . . . . . . . . . . . . . 5-13

Figure 5-34 5-34

Throttle control rod (see Rod, throttle control) Throttle linkage (see Linkage, throttle control) Tie rod, crankcase: Installation . . . . . . . . . . . . . . . . 7-5 5-176 - 5-171 Removal . . . . . . . . . . . . . . . . . . . 5-15 5-171 - 5-176 Tie rod, turbosupercharger (see Mounting base tie rod, turbosupercharger) Tools and equipment, improvised (see Improvised tools and equipment) Tools and equipment, special (see Special tools and equipment) Torque specifications . . . . . . . . . 6-7 Transmission adapter (see Adapter, transmission) Troubleshooting: Air intake system . . . . . . . . . 3-7 Cooling system . . . . . 3-10 Engine . . . . . . . . . . . . . . . . . . . 3-4 Fuel system . . . . . . . . . . . . . . 3-8 General instructions . . . . . . . 3-2, 3-3 Generating system . . . . . . . . . 3-6 Intake manifold heater, fuel system . . . . . . . . . . . . . . 3-11 Lubrication system . . . . . . . . 3-9 Purpose . . . . . . . . . . . . . . . 3-1 Starting system . . . . . . . . . . . . . . . . . . . . . 3-5 Tube bracket, fuel injection (see Bracket, fuel injection tube) Tube, crankcase breather: Assembly . . . . . . . . . . . . . . . . . 6-64c Cleaning . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . 6-64a Inspection . . . . . . . . . . . . . . . . 6-64b Installation . . . . . . . . . . . . . . . 7-13b 5-76 - 5-71 Removal . . . . . . . . . . . . . . . . . 5-8 5-71 - 5-76 Repair . . . . . . . . . . . . . . . . . . . 6-64b Tube, cylinder head oil drain: Cleaning . . . . . . . . . . . . . . . . . 6-2 Inspection . . . . . . . . . . . . . . . . 6-3 Installation . . . . . . . . . . . . . . . 7-15b 4-114, 4-113, 4-108 - 4-106, 5-33 - 5-28 Removal . . . . . . . . . . . . . . . . . .5-8 5-71 - 5-76 Repair . . . . . . . . . . . . . . . . . . . 6-64b Tube, fire extinguisher: Assembly . . . . . . . . . . . . . . . . . 6-64c Cleaning . . . . . . . . . . . . . . . . . 6-2 Disassembly . . . . . . . . . . . . . . 6-64a Inspection . . . . . . . . . . . . . . . . 6-64b Installation . . . . . . . . . . . . . . . 7-l2a 5-90 - 5-88 Removal . . . . . . . . . . . . . . . . . 5-9 5-88 - 5-90 Repair . . . . . . . . . . . . . . . . . . . 6-64b Tube, fuel check valve: Installation, . . . . . . . . . . . . . . 7-l5c 5-25 Removal . . . . . . . . . . . . . . . . . 5-6 5-25 Tube, fuel drain: Assembly . . . . . . . . . . . . . . . . . . 6-58c 6-247, 6-246 Cleaning . . . . . . . . . . . . . . . . . 6-58b Disassembly . . . . . . . . . . . . . . . 6-58a 6-246, 6-247 Inspection . . . . . . . . . . . . . . . . 6-58b 9-10

5-63 - 5-61, 7-29 5-61 - 5-63

6-248, 6-249 5-67 - 5-64, 5-86 5-64 - 5-67

6-250 6-250

4-110 - 4-106 4-106 - 4-110 6-251 6-251 5-24, 5-23 5-23, 5-24

6-239 - 6-237 6-237 - 6-239 5-60 - 5-51 5-51 - 5-60

6-239 - 6-237 6-237 - 6-239 5-60 - 5-51 5-51 - 5-60

5-156, 7-10, 5-149 5-148 - 5-150

INDEX - Continued
Paragraph Turbosupercharger: Data . . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . . 1-19, 1-20 Installation . . . . . . . . . . . . . . . . . . . . . 7-17b Removal . . . . . . . . . . . . . . . . . . 4-4 Turbosupercharger oil hose (see Hose, turbosupercharger oil) 4-33 - 4-18 4-18 - 4-33 Figure Paragraph Valve, cylinder intake: Adjusting . . . . . . . . . . . . . . . . . 4-23 Cleaning . . . . . . . . . . . . . . . . . 6-30 Data . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . 1-15 Inspection . . . . . . . . . . . . . . . . 6-31 Installation . . . . . . . . . . . . . . . 6-34 Overhaul standards . . . . . . . . 6-15 Removal . . . . . . . . . . . . . . . . . 6-29 Repair . . . . . . . . . . . . . . . . . . . 6-33 Timing . . . . . . . . . . . . . . . . . . . 4-24, 7-10 Figure

4-188

U Upper cover frame (see Frame, upper cover) Upper cover frame support (see Frame, upper cover) Ultrasonic inspection . . . . . . . . 6-32 V Valve, auxiliary oil filter bypass: Cleaning . . . . . . . . . . . . . . . . . . . 6-38b Inspection . . . . . . . . . . . . . . . . . . 6-38c Installation . . . . . . . . . . . . . . . . . 4-6 Removal . . . . . . . . . . . . . . . . . . . 4-6 Repair . . . . . . . . . . . . . . . . . . . . . 6-38d Valve clearance adjusting screws: Installation . . . . . . . . . . . . . . . . . 4-15

4-195 - 4-197, 4-200, 4-201, 4-189

4-92, 4-91 4-91, 4-92 6-112 4-161 - 4-158, 4-162 - 4-164, 4-157 - 4-153, 4-165, 4-151 - 4-126, 4-38 - 435, 4-88, 434

4-34 - 4-38, 4-126 - 4-135, 4-141 - 4-160 Valve cover, rocker arm (see C over, valve rocker arm) Valve, cylinder exhaust: Adjusting . . . . . . . . . . . . . . . . . . 4-23 4-18b Cleaning . . . . . . . . . . . . . . . . . . . 6-30 Data . . . . . . . . . . . . . . . . . . . . . . 1-24 Description . . . . . . . . . . . . . . . . 1-15 Inspection . . . . . . . . . . . . . . . . . 6-31 Installation . . . . . . . . . . . . . . . . 6-34 Overhaul standards . . . . . . . . . 6-15 Removal . . . . . . . . . . . . . . . . . . 6-29 Repair . . . . . . . . . . . . . . . . . . . . 6-33 Timing . . . . . . . . . . . . . . . . . . . . .4-24 4-195 - 4-197, 4-200, 4-201, 4-189

Removal . . . . . . . . . . . . . . . . . . 4-15

Valve, fuel check: Adjustment . . . . . . . . . . . . . . . 6-56c, d Assembly . . . . . . . . . . . . . . . . . . 6-56c, 6-242, 6-241, d 6-243 Cleaning . . . . . . . . . . . . . . . . 6-2 Description . . . . . . . . . . . . . . . . 1-18 Disassembly . . . . . . . . . . . . . . . 6-56a 6-241, 6-242 Inspection . . . . . . . . . . . . . . . . . 6-3 Installation . . . . . . . . . . . . . . . . . 7-15c 5-25 Removal . . . . . . . . . . . . . . . . . . 6-5 6-259 Repair . . . . . . . . . . . . . . . . . . . 6-4 Valve, main oil cooler bypass: Cleaning . . . . . . . . . . . . . . . . . . 6-2 Inspection . . . . . . . . . . . . . . . . 6-30c Installation . . . . . . . . . . . . . . . . 4-6 4-90, 4-89 Overhaul standards . . . . . . . . Table 6-22 4-89, 4-90 Removal, . . . . . . . . . . . . . . . . .4-6 Repair . . . . . . . . . . . . . . . . . . . 6-38d Valve, oil pressure regulating: Cleaning . . . . . . . . . . . . . . . . . . 6-2 Inspection . . . . . . . . . . . . . . . . 6-38c 4-93 Installation . . . . . . . . . . . . . . .4-6 Overhaul standards . . . . . . . . Table 6-22 4-93 Removal . . . . . . . . . . . . . . . . . 4-6 Repair . . . . . . . . . . . . . . . . . . . 6-38d . . . . . Valve rocker arm (see Rocker arm, valve) Valve rocker arm cover ( see Cover, valve rocker arm) Vane, cooling fan: Cleaning . . . . . . . . . . . . . . . . . 6-2 Inspection . . . . . . . . . . . . . . . . 6-3 4-35, 4-34 Installation . . . . . . . . . . . . . . . 7-16d 4-34, 4-35 Removal . . . . . . . . . . . . . . . . .

9-11

APPENDIX LIST OF APPLICABLE

A PUBLICATIONS

Section I.

GENERAL

INFORMATION

1. Purpose. The information contained in this Appendix has been prepared as a reference list of those a r m y p u b l i c a t i o n s p e r t i n e n t t o t h e the maintenance of and operation vehicle / weapons s y s t e m s i n c o r p o r a t i n g t h e materiel supported by this public action. Listings. T h e 2. Arrangement of publications listings contained in each section of

this Appendix are arranged in numerical order by publication number.

3. Requisitioning of Publications. Copies of the publications referenced herein, which are required in the performance of your Mission, may be requisitioned on DA Form 17 from, Commanding Officer AG Publications Center, 1655 Woodson Road, St. Louis, Missouri 63144.

Section Il. TECHNICAL MANUALS

(Operator and Maintenance)
PUBLICATION NUMBER

TITLE Launcher, M60A1 Tank Chassis, Transporting: for Bridge, Armored-Vehicle Launched, Scissoring Type, Class 60 (5420-889-220)

DATE

TM5-5420-202-10 . . . . . . . . . . . . . Operator's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Feb 68 TM 5-5420-202-20 . . . . . . . . . . . . . Organizational Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . 25 Feb 68 TM 5-5420-202-35 . . . . . . . . . . . . . DS, GS and Depot Maintenance Manual. . . . . . . . . . . . . . . . . . . . . . 29 Sept 69 Tank, Combat, Full-Tracked: M60A1, w/e (2350-756-8497); M60, w/e, (2350-678-5773) and Vehicle, Combat Engineer, Full-Tracked, M728, w/e (2350-756-1797): TM 9-2300-378-35/1 . . . . . . . . . DS, GS and Depot Maintenance Manual . . . . . . . . . . . . 24 Jan 68 Tank, Combat, Full-Tracked: M60A1 w/e and M60, w/e (2350-678-5773): TM 9-2350-215-10 . . . . . . . . . . . . . Operators Manual . . . . . . . . . . TM 9-2350-215-20 . . . . . . . . . . . . . Organizational Maintenance Manual . . . . . . TM 9-2350-215-50 . . . . . . . . . . . .. Depot Maintenance Manual . . . (2350-756-8497) Feb 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Feb 65 . . . . . . . . . . . . . . . 3 Jun 63

Vehicle, Combat Engineer, Full-Tracked, M728, w/e (2350-795-1797) TM 9-2350-222-10 . . . . . . . . . . . . . Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Aug 65 TM 9-2350-222 -20 . . . . . . . . . . . . Organizational Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . 27 Sep 65 Tank, Combat Full-Tracked: 90-MM Gun, M48A3, w/e (2350-895-9145) TM 9-2350-224-10 . . . . . . . . . . . . . Operators Manual, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Jan 66 TM 9-2350-224 -20 . . . . . . . . . . . . . Organizational Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . 28 Jan 66 TM 9-2350-224-35 . . . . . . . . . . . . . Field and Depot Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . 24 Jan 63 Transmission, CrossDrive, Assembly, Model CD-850-5 (2520-333-3522) TM 9-2520-223-35 . . . . . . . . . . . . . Field and Depot Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . 21 Jul 59 Pump, Metering, Fuel Injection, Assembly (2910-473-8003 and 2910-064-6265 ) TM 9-2910-212-34 . . . . . . . . . . Field Maintenance Manual (Including RPSTL) . . . . . . . . . . . . . . . 28 Nov 62

A-1

PUBLICATION NUMBER

TITLE Pump, Fuel, Engine Assembly

DATE

TM 9-2910-213-34 . . . . . . . . . . . . . Field Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nov 62 TM 9-2910-213-35 . . . . . . . . . . Field and Depot Maintenance Manual . . . . . . . . . . . . . . . . . . 13 Jan 64 Generator, Engine, Assembly (300 Amp) (2920-294-3472, 2920-445-0857, 2920-563-0299, 2920-786-1175, 2920-830-1293, 2920-830-6660, and 6115-629-1149) TM 9-2920-224-35 . . . . . . . . . . . . . Field and Depot Maintenance Manual . . . . . . . . 26-Feb 64 (including RPSTL) Starter, Engine, Electrical Assembly (2920-796-2616 and 2920-793-1557) TM 9-2920-232-34 . . . . . . . . . . . . . DS and GS Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Nov 62 (Including Repair Parts List) Turbosupercharger, Engine, Assembly (2990-678-4677 and 2990-678-4678) TM 9-2990-200-34 . . . . . . . . . . . . . Field Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . 8 Nov 62 TM 9-2990-200-35 . . . . . . . . . . . . . Field and Depot Maintenance Manual . . . . . . . . . . . . . Jun 60

Section III. TECHNICAL MANUAL

(Repair Parts and_Special Tools List (RPSL)) PUBLICATION NUMBER TITLE Tank, Combat Full-Tracked, M60A1E2, w/e (2350-930-3590); M60A1, w/e (2350-756-8497); M60, w/e (2350-678-5773); M48A3, w/e (2350-895-9154 and Vehicle, Combat Engineer, Full-Tracked, M728, w/e (2350-795-1797) TM 9-2300-378-20P/1 . . . . . . Organizational Maintenance RPSTL (Hull) . . . . . . . . . . 19 Aug 69 TM 9-2300-378-35 P/1-1 . . . . . . . DS, GS and Depot RPSTL (Hull) . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Feb 70 Transmission, Cross Drive, Assembly, Model CD-850-5 (2520-333-3522) TM 9-2520-223-35P . . . . . Field and Depot Maintenance RPSTL . . . . . . . . . . 14 May 63 DATE

Section IV. LUBRICATING ORDERS (LO)

PUBLICATION NUMBER LO 0-2350-215-12 LO 9-2350-222-12 LO 9-2350-224-12 TITLE Tank, Combat Full-Tracked: 105-MM Gun, M60A1 and M60 Vehicle, Combat Engineer, Full-Tracked, M728 Tank, Combat Full-Tracked, M48E1 DATE 27 Jun 69 27 Jun 69 12 Jun 69

A-2

Section V. GENERAL TYPE EQUIPMENT PUBLICATIONS

PUBLICATION NUMBER DA PAM 310-1 DA PAM 310-2 DA PAM 310-4 DA PAM 310-5 DA PAM 310-6 TM 9-207 TM TM TM TM TM 9-208-1 9-214 9-273 21-306 38-750 TITLE Index of Administrative Publications Index of Blank Forms Index of Technical Manuals, Technical Bulletins, Supply Manual (Type 7, 8 and 9), Supply Bulletins and Lubrication Orders Index of Graphic Training Aids and Devices Index of Supply Catalogs and Supply Manuals Operation and Maintenance of Army Material in Extreme Cold Weather O to -65 Cleaning of Ordnance Materiel Inspection, care and Maintenance of Anti-Friction Bearings Lubrication of Ordnance Material Manual for the Tracked Vehicle Driver Army Equipment Record Procedures DATE

19 Nov 59

A-3

APPENDIX B DIRECT SUPPORT, GENERAL SUPPORT, AND DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST

Section I INTRODUCTION 1. Scope

This appendix lists repair parts and special tools required for the performance of direct support, general support and depot maintenance of Engine, with Container: Turbosupercharged, Diesel, Fuel Injection, 90-degree V Type, Air Cooled, 12 Cylinder Assembly, Continental Models AVDS-1790-2M (2815-856-4996), AVDS-1790-2A and AVDS-1790-2AM (2815856.9005). Part number and Federal stock number indexes are also included. Federal Stock numbers in ascending numerical sequence, cross-referenced to the illustration figure number and item number.

3. Explanation of columns
The following provides an explanation of columns in the tabular lists in Sections II and III: a. Source, Maintenance, and Recoverability Codes (SMR), Column 1. (1) Source code, indicates the selection status and source for the listed item. Source c o d e s used are:
Code M Explanation Repair parts which are not procured or stocked as separate supply items but are to be manufactured in indicated maintenance levels. The lowest maintenance level authorized to manufacture the item will be entered in the second digit position of the source code. Repair parts which are high mortality parts, stocked in or supplied from the GSA/DSA or Army supply system, and authorized for use as indicated maintenance categories Repair parts which are procured and stocked for insurance purposes because the combat or military essentiality of the end item dictates that a minimum quantity be available in the supply system. Applied to repair parts which are not procured or stocked, the requirement for which will be supplied by use of the next higher procured or stocked component or assembly. Applied to repair parts which are not stocked. The indicated maintenance category requiring such repair parts will attempt to obtain these parts by cannibalization; if not obtainable by cansuch repair parts will be nibalization, requieitioned with supporting justification through normal supply channels.

2. General
This Repair Parts and Special Tools List is divided into the following sections: a. Repair Parts - Section II. A list of engine parts, in Government Group number sequence and keyed to figure and number, showing authorized repair parts for the performance of maintenance at the direct support, general support and depot levels. b. Special Tools and Test Equipment Section III. A list of special tools and test equipment authorized for the performance of maintenance at the direct support, general support and depot levels is given in ascending Federal stock number sequence, cross-referenced to illustration figure number and item number. Quantities shown in the Special Tools List are those required for each support unit charged with the responsibility of supporting this equipment. c. General Use Standardized Parts - Section IV. A list of all standard hardware and parts in alphabetical part name order with the hardware listed in ascending sizes. d. Part Number and Federal Stock Number Indexes - Section V. A list of part numbers and

P2"

X1

X2

B-1

(2) Maintenance code, indicates the lowest category of maintenance authorized to install the list item. The maintenance level codes are:
Code O Explanation Organizational maintenance level, providing local end item repair and return to service, or on cite repair service. Direct support maintenance level, providing either local mobile or direct service unit fried shop repair and return to use service. General support maintenance level, providing mobile or fixed shop repair and return to user, or to supply stock center. Depot maintenance level, providing fried shop repair, Major facilities, and return to supply stock service.

(3) Recoverability code, indicates whether unserviceable items should be returned for recovery or salvage. Items not coded are expendable. Recoverability codes are:
Code "R" Explanation Applied to repair parta and assemblies which are repaired at DSU and GSU levels. These repair parts which are not economically repairable at depot level will be recovered at DS / GS maintenance levels and will be replaced from supply on an exchange basis. Applied to high dollar value recoverable repair parts which are subject to special handling and are most economically repaired, overhauled or rebuilt at depot maintenance level. These parts will be recovered at depot level and will he replaced from supply on an exchange basis. Such repair parts normally are repaired or overhauled at depot maintenance activities.

quantities included in kits, sets, and assemblies are shown in front of the repair part name. Material required for manufacture or fabrication is identified. The Description Column also has a heading denoting the Government Grouping that parts belong to, as shown in TM 750-93-1: A l l standard hardware and Military standard parts are identified in the Description Column with sizes and given in Group 9501 list. Standard t h e g r o u p in p a r t s a r e a r r a n g e d within alphabetical part name order, in ascending sizes. d. Unit of Measure, Column 4. A t w o character alphabetical abbreviation indicating the amount or quantity of the item upon which the allowances are based, e.g., ea, pr, ft, yd, etc. e. Quantity Incorporated in Unit, Column 5. This column indicates the quantity of the item used in an engine. f. 30-Day DS/GS Maintenance Allowances, Columns 6 and 7. Note. Allowances in GS column are for GS maintenance only. (1) The allowance columns are divided into three subcolumns. Indicated in each subcolumn, opposite the first appearance of each item, is the total quantity of items authorized for the number o f e q u i p m e n t s (engines) supported, Items authorized for use as required but not for initial stockage are identified with an asterisk in the allowance column. (2) The quantitive allowances for DS/GS levels of maintenance will represent initial stockage for a 30-day period for the number of equipments (engines) supported. g. 1-Year Allowances Per 100 Equipments/Contingency Planning P u r p o s e s , Column 8. This column indicates opposite the first appearance of each item the total quantity required for distribution and contingency planning purposes. The range of items indicates total quantities of all authorized items required to provide for adequate support of 100 equipments (engines) for one year. h. Depot Maintenance Allowance Per 100 Equipments (Engines), Column 9. This column indicates opposite the first appearance of each item, the total quantity authorized for depot maintenance of 100 equipments (engines). Items authorized for use but not for initial stockage are identified with an asterisk in the allowance column.

b. F e d e r a l S t o c k N u m b e r , C o l u m n 2 . T h i s column indicates the Federal stock number assigned to the item and will be used for requisitioning purposes. c. Description, C o l u m n 3 . T h i s c o l u m n i n dicates the Federal item name and a brief description of the item. A part number or other reference number is preceded by the applicable five-digit Federal supply code for manufacturers in parentheses. All reference numbers that are not preceded by a Federal supply code are to be construed as 19207 items (Army TankAutomotive Command, Warren, Michigan). The words early, intermediate, and late are used to denote engine production engineering changes. These descriptive words are used in lieu o f e n g i n e s e r i a l n u m b e r effective points. Reference to the pertinent illustration will enable identification of part (s) required. Repair parts

B-2

i. Illustration, Column 10. (1) Figure Number, Column 10a. I n d i c a t e s the figure number of the illustration in which the item is shown. (2) I t e m N u m b e r o r S y m b o l , C o l u m n 1 0 b . Indicates the callout number used to reference the item in the illustration. (3) Each illustration carries a legend for every item on the illustration, cross-referenced to the Government Grouping number where it appears in the parts listing. (4) Components of kits and sets appear in the listing of the kit or set and parts may not be in the normal figure and item number sequence. These parts are listed only in the kit or set.

5. Abbreviations and Symbols.

a. Abbreviations. al . . . . . . . . . . . . .. aluminum asb . . . . . . . . . . . . . asbestos assy . . . . . . . . . . . . assembly br . . . . . . . . . . . . . . brass carb-S . . . . . . . . . . carbon steel cd . . . . . . . . . . . . . . cadmium cop. . . . . . . . . . . . . copper corr-res-S . . . . . . . corrosion resistant steel D.C. . . . . . . . . . . . Direct Current deg . . . . . . . . . . . . degree dia . . . . . . . . . . . . . diameter dld . . . . . . . . . . . . . drilled did-f/c-pin . . . . . drilled for cotter pin did-f/lkg-wire . . drilled for locking wire DR . . . . . . . . . . . . double row ea . . . . . . . . . . . . . each e.g. . . . . . . . . . . . for example etc . . . . . . . . . . . . and so forth ext-teeth . . . . . . . . external teeth ext-thd . . . . . . . . . external thread exter . . . . . . . . . . . external f/ . . . . . . . . . . . . for fig. . . . . . . . . . . . . figure fin. . . . . . . . . . . . . finish ft . . . . . . . . . . . . . . feet hd . . . . . . . . . . . . . head hex . . . . . . . . . . . . hexagon hex-hd . . . . . . . . . hexagon head id . . . . . . . . . . . . . inside diameter in . . . . . . . . . . . . . inch inc . . . . . . . . . . . . incorporated int-thread . . . . . . internal thread inter . . . . . . . . . . . internal lg . . . . . . . . . . . . . long LH . . . . . . . . . . . . left hand lkg . . . . . . . . . . . . locking it . . . . . . . . . . . . . . light (weight) max . . . . . . . . . . . maximum med . . . . . . . . . . . medium med-carb-S . . . . . medium carbon steel min . . . . . . . . . . . minimum NC . . . . . . . . . . . . A m e r i c a n N a t i o n a l C o a r s e Thread ni b . . . . . . . . . . . . nickel NF . . . . . . . . . . . . A m e r i c a n N a t i o n a l F i n e Thread

4. How to Locate Repair Parts

a. When Federal Stock Number or P a r t Number is Unknown. (1) Use the Table of Contents and determine the functional group or assembly group by illustration number where the part belongs. Illustrations are prepared by functional groups, which may contain more than one government group. (2) Identify the repair part on the. illustration and note the illustration and item number of the repair part. (3) In the repair parts list (Section 2 of this Appendix), find the functional group number and locate the repair part by illustration and item number. b. When Federal Stock Number or Part Number is Known. (1) Using the index of Federal stock numbers to illustration or part number to illustration and item number, find the Federal Stock Number or part number. These indexes are a r r a n g e d i n ascending F e d e r a l S t o c k Number and alpha-numerical sequence, cross-referenced to illustration, figure, and item number. (2) Find the repair part item on the legend of the illustration and note the functional group. (3) Using the repair parts listing (Section 2), find the functional group of the repair part and the illustration and item number as noted in the index of Federal stock numbers.

B-3

No . . . . . . . . . . . . number nom . . . . . . . . . . . nominal NPT N P T F od . . . American Standard Pipe Thread S t a n d a r d Taper T a p e r

A m e r i c a n . . .

11583 1 4351 19207 21335 21450

Pipe Thread (Dryseal) . . outside diameter

pc(s) . . . . . . . . . . piece(s) phos-ctd phosphate coated pltd . . . . . . . . . . . plated pr . . . . . . . . . . . . . pair psi . . . . . . . . pounds pt. . . . . . . . . . . . . point rad . . . . . . . . . . . radial per square inch

24617 29337 43991 53477 70040 73134 73370 81348

rd-hd . . . . . . . . . . round head RH . . . . . . . . . . . right hand S . . . . . . . . . . . . . steel sltd . . . . . . . slotted SR . . . . . . . . . . . . single row st. . . . . . . . . . . . . street stld-S . . . . . . . . . . stainless steel thd . . . . . . . . . . . thread (ed) (s) thk. . . . . . . . . . . . thick TM UNF
W

. . .

. .

. . .

. .

Technical Unified

Manual National Fine

81349

UNC ., . . . . . . Unified National Coarse / . . . . . . . . . . . with wd . . . . . . . . . . . . wide (width) x . . . . . . . . . . . . . . by (as in 2 x 4)

w/o . . . . . . . . . . without yds . . . . . . . . . . . . yards zn . . . . . . . . . . . . z i n c zn-pltd . . . . . . . .zinc plated

86988 88044

90005 94581 96906 99551

b. Symbols. *Indicates items are authorized for replacement, but not authorized for stockage. ** Indicates items available as part of SET or KIT shown. 6. Federal Supply Codes for Manufacturers 00736 Air-Maze Division North American Rockwell Corporation American Bosch Division American Bosch Arms Corporation Bowser, Inc.

Bowser & Briggs Filtration Division Champion Spark Plug Company Continental Motors Corporation Army Tank-Automotive Center Fafnir Bearing Company Division of Textron, Inc. Ordnance Corps Engineering Standards Rock Island Arsenal General Motors Corporation Hoover Ball Division Hoover Ball and Bearing Company Norma-Hoffman Bearings Corporation Schraders A. and Son Division Scovill Manufacturing Company A C Spark Plug Division General Motors Corporation Heim Universal Corporation Fram Corporation Federal Specifications Promulgated by General Services Administration Military Specifications Promulgated by Standardization Division Director of Logistic Services DSA Sier-Bath Gear Company, Inc. Aeronautical Standards Group, Departments of Navy and Air Force Bendix Corporation Filter Division National Utilities Corporation Military Standard Bendix Corporation Utica Division

7. Recommendations for Maintenance Publication Improvements Report of errors, omissions and recommendations for improving this publication by the individual user is encouraged. Reports should be submitted on DA Form 2028 (Recommended Changes to DA Publications) and forwarded direct to Commanding General, U.S. Army Tank-Automotive Warren, Command, Michigan, 48090, ATTN: AMSTA-MCP.

01843 08181

B-4

Section I

B-5

B - 6

B-7

B-8

B - 9

B-10

B-11

B-12

B-13

B-14

B - 1 5

B - 1 6

B-17

B - 1 8

B - 1 9

B-20

B-21

B-22

B-23

6-24

B-25

B-26

B-27

B-28

B-29

B-30

B-31

B-32

B-33

B-34

B-35

B-36

B-37

B-38

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-66

B-67

B-68

B-69

B-70

B-71

B-72

B-73

B-74

B-74

B-75

B-76

B-77

B-78

B-79

B-80

B-81

B-82

B-83

B-84

B-85

B-86

B-87

B-88

B-89

B-90

B-91

B-92

B-93

B-94

B-95

B-96

B-97

B-98

B-99

B-100

B-101

B-102

B-103

B-104

B-105

B-106

B-107

B-108

B-109

B-110

B-111

B-112

B-113

B-114

B-115

B-116

B-117

B-118

B-119

SECTION III

B-120

B-121

B-122

B-123

B-124

SECTION IV

B-125

B-126

B-127

B-128

B-129

B-130

B-131

B-132

B-133

B-134

B-135

B-136

B-137

B-138

B-139

B-140

B-141

B-142

B-143

B-144

SECTION V. FEDERAL STOCK NUMBER AND PART NUMBER INDEXES

FEDERAL STOCK NUMBER CR0SS REFERENCED TO PART NUMBER AND FIGURE AND ITEM NUMBER
FederaI Stock No. Part No, Fig. No. Item No. Federal Stock No. Part No, Fig, No. Item No.

1660-025-3493 2520-420-4982 2520-678-3171 2540-453-5.404 2590-134-4815 2590-437-0990 2590-629-1268 2590-678-4129 2590-838-3596 2590-851-4909 2590-932-5001 2805-304-9365 2805-407-6761 2805-599-0942 2805-678-4243 2805-678-4244 2805-679-1591 2805-733-8667 2805-753-9838 2805-753-9839 2805-760-5837 2805-760-5838 2805-774-4610 2805-774-4798 2815-064-6270 2815-071-8124 2815-071-8125 2815-071-8126 2815-073-5129 2815-110-4093 2815-117-0829 2815-117-9337 2815-122-4963 2815-125-3891 2815-136-1201 2815-177-7918 2815-177-8216 2815-177.8243 2815-177-9897 2815-179-7047 2815-193-8192 2815-193-8200 2815-193-8203 2815-193-8210 2815-193-8211 2815-193-8212 2815-193-8213 2815-193-8214 2815-193-8215 2815-193-8216 2815-193.8217 2815-193-8218 2815-194-2450 2815-194-2453 2815-194-2481 2815-235-4445 2815-238-9191 2815-239-5810 2815-356-8502 2815-402.2170 2815-404-7444 2815-406-4610 2815-406-4611

96906-51085-1 1065262 8725277 10882654 11641819 10887592 8679577 8682781 10889714 8682683 8682677 8357819 10865283 8717158 7320442 7320462 7744617 7338667 7539838 7539839 8682756 8682757 7744610 7744798 10912450 8682753 8761037 8761023 8761192 7320414 10898862 7062195 8761161 8725253 8682817 8682751 10865267 8761156 10865498 5704344 8761089 8682560 8682762 8761008 11641919 8682761 8682676 8682755 8761098 10865365 8761101 10951124 10865363 8761009 8761472 8682662 8725184 10865334 8761232 10865422 10912453 8682749 8682748

B-2 1 B-22 B-6 B-21 B-15 B-15 B-7 B-18 B-18 B-5 B-18 B-24 B-5 B-7 B-7 B-8 B-4 B-26 B-4 B-4 B-22 B-22 B-4 B-4 B-1 B-10 B-9 B-9 B-10 B-5 B-2 B-21 B-9 B-5 B-5 B-5 B-22 B-13 B-5 B-4 B-22 B-22 B-22 B-22 B-22 B-22 B-18 B-22 B-23 B-23 B-23 B-24 B-23 B-22 B-11 B-6 B-2 B-17 B-22 B-1 1 B-3 B-13 B-13

44 32 47 5 13 25 70 11 25 49 20 42 31 43 20 27 15 72 40 38 42 38 20 19 1 20 6; 8 22 1 14 62 14 21 43 31 46 33 1 5 56 52 25 48 17 43 6 5 2 11 7 53 27 34 44 8 41 16 9 11 49

2815-406-4612 2815-406-4613 2815-406-4614 2815-406-4615 2815-406-4616 2815-406-4617 2815-406-4618 2815-406-4620 2815-406-4621 2815-406-4622 2815-406-4623 2815-406-7289 2815-411-3965 2815-411-5789 2815-412-9192 2815-454-8599 2815-455-9495 2815.455-9496 2815-457.9309 2815-485-9555 2815-489-2575 2815-489-2576 2815-545-1563 2815-575-0398 2815-575-0399 2815-617-8626 2815-678-1837 2815-678-1838 2815-678-1841 2815-678-1842 2815-678-3194 2815-678-3195 2815-678-3198 2815-678-3199 2815-678-3200 2815-678-3201 2815-678-3202 2815-678-3203 2815-678-3207 2815-678-3208 2815-678-3209 2815-678-3210 2815-678-3211 2815-678-3213 2815-678-3214 2815-678-3215 2815-678-3216 2815-678-3217 2815-678-3218 2815-678-3219 2815-678-3220 2815-678-3221 2815-678-3222 2815-678-3223 2815-678-3225 2815-678-3226 2815-678-3227 2815-678-3228 2815-678-3229 2815-678-3230 2815-678-3270 2815-678-4233 2815-678-4236

10951460 8682441 8761082 11641922 10935613 8761128 8682467 8761033 10935623 10865022 10883083 8761481 7320451 8682739 8761469 7320408 8761148 8682540 10912162 8761193 8682737 7320415 10882968 8761598 8761030 10882611 570261S 5702614 8724974 5702609 8725293 8725281 8725180 8725179 8725177 8725176 8725004 8725003 7320429 7320428 7320427 7320396 7320395 8761517 8761521 8761527 8761547 8761513 8725222 8725266 8725255 8725239 8725240 8725276 8764948 8725261 8725254 8725140 5702617 5702616 8682505 8761440 8682814

B-19 B-7 B-13 B-7 B-7 B-7 B-5 B-13 B-7 B-10 B-10 B-n B-9 B-24 B-24 B-4 B-22 B-5 B-7 B-10 B-2 :.: B-10 B-24 B-6 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-12 B-12 B-12 B-12 B-12 B-6 B-6 B-6 B-6 B-6 B-6 B-3 B-2 B-2 B-2 B-3 B-3 B.15 B-14 B-14

28 22 18 60 35 75 34 40 41 26 21 39 64 50 3 29 36 6 69 5 7 9 11 10 18 48 5 5 i 33 34 37 37 37 14 17 16 18 22 35 11 16 17 5 20 4 11 76 16 13 12 15 39 79 71 4 32 31

B-145

Federal Stock No.

Part No.

Fig. No.

Item No.

Federal Stock No.

Part No.

Fig. No.

Item No.

2815-678-4238 2815-678-4239 2815.678-4246 2815-679-4961 2815-679-4961 2815-679-4962 2815-679-4963 2815-679-4964 2815-679-4966 2815-679-4968 2815-679-4969 2815-679-4970 2815-679-4971 2815-679-4972 2815-679-5664 2815-679-5665 2815-679-5666 2815-679-5667 2815-679-5668 2815-679-6482 2815-679-7062 2815-679-7063 2815-679-7064 2815-679-8053 2815-679-8054 2815-679-8055 2815-679-8056 2815-679-8057 2815-679-8058 2815-679-8059 2815-708-3018 2815-760-5871 2815-763-1402 2815-765-9711 28i5-765-9712 2815.767-3200 2815-795-1800 2815-808-2407 2815-808-2408 2815-808-2421 2815-808-2470 2815-817-9538 2815-821-4002 2815-833-8162 2815-833-8164 2815-834-1158 2815-834-1159 2815-846-1824 2815-851-6551 2815-851-9176 2815-856-4996 2815-856-9005 2815-861-1447 2815-861-1448 2815-861-3829 2815.866-2196 2815-869-3595 2815-876-2324 2815-884-1981 2815-895-6430 2815-896.6165 2815-896-6165 2815-896-6166 2815-899-1504 2815-937-1467 2815-937.4846 2910-031-9083 B-146

8682691 8682689 8725248 8682523 8682523 8761130 8725265 8725113 8725101 8725087 7025892 8682734 8725249 8682820 8761160 8761159 8761158 8761157 8761021 8682772 8682800 8698759 8682769 8761280 8682564 8761281 8761414 5702619 7320430 8682468 10865289 8682721 10883731 10865297 10865299 10865393 10882610 5702757 10951482 11602061 11602063 10882613 10883072 8682527 10865180 8682524 8761162 10898919 10898962 10898777 5702666 5702670 10898779 10898915 10898778 10882928 8761190 10882925 7025886 10898891 10898793 10898793 10898794 108989~3 8761022 8725226 7413736

B-14 B-14 B-27 B-7 B-8 B-7 B-1 B-9 B-9 B-9 B-2 B-3 B-3 B-3 B-13 B-13 B-13 B.13 B-13 B-10 B-13 B-13 B-13 B-5 B-5 B-5 B-5 B-5 B-5 B-5 B-5 B-5 B-28 B-4 ;~:6 B-3 B-20 B-19 B.20 B-19 B-3 B-7 B-8 B-10 B-8 B-9 B-9 B-9 B-14 B-1 B-14 B-14 B-3 B-9 B-lo B-9 B-6 B-9 B-1 1 B-1 1 B-n B-6 B-14 B-26 B-20

15 34 4 19 7 7 1 38 37 50 6 16 12 10 41 30 31 42 23 12 24 19 43 41 13 42 5 7 30 32 17 21 13 12 93 4 41 13 45 5 14 1 15 2 4 47 42 33 10 : 54 4 52 56 12 18 42 12 31 12 84 17

2910-064-6262 2910-064-6265 2910-064-6269 2910-078-4866 2910-078-5308 2910-078-5309 2910-078-5310 2910-078-5311 .2910-078-5312 2910-078-5313 2910-078-5314 2910-078.5315 2910-078-5316 2910-078-5317 2910-078-5318 2910-078-5319 2910-106-1981 2910-134-4734 2910-135-6523 2910-168-2624 2910-203-3322 2910-402-4422 2910-402-4423 2910-402-4424 2910-402-4425 2910-410-5755 2910-410-5756 2910-410-5758 2910-455-5836 2910-545-1558 2910-678-3282 2910-678-3285 2910-678-3290 2910-678-3292 2910-678-3294 2910-678-3299 2910-678-4673 2910-678.4722 2910-678-4725 2910-678-4728 2910-678-4729 2910-678-4730 2910-678-4734 2910-741-0397 2910-741-5354 2910-762-4587 2910-767-1733 2910-767-1734 2910-767-1735 2910-781-1457 2910-781-1458 2910-781-1461 2910-781-1462 2910-781-1463 2910-790-2301 2910-790-2303 2910-791-3352 2910-792-5393 2910-795-1783 2910-795-1795 2910-801-1152 2910-821-0659 2910-827-2816 2910-851-5360 2910-878-9932 2910-878-9933

10912481 10912447 10912452 10935359 10865394 10865396 10865398 _ 10865400 10865402 10865404 10865406 10865408 10865410 10865412 10865414 10865416 86988-C3062-8 10951434 10898738 10865170 90005-A26422 8761085 10865074 10912391 10935539 10865332 10865335 10865331 10882772 5702641 8764641 8761510 8761502 8761485 8761492 7324661 8725292 7320464 7323990 8682729 8682731 8761041 8764982 96906-28741-8-0204 7415354 5704366 10865426 10865444 10865425 10935214-4 10951429-1 10951429-2 10951463 11591013 8759089 7335555 8729071 10882940 8395476 10882764 5702738 10882768 10883098 8729069 01843-SR7828-1 99066-GU7837

B-16 B-15 B-16 B-16 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-16 B-19 B-26 B-19 B-20 B-2 B-19 B-13 B-26 B-17 B-17 B-17 B-6 B-27 B-19 B-19 B-n B-17 B-17 B-17 B-15 B-26 B-16 B-27 B-27 B-27 B-26 B-19 B-15 B-16 B-21 B-21 B-21 B-19 B-19 B-19 B-19 B-19 B-17 B-21 B-20 B-17 B-19 B-19 B.20 B-19 B-27 B-2o B-16 B-16

28 6 25 8 6 5 4 3 2 1 30 31 32 33 34 35 9.3 19 43 15 15 2 7 6 40 36 29 46 63 13 44 22 18 12 22 11 20 13 17 6 25 48 23 31 23 19 27 31 29 26 33 28 15 6 27 16 50 55 16 5.4 4.1 5

Federal Stock No.

Part No.

Fig. No,

Item No.

Federal Stock No.

Part No,

Fig. No,

Item No.

2910-879-1666 2910-907-9566 2910-936-2276 2910-967-9870 2910-999-9452 2910-999-9453 2910-999-9454 2910-999-9455 2920-063-8127 2920-177-7844 2920-245-8162 2920-248-4631 2920-318-4127 2920-402-5204 2920-402-5205 2920-455-5835 2920-498-9358 2920-647-3899 2920-678-7101 2920-767-1736 2920-771-6968 2920-803-0259 2920-830-6660 2920-902-3187 2920.973-1557 2930-068-6113 2930-077-2818 2930-107-1221 2930-156-9408 2930-168-2625 2930-169-5798 2930-177-9162 2930-179-7049 2930-179-7051 2930-350-9394 2930-350-9395 2930-350-9396 2930-350-9397 2930-350-9398 2930-350-9399 2930-350-9400 2930-350-9401 2930-402-4419 2930-402-4420 2930-402-4421 2930-406-7294 2930-408-4684 2930-411-5749 2930-421-1590 2930-421-1591 2930-421-1592 2930-435-4564 2930-435-4568 2930-435-4572 2930-435-7644 2930-436-3196 2930-436-3197 2930-436-3206 2930-436-3207 2930-436-3208 2930-437-7179 2930-438-1590 2930-442-5894 2930-442.5895 2930-442=5896 2930-446-1757 2930-453-5362

10882641 10865333 99066-SD7877 5702690 1094790 10951426 10951427 10951430 10884037 10882773 10883748 8682765 8666738 10865001 10882761 10882765 10882774 11583-XED89D 7084278 7062196 10883740 10883737 10889713 10935473 8712242 8761155 8761239 10865268 10935541 8682738 8682782 8761206 8761058 8761049 8761122 8761476 8761477 8761100 8761123 7320469 11641930 8682658 8761104 10898756 8761270 8761103 7320480 7320463 8761069 8761068 8761057 10951075 10951079 10951084 8761064 10865266 10865252 8761107 8682623 10865250 11641931 8725233 8761269 8682682 8761099 10865272 10865319

B-n B-17 B-16 B-20 B-19 B-19 B-19 B-19 B-28 B-14 B-28 B-27 B-15 B-7 B-7 B-7 B-7 B-21 B-15 B-21 B-28 B-28 B-15 B-28 B-15 B-26 B-27 B-22 B-26 B-24 B-24 B-26 B-24 B-24 B-24 B-24 B-24 B-24 B-24 B-26 B-24 B-25 B-22 B-22 B-22 B-24 B-26 B-26 B-22 B-22 B-22 B-27 B-27 B-27 B-27 B-22 B-22 B-22 B-22 B-22 B-22 B-26 B-22 B-25 B-2 2 B-22 B-22

51 9 1 22 37 8 61 17 29 19 62 17 18 29 15 26 13 27 9 18 20 19 5 24 82 31 21 88 51 20 65 37 19 33 52 45 38 39 57 12 3 12 16 44 36 62 58 33 13 24 52 46 49 41 14 28 35 39 18 24 39 9 17 i5 22 11

2930-453-5363 2930-453-5364 2930-453-5376 2930-457-0314 2930-457-0319 2930-457-6731 2930-498-9359 2930-522-2576 2930-570-9707 2930-678-3255 2930-678-3256 2930-678-3257 2930-678-3265 2930-678-3266 2930-678-3267 2930-678-3268 2930-678-3269 2930-678-3271 2930-678-4665 2930-678-4667 2930-678-4668 2930-678-4669 2930-678-4670 2930-678-4671 2930-678-7099 2930-678-5742 2930-679-8090 2930-679-8091 2930-679-8092 2930-679-8093 2930-765-4364 2930-766-0903 2930-774-4858 2930-902-3189 2930-933-6957 2930-937-1430 2930-938-8179 2930-997-1537 2930-998-4724 2940-067-7900 2940-115-9014 2940-121-6177 2940-436-3223 2940-678-3276 2940-678-3277 2940-678-3278 2940-678-3279 2940-678-3280 2940-863-7737 2940-884-4801 2940-937-1450 2940-939-7123 2990-064-6263 2990-064-6264 2990-068-6115 2990-369-8766 2990-402-4427 2990-402-4428 2990-402-4429 2990-402-4430 2990-402-4431 2990-402-4432 2990-402-4433 2990-402-5201 2990-411-8330 2990-453-5386 2990-453-5387

10865320 10865240 10865247 8761258 8761106 8761029 8725227 8682626 8761092 8761287 8761260 8761230 8761020 8761050 8761062 5702620 5702622 8682455 8682802 8682693 8682692 8682679 8761149 8761262 5702621 8761242 8682701 8682492 8682620 8682700 10865351 10865437 7744858 10935537 8761066 8761294 8761032 8682785 10865277 8725257 8725193 00736-03T786-140 8761542 8682815 8725201 8725203 8725286 8725250 8748329 5702659 10882766 7087519 10912478 10912477 10865361 7062197 8761189 10865324 8761016 8682558 8761018 8682750 8761086 8761163 10935471 8682752 8682451

B-22 B-22 B-22 B-27 B-21 B-24 B-26 B-22 B-24 B-26 B-27 B-25 B-26 B-25 B-27 B-27 B-26 B-26 B-24 B-24 B-24 B-24 B-24 B-24 B-26 B-25 B-23 B-23 B-23 B-23 B-26 B-24 B-22 B-27 B-27 B-24 B-25 B-25 B-22 B-6 B-6 B-6 B-6 B-6 B-6 B-6 B-6 B-6 B-6 B-6 B-6 B-6 B-15 B-15 B-26 B-2 1 B-10 B.18 B-18 B-13 B-18 B-13 B-13 B-10 B-28 B-13 B-13

34 25 26 20 37 17 53 40 11 49 39 12 54 19 60 51 43 1 41 53 54 25 18 9 14 16 8 9 44 51 58 22 12 10 14 29 21 27 61 28 3 23.3 53 73 75 23.1 52 58 1 1 3 32 3 27 2 2 7 8 10 24 8 52 3 B-147

Federal Stock No.

Part No,

Fig. No.

Item No.

Federal Stock No.

Part No.

Fig. No.

Item No.

2990-484-0771 2990-498-2398 2990-498.9356 2990-678-3250 2990-678-3251 2990-678-3252 2990-678-3264 2990-678-3286 2990-678-3291 2990-678-4676 2990-678-4681 2990-678-4695 2990-770-1641 2990-771-6969 2990-897-2849 2990-974-7605 3010-087-9530 3040-179-6656 3040-402-5217 3040-406-1536 3040-406.1537 3110-120-4367 3110-144-8518 3110-144-8662 3110-144-8927 3110-155-6675 3110-185-6535 3110-186-0964 3110-227-3620 3110-462-0392 3110-481-4825 3110-516-5290 3110-516-5490 3110-529-9480 3110-554-2979 3110-554-3197 3110-554-3272 3110-554-6080 3110-555-5207 3120-477-3780 3120-491-0314 3120-516-0953 3120-516-0955 3120-678-1869 3120-679-8098 3120-735-0201 4370-223-7007 4710-150-6187 4710-192-9436 4710-194-2531 4710-194-2566 4710-245-8305 4710-401-4368 4710.406-1528 4710-438-1811 4710-457-0479 4710-477-9899 4710-477.9900 4710-485-9651 4710-804-9249 4710-805-4149 4720-177-6186 4720-177-6188 4720-177.6189 4720.202-7457 4720-278-1110 4720-278.1112 B-148

B-18 8682783 B-14 8725275 B-13 10912390 B-12 8761553 B-12 8761549 B-12 8761499 B-12 8761559 B-1 1 8761507 B-1 1 8761491 B-15 7320459 B-13 8682797 B-21 86825d3 B-2 1 7062198 B.28 10883745 B-7 8761109 B-2 1 7062194 B-16 10951167 B-26 8725243 B-18 10865323 B-18 8761015 B-18 8682786 B-26 21450-709460 B-9 21450-700078 B-26 21450-700081 B-26 21450-714038 B-14 214r 700580 B-9 21450-711004 B-9 21450-711206 B-18 8393931 B-27 10951369 B-26 8761390 29337-3L08M46 B-26 B-14 21335-207K B-27 21335-911OK B-27 21335-9109KFS179 B-26 21335-206KFS1O179 29337-3L11M46 B-27 43991-5306 B-14 21335-307K B-27 57043s1 B-4 5704348 B-3 73134-HMS5FG B-18 B-18 73134-HM5MG B-4 8724980 B-5 8682745 7350201 B-8 8761597 B-10 B-1 1 8761131 11641927 B-7 10865420 B-11 8761448 B-n 7320458 B-13 10951368 B-n 10882791 B-10 10882890 I B-1 1 10865182 B-10 8761052 B-10 8761059 B-10 8761479 B-n 83616-NS4TypeH B-2 1 7017826 B-2 1 10898793-1 B-1 1 10951341-1 B-17 10951341-2 B-17 MIL-H-60004.000 in. idB-13 81349-MILH-6000 B-7 33HO0344082 B-26

14 :! 13 12 2 19 1 47 29 16 10 8 12 42 29 11 48 32 23 35 24 48 52 31 4 30 29 1 40 32 29 9 12 44 14 5 6: 5 6 33 5: 20 13 24 65 36 43 14 10 9 30 19 27 23 11 51 40 9 14 16 13 64 61

4720-278-1113 4720-420-4396 4720-461-9797 4720-477-3712 4720-720:2050 4720-741-0397 4720-996-8329 4730-032-2220 4730-044-4035 4730-044-4689 4730-044-4689 4730-044-4689 4730-044-4689 4730-044-4689 4730-044-4689 4730-044.4715 4730-044-4715 4730-052-9876 4730-052-9876 4730:052-9877 4730-052-9877 4730-069-1184 4730-090.9182 4730-124-1376 4730-168-1935 4730-196-0888 4730-196-0903 4730-200-0525 4730-202-6692 4730-223-7014 4730-231-4009 4730-254-1801 4730.277-9305 4730-278-0375 4730-278-2065 4730-278-2065 4730-278-2065 4730-278-2068 4730-278-3030 4730-278-3388 4730-278-3388 4730-278-3912 4730-278-4496 4730-278-5824 4730-289-8619 4730-334-7838 4730-350-9786 4730-402-5143 4730-406-4609 4730-406-7307 4730-406-7308 4730-406-7309 4730-457-1984 4730-542-2813 4730-554-8015 4730-585-2906 4730-595-4402 4730-640-6582 4730-678-330b 4730-678-3494 4730-679-5682 4730-699-7899 4730-710-9486 4730-753-9274 4730-753-8997

MIL-H-600-1.000 in.idB-10 96906-28741-8-0134 -B-19 96906-28741-8-0300 B-19 10935214-3 B-7 B-19 96906-28741-8-0340 96906-28741-8-0204 B-19 B-19 96906-28741-8-0260 !J4581-KU20-75-450S B-13 21450-444035 B-19 7538990 B-2 7538990 B-6 7538990 B-9 7538990 B-13 7538990 B-26 7538990 B-26 21450-444715 21450-444715 2 96906-39210-13 B-19 96906-39210-13 B-21 96906-39212-3 B-19 96906-39212-3 B-21 96906-39210-1 B-21 8698852 B-21 10889688 B-26 10898735 B-26 81348B-6 81348-WW-P-471 B-21 Type 1 ClaSa 1 l%x%in. 21450-189944 B-19 21450-127956 B-11 8682816 B-5 96906-20822-4 B-2 1 96906-39231-3 B-2 88044-825-4 B-21 88044-775-4 B-17 21450-502919 B-5 21450-502919 B-1 1 21450-502919 B-26 21450-502915 B-10 7403610 B-6 21450-117243 B-20 21450-117243 B-20 21450-125837 B-2 96906-39202-3 B-19 88044-779-4 B-17 B-19 96906-21922-4 9402708 B-1 1 96906-39206-9 B-19 10951334 B-19 8761137 B-13 8682799 B-13 8761138 B:13 8761594 B-12 8761449 B-n 96906-21922-2C B-21 96906-21921-4 B-19 21450-423185 B-21 88044-833-8J B-19 21450-443977 B-21 7324900 B-6 8764950 B-n 8761091 B-lo 7954708 B-8 21450-444476 B-21 7539274 B-19 7538997 B-2

7 43 42 37 64 48 57 12 2 64 10 22 39 17 68 7 15 58 41 59 39 52 27 66 105 37 16 60 45 24 18 40 30 15 1 6: 6 74 8.3 19 35 38 17 32 7 54 56 28 32 29 4 4 53 21 17 9 48 41 6 17 21 28 49 50

Federal Stwk No.

Part No.

Fig, No,

No.

Federal StockNo,

Part No.

Fig.

No.

Item No.

4730-753-8997 4730-776-7336 4730-776-7336 4730-776-7337 4730-776-7337 4730-781-6530 4730-781-6530 4730-803-7728 4730-805-0676 4730-810-7039 4730-815-0248 4730-902-3188 4730-908-3193 4730-908-3193 4730-908-3194 4730-908-6292 4730-908-6293 4730-909-8627 4730-933-3138 4730-958-4069 4820-242-4064 4820-304-9415 4820-406-4619 4910-554-1317 4910-795-7950 4910-795-7951 4910-795-7952 4910-795-7953 4910-795-7954 4910-795-7955 4910-795-7956 4910-795-7957 4910-795-7958 4910-795-7961 4910-856-4137 4910-870-6283 4910-919-2884 4910-937-4261 4910-986-9873 5110-708-3696 5110-708-3697 5110-708-3698 5110-708-3699 5120-078-3809 5120-221-7947 5120-251-1527 5120-310-4668 5120-448-0400 5120-448-0401 5120-448-0402 5120-448-0404 5120-448-7993 5120-473-7222 5120-575-7767 5120-672-8897 5120-678-5282 5120-678-5285 5120-678-5286 5120-678-5287 5120-678-5288 5120-710-7437 5120-723-6833 5120-752-9755

7538997 B-6 7767336 B-2 7767336 B-6 7767337 B-2 7767337 B-8 96906-39206-3 B-19 96906-39206-3 B-21 10865290 B-17 10865466 B-21 21450-423618 B-2 1 9402827 B-n 10935536 B-19 96906-35842-12 B-n 96906-35842-12 B-11 96906-35842-11 B-7 96906-35842-14 B-28 96906-35842-15 B-28 96906-35842-13 B-7 8761555 B-1 1 81348-WW-C440 B-19 Type E 0.500 in. cd 53477-645A6 B-32 8376456 B-32 8725224 B-6 8708419 B-29 10882892 B-30 10882790 B-3o 10882651 B-30 10882963 B.30 10882945 B-29 10882958 B-29 10882888 B-3o 10882891 B-30 10882949 B-30 8743025 B-30 10912260 B-29 10899180 B-29 10952220 B-29 10935532 B-3 1 10898928 7083696 B-30 7083697 B-30 7083698 B-30 7083699 B-30 10935497 B-30 81348-GGG-W-686 B-30 7751056 B-30 8708712 B-30 10882953 B-30 10882954 B-30 10883052 B-30 10883075 B-29 10883058 B-3o 5379997 B-3o 8708361 B-30 8761582 B-30 8761297 B-3o 8761535 B-29 8761560 B-3o 8761561 B-30 8761568 B-3o 8375324 B-3o 81349-MILT-O021309AB-30 Table VIII, Type V Sise 2 GGG-P-480A-Type2, B-30 Class3, Style.B, Sise 22

35 68 6 52 11 62 43 19 42 54 46 1 17 41 51 6 13 56 26 30 9 7 14 5 33 7 13 20 8 7 11 32 16 27 1 2 9 1 41 43 42 39 25 28 38 21 10 9 35 4 21 5 36 1 34 6 44 30 24 2 37 12

5120-789-4881 5120-793-7895 5120-793-7896 5120-795-0177 5120-797-2405 5120-797-2407 5120-837-5091 5120-871-7198 5120-873-6943 5120-875-9556 5210-793-7897 5210-793-7898 5210-793-7899 5220-988-8774 5305-068-0515 5305-071-2506 5305-071-2506 5305-206-3851 5305-225-3839 5305-225-3842 5305-253-5618 5305-253-5618 5305-267-8982 5305-267.8983 5305-269-2803 5305-269-2806 5305-269-3235 5305-269-3236 5305-269-3236 5305-269-3237 5305-269-3238 5305-269-3240 5305-269-3243 5305-269-3245 5305-486-2901 5305-531-1097 5305-655-6361 5305-655-6556 5305-655-9663 5305-678-3327 5305-682-5881 5305-709-8515 5305-709-8523 5305-710-4189 5305-710-4194 5305-710-4195 5305-715-1221 5305-725-0154 5305-727-3804 5305-753-7088 5305-801-5747 5305-811-0638 5305-817-9326 5305-817-9326 5305-891-7871 5305-897-7481 5305-897-7481 5305-910-7369 5305-914-6131 5305-958-4346

10935476 10882747 10882653 7950177 81349-MILT21309 Type 3, Class 1, Style A 81349-MILT21309 Type 3, Class 1, Style A 8375091 11610167 11610150 11610171 10882617 10882615 10882616 10912589 96906-90727-8 96906-90728-3 96906-90728-3 8717161 96906-90725-8 96906-90728-9 96906-21318-27 96906-21318-27 96906-90726-15 96906-90726-16 96906-90726-60 96906-90726-63 96906-90727-59 96906-90727-60 96906-90727-60 96906-90727-61 96906-90727-62 96906-90727-64 96906-90727-67 96906-90727-69 73370-X21820 96906-35308-365 96906-90727-6 96906-35266-70 7340190 8725291 96906-51093-4 96906-90727-88 96906-90727-87 96906-90726-84 96906-51981-36 96906-90727-112 96906-90725-165 96906-35291-165 96906-35308-364 96906-51096-64 96906-51096-60 96906-51096-60 10865321 10898763 10898763 96906-51096-306 96906-18153-63 96906-35207-215

B-30 B-30 B.30 B-30 B-30 B-30 B-30 B-30 B-30 B-30 B-30 B-30 B-30 B-29 B-28 B-22 B-23 B-7 B-20 B-17 B-2 B-7 B-19 B-23 B-19 B-13 B-28 B-13 B-13 B-26 B-26 B-25 B-13 B-25 B-20 B-12 B-27 B-21 B-22 B-6 B-8 B-19 B-5 B-2 B-32 B-32 B-3 B-2 B-32 B-32 B-12 B-9 B-2 1 B-24 B-18 B-22 B-24 B-5 B-26 B-n

27 6 8 22 4 3 14 15 40 23 19 17 18 3 22 49 4 4 10 37 74 2 53 20 6 53 11 7 57 63 83 4 4 9 1 1 28 45 6 32 9 3 11 94 11 12 17 4 13 13 3 11 2 8 30 17 26 46 87 48 B-149

Federal
Stwk

No.

5305-988-1723 5305-993-1848 5305-993-1851 5305-993-1851 5305-993-1851 5305-993-1851 5306-017-6143 5306-019-2417 5306-042-5592 5306-042-5828 5306-050-1238 5306-050-1238 5306-050-1238 5306-050-1238 5306-050-1238 5306-051-4075 5306-051-4075 5306-051-4075 5306-051-4075 5306-051-4076 5306-051-4076 5306-051-4076 5306-051-4084 5306-051-4087 5306-150-9104 5306-150-9104 5306-151-1420 5306-151-2623 5306-151-2626 5306-180-0238 5306-180-0321 5306-180-3357 5306-182-2014 5306-182-2023 5306-182.2023 5306-182.2024 5306-182-2025 5306-182-2026 5306.182-2026 5306-182-2026 5306-182-2029 5306-206-3850 5306-206-4931 5306-225-8504 5306-225-8511 5306.225-9086 5306-225-9103 5306-225-9107 5306-335-4244 5306-400-7637 5306-413-4373 5306-453-5589 5306-527-4128 5306-616-1248 5306-616-1248 5306-616-1248 5306-616-1248 5306-616-2618 5306-638-5288 5306-678-1885 5306-678-1887 5306-678-3316 5306-678-3323 5306-678-3324 5306-678-3324 5306-678.3324 5306-678-3325

Part No. 7323986 96906-35207-265 96906s35207-267 96906-35207-267 96906-35207-267 96906-35207-267 96906-51937-7 21450-192417 24617-425592 21450-425828 96906-90727-32 96906-90727-32 96906-90727-32 96906-90727-32 96906-90727-32 96906.90727-33 96906-90727-33 96906-90727-33 96906-90727-33 96906-90727-34 96906-90727-34 96906-90727-34 96906-90727-42 96906-90727-45 7414569 7414569 88044-4-14A 88044-4-20A 7415117 88044-6-5A 88044-177-24 88044-5CH11 88044-4H.3A 7346699 7346699 88044-5H5A 88044-5H6A 88044-5H7A 88044-5H7A 88044F5H7A 88044-5H12A 8717322 88044-4-3A 96906-90725-40 96906-90725-47 96906-90726-31 96906-90726-48 96906-90726-52 8365671 7416636 10882750 10883080 88044.5PC14A 88044-5-4A 88044-5-4A 88044-5-4A 88044-5-4A 88044-5-12A 88044-7H1OA 8761432 8724979 7320407 7039747 7039746 7039746 7039746 8761337

Fig, No. B-14 B-7 B-11 B-17 B-19 B-21 B-30 B-19 B-18 B-21 B-7 B-7 B-1 1 B-15 B-28 B-7 B.1O B-1 1 B-28 B-5 B-7 B-18 B-10 B-4 B.11 B-26 B-17 B-4 B-12 B-25 B-13 B.18 B-9 B-2 B-9 B-9 B-8 B-2 B-5 B-27 B-27 B-3 B-22 B-10 B-10 B-7 B-19 B-19 B-4 B-2 B-7 B-7 B-27 B-21 B.22 B-22 B-24 B-4 B-3 B-23 ::: B-6 B-6 B-7 B-7 B-25

Item No. 27 53 20 25 35 33 29 25 31 24 57 61 53 14 14 9 11 13 1 15 12 13 22 28 37 34 7 25 14 2 50 5 31 43 k 31 100 2 56 45 11 4 1 25 49 44 17 30 13 25 11 42 26 19 27 15 24 14 10 7 26 65 44 33 72 8

Federal Stcck No. 5306-678-3531 5306-678-4259 5306-678-4260 5306-678-4262 5306-678-6889 5306.741.4584 5306-741-4584 5306-741-4584 5306-774-4685 5306-774-4720 5306-807-9371 5306-816-9326 5306-817-6131 5306-837-9469 5306-852-7104 5306.944.7537 5306-993-1851 5307-145-4675 5307-207-8619 5307-207-8620 5307-264-2471 5307-264-2472 5307-264-2472 5307-272-6331 5307-272-6331 5307-272-6332 5307-272-6332 5307-272-6334 5307-272-6335 5307-410-5830 5307-438-1809 5307-477-3736 5307-533-3382 5307-533-3383 5307-638-7608 5307.638-7608 5307-638-7608 5307-638-7608 5307-678-3314 5307-678-3315 5307-678-3320 5307-678-3321 5306.678-3328 530j-678-3329 5307-678-3506 5307-678-3507 5307-678-3509 5307-678-3510 5307-678.3513 5307-678-3514 5307.678-3515 5307-678-3516 5307-678-3517 5307-678-3518 5307-678-3519 5307-678-3520 5307-678-3521 5307-678-3521 5307-678-3522 5307-678.3522 5307-678-3523 5307-678-3524 5307-678-3525 5307-678-3526 5307-678-3528 5307-678-3529 5307-678-3529

Part No, 7340060 7341633 7323988 10863824 8761272 7414584 7414584 7414584 7744685 7744720 88044.178H41A 96906-51096-60 21450-596281 10898746 96906-51096-335 88044-176C6A 96906-35207-267 77445-77913P8 7971983 7971982 7744564 7744813 7744813 8365809 8365809 8365810 8365810 8691451 8691452 10882970 7084497 7084498 10882638 10882637 14351-401975PO07 14351-401975PO07 14351-401975PO07 14351-401975PO07 8725298 7039742 7992673 7992674 8761204 8761203 8682805 8682804 8682501 8682500 7992698 7992697 7992694 7992693 7992686 7992685 7992682 7992681 7992678 7992678 7992677 7992677 7992670 7992669 7992658 7992657 7992653 7992646 7992646

Fig. No. B-8 B-27 B-15 B-32 B-2 B-22 B-24 B-24 B.5 B-23 B-15 B-21 B-3 B-27 B-26 B-16 B-1 1 B-5 B-26 B-26 B-26 B-5 B-26 B-13 B-26 B-13 B-26 B-9 B-9 B-2 B-2 B-2 B-9 B-9 B-6 B-6 B-26 B-26 B-4 B-4 B-26 B-26 B-26 B-26 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2

hem No. 34 7 10 15 30 23 16 29 20 17 7 2 2 12 6 15 33 40 20 20 104 29 104 38 15 38 15 13 13 71 98 98 15 15 9 50 23 67 52 45 71 71 77 77 29 29 27 27 92 92 21 21 56 56 55 55 24 54 24 54 57 57 28 28 25 22 59

B-150

Federal Stock No

Part No.

Fig. No.

Item No,

Federal Stock No,

Part No.

Fig. No.

Item No.

5307-678-3530 5307-678-3530 5307-678-3533 5307-678-3534 5307-678-3535 5307-678-3536 5307-678-6876 .-. 530i-iii6877 5307-678-6880 5307-678-6880 5307-678-6881 5307-678-6881 5307-678-6882 5307-678-6883 5307-678-6884 5307-678-6885 5307-678-6887 5307-678-6888 5307-678-6890 5307-678-6890 5307-678-6891 5307-678-6891 5307-679-4985 5307-679-4985 5307-679-4986 5307-679-4987 5307-679-4988 5307-679-4989 5307-679-4989

530?-679-4990
5307-679-5684 5307-682-5820 5307-706-5766 5307-706-5767 5307-727-4938 5307-733-8646 5307-734-8596 5307-734-8668 5307-734-8668 5307-734-8668 5307-734-8668 5307-734-8671 5307-734-8782 5307-734-8782 5307-734-8783 5307-734-8797 5307-734-8798 5307-734-8803 5307-734-8803 5307-734-8803 5307-734-8804 5307-734-8804 5307-734-8804 5307-734-8812 5307-734-8813 5307-741-0162 5307-741-0163 5307-741-0395 5307-741-5384 5307-741-5385 5307-774-4555 5307-774-4555 5307-774-4572 5307-77%-4573 5307-774-4605 5307-774-4795 530J-774-4803

7992645 7992645 7084439 7084438 7044069 7044068 7084444 7084445 7992649 7992649 7992650 7992650 7992665 7992666 7992689 7992690 8761199 8761200 8761443 8761443 8761442 8761442 7046669 7046669 7363446 7363443 736447 7046670 7046670 7363442 7084530 8682787 7065766 7065767 7767340 7338646 7348596 7348668 7348668 7348668 7348668 7348671 7348782 7348782 7348783 7348797 7348798 7348803 7348803 7348803 7348804 7348804 7348804 7348812 7348813 14351-401874S 7410163 7410395 7415384 7415385 7744555 7744555 7744572 7744s73 7744605 7744795 7744803

B-2 B-2 B-7 B-7 B-2 B-2 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-26 B-2 B-26 B-2 B-26 B-9 B-26 B-9 B-9 B-9 B-9 B-26 B-9 B-13 B-13 B-26 B-26 B-2 B-5 B-8 B-6 B-6 B-26 B-26 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 B-26 B-2 B-2 B-26 B-6 B-6 B-26 B-26 B-8 B-14 B-14 B-4 B-6 B-6 :::6 B-26 B-4

22 59 21 21 23 23 89 89 80 95 80 95 103 103 10 10 94 94 26 92 26 92 34 18 35 14 35 34 18 14 25 9 19 19 87 40 17 9 50 23 67 87 67 86 86 69 69 19 53 22 19 53 22 8 8 90 90 17 26 26 43 77 67 67 78 78 43

5307-774-4803 5307-776-7333 5307-776-7334 5307-776-7348 5307-776-7361 5307-776-7804 5307-776-7804 5307-776-7804 5307-776-7805 5307-776-7805 5307-801-4819 5307-806-6047 5307-837-7791 5307-866-6736 5307-866-6736 5307-866-6736 5307-866-6737 5307-866-6737 5307-866-6737 5307-954-6460 5307-995-8205 5310-012-0239 5310-012-2198 5310-012-4553 5310-022-5853 5310-045-3296 5310-061-7325 5310-062-4954 5310-080-6004 5310-080-6004 5310-081-4219 5310-081-4219 5310-088-0552 5310-088-0552 5310-088-0552 5310-088-0553 5310-088-0553 5310-088-0553 5310-088-0553 5310-088-0553 5310-088-0553 5310-088-0553 5310-141-1795 5310-141-1795 5310-141-1795 5310~149-9116 5310-167-0816 5310-167-0818 5310-167-0818 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310.167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0821

7744803 7767333 7767334 7767348 7767361 7767804 7767804 7767804 7767805 7767805 7084531 7039744 7738011 8666736 8666736 8666736 8666737 8666737 8666737 8365383-3 8365383-2 96906-35337-29 7403193 96906-35756-17 21450-225853 96906-35338-43 96906-21045-4 96906-21045-8 96906-15795-214 96906-15795-214 96906-27183-12 96906-15795-212 96906-21O44-N7 96906-21O44-N7 96906-21O44-N7 96906-21O44-N5 96906-21O44-N5 96906-21O44-N5 96906-21O44-N5 96906-21O44-N5 96906-21O44-N5 96906-21O44-N5 88044-960-416 88044-960-416 88044-960-416 96906-20002C8 88044-960-6 88044-960-10 88044-960-10 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 21450-502204

B-6 B-9 B-9 B-7 B-7 B-4 B-6 B-13 B-6 B.13 B-13 B-4 B-13 B-7 B-7 B-8 B-7 B-7 B-8 B-24 B-24 B-19 B-18 B-14 B-13 B-21 B-17 B-15 B-13 B-28 B-2 1 B-28 B-2 B-14 B-24 B-7 B-7 B-7 B-7 B-21 B-24 B-26 ::;9 B-27 B-15 B-2 B-2 1 B-23 B-2 B-4 B-5 B-6 B-6 B-6 B-9 B-n B-12 B-13 B-15 B-18 B-19 B-25 B-26 B-26 B-27 B-3

77 59 59 24 24 51 78 37 78 37 25 45 15 17 27 14 17 27 14 56 56 23 15 11 21 47 11 31 52 9 11 3 32 23 48 16 28 59 74 12 13 59 38 51 64 9 75 45 12 97 23 4 H 71 17 34 9 44 21 10 46 7 4: 55 22

B-151

Federal Stock No.

Part No.

Fig.
No.

Item No.

Federal Stock No.

Part No.

Fig, No.

Item No.

5310-167-0822 5310-167-0822 5310-167-0822 5310-167-0822 5310-167-0822 5310-167-0823 5310-167-0835 5310-176-8108 5310-208-5775 5310-208-5775 5310-209-0786 5310-209-0786 5310-209-0965 5310-209-0965 5310-209-2629 5310-209-2629 5310-239-5848 5310-275-3683 5310.282-7822 5310-298-9252 5310-333-7348 5310-333-7348 5310-333-7348 5310-333-7348 5310-333-7348 5310-333-7348 5310-333-7348 5310-333-7348 5310-333-7348 5310-333-7348 5310-333-7348 5310-333-7348 5310-333-7348 5310-402-8379 5310-406-7319 5310-407-9566 5310-407-9566 5310-407-9566 5310-407-9566 5310-407-9566 5310-407-9566 5310-407-9566 5310-407-9566 5310-407-9566 5310-407-9566 5310-407-9566 5310-489-8351 5310-489-8351 5310-491-0327 5310-535-6688 5310-582-5965 5310-582.5965 5310-582-5965 5310-582.5965 5310-584-5272 5310-584-7888 5310-584-7888 5310.588-0393 5310-616-3554 5310-637-3057 5310-637-9541 5310-637-9541 5310-637-9541 5310-637-9541 5310-637-9541 5310-637-9541 5310-638-2247
B-152

88044-960-716 88044-960-716 88044-960-716 88044-960-716 88044-960-716 88044-960-816 21450-502220 88044-320-4 96906-24400-8 96906.24400-8 96906-35335-33 96906-35335-33 96906-35338-47 96906-35338-47 7767350 7767350 10865381 96906-35335-40 96906-24400-10 21450-423884 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8761420 8761244 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 11640132 11640132 10889715 8745480 96906-35338-44 96906-35338-44 96906-35338-44 96906-35338-44 96906-35338-48 96906-35338-51 96906-35338-51 8679574 %;;;;:335.29 96906-35338-46 96906-35338-46 96906-35338-46 96906-35338-46 96906-35338-46 96906-35338-46 21450-455332

B-2 B-5 B-14 B-19 B-24 B-15 B-17 B-27 B-n B-19 B-22 B-23 B-19 B-32 B-8 B-26 B-26 B-19 B-n B-17 B-2 B-5 B-6 B-6 B-7 B-7 B-8 B-9 B-14 B-25 B-26 B-26 B-26 B-26 B-26 B-5 B-7 B-7 B-8 B-lo B-1 1 B-13 B-15 B-18 B-19 B-28 B-12 B-15 B-18 B-6 B-19 B.20 B-22 B-28 B-2 B-i6 B-32 B-22 B-n B-13 B-13 B-16 B-16 B-19 B-25 B-28 B-18

93 12 24 40 47 30 39 65 25 11 54 3 4 10 32 33 97 14 2 20 84 27 42 49 10 30 33 10 18 13 2 36 70 12 38 3 48 58 29 2 14 22 15 12 47 2 7 2 24 51 52 11 50 23 5 16 3 2 49 34 5 9.5 14 5 1 10 34

5310-638-6274 5310-638-6274 5310-655-9370 5310-655-9590 5310-655-9869 5310-655-9937 5310-655-9975 5310-655-9975 5310-656-0111 5310-678-5370 5310-679-5685 5310-679-9880 5310-682-5631 5310-682-5851 5310-682-5823 5310-682-5824 5310-685-8217 5310-685.8218 5310-720-7627 5310-737-2030 5310-741-4564 5310-741-4564 5310-753-4014 5310-763-8901 5310-763-8920 5310-774-4570 5310-774-4570 5310-776-7317 5310-776-7318 5310-776-7728 5310-809-4058 5310-809-4061 5310-809-8533 5310-809-8540 5310-809-8541 5310-820-6653 5310-842-1295 5310-842-1488 5310-842-1488 S31O-842-1488 5310-849-6883 5310-849-6883 5310-849-6883 5310-849-6883 5310-849-6883 5310-849-6883 5310-849-6883 5310-849-6883 5310-851-4278 5310-853-9335 5310-861-1406 5310-877-5796 5310-877-5796 5310-877-5796 5310-877-5797 5310-877-5797 5310-886-3000 5310-886-3000 5310-886-3001 5310-902-6676 5310-902-6676 5310-902-6676 5310-902-6676 5310-934-9734 5310-950-0039 5310-950-0039 5310-950-0039

21450-596610 21450-596610 96906-35340-47 7340058 8761273 8724978 8764639 8764639 96906-15795-703 7323994 8744055 8682774 8666561 7323991 8761229 8761241 8761227 7340061 8761279 7372030 7414564 7414564 8725151 96906-51968-23 97906-51967-20 7744570 7744570 7767317 7767318 7767728 96906-27183-10 96906-27183-15 96906-27183-23 96906-27183-25 96906-27183-27 96906-35338-50 96906-35692-29 96906-35692-21 96906-35692-21 96906-35692-21 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-13 7324901 96906-35691-13 7748837 96906-21O44N4 96906-21O44N4 96906-21O44N4 96906-21O44N3 96906-21O44N3 10912163-1 10912163-1 10912163-2 96906-21O83N3 96906-21O83N3 96906-21O83N3 96906-21O83N3 96906-35650-342 96906-21O44-N6 96906-21O44-N6 96906-21O44-N6

B-2 B-14 B-14 B-16 B-14 B-4 B-22 B-24 B-7 B-17 B-10 B-13 B-22 B-2 B-27 B-27 B-27 B-7 B-2 B-6 B-22 B-24 B-4 B-32 B-32 B-12 B-15 B-4 B-7 B-25 B-2o B-13 B-19 B-n B-1 7 B-32 B-13 B-2 B-3 B-26 B-2 B-7 B-9 B-14 B-18 B-25 B-26 B-27 B-9 B.18 B-16 B-5 B-22 B-23 B-7 B-19 B-22 B-24 B-22 B-1 1 B-17 B-21 B-23 B-1 1 B-2 B-5 B-6

96 6 28 17 21 3 10 31 1 13 16 33 7 33 34 29 35 66 77 15 20 5 54 1: 6 3 32 34 11 12 54 10 3 21 17 48 15 21 40 38 67 18 13 9 20 :: 40 29 24 37 3 18 55 34 20 5 2 22 26 36 11 50 81 26 29

Federal Stock No,

Part No.

Fig, No.

Item No.

Federal Stock No.

Part No,

Fig, No.

Item No.

5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310=982-4912 5310-842-1488 5310.982-6809 5315-012-4553 5315-013-7214 5315-019-0777 5315-058-9929 5315-058-9929 5315-058-9929 531.5-141.6337 5315-141-6338 5315-234-1863 5315-234-1864 5315-238-9239 5315-241-2916 5315-241-2916 5315-252-5987 5315-282-1510 5315-298-1481 5315-490-5588 5315-497-9650 5315-616-5526 5315-753-8333 5315-753-8333 5315.753-8333 5315-753-9735 5315-776-7363 5315-816-1794 5315-828-4485 5315-839-2325 5315-839-5820 5315-842-3044 5320-264-4293 5325-174-9038 5325-182-4707 5325-1849846 5325-276-6096 5325-276-6096 5325-276-6096 5325-682-1471 5325-682-7076 5330-171-6649

96906-21 O44-N6 96906-21 O44-N6 96906-21 O44-N6 96906-21 O44-N6 96906-21 O44-N6 96906-21 O44-N6 96906-21 O44-N6 96906-21 O44-N6 96906-21 O44-N6 !)6906-21O44-N6 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-20145-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-35692-21 96906-21 O44N1O 96906-35756-17 96906-24665-359 96906-24665-291 21450-589929 12450-589929 21450-589929 8717298 8717299 96906-24665-300 96906-24665-302 8725256 88044-122718 88044-122718 96906-24665-138 7338669 96906-24665-357 10882757 8682763 96906-35756-8 96906-24665.145 96906-24665-145 96906-24665-145 7539735 7767363 96906-24665-285 9$906-16555-655 96906-24665-132 96906-24665-134 96906-24665-283 96906-20426A4-20 96906-35489-20 10935447 96906-35489-10 96906-35489-74 96906-35489-74 96906-35489-74 96906-35490-16 7998574 96906-28775-223

B-6 B-7 B-7 B-13 B-14 B-15 B-25 B-26 B-26 B-26 B-6 B-6 B-6 B-8 B-1 1 B-1 1 B-12 B-13 B-15 B-15 B-18 B-21 B-22 B-24 B-24 B-26 B-26 B-15 B-14 B-25 B-14 :::6 B.26 B-3 B-3 B-13 B-2 B-2 B-4 B-26 B-6 B-8 B-9 B-27 B-26 B-18 B-18 B-26 B-26 B-2 B-3 B-6 B-18 B-25 B-27 B-3 B-6 Bb7 B-21 B-21 B-13 B-2 1 B-24 B-22 B-24 B-14

43 31 71 1 19 18 16 1 35 69 19 55 70 4 29 40 8 20 20 28 3 4 8 21 55 45 76 26 11 5 16 60 27 86 18 18 47 76 82 50 13 23.3 24 41 32 101 4 4! 75 34 25 23.2 18 6 66 20 22 36 21 22 56 6 3: 10 8

5330-187-3615 5330-199-5884 5330-199-5886 5330-256-0201 5330-265-1089 5330-269-2844 5330-269-2845 5330-290-8154 5330-290-8154 5330-291-2830 5330-291-7390 5330-292-7363 5330-297-9990 5330-410-9803 5330-411-2512 5330-411-2513 5330-438-1861 5330-411-5803 5330-493-2938 5330-498-6341 5330-498-6341 5330-498-6341 5330-514-5678 5330-542-1329 5330-542-1586 5330-543-3261 5330-576-9732 5330-579-3156 5330-579-3156 5330-579-6861 5330-579-7918 5330-579-8156 5330-579-8157 5330-580-3846 5330-582-2133 5330-582-2133 5330-582-2855 5330-584-1186 5330-585-6663 5330-599-2934 5330-618-0800 5330-632-2098 5330-641-3407 5330-663-4773 5330-663-4773 5330-678-3313 5330-678-3508 5330-678-5386 5330-678-5388 5330-678-7106 5330-679-6483 5330-738-0543 5330-772-3892 5330-855-6045 5340-050-2740 5340-050-2740 5340-057-3043 5340-088-1255 5340-089-8830 5340-089-8836 5340-114-0093 5340-177-4213 5340-193-0104 5340-194-4714 5340-200-8975 5340-205-4658

21450-546908 96906-35769-31 96906-35769-35 88044-6230-16 96906-29513-125 96906-35769-47 96906-35769-34 7045881 7045881 21450-500241 5165292 7416751 96906-28775-222 10935621 7320441 8682754 10912558 8761274 10912270 10935478 10935478 10935478 8764886 96906-28775-120 96906-28775-118 96906-35769-6 96906-28775-226 96906-28775-116 96906-28775-116 96906-28775-236 96906-28775-229 96906-28775-212 96906-28775.327 96906-28775-325 96906-28775-011 96906-28775-011 96906-28775-113 96906-28775-331 96906-28775-110 96906-28775-112 96906-28775-335 7033684 96906-28775-224 8720953 8720953 8725296 8682764 8682770 8682680 8395460 8761087 7767519 7723892 96906-35769-9 21450-502740 21450-502740 21450-573043 96906-21333-96 8682702 99066-SR7827 10865374 21450-501522 88044-735-12 10899041 21450-583288 8717162

B-27 B-8 B-6 B-16 B-20 B-6 B-6 B-6 B-7 B-5 B-4 B-2 B-5 B-7 B-9 B-2 B-14 B-9 B-32 B-13 B-21 B-24 B-14 B-9 B-16 B-6 B-26 B-9 B-15 B-14 B-5 B-6 ;:;6 B-5 B-26 B-2 B-13 B-26 B-26 B-13 B-4 B-7 B-20 B-20 B-4 B-8 B-1 1 B-1 1 B-14 B-15 B-5 B-2 B-10 B-1 1 B-17 B-n B-21 B-23 B-16 B-21 B-2 B-7 B-26 B-26 B-7

53 23 68 9.2 16 2 40 33 13 35 55 90 44 39 6 6 17 61 5 54 3 6 25 8 6 62 4 9 11 22 8 39 38 56 28 73 3 36 42 81 26 27 23 2.1 5.2 31 6 15 28 14 5 39 6 14 21 23 5 37 13 3 7 51 54 8 55 5

B-153

Faderal Stock No. 5340-205-9307 5340-209-0174 5340-220-5168 5340-242-5599 5340-242-5600 5340-242-5601 5340-282-1619 5340-282-5278 5340-282-7509 5340-286-2458 5340-291-3484 5340-291-3488 5340-291-3492 5340-291-3492 5340-291-3492 5340.291-3492 5340-291-3492 5340-291-3495 5340-291-3495 5340-291-3495 5340-291-3495 S340-291-3495 5340-291-3495 5340-291-3495 5340-291-3495 5340-298-9406 5340-298-9406 5340-298-9406 5340-402-4435 5340-407-0664 5340-407-0666 5340-434-6850 5340-437-7210 5340-437-7211 5340-449-2580 5340-453-5595 5340-456-1792 5340-456-1798 5340-456-1799 5340-463-2908 5340-4840865 5340-498-8347 5340-490-0871 5340-490-0872 5340-514-2321 5340-514-2321 5340-514-2321 5340-526-2559 5340-535-6469 5340-535.6471 5340-535-6471 5340-616-5014 5340-634-7860 5340-663-1245 5340-678-3309 5340-678-3310 5340-678-3311 5340-678-3311 5340-678-3311 5340-678-3532 5340-678-4257 5340-679-8116 5340-679-8116 5340.682-1619 5340-737-4145 5340-738-4968 5340-738-5174

Part No.

Fig.
No. No.

Federal
Stock No.

8698764 8698689 8725196 8682771 10912444 10883940 96906-16625-3354 96906-16624-3031 96906-21333-62 96906-122161 96906-124696 96906-21208F8-15 96906-21208F6-15 96906-21208F6-15 96906-21208F6-15 96906-21208F615 96906-21208F6-15 96906-214697 96906-124697 , 96906-124697 96906-124697 96906-124697 96906-124697 96906-124697 96906-124697 96906-21919-G9 96906-21919439 96906-21919-(39 8761164 10951462 10865375 96906-35914-112 10935443-1 10935443-2 10884034 10883941 10865317 10884033 10882767 8761243 8761070 10882771 10865316 8725236 96906-21208F5-20 96906-21208F5-20 96906-21208F5-20 96906-21919F2 96906-21919433 96906-21919-Gld 96906-21919G16 9690tP35914-114 96906-21208F7-15 96906-16632-1031 8352636 8352635 8352634 8352634 8352634 7320411 8761413 7017550 7017550 21450-586365 7374145 7384968 7385174

B-13 B-13 B-6 B-7 B-7 B-28 B-14 B-9 B-19 B*2O B-28 B-4 B-2 B-8 B-8 B-8 B-25 B-2 B-2 B-2 B-6 B-8 ::;6 B-26 B-1 1 B-17 B-19 B-23 B-19 B-21 B-24 B-12 B-12 B-28 B-28 B-17 B-28 B-21 B-1 2 B-24 B-1 1 B-17 B-2 B-2 B-5 B-26 B-21 B-1 1 B-1 1 B-21 B-24 B-2 B-27 B-2 B-4 B-2 B-4 B-26 B-2 B-27 B-4 B-5 B-27 B-6 B-n B-15

27 35 25 8 50 4 3 56 39 20 24 44 73 12 16 18 15 48 65 66 5 19 28 85 91 23 24 12 15 24 25 24 15 18 15 7 10 16 49 10 34 52 38 49 45 25 16 34 32 31 35 2 95 33 18 42 l-? 46 79 31 2 49 10 5; 19 16

5340-740-3580 5340-754-1083 5340-754-1083 5340-799-4794 5340-801-2500 5340-803-7304 5340-803-7305 5340-804-2786 5340-804-3891 5340-809-1490 5340-809-1490 5340-834-3854 5340-834-3854 5340-847-0734 5340-847-0734 5340-882-5939 5340-990-7159 5350-068-0501 5355-776-7331 5360-410-5836 5365-235-1941 5365-402-8380 5365-407-7003 5365-407-7011 5365-408-1268 5365-408-1270 5430-493-4057 5430-493-4057 5930-688-9882 5930-692-9258 6620-734-6573 6620-993-5546 6645-179-2712 6645-420-5072 6680-973-1263 6685-814-5271 6685-906.0156 6850-264-6572 8115-856-8147 9320-181-0118 9320-181-0118 9320-181-0119 9320-181-0119 9525-803-3044 9525-803-3044 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990.7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799

Part No. 7403580 96906-16625-1137 96906-16625-1137 7994794 96906-16625-1112 96906-16624-1156 96906-16624-1062 96906-16625-1125 96906-16625-1150 96906-21333-98 96906-21333-98 8343854 8343854 96906-21209-F5-15 96906-21209-F5-15 96906-16625-3283 96906-21268-F6-20 96906-90725-5 7767331 10935614 5702674 8725218 8761268 8682674 7320384 8725246 10865464 10865464 81349-M12285-1-5 96906-90530-2 7346573 96906-24539-1 11641917 11640392 96906-29132-1 96906-24537-1 8355883 81349-MILD-3464, Class I 10912269 8761271 8761271 8682670-8 8682670-8 96906-20995NC32 96906-20995NC32 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40

Fig. No. B-24 B-5 B-18 B-6 B-3 B-26 B-18 B-26 B-26 B-19 B-21 B-6 B-6 B-4 B-19 B-14 B-2 B-22 B-2 B-7 B-16 B-6 B-23 B-26 B-4 B-6 B-n B-1 1 B-6 B-2 B-24 B-2 B-3 1 B-15 B-5 B-6 B-32 B-32 B-32 B-22 B-24 B-24 B-24 B-2 B-27 B-2 B-2 B-2 B-2 B-3 B-3 B-5 B-5 B-6 B-6 B-7 B-7 B-7 B-8 B-8 B-9 B-9 B-lo B-14 B-15

Item No. 23 18 26 66 3 28 16 37 26 36 20 20 63 47 20 1 72 17 9 46 1 19 30 21 69 35 38 36 41 22 36 2 12 48 38 8 14 45 30 35 49 11 11 14 16 37 42 1 13 19 45 45 64 32 68 73 10 22 2 19 18 5 fl

B-154

Federal Stock ~0,

Part so.

Fig. No.

Item No.

Federal Stock No.

Part No.

Fig. No.

Item No.

9525-990-7799

9525-990-7:99 9525 -990-; ;99 9525-990-;;99 9525-990.TT99

96906.20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40

B-21 B-22 B-24 B.24 B-26

1 46 9 27 5

9525.990-7799 9525-990.7799 9905.407-5099 9905.407-5100 9905-419.5829

96906-20995NC40 96906-20995NC40 10882826 10882827 10912455

B-27 B.27 B-7 B-7 B-2

43 57 3 77 63

B-155

PART NUMBER CROSS REFERENCED TO FEDERAL STOCK NUMBER

AND FIGURE AND ITEM NUMBER
Part No. Federel Stock No. Fig. No. No. Part No, Federal Stock No. Fig. No. Item No

GGG-P-480A-Type 2, Class3, Style B, Size 22 MIL-H-60001.000 in. id MIL-H-60004.000 in. id 33 H-00344082 00736-03T177C164 00736-03T786.140 01843-HH78371 01843-NT7899 01843-SP7824 01843-SR7828-1 01843-SR7828-2 01843-SR7828-3 01843-SR7828-4 01843-SR7828-5 01843-SR7829 01843-VB77144-4 01843-VA77162 05821-241528 08181-28M68 08181-28M94 11583-XED89D 14351-401874S 14351-401975PO07 14351-401975PO07 14351-401975PO07 14351-401975PO07 21335-206KFS1O179 21335-207K 21335-307K 21335-9109KFS179 21335-911OK 21450-117243 21450-117243 21450-125837 21450-127956 21450-189944 21450-192417 21450-225853 21450-423185 21450-423618 21450-423884 21450-425828 21450.443977 21450-444035 21450-444476 21450-444715 21450-444715 21450-455332 21450-500241 21450-501522 21450-502204 21450-502220 21450-502740 21450-502740 21450-502915 21450-502919 21450-502919 21450-502919 21450-546908 8-156

5120-752-9755 4720-278-1113 4720-202-7457 4720-278-1112 2940.121-6177

B-30 B-10 B-13 B-26 B-6 B-6 B.16 B-16 B-16 B-16 B-16 B-16 B-16 B-16 B-16 B-16 B-16 B-16 B-20 B-29 B-21 B-26 B-6 B-6 B-26 B-26 B-26 B-14 B-27 B-27 B-27 B-20 B-20 B-2 B-1 1 B-19 B-19 B-13 B-21 B-21 B-17 B-21 B.21 B-19 B-2 1 B-6 B-8 B-18 B-5 B-2 B-3 B-17 B-1 1 B-17 B.1O B-5 B-n B-26 B-27

12 7 13 61 60 61 2 26 32 4.1 4.2 4.3 4.4 4.5 30 27 29 10 18 9 13 90 9 50 23 67 14 9 61 44 12 8.3 19 35 45 60 25 21 17 54 20 24 48 2 28 7 15 34 35 51 22 39 21 23 6 1 6: 53

2910-878-9932

2920-647-3899 5307-741-0162 5307-638-7608 5307-638-7608 5307-638-7608 5307-638-7608 3110-554-3197 3110-516-5490 3110-555-5207 3110-554-2979 3110-529-9480 47$0-278-3388 4730-278-3388 4730-278-3912 4730-202-6692 4730-200-0525 5306-019-2417 5310-022.5853 4730-585.2906 4730-810-7039 5310-298-9252 5306-042-5828 4730-640-6582 4730-044-4035 4730-710-9486 4730-044-4715 4730-044-4715 5310-638-2247 5330-291-2830 5340-177-4213 5310-167-0821 5310.167-0835 5340-050-2740 5340-050-2740 4730-278-2068 4730-278-2065 4730-278-2065 4730-278-2065 5330-187-3615

21450-573043 5340-057-3043 21450-583288 5340-200-8975 21450-586365 5340-682-1619 21450-589929 5315-058-9929 21450-589929 5315-058-9929 21450-589929 5315-058-9929 21450-596281 5306-817-6131 21450.596610 5310-638-6274 21450-596610 5310-638-6274 21450-700078 3110-144-8518 21450-700081 3110-144-8662 21450-700580 3110-155-6675 21450-709460 3110-120-4367 21450-711004 3110-185-6535 21450-711206 3110-186-0964 21450-714038 3110-144-8927 24617-425592 5306-042-5592 29337-3L08M46 3110-516-5290 29337-3L11M46 3110-554-3272 43991-5306 3110-554-6080 53477-645A6 4820-242-4064 70040-1581742 73134-HM5MG 3120-516-0955 73134.HML5FG 3120-516-0953 73370-10428 73370-X21820 5305-486-2901 73370-X117220 73370-117228 77445-77913P8 5307-145-4675 81348-GGG-W-686 5120-221-7947 81348-WW-C400 4730-958-4069 Type E 0.500 in. od 81348-WW-P471 Type 14730-196-0903 Clallnl-yix )fl in. 5930-688-9882 81349-M12285-1-5 6850-264-6572 81348-MIL-D-3464 Class I 4720-278-1110 81349-MILH-6000 5120-797-2407 81349-MILT21309 Type3 CbmI Style A 5120-797-2405 81349-MILT21309 Type3 Class I Style A 5120-723-6833 81349-MILT 0021309A Table VII, Type V$ze2 4710-804-9249 83616-NS4TypeH 86988-C3062-1 86988-C3062-2 86988-C3062-3 86988-C3062-4 86988-C3062-5 86988-C3062-8 2910-106-1981 86988-C3062-9 86988-C3062-11 5306-206-4931 88044-4-3A 5306-182-2014 88044-4H-3A 5306-151-1420 88044-4-14A 5306-616-1248 88044.5-4A 5306-616-1248 88044-5-4A 5306-616-1248 88044-5-4A

B-n B-26 B-27 B-2 B-26 B-26 B-3 B-2 B-14 B-9 B-26 B-14 B-26 B-9 B-9 B-26 B-18 B-26 B-27 B-14 B-32 B-5 B-18 B-18 B-20 B-2o B-20 B-20 B-5 B-30 B-19 B-21 B-6 B-32 B-7 B-30 B-30 B-30 B-2 1 B-16 B-16 B-16 B-16 B-16 B-16 B-16 B-22 B-9 B-17 B-2 1 B-22 B-22

5 55 9 60 27 86 2 96 6 48 52 4 24 30 29 31 31 29 5 2 9 47 33 6 3 1 26 4 40 28 30 16 36 14 64 3 4 37 51 18 21 19 9.4 9.3 22 9.6 4 31 7 26 19 27

Part No,

Federal Stock No.

Fig.
No.

Item No.

Part No.

Federal Stock No.

Fig.

88044-5-4A 88044.5CH 11 88044-5H5A 88044-5H6A 88044-5H7A 88044-5H7A 88044-5H7A 88044-5-12A 88044-5H12A 88044-5 PC14A 88044-5-20A 88044-6-5A 88044-7H1OA 88044-176C6A 88044-177-24 88044-178H41A 88044-320-4 88044-735-12 88044-775-4 88044-779-4 88044-825-4 88044-883-8J 88044-960-6 88044-960-10 88044-960-10 88044-960-416 88044-960-416 88044-960-416 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044-960-516 88044960-716 88044-960-716 88044-960-716 88044-960-716 88044-960-716 88044-960-816 88044-6230-16 88044-122718 88044-122718 90005-A26422 90005-053340 90005-053344 90005-053345 90005-053347 90005-053348 90005-053349 94581 -KU20-75-450S 96906-15795-212 96906-15795-212 96906-15795-214 96906-15795-214 96906-15795-703

5306-616-1248 5306-180-3357 5306-182-2024 5306-182-2025 5306-182-2026 5306-182-2026 5306-182-2026 5306-616-2618 5306-182-2029 5306-527-4128 5306-151-2623 5306-180-0238 5306-638-5288 5306-944-7537 5306-180-0321 5306-807-9371 5310-176-8108 5340-193-0104 4730-278-0375 4730-278-5824 4730-277-9305 4730-595-4402 5310-167-0816 5310-167-0818 5310-167-0818 5310-141-1795 5310-141-1795 5310-141-1795 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0820 5310-167-0822 5310-167-0822 5310-167-0822 5310-167-0822 5310-167-0822 5310-167-0823 5330-256-0201 5315-241-2916 5315-241-2916 2910-203-3322

4730-032-2220 5310-081-4219 5310-081-4219 5310-080-6004 5310-080-6004 5310-656-0111

B-24 B-18 B-9 B-8 B-2 B-5 B-27 B-4 B-27 B-27 B-4 B-25 B-3 B-16 B-13 B-15 B-27 B-7 B-17 B-17 B-2 1 B-19 B-2 B21 B-23 B-5 B-19 B-27 B-2 B-4 B-5 B-6 B-6 B-6 B-9 B-n B-12 B-13 B-15 B-18 B-19 B-25 B-26 B-26 B-27 B-2 B-5 B-14 B-19 B-24 B-15 B-16 B-4 B-26 B-20 B-20 B-2o B-20 B-20 B-20 B-20 B-13 B-2 1 B-28 B-13 B-28 B-7

15 5 5 31 100 2 56 24 45 42 25 2 14 15 50 6: 54 15 17 30 9 75 45 12 38 51 64 97 23 4 18 54 71 17 34 9 44 21 10 46 7 7 46 55 93 12 24 40 47 30 9.2 50 13 15 7 23 21 22 25 24 12 11 5; 9 1

96906-16555-655 96906-16624-1062 96906-16624-1156 96906-16624-3031 96906-16625-1112 96906-16625-1125 96906-16625-1137 96906-16625-1137 96906-16625-1150 96906-16625-3283 96906-16625-3354 96906-16632-1031 96906-18153-63 96906-20002C8 96906-20426A4-20 96906-20822-4 96906-20995NC32 96906-20995NC32 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906.20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-20995NC40 96906-21O44N3 96906-21O44N3 96906-21044~4 96906-21O44N4 96906-21O44N4 96906-21O44N5 96906-21O44N5 96906-21O44N5 96906.21O44N5 96906-21O44N5 96906-21O44N5 96906-21O44N5 96906-21O44N6 96906-21O44N6 96906-21O44N6 96906-21O44N6 96906-21O44N6 96906-21O44N6 96906-21O44N6 96906-21O44N6 96906-21O44N6 96906-21O44N6

5315-828-4485 5340-803-7305 5340-803-7304 5340-282-5278 5340-801-2500 5340-804-2786 5340-754-1083 5340-754-1083 5340-804-3891 5340-882-5939 5340-282-1619 5340-663-1245 5305-914-6131 5310-149-9116 5320-264-4296 4730-231-4009 9525-803-3044 9525-803-3044 9525-990-7799 9525-990.7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-77~9 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 9525-990-7799 5310-877-5797 5310-877-5797 5310-877-5796 5310-877-5796 5310-877-5796 5310-088-0553 5310-088-0553 5310-088-0553 5310-088-0553 5310-088-0553 5310-088-0553 5310-088-0553 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950-0039 5310-950.0039 5310-950-0039

No. B-18 B-18 B-26 B-9 B-3 B-26 B-5 B-18 B-26 B-14 B-14 B-27 B-26 B-15 B-6 B-21 B-2 B-27 B-2 B-2 B-2 B-2 B-3 B-3 B-5 B-5 B-6 B-6 B-7 B-7 B-7 B-8 B-8 u B.1O B-14 B-15 B-21 B-22 B-24 B-24 B-26 B.27 B-27 :;9 B-5 B-22 B-23 B-7 B-7 B-7 B-7 B-21 B-24 B-26 B-2 B-5 B-6 B-6 B-7 B-7 B-13 B-14 B-15 B-25

Item No.

18 16 28 56 3 37 18 26 26 : 33 87 9 22 18 11 11 14 16 37 42 1 13 19 45 45 64 32 68 73 10 22 2 19 18 5 8 1 46 9 27 5 43 57 55 34 37 3 18 16 :: 74 12 :; 81 26 29 43 31 71 1 19 18 16 B-157

Part No,

Federal Stock No.

Fig. No,

Item No.

Part iv>,

Federal Stock No.

Fig.
No.

Item
No.

96906-21 O44N6 96906-21 O44N6 96906-21 O44N6 96906-21 O44N7 96906-21 O44N7 96906-21 O44N7 96906-21 O44N1O 96906-21045-4 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-5 96906-21045-8 96906-21O83N3 96906-21O83N3 96906-21O83N3 96906-21O83N3 96906-21208F5-20 96906-21208F5-20 96906-21208F-20 96906-21208F6-15 96906-21208F6-15 96906-21208F6-15 96906-21208F6-15 96906-21208F6-15 96906-21208F6-20 96906-21208F7-15 96906-21208F8-15 96906-21209F5-15 96906-21209F5-15 96906-21318-27 96906-21318-27 96906-21333-62 96906-21333-96 96906-21333-98 96906-21333-98 96906-21919F2 96906-21919G3 96906-21919G9 96906-21919G9 96906-21919G9 96906-21919G16 96906-21919G16 96906-21921-4 96906-21922-2C 96906-21922-4 96906-24400-8 96906-24400-8 96906-24400-10 96906-24537-1 96906-24539-1 96906-24665-132 96906.24665-134 96906-24665-138 96906-24665-145

5310-950-0039 5310-950-0039 5310-950-0039 5310-088-0552 5310-088-0552 5310-088-0552 5310-982-6809 5310-061-7325 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-982-4912 5310-062-4954 5310-902-6676 5310-902-6676 5310-902-6676 5310-902-6676 5340-514-2321 5340-514-2321 5340.514-2321 5340-291-3492 5340-291-3492 5340-291-3492 5340-291-3492 5340-291-3492 5340-990-7159 5340-634-7860 5340-291-3488 5340-847-0734 5340-847-0734 5305-253-5618 5305-253-5618 5340-282-7509 5340-088-1255 5340-809-1490 5340-809-1490 5340-526-2559 5340-535-6469 5340-298-9406 5340-298-9406 5340-298-9406 5340-535-6471 5340-535-6471 4730-554-8015 4730-542-2813 4730-289-8619 5310-208-5775 5310-208-5775 5310-282-7822 6685-814-5271 6620-993-5546 5315-839-2325 5315-839-5820 5315-252-5987 5315-753-8333

B-26 B-26 B-26 B-2 B-14 B-24 B-15 B-17 B-6 B-6 B-6 B-8 B-1 1 B-n B-12 B-13 B-15 B-15 B-18 B-21 B-22 B-24 B-24 B-26 B-15 B-1 1 B-17 B-21 B-23 B-2 B-5 B.26 B-2 B-8 B-8 B-8 B-25 B-2 B-2 B-4 B-4 B-19 B-2 B-7 B-19 B-21 B-19 B-21 B-21 B-1 1 B-1 1 B-17 B-19 B-1 1 B-21 B-19 B-21 B-19 B-n B-19 B-11 B-6 B-2 B-25 B-27 B-6 B-18

1 35 69 32 23 48 26 11 19 55 70 4 29 40 8 20 20 28 3 4 8 21 55 45 31 22 :2 11 45 25 16 73 12 16 18 15 72 95 44 47 20 74 2 39 37 36 20 34 32 23 24 12 31 35 21 53 32 25 11 3: 36 6 66 23.3 8

96906-24665-145 96906-24665-145 96906-24665-283 96906-24665-285 96906-24665.291 96906-24665-300 96906-24665-302 96906-24665-357 96906-24665-359 96906-27183-10 96906-27183-15 96906-27183-23 96906-27183-25 96906-27183-27 96906-28741-8-0134 96906-28741-8-0204 96906-28741-8-0260 96906-28741-8-0300 96906-28741-8-0340 96906-28775-011 96906-28775-011 96906-28775-110 96906-28775-112 96906-28775-113 96906-28775-116 96906-28775-116 96906-28775-118 96906-28775-120 96906-28775-212 96906-28775-222 96906-28775-223 96906-28775-224 96906-28175-226 96906-28775-229 96906-28775-236 96906-28775-325 96906-28775-327 96906-28775-331 96906-28775-335 96906-29513-125 96906-35207-215 96906-35207-265 96906-35207-267 96906-35207-267 96906-35207-267 96906-35207-267 96906-35207-267 96906-35266-70 96906-35291-165 96906-35308-364 96906-35308-365 96906-35335-29 96906-35335-33 96906-35335-33 96906-35335-40 96906-35337-29 96906-35338-43 96906-35338-44 96906-35338-44 96906-35338-44 96906-35338-44 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338.45 96906-35338-45

5315-753-8333 5315-753-8333 5315-842-3044 5315-816-1794 5315-019-0777 5315-234-1863 5315-234-1864 5315-298-1481 5315.013-7214 5310-809-4058 5310-809-4061 5310-809-8533 5310-809-8540 5310-809-8541 4720-420-4396 2910-741-0397 4720-996-8329 4720-461-9797 4720-720-2050 5330-582-2133 5330-582-2133 5330-585-6663 5330-599-2934 5330-582-2855 5330-579-3156 5330-579-3156 5330-542-1586 5330-542-1329 5330-579-8156 5330-297-9990 5330-171-6649 5330-641-3407 5330-576-9732 5330-579-7918 5330-579-6861 5330-580-3846 5330-579-8156 5330-584-1186 5330-618-0800 5330-265-1089 5305-958-4346 5305-993-1848 5305-993-1851 5306-993-1851 5305-993-1851 5305-993-1851 5305-993-1851 5305-655-6556 5305-753-7088 5305-801-5747 5305-531-1097 5310-616-3554 5310-209-0786 5310-209-0786 5310-275-3683 5310-012-0239 5310-045.3296 5310.582-5965 5310-582-5965 5310-582-5965 5310-582-5965 5310-407-9566 5310-407-9566 5310-407-9566 5310.407-9566 5310-407-9566 5310-407-9566

B-26 B-26 B-3 B-6 B-14 B-13 B-2 B-9 B-25 B-20 B-13 B-19 B-n B-17 B-19 B-19 B-19 B-19 B-19 B-5 B-26 B-26 B-26 B-2 B-9 B-15 B-16 B-9 B-6 B-5 B-14 B-7 B-26 B-5 B-14 B-26 B-7 B-13 B-13 B.~o B-n B-7 B-n B-n B-17 B-19 B-21 B-21 B-32 B-12 B-12 B-n B-22 B-23 B-I9 B-19 B-2 1 B-19 B-2o B-22 B-28 B-5 B-7 B-7 B-8 B-lo B-n

41 75 20 23.2 16 47 76 41 IJ 12 54 10 3 21 43 48 57 42 64 28 73 42 81 3 9 11 6 8 39 44 8 23 4 8 22 56 38 36 26 16 48 53 20 33 25 35 33 46 13 3 1 49 54 3 14 23 47 52 11 50 23 3 48 58 29 2 14

B-158

Part No.

Federal Stock No,

Fig, No.

No,

Part No,

Federal Stock No.

Fig. No,

Item No.

96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-45 96906-35338-46 96906-35338-46 96906-35338-46 96906-35338-46 96906-35338-46 96906-35338-46 96906-35338-47 96906-35338-47 96906-35338-48 96906-35338-50 96906-35338-51 96906-35338-51 96906-35340-47 96906-35489-10 96906-35489-20 96906-35489-74 96906-35489-74 96906-35489-74 96906-35490-16 96906-35650-342 96906-35691-13 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-13 96906-35692-21 96906-35692-21 96906-35692-21 96906-35692-21 96906-35692-29 96906-35756-8 96906-35756-17 96906-35769-6 96906-35769-9 96906-35769-31 96906-35769-34 96906-35769-35 96906-35769-47 96906-35842-11 96906-35842-12 96906-35842-12 96906-35842-13 96906-35842-14 96906-35842-15 96906-35914-112 96906-35914-114 96906-39132-1 96906-39202-3 96906-39206-3 96906-39206-3 96906-39206-9 96906-39210-1 96906-39210-13 96906-39210-13 96906-39212-3 96906-39212-3 96906-39231-3 96906-51085-1

5310-407.9566 5310-407-9566 5310-407-9566 5310-407-9566 5310-401-9566 5310-637-9541 5310-637-9541 5310-637-9541 5310-637-9541 5310-637-9541 5310-637-9541 5310-209-0965 5310-209-0965 5310-584-5272 5310-820-6653 5310-584-7888 5310-584-7888 5310-655-9370 5325-184-9846 5325-174-9038 5325-276-6096 5325-276-6096 5325-276-6096 5325-682-1471 5310-934-9734 5310-853-9335 5310-849-6883 5310-849-6883 5310-849-6883 5310-849-6883 5310-849-6883 5310-849-6883 5310-849-6883 5310-849-6883 5310-842.1488 5310-842-1488 5310-842-1488 5310-842-1488 5310-842-1295 5315-616-5526 5310-012-4553 5330-543-3261 5330-855-6045 5330-199-5884 5330-269-2845 5330-199-5886 5330-269-2844 4730-908-3194 4730-908-3193 4730-908-3193 4730-909-8627 4730-908-6292 4730-908-6293 5340-434-6850 5340-616-5014 6680-973-1263 4730-278-4496 4730-781-6530 4730-781-6530 4730-350-9786 4730-069-1184 4730-052-9876 4730-052-9876 4730-052-9877 4730-052-9877 4730-254-1801 1660-025-3493

B-13 B-15 B-18 B-19 B-28 B-13 B-16 B-16 B-19 B-25 B-28 B-19 B-32 B-2 B-32 B-16 B-32 B-14 B-2 1 B-7 B-13 B-21 B-24 B-22 B-n B-18 B-2 B-7 B-9 B-14 B-18 B-25 B-26 B-27 B-2 B-3 B-26 B-26 B-13 B-18 B-14 B-6 B-10 B-8 B-6 B-6 B-6 B-7 B-1 1 B-1 1 B-7 B-28 B-28 B-24 B-24 B-5 B-19 B-19 B-21 B-19 B-21 B-19 B-21 B-19 B-21 B-2 B-21

22 15 12 47 2 5 9.5 14 5 1 10 4 10 5 17 16 3 28 22 36 56 6 7 30 50 29 38 67 18 13 9 20 76 54 15 21 40 76 48 4 11 62 14 23 40 68 2 51 17 41 56 6 13 24 2 48 38 62 43 54 52 58 41 59 39 40 44

96906-51093-4 96906-51096-60 96906-51096-60 96906-51096-64 96906-51096-306 96906-51096-335 96906-51037-7 96906-51967-20 96906-51968-23 96906-51981-36 96906-90530.2 96906-90725-5 96906-90725-8 96906-90725-40 96906-90725-47 96906-90726.15 96906-90726-16 96906-90726-31 96906-90726-48 96906-90726-52 96906-90726-60 96906-90726-63 96906-90726-84 96906-90726-89 96906-90726-90 96906-90727-6 96906-90727-8 96906-90727-32 96906-90727-32 96906-90727-32 96906-90727.32 96906-90727-32 96906-90727-33 96906-90727-33 96906-90727-33 96906.90727-33 96906-90727-34 96906-90727-34 96906-90727-34 96906-90727-42 96906-90727-45 96906-90727-59 96906-90727-60 96906-90727-60 96906-90727-61 96906.90727-62 96906-90727-64 96906-90727-67 96906-90727-69 96906-90727-87 96906-90727-88 96906.90727-112 96906-90728-3 96906-90728-3 96906-90728-9 96906-122161 96906-124696 96906-124697 96906-124697 96906-124697 96906-124697 96906-124697 96906-124697 96906-124697 96906-124697 99066-GU7837

5305-682-5881 5306-816-9326 5306-816-9326 5305-811-0638 5305-910-7369 5306-852-7104 5306-017-6143 5310-763.8920 5310-763-8901 5305-715-1221 5930-692-9258 5350-068-0501 5305-225-3839 5306-225-8504 5306-225-8511 5305-267-8982 5305-267-8983 5306.225-9086 5306-225-9103 5306-225-9107 5305.269-2803 5305.269-2806 5305.710-4189 5305-710-4194 5305-710-4195 5305-655-6361 5305-068-0515 5306-050-1238 5306.050-1238 5306-050-1238 5306-050-1238 5306-050-1238 5306-051-4075 5306-051-4075 5306-051-4075 5306-051-4075 5306-051-4076 5306-051-4076 5306-051-4076 5306-051-4084 5306-051-4087 5305-269-3235 5305-269-3236 5305.269-3236 5305-269-3237 5305-269-3238 5305-269.3240 5305-269-3243 5305-269-3245 5305-709-8523 5305-709-8515 5305-725-0154 5305-071-2506 5305-071-2506 5305-225-3842 5340-286-2458 5340-291-3484 5340-291-3495 5340-291-3495 5340-291-3495 5340-291-3495 5340-291.3495 5340-291-3495 5340-291-3495 5340-291-3495 2910-878-9933

B-8 B-21 B-24 B-9 B-5 B-26 B-30 B-32 B-32 B-3 B-2 B-22 B-2o B-10 B-10 B-19 B-23 B-7 B-19 B-19 B-19 B-13 B-2 B-32 B-32 B-27 B-28 B-7 B-7 B-n B-15 B-28 B-7 B-lo B-1 1 B-28 B-5 B-7 B-18 B-10 B-4 B-28 B-13 B-13 B-26 B-26 B-25 B-13 B-25 B-5 B-19 B-2 B-22 B-23 B-17 B-2o B-28 B-2 B-2 B-2 B-6 B.8 B-9 B-26 B-26 B-16

9 2 8 11 46 6 29 18 2 17 41 17 10 1 25 53 20 49 44 17 6 53 94 11 12 28 22 57 61 53 14 14 9 11 13 1 15 12 13 22 28 11 7 57 63 83 4 4 9 11 3 4 49 4 37 20 24 48 65 66 5 19 28 85 91 5

B-159

Part No. 99066-SD7877 99066-SR7827 99551-648557 99551-2480888 81348 5165292 5379997 5702609 5702614 5702615 5702616 5702617 5702619 5702620 5702621 5702622 5702641 5702659 5702666 5702670 5702674 5702690 5702738 5702757 5704344 5704348 5704351 5704366 7017550 7017550 7017826 7025886 7025892 7033684 7039742 7039744 7039746 7039746 7039746 7039747 7044068 7044069 7045881 7045881 7044669 7046669 7046670 7046670 7053981 7062194 7062195 7062196 7062197 7062198 7065766 7065767 7083696 7083697 7083698 7083699 7084278 7084438 7084439 7084444 7084445 7084497 7084498

Federal Stock No. 2910-936-2276 5340-089-8836 4730-196-0888 5330-291-7390 5120-473-7222 2815-678-1842 2815-678-1838 2815-678-1837 2815-678-3230 2815-678-3229 2815-679-8057 . 2930-678-3268 2930-678-7099 2930-678-3269 2910-545-1558 2940-884-4801 2815-856-4996 2815-856-9005 5365-235-1941 2910-967-9870 2910-801-1152 2815-808-2407 2815-179-7047 3120-491-0314 3120-477-3780 2910-762-4587 5340-679-8116 5340-679-8116 4710-805-4149 2815*884-1981 2815-679-4969 5330-632-2098 5307-678-3315 5307-806-6047 5306-678-3324 5306-678-3324 5306-678-3324 5306-678-3323 5307-678-3536 5307-678-3535 5330-290-8154 5330-290-8154 5307-679-4985 5307-679-4985 5307-679-4989 5307-679-4989 2990-974-7605 2815-117-9337 2920-767-1736 2990-369-8766 2990-770-1641 5307-706-5766 5307-706-5767 5110-708-3696 5110-708-3697 5110-708-3698 5110-708-3699 2920-678-7101 5307-678-3534 5307-678-3533 5307-678-6876 5307-678-6877 5307-438-1809 5307-477-3736

Fig. No. B-16 B-16 B-16 B-16 B-6 B-4 B-30 B-4 B-4 B-4 B-3 B-3 B-5 B-27 B-26 B-26 B-27 B-6 B-1 B-16 B-20 B-20 B-20 B.4 B-3 B-4 B-16 B-4 B-5 B-2 1 B-6 B-2 B-4 B-4 B-4 B-6 B-7 B-7 B-6 B-2 B-2 B-6 B-7 B-9 B-26 B-9 B-26 B-2 B-21 B-2 1 B-21 B-2 1 B-2 1 B-26 B-26 B-30 B-3o B-3o B-30 B-15 B-7 B-7 B-26 B-26 B-2 B-2

Item
No.

Part
No.

Federal Stock NO 5307-679-5684 5307-801-4819 2940-939-7123 5365-408-1268 2815-678-3211 2815-678-3210 5306-678-3316 2815-454-8599 5340-678-3532 2815-110-4093 2815-489-2576 2815-678-3209 2815-678-3208 2815-678-3207 2815-679-8058 5330-411-2512 2805-678-4243 2815-411-3965 4710-245-8305 2990-678-4676 2805-678-4244 2930-411-5749 2910-678-4722

Fig, No. B-13 B-13 B-6 B-4 B-4 B-4 B-27 B-27 B-4 B-4 B-2 B-5 B-5 B-4 B-4 B-4 B-4 B-5 B-26 B-9 B-7 B-3 B-9 B-13 B-15 B-9 B-8 B-26 B-26 B-8 B-8 B-26 B-2 B-26 B-26 B-16 B-4 B-4 B-8 B-2 B-17 B-14 B-15 B-16 B-17 B-6 B-9 B-21 B-5 B-26 B.8 B-16 B-8 B-7 B-22 B-27 B-24 B-2 B-9 B-8 B-6 B-6 B-26 B-26 B-2 B-2 B-2

Item No. 25

1 3 13 12 37 55 5 5 5

5 49 10 40 56 6 27 45 45 44 33 72 65 23 23 33 13 34 18 34 18 85 29 14 9 32 8 19 19 41 43 42 39 27 21 21 89 89 98 98

7084530 7084531 7087519 7320384 7320395 7320396 7320400 7320404 7320407 7320408 7320411 7320414 7320415 7320420 7320427 7320428 7320429 7320430 7320440 7320441 7320442 7320444 7320451 7320458 7320459 7320461 7320462 7320463 7320464 7320465 7320466 7320469 7320476 7320478 7320480 7320485 7320495 7320496 7323983 7323991 7323994 7323986 7323988 7323990 7324661 7324900 7324901 7335555 7338646 7338667 7338669 7340058 7340060 7340061 7340190 7341633 7346573 7346699 7346699 7348596 7348668 7348668 7348668 7348668 7348671 7348782 7348782

22 9 39 18 16 17 7 64 6 20 8 64 :; 7 27 58 11 26 30 57 83 50.1 62 32 9.1 9.2 28 33 13 27 10 20 12 41 40 15 40 72 24 17 34 66 .6 7 22

2930-350-9399 2930-408-4684

5310-682-5851 5310-678-5370 5305-988-1723 5306-678-4260 2910-678-4725 2910-678-3299 4730-678-3303 5310-851-4278 2910-790-2303 5307-733-8646 2805-733-8667 5315-282-1510 5310-655-9590 5306-678-3531 5310-685-8218 5305-655-9663 5306-678-4259 6620-734-6573 5306-182-2023 5306-182-2023 5307-734-8596 5307.734-8668 5307-734-8668 5307-734-8668 5307-734-8668 5307-734-8671 5307-734-8782 5307-734-8782

50 23 67 87 67 86

B-160

Part No.

Federal Stock No.

Fig.
No.

Item No.

Part No.

Federal Stock No.

Fig. No.

Item No.

7348783 7348797 7348798 7348803 7348803 7348803 7348804 7348804 7348804 7348812 7348813 7350201 7350206 7363442 7363443 7363446 7363447 7372030 7374145 7384968 7385174 7403193 7403580 7403610 7403615 7410163 7410395 7413736 7414564 7414564 7414569 7414569 7414584 7414584 7414584 7415112 7415117 7415354 7415384 7415385 7416621 7416591 7416591 7416636 7416751 7538990 7538990 7538990 7538990 7538990 7538990 7538997 7538997 7539274 7539735 7539838 7539839 7538990 7723892 7738011 7744555 7744555 7744564 7744570 7744570 7744572 7744573

5307-734-8783 5307-734-8797 5307-734-8798 5307-7348803 5307-734-8803 5307-734-8803 5307-734-8804 5307-734-8804 5307-7348804 5307-734-8812 5307-734-8813 3120-735-0201 5307-679-4990 5307-679-4987 5307-679-4986 5307-679-4988 5310-737-2030 5340-737-4145 5340-738-4968 5340-738-5174 5310-012-2198 5340-740-3580 4730-278-3030 5340-409-8060 5307-741-0163 5307-741-0395 2910-031-9083 5310-741-4564 531 O-741-4564 5306-150-9104 5306-150-9104 5306-741-4584 5306-741-4584 5306-741-4584 5306-151-2626 2910-741-5354 5307-741-5384 5307-741-5385

5306-400-7637 5330-292-7363 4730-0444689 4730-0444689 4730-0444689 4730-0444689 4730-0444689 4730-0444689 4730-753-8997 4730-753-8997 4730-753-9274 5315-753-9735 2805-753-9838 2805-753-9839 5330-772-3892 5307-837-7791 5307-7744555 5307-774-4555 5307-2642471 5310-7744570 5310-774-4570 53V7-774-4572 5307-774-4573

B-2 B-2 B-2 B-2 B-2 B-26 B-2 B-2 B-26 B-6 B-6 B-8 B-10 B-9 B-9 B-9 B-9 B-6 B-6 B-1 1 B-15 B-18 B-24 B-6 B-5 B-26 B-8 B-20 B-22 B-24 B-1 1 B-26 B-22 B-24 B-24 B-2 B-12 B-15 B-14 B-14 B-20 B-2 B-2 B-2 B-2 B-2 B-6 B-9 B-13 B-26 B-26 B-2 B-6 B-19 B-2 B-4 B-4 B-13 B-2 B-13 B-4 B-6 B-26 B-12 B-15 B-6 B-6

86 69 69 !: 22 19 53 22 8 8 20 7 14 14 35 35 & 19 16 15 23 ;; 90 17 17 20 5 37 34 23 16 29 10 14 23 26 26 14 80 89 13 90 64 10 22 39 17 68 50 35 49 34 40 38 45 6 15 43 77 104 6 3 67 67

7744605 7744610 7744617 7744685 7744720 7744795 7744798 7744803 7744803 7744813 7744813 7744858 7748837 7748870 7748905 7751056 7767317 7767318 7767331 7767333 7767334 7767336 7767336 7767337 7767337 7767340 7767348 7767350 7767350 7767361 7767363 7767519 7767728 7767804 7767804 7767804 7767805 7767805 7950177 7954708 7971982 7971983 7998574 7992645 7992645 7992646 7992646 7992649 7992649 7992650 7992650 7992653 7992657 7992658 7992665 7992666 7992669 7992670 7992673 7992674 7992677 7992677 7992678 7992678 7992681 7992682 7992685

5307-774-4605 2805-774-4610 2805-678-1591 5306-774-4685 5306-774-4720 5307-774-4795 2805-774-4798 5307-774-4803 5307-774-4803 5307-264-2472 5307-264-2472 2930-774-4858 5310-861-1406 5120-251-1527 5310-776-7317 5310-776-7318 5355-776-7331 5307-776-7333 5307-776-7334 4730-776-7336 4730-776-7336 4730-776-7337 4730-776-7337 5307-727-4938 5307-776-7348 5310-209-2629 5310-209-2629 5307-776-7361 5315-776-7363 5330-738-0543 5310-776-7728 5307-776-7804 5307-776-7804 5307-776-7804 5307-776-7805 5307-776-7805 5120-795-0177 4730-699-7899 5307-207-8620 5307-207-8619 5325-682-7076 5307-678-3530 5307-678-3530 5307-678-3529 5307-678-3529 5307-678-6880 5307-678-6880 5307-678-6881 5307-678-6881 5307-678-3528 5307-678-3526 5307-678-3525 5307-678-6882 5307-678-6883 5307-678-3524 5307-678-3523 5307-678-3320 5307-678-3321 5307-678-3522 5307-678-3522 5307-678-3521 5307-678-3521 5307-678-3520 5307-678-3519 5307-678-3518

B-26 B-4 B-4 B-5 B-23 B-26 B-4 B-4 B-6 B-5 B-26 B-22 B-16 B-6 B-6 B-30 B-4 B-7 B-2 B-9 B-9 B-2 B-6 B-2 B-8 B-2 B-7 B-8 B-26 B-7 B-3 B-5 B-25 B-4 B-6 B-13 B-6 B-13 B-30 B-8 B-26 B-26 B-24 B-2 B-2 B-2 B-2 B-26 B-26 B-26 B-26 B-2 B-2 B-2 B-26 B-26 B-2 B-2 B-26 B-26 B-2 B-2 B-2 B-2 B-2 B-2 B-2

78 20 15 20 17 78 19 43 77 29 104 51 24

38 32 34 9 59 59 68 6 52 11 87 24 32 33 24 25 39 11 51 78 37 78 37 22 21 20 20 10 22 59 22 59 80 95 80 95 25 28 28 103 103 57 57 71 71 24 54 :; 55 55 56

B-161

Part
No.

Federal
Stock No.

Fig. No.
B-2 B-26 B-26 B-2 B-2 B-2 B.2 B-6 B-22

rt.en
No.
56 10 10 21 21 92 92 66 37.2 20 63 17 46 79 42 18 8 42 64 56 56 30 38 ;: 15 14 2 7 1; 16 7 17 27 14 17 27 14 17 2 84 27 42 49 10 30 33 10 18 13 3; 70 70 22 5; 34 30 20 21 14 27 27 10 4

Part
No.

Federal
Stock

No.

Fig, No.

Item
so

7992686 7992689 7992690 7992693 7992694 7992697 7992698 7994794 8343678 8343854 8343854 8352634 8352634 8352634 8352635 8352636 8355883 8357819 8357967-4 8365383-2 8365383-3 8365671 8365809 8365809 8365810 8365810 8375091 8375324 8376456 8393931 8395460 8395476 8666561 8666736 8666736 8666736 8666737 8666737 8666737 8666738 8679574

5307-678-3517 5307.678-6884 5307.678-6885 5307-678.3516 5307-678-3515 5307-678-3514 5307-678.3513 5340-799-4794 5340-834.3854 5340-834-3854 5340-678-3311 5340-678-3311 5340-678-3311 5340.678-3310 5340-678-330g 6685-906-0156 2805-304-9365 5307.995-8205 5307.9566460 5306-335-4244 5307-272.6331 5307-272-6331 5307-272-6332 5307-272-6332 5120-837-5091 5120-710-7437 4820-304.9415 3110-227-3620 5330-678-7106 2910-795-1783 5310.682-5631 5307-866-6736 5307-866-6736 5307-866-6736 5307-866-6737 5307-866-6737 5307-i166-6737 2920-318-4127 5310-588-0393 5310-333-7348 53J0-333-7348 5310.333-7348 5810-333-7348 5310-333.7348 5310-333.7348 5310-333-7348 5310-333-7348 5310-333-7348 $310.333-7348 5310.333-7348 5310-333-7348 5310-333-7348 2590b629-1268 2815-406-4613 2990-453-5387 2930-678.3271 2815A406-4618 2815-679.8056 2930-679-8091 5307-678.3510 5307-678-3509 2990-678-4695 2815-678-3270

B-6
B-6 B-2 ;:;6 B.4 :::2 B-24 B-7 B.24 B-24 B.4 B-13 B-26 B-13 B-26 B-3o B-30 B.32 B-18 B-14 B-19 B-22 B-7 B-7 B-8 B-7 B-7 B-8 B-15 B-22 B-2 B-5 B-6 B-6 B-7 B-7 B-8 B-9 B-14 B-25 B-26 B-26 B-26 B.7 B-7 B-13 B-26 B-5 :: B-26 B-23 B-2 B-2 B-21 B-15

86795i6
8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679576 8679577 8682441 8682451 8682455 8682467 8682468 8682469 8682469 8682492 8682500 8682501 8682503 8682505

8682512 8682513 8682513 8682523 8682523 8682524 8682527 8682539 8682540 8682553 8682558 8682560 8682564 8682620 8682623 8682626 8682658 8682662 8682665 8682670-8 8682670-8 8682671 8682673 8682674 8682676 8682677 8682679 8682680 8682682 8682683 8682684 8682684 8682689 8682691 8682692 8682693 8682700 8682701 8682702 8682708 8682709 8682711 8682721 8682729 8682730 8682731 8682732 8682733 8682734 8682736 8682737 8682738 8682739 8682745 8682748 8682749 8682750 8682751 8682752 8682753 8682754 8682755 8682756 8682757 8682761 8682762 8682763

2815-679-4961 2815-679-4961 2815-834-1158 2815-833-8162 2815-455-9496 2990-402-4430 2815-193-8200 2815-679-8054 2930-679-8092 2930-436-3207 2930-522-2576 2930-350.9401 2815-235-4445 9320-181-0119 9320-181-0119 5365-407.7011 2815-193-8213 2590-932-5001 2930-678-4669 5330-678-5388 2930.442-5895 2590-851-4909 2815-678-4239 2815-678-4238 2930-678-4668 2930-678-4667 2930-679.8093 2930-679-8090 5340-089-8830

B-2 B-2 B-26 B-7 EM B-8 B-8 B-26 B-5 B-26 B-13 B-22 B-5 B-23 B-22 B-22 B-25 B-6 B-27 B-24 B-24 B-24 B-24 B-26 B-18 B-18 B-24 B-1 1 B-25 ;~;6 B-26 B-14 B-14 B-24 B-24 B-23 B-23 B-23 B-18 B-18 B-9 B-5 B-27 B-27 B-27 B-27 B-27 B-3 B-2 B-2 B-24 B-24 B-5 B-13 B-13 B-13 B-5 B.13 B-lo B-2 B-22 B-22 B-22 B-22 B-22 B-26

62 58 102 19 1 98 6 74.2 2 5 13 16 39 40 3 34 15 35 49 49 35 30 17 20 53 28 17 49 50.2 74.1 34 15 41 1 8 9 13 21 19 57 17 13 19 17 14 3 16 8 7 51 50 50 49 11 8 43 52 20 6 43 42 38 48 56 101

2815-760-5871 2910-678-4728 2910.678-4729 2815-679-4970 2815-489-2575 2930-168-2625 2815-411.5789 3120-679-8098 2815-406-41$11 2815-406-4610 2990.402-4432 2815-177-7918 2990-453-5386 2815-071-8124 5330-441-2513 2815-193-8214 2805-760-5837 2805-760-5838 2815-193-8212 2815.193-8203 5315-497-9650

B-162

Part No,

Federal Stock No,

Fig, No.

Item No.

Part No,

Federal Stock No.

Fig. No,

Item No.

8682764 8682765 8682769 8682770 8682771 8682772 8682774 8682781 8682782 8682783 8682785 8682786 8682787 8682797 8682799 8682800 8682802 8682804 8682805 8682814 8682815 8682816 8682817 8682820 8691451 8691452 8698689 8698690 8698759 8698764 8698852 8708361

5330-678-3508 2920-248-4631 2815 -679-7C!64 5330-678-5386 5340-242-5599 2815-679-6482 5310-679-9880 2590-678-4129 2930-169-5798 2990-484-0771 2930-997-1537 3040-406-1537 5307-682-5820 2990-678-4681 4730-406-7307 2815-679-7062 2930-678-4665 5307-678-3507 5307-678-3506 2815-678-4236 2940-678-3276 4730-223-7014 2815-136-1201 2815-679-4972 5307-272-6334 5307-272-6335 5340-209-0174 5310-637-3057 2815-679-7063 5340-205-9307 4730-090-9182 5120-575-7767 4910-554-1317 5120-310-4668 2920-973-1557 2805-599-0942 5305-206-3851 5340-205-4658 5315-141-6337 5315-141-6338 5306-206-3850 5330-663-4773 5330-663-4773 2815-678-1841 5310-655-9937 5306-678-1887 3120-678-1869

8717158 8717161 8717162 8717298 8717299 8717322 8720953 8720953 8724974 8724976 8724977 8724978 8724979 8724980 8724985 8724985-1 8724986 8724986-1 8724987 8724987-1 8724995 8724995-1 8724996 8724996-1 8725003 8725004 8725084 8725087 8725096 8725099 8725100

2815-678-3203 2815-678-3202 2815-679-4968

B-8 B-27 B-13 B-n B-7 B-10 B-13 B-18 B-24 B-18 B-25 B-18 B-13 B-13 B-13 B-13 B-24 B-2 B-2 B-14 B-6 B-5 B-5 B-3 B-9 B-9 B-13 B-13 B-13 B-13 B-2 1 B-30 B-29 B-30 B-15 B-7 B-7 B-7 B-7 B-3 B-3 B-3 B-20 B-20 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-4 B-3 B-3 B-3 B-3 B-3 B-3 B-3 B-3 B-4 B-4 B-3 B-9 B-9 B-9 B-9

6 62 43 15 8 12 33 11 20 14 14 35 9 17 32 24 43 29 29 31 3 24 21 10 13 13 35 34 19 27 27 36 5 21 24 44 43 4 5 18 18 11 2.1 5.2 1 6 4 3 7 8 5 5 i.1 -i.4 7.4 7.1 -(.2 2.3 7.3 7.2 14 37 19 50 49 36 43

8725101 8725113 8725115 8725119 8725120 8725121 8725130 8725134 8725140 8725141 8725145 8725146 8725151 8725170 8725176 8725177 8725179 8725180 8725181 8725184 8725193 8725195 8725196 8725197 8725201 8725203 8725207 8725211 8725218 87~5222 8725224 8725225 8725226 8725227 8725229 8725232 8725233 8725236 8725238 8725239 8725240 8725243 8725246 8725248 8725249 8725250 8725253 8725254 8725255 8725256 8725257 8725261 8725265 8725266 8725273 8725275 8725276 8725277 8725281 8725286 8725291 8725292 8725293 8725296 8725298 8729069

2815-679-4966 2815-679-4964

2815-678-3228

5310-753-4014 2815-678-3201 2815-678-3200 2815-678-3199 2815-678-3198 2815-238-9191 2940-115-9014 5340-220-5168 2940-678-3277 2940-678-3278 5365-402-8380 2815-678-3218 4820-406-4619 2815-937-4846 2930-498-9359 2930-438-1590 5340-490-0872 2815-678-3221 2815-678-3222 3040-179-6656 5365-408-1270 2815-678-4246 2815-679-4961 2940-678-3280 2815.125-3891 2815-678-3227 2815-678-3220 5315-238-9239 2940-067-7900 2815-678-3226 2815-679-4963 2815-678-3219 2990-498-2398 2915-678-3223 2520-678-3171 2815-678-3195 2940-678-3279 5305-678-3327 2910-678-4673 2815-678-3194 5330-678-3313 5307-678-3314 2910-851-5360

B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-2 BJ2 B-2 B~2 B-4 B~2

37 38 39 20 24 25 46 45 ,1 88 99 46 54 ;8

B-4 B-4 B-2 B-2 B-6 B-6 B-6 B-6 B-6 B-b B-6 B-6 B-6 B-6 B-6 B-5 B-26 B-26 B-5 B-9 B-26 B-2 B-2 B-6 B-6 B-26 B-6 B-27 B-3 B-6 B-5 B-2 B-6 B-2 B-6 B-2 B-l-1 B-6 B-2 B-14 B-6 B-6 B-4 B-6 B-6 B-15 B-4 B-4 B-4 B-20

37 37 91 44 27 72 25 26 23.3 53 24 Ii 1 4 14 i60~ 84 53 16.1 16 39 49 -iO 16 13 48 69 4 12 75 14 79 76 82 21 39 11 47 20 12 47 34 73 32 22 33 31 52 5.4

B-163

Part No. 8729070 8729071 8737840 8743025 8744055 8745480 8748329 8759089 8761008 8761009 8761010 8761011 8761015 8761016 8761018 8761020 8761021 8761022 8761023 8761029 8761030 8761032 8761033 8761037 8761041 8761046 8761047 8761048 8761049 8761050 8761052 8761057 8761058 8761059 8761062 8761063 8761064 8761066 8761067 8761068 8761069 8761070 8761080 8761081 8761082 8761085 8761086 8761087 8761089 8761091 8761092 8761098 8761099 8761100 8761101 8761103 8761104 8761106 8761107 8761109 8761122 8761123 8761124 8761125 a7bl127 8761128 8761129

Federal Stwk No. 2910-791-3352 4910-795-7961 5310-679-5685 5310-535-6688 2940-863.7737 2910-790-2301 2815-193-8210 2815-194-2453 3040-406-1536 2990-402-4429 2990-402-4431 2930-678-3265 2815-679-5668 2815-937-1467 2815-071-8126 2930-457-6731 2815-575-0399 2930.938-8179 2815-406-4620 2815-071-8125 2910-678-4730

2930-179-7051 2930-678-3266 4710-477-9899 2930-421-1592 2930-179-7049 4710-477-9900 2930-678-3267 2930-435-7644 2930-933-6957 2930-421-1591 2930-421-1590 5340-484-0865 2815-406-4614 2910-402-4422 2990-402-4433 5330.679-6483 2815.193-8192 4730-679-5682 2930-570-9707 2815-193-8215 2930-442.5896 2930-350-9397 2815-193-8217 2930.406-7294 2930-402-4419 2930-457-0319 2930-436-3206 2990-897-2849 2930-350-9394 2930-350-9398

2815-406-4617

Fig. No. B-20 B-20 B-20 B-30 B-10 B-6 B-6 B-17 B-22 B-22 B-24 B-24 B-18 B-18 B-18 B-26 B-13 B-14 B-9 B-24 B-24 B-25 B-13 B-9 B-27 B-13 B-24 B-24 B.24 B-25 B-10 B-22 B-24 B-10 B-27 B-27 B-27 B-27 B-27 B-22 B-22 B-24 B-2 B.14 B-13 B-2 B-13 B-15 B-22 B-10 B-24 B-23 B-22 B-24 B-23 B-24 B*22 B.21 B-22 B-7 B-24 B-24 B-7 B-8 B-7 B-7 B-7

Item No. 5.3 6 2.3 27 16 51 23.1 28 52 53 30 46 23 2 7 54 23 12 63 17 18 10 40 3 6 45 32 40 19 19 27 24 37 23 60 59 41 22 26 13 33 34 12 30 18 2 10 5 1 17 11 6 15 38 2 36 12 37 35 42 33 39 6 5 78 75 76

Part No. 8761130 8761131 8761132 8761137 8761138 8761148 8761149 8761155 8761156 8761157 8761158 8761159 8761160 8761161 8761162 8761163 8761164 8761186 8761189 8761190 8761192 8761193 8761199 8761200 8761203 8761204 8761206 8761223 8761226 8761227 8761229 8761230 8761232 8761238 8761239 8761241 8761242 8761243 8761244 8761250 8761251 8761253 8761255 8761257 8761258 8761259 8761260 8761261 8761262 8761268 8761269 8761270 8761271 8761271 8761271.1 8761271-1 8761272 8761273 8761274 8761279 8761280 8761281 8761287 8761294 8761295 8761297 8761300

Federal Stock No. 2815-679-4962 4710-150-6187 4730-406-4609 4730-406-7308 2815-455-9495 2930-678-4670 2930-068-6113 2815-177+243 2815-679-5667 2815-679-5666 2815-679-5665 2815-679-5664 2815-122-4963 2815-834-1159 2990-402-5201 5340-402-4435 2990-402-4423 2815-869-3,595 2815-073-5129 2815-485-9555 5307-678-6887 5307-678-6888 5307-678-3329 5307-678-3328 2930-177-9162 5310-685-8217 5310-682-5823 2930-678-3257 2815-356-8502 5310-408-2530 2930-077-2818 5310-682-5824 2930-679-5742 5340-462-2908 5310-406-7319

Fig.

No.
B-7 B-11 B-8 B-13 B-13 B-22 B-24 B-26 B-13 B-13 B-13 B-13 B-13 ;: B-lo B-23 B-26 B-lo B-lo B-lo B-lo B-26 B-26 B-26 B-26 B-26 B-5 B-26 B-27 B-27 B-25 B-22 B-27 B-27 B-27 B-25 B-12 B-26 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-24 B-23 B-22 B-22 B-22 B-24 B-22 B-24 B-2 B-14 B-9 B-2 B-5 B-5 B-26 B-24 B-6 B-30 B-22

2930-457-0314 2930-678-3256 2930-678-4671 5365-407-7003 2930-442-5894 2930-402-4421 9320-181-0118 ~320.181.ol18

5306-678-6889 5310-655-9859 5310-720-7627 2815.679-8053 2815-679-8055 2930-678-3255 2930-937-1430 5120-678-5282

Item No. 7 24 8 28 29 36 54 82 46 42 31 30 41 62 4 24 15 44 3 4 8 5 94 94 77 77 65 23 61 35 34 12 41 30 31 29 18 10 38 36 23 27 25 38 20 21 39 24 25 19 9 44 45 30 45 28 30 21 61 77 41 42 49 12 30 34 55

8-164

Part
No.

Federal Stock No.

Fig.
No.

Item No,

Part No,

Federal Stock No,

Fig. No.

Item No.

8761301 8761327 8761328 8761329 8761330 8761331 8761337 8761388 8761390 8761412 8761412 8761413 8761414 8761420 8761432 8761440 8761442 8761442 8761443 8761443 8761448 8761449 8761469 8761470 8761472 8761476 8761477 8761479 8761481 8761485 8761490 8761491 8761492 8761499 8761502 8761507 8761510 8761513 8761517 8761521 8761527 8761535 8761542 8761547 8761549 8761553 8761555 8761559 8761560 8761561 8761568 8761582 8761594 8761597 8761598 8764639 8764639 8764641 8764886 8764887 8764887 8764948 8764950 8764982 9402708 9402827 10863824

5306-678-3325 3110-481-2825 5340-678-4257 2815-679-8056 5310-402-8379 5306-678-1885 2815-678-4233 5307-678-6891 5307-678-6891 5307-678-6890 5307-678-6890 4710-194-2566 4730-457-1984 2815-412-9192 2815-194-2481 2930-350-9395 2930-350-9396 4710-485-9651 2815-406-7289 2910-678-3292 2990-678-3291 2910-678-3294 2990-678-3252 2910-678-3290 2990-678-3286 2910-678-3285 2815-678-3217 2815-678-3213 2815-678-3214 2815-678-3215 5120-678-5285 2940-436-3223 2815-678-3216 2990-678-3251 2990-678-3250 4730-933-3138 2990-678-3264 5120-678-5286 5120-678-5287 5120-678-5288 5120-672-8897 4730-406-7309 4370-223-7007 2815-575-0398 5310-655-9975 5310-655-9975 2910-678-3282 5330-514-5678 2815-678-3225 4730-678-3494 2910-678-4734 4730-334-7838 4730-815-0248 5306-678-4262

B-27 B-4 B-3 B-3 B-3 B-3 B-25 B-22 B-26 B-16 B-26 B-27 B-5 B-26 B-23 B-14 B-2 B-26 B-2 B-26 B-n B-n B-24 B-24 B-n B-24 B-24 B-n B-11 B-17 B-13 B-1 1 B-17 B-12 B-1 1 B-n B-19 B-12 B-12 B-12 B.12 B-29 B-6 B-12 B-12 B-12 B-1 1 B-12 B-3o B-30 B-30 B-3o B-12 B-lo B-lo B-22 B-24 B-19 B-14 B-22 B-24 B-3 B-1 1 B-26 B-n B-1 1 B-32

37.1 5 7.1 7.4 7.2 7.3 8 47 32 9.1 100 2 5 12 10 32 26 92 26 92 43 4 3 4 27 52 45 11 39 22 13 47 18 2 44 1 13 20 11 16 17 6 28 5 12 13 26 19 44 30 24 1 4 13 10 :: 63 25 46 27 15 6 25 7 46 15

10865001 10865022 10865074 10865170 10865180 10865182 10865183 10865184 10865240 10865247 10865250 10865252 10865262 10865266 10865267 10865268 10865272 10865277 10865283 10865289 10865290 10865292 10865297 10865298 10865299 10865316 10865317 10865319 10865320 10865321 10865322 10865323 10865324 10865331 10865332 10865333 10865334 10865335 10865336 10865351 10865355 10865361 10865363 10865364 10865365 10865369 10865374 10865375 10865381 10865382 10865383 10865393 10865394 10865396 10865398 10865400 10865402 10865404 10865406 10865408 10865410 10865412 10865414 10865416 10865420 10865422 10865425

2920-402-5204 2815-406-4622 2910-402-4423 2910-168-2624 2815-833-8164 4710-457-04-i9 2930-453-5364 2930-453-5376 2930-436-3208 2930-436-3197 2520-420-4982 2930-436-3196 2815-177-8216 2930-107-1221 2930-446-1757 2930-998-4724 2805-407-6761 2815-708-3018 4730-803-7728 2815-765-9711 2815-765-9712 5340-490-0871 5340-456-1792 2930-453-5362 2930-453-5363 5305-891-7871 3040-402-5217 2990-402-4428 2910-410-5758 2910-410-5755 2910-907-9566 2815-239-5810 2910-410-5756 2930-765-4364 2999-068-6115 281.5-194-2450 2815-193-8216 5340-114-0093 5340-407-0666 5310-239-5848 2815-767-3200 2910-078-5308 2910-078-5309 2910-078-5310 2910-078-5311 2910-078-5312 2910-078-5313 2910-078-5314 2910-078-5315 2910-078-5316 2910-078-5317 2910-078-5318 2910-078-5319 4710-194-2531 2815-402-2170 2910-767-1735

B-7 B-10 B-19 B-19 B-10 B-10 B-3 B-3 B-22 B-22 B-22 B-22 B-22 B-22 B-22 B-22 B-22 B-22 B-5 B-5 B-17 B-16 B-4 B-4 B-4 B-17 B-17 B-22 B-22 B-18 B-18 B-18 B-18 B-17 B-17 B-17 B-17 B-17 B-9 B-26 B-27 B-26 B-23 B-23 B-23 B-4 B-2 1 B-21 B-26 B-26 B-26 B-26 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-17 B-n B-1 1 B-2 1

18 26 7 15 15 19 23 24 25 26 18 28 32 14 31 21 22 29 31 32 19 7 13 41 12 38 10 11 34 30 28 32 27 29 40 9 8 36 58 9 63 3 7 1 5 9.3 7 25 97 96 99 93 6 5 4 3 2 1 30 31 32 33 34 35 36 16 19

B-165

Part No.

Federal
Stock No.

Fig.
No.

Item No.

Part
No.

Federal
Stock No.

Fig,
No.

Item No.

10865426 10865437 10865444 10865464 10865464 10865466 10865498 10882610 10882611 10882613 10882615 10882616 10882617 10882637 10882638 10882641 10882649 10882650 10882651 10882653 10882654 10882728 10882747 10882750 10882757 10882761 10882764 10882765 10882766 10882767 10882768 10882771 10882772 10882773 10882774 10882777 10882780 10882790 10882791 10882826 10882827 108.82888 10882890 108~2891 10882892 10882925 10882926 10882927 10882928 10882940 10882945 10882949 10882953 10882954 10882958 10882963 10882968 10882970 10883052 10883058 10883072 10883075 10883080 10883083 10883098 10883731 10883737

2910-767-1733 2930-766-0903 2910-767-1734 5430-493-4057 5430-493-4057 4730-805-0676 2815-177-9897 2815-795.1800 2815-617-8626 2815-817-9538 5210-793-7898 5210-793-7899 5210-793-7897 5307-533-3383 5307-533-3382 2910-879-1666 4910-795-7952 5120-793-7896 2540-453-5404 5120-793-7895 5306-413-4373 5315-490-5588 2920-402-5205 2910-795-1795 2920-455-5835 2940-937-1450 5340-456-1799 2910-821-0659 5340-489-8347 2910-455-5836 2920-177-7844 2920-498-9358 4910-795-7951 4710-406-1528 9905-407-5099 9905-407-5100 4910-795-7956 4710-438-1811 4910-795-7959 4910-795-7950 2815-876-2324

2815-866-2196 2910-792-5393 4910-795-7954 4910-795-7958 5120-448-0400 5120-448-0401 4910-795-7955 4910-795-7953 2815-545-1563 5307-410-5830 5120-448-0402 5120-448-7993 2815-821-4002 5120-448-0404 5306-453-5589 2815-406-4623 2910-827-2816 2815-763-1402 2920-803-0259

B-2 1 B-24 B-2 1 B-1 1 B-n B-2 1 B-5 B-3 B-6 B-3 B-30 B-30 B-30 B-9 B-9 B-n B-27 B-27 B-30 B-30 B-21 B-9 B-30 B-7 B-27 B-7 B-19 B-7 B-6 B-2 1 B-19 B-n B-6 B-14 B-7 B-2 1 B-2 1 B-30 B-10 B-7 B-7 B-30 B-1 1 B-30 B-30 B-9 B-9 B-9 B-9 B-17 B-29 B-30 B-30 B-30 B-29 B-30 B-4 B-2 B-3o B-30 B-7 B-29 B-7 B-10 B-27 B-28 B-28

31 44 23 35 38 40 33 4 48 5 17 18 19 15 15 51 8.1 8.2 13 8 5 44 6 25 32 29 50 15 52 49 55 52 46 29 26 38 50 7 9 3 77 11 30 32 33 52 53 55 54 27 8 16 10 9 7 20 11 71 35 31 14 8 11 21 16 21 20

10883740 10883745 10883748 10883940 10883941 10884033 10884034 10884037 10885485 10887592 10889688 10889711 10889713 10889714 10889715 10898735 10898738 10898746 10898756 10898763 10898763 10898777 10898778 10898779 10898793 10898793 10898793-1 10898794 10898861 10898862 10898874 10898875 10898877 10898878 10898888 10898891 10898907 10898908 10898910 10898915 10898919 10898928 10898933 10898962 10899041 10899180 10912162 10912163-1 10912163-1 10912163-2 10912260 10912261 10912262 10912269 10912270 10912271 10912298 10912390 10912391 10912444 10912447 10912450 10912452 10912453 10912455 10912477 10912478

2920-771-6968 2990-771-6969 2920-245-8162 5340-242-5601 5340-453-5595 5340-456-1798 5340-449-2580 2920-063-8127 2590-437-0990 4730-124-1376 2920-830-6660 2590-838-3596 5310-491-0327 4730-168-1935 2910-135-6523 5306-837-9469 2930-402-4420 5305-897-7481 5305-897-7481 2815-851-9176 2815-861-3829 2815-861-1447 2815-8 6-6165 2815-89 -6165 i 4720-177-6186 2815-896-6166 2815-117-0829

2815-895-6430

2815-861-1448 2815-846-1824 4910-986-9873 2815-899-1504 2815-851-6551 5340-194-4714 4910-870-6283 2815-457-9309 5310-886-3000 5310-886-3000 5310-886-3001 4910-856-4137 8115-856-8147 5330-493-2938 2990-498-9356 2910-402-4424 5340-242-5600 2910-064-6255 2815-064-6270 2910-064-6269 2815-404-7444 9905-419-5829 2990-064-6264 2990-064-6263

B-28 B-28 B-28 B-28 B-28 B-28 B-28 B-28 B-20 B-15 B-26 B-27 B-15 B-18 B-18 B-26 B-26 B-27 B-22 B-22 B-24 B-14 B-3 B-14 B-1 1 B-1 1 B-n B-n B-2 B-2 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-9 B-14 B-9 B-32 B-6 B-9 B-26 B-29 B-7 B-22 B-24 B-22 B-29 B-8 B-8 B-32 B-32 B-32 B-32 B-13 B-13 B-7 B-15 B-l-1 B-16 B-3 B-2 B-15 B:15

18 12 19 4 7 16 15 17 2.2 25 66 3 19 25 24 105 43 12 16 17 26 33 8 10 18 42 9 12 61 1 23 51 27 60 21 12 33 26 32

4; 1 31 42 8 2 69 20 5 2 1 13 25 5 6 1

25 9 63 1 1

B-166

Part N%. 10912481 10912558 10912589 10935214-1 N3935214-3 10935214-4 10935359 10935443-1 10935443-2 1o935447 10935471 10935473 10935476 10935478 10935478 10935478 10935497 10935532 10935536 10935537 10935539 10935540 10935541 10935613 10935614 10935615 10935619 10935621 10935622 10935623 10947970 10951061 10951075 10951077 10951079 10951081 10951083 10951084 10951119 10951122 10951123 10951124 10951167 10951230 10951231 10951334

Strck No.
29J0-064-6262 5330-438-1861 5220-988-8774 4720-477-3712 2910-781-1457 2910.078-4866 5340-437-7210 5340-437-7211 5325-182-4707 2990-411-8330 2920.902-3187 5120-789-4881 5330-498-6341 5330-498-6341 5330-498-6341 5120-078-3809 4910-937-4261 4730-902-3188 2930-902-3189 2910-402-4425 2930-156-9408 2815-406-4616 5360-410-5836 5330-410-9803 2815-406-4621 2910-999-9452 2930-435-4564 2930-435-4568 2930-435-4572

Federal

$
B.16 B.14 B-29 B-? B-7 B-19 B-16 B-12 B-12 B-2 1 B-28 B.28 B-3o B-13 B-2 1 B-24 B-30 B-3 1 B-19 B-27 B-26 B-26 B-26 B-7 B-7 B-7 B-7 B-7 B-7 B-7 B-19 B-16 B-27 B-27 B-27 B-27 B-27 B-27 B-27 B-24 B-7 B-24 B-16 B-32 B-32 B-19

No.

Part No. 10951341.1 10951341-2 10951368 10951369 10951394 10951395 10951396 10951426 10951427 10951429-1 10951429-2 10951430 10951434 10951434-1 10951460 10951462 10951463 10951482 10952220 11591013 11602061 11602062 11602063 11602943 11610150 11610167 11610171 11610232 11640132 11640132 11640392 11641819 11641917 11641919 11641922 11641923 11641927 11641928 11641930 11641931 11641939 11641940 11642028 11642029 11642030

Federal Stock No, 4720-177-6188 4720-177-6189 4710-401-4368 3110-462-0392

Fig, No. B-17 B-17 B-1 1 B-27 B-4 B-4 B-4 B-19 B-19 B-19 B-19 B-19 B-19 B-19 B19 B-19 B-19 B-19 B-29 B-19 B-2o B-2o B-19 B-20 B-30 B-30 B-3o B-2o B-12 B-15 B-15 B-15 B-3 1 B-22 B-7 B-7 B-7 B-7 B-24 B-22 B-24 B-24 B-4 B-4 B-4

Item No. 14 16 10 40 10.3 10.2 10.1 37 3! 29 61 19 18 28 24 26 41 3; 13 8.1 45 5.1 40 15 82: 7 2 12 13 2 25 60 63 65 62 12 24 14 14 10,2 10.1 10,3

28 17 3 37 37 27 8 15 18 21 8 5 27 55 3 6 25 1 5: 47 88 35 46 52 47 39 45 41 22 31 52 50 46 47 48 49 51 12 40 11 11 4 :

2910-999-9453 2910-999-9454 2910.781.1458 2910-781-1461 2910.999-8455 2910-134-4734 2815-406-4612 5340:407-0664 2910-781-1462 2815-808-2408 4910:919-2884 2910-781-1463 2815.808-2421 2815-808-2470 5120-873-6943 5120-871-7198 5120-875-9556 5310-489-8351 5310-489-8351 6645-420-5072 2590-134-4815 6645.179-2712 2815-193-8211 2815-406-4615 4710-193-9436 5340-409-8055 2930-350-9400 2930-437-7179

2815-193-8218 3010-087-9530 4730-402-5143

B-167

Figure B-1. Engine Shipping and Storage Container.

B-168A B-168B

FIGURE B-2

B-169A

Figure B-2. Crankcase and Associated Parts-Partially Exploded View.

B-169B

FIGURE B-3

Figure B-3. Crankshaft Assembly, Flywheel Damper, Bearings and Associated Parts-Exploded View.

B-170A

B-170B

FIGURE B-4

Figure B-4. Cylinder and Head Assembly, Piston, Connecting Rod and Associated Parts-Exploded View.

B-171A

B-171B

FIGURE B-5

Figure B-5. Camshaft and Drive Gears-Exploded View.

B-172A

B-172B

FIGURE B-6

B-173A

Figure B-6. Damper Housing, Oil Filters and Associated Parts-Exploded View.

B-173B

FIGURE B-8

Figure

B-8. Oil Pan

Baffles,

Studs,

Inserts

and Associated

Parts-Exploded

View.

B-175B B-175A

FIGURE B-9

Figure B-9. Oil Pump,

Tubes

and Associated

Parts-Exploded

View.

B-176A B-176B

FIGURE B-10

Figure

B-10.

Cylinder

Head Oil Drain Tubes Exploded View.

and Associated

Parts-

B-177A

B-177B

FIGURE B-11

Figure

B-11. Breather Tube, Fire Extinguisher Tube, Lines and Associated Parts-Exploded

Electrical View.

Lead,

Oil

B-178A

B-178B

FIGURE B-12

B-179A
Figure B-12. Exhaust Manifolds and Associated Parts-Exploded View.

B-179B

FIGURE B-13

Figure

B-13.

Intake

Manifold, Tubes, Turbosupercharger Tie Rod and Support and Associated Parts-Exploded View.

B-180A

B-180B

FIGURE B-14 GROUP NO. 0109 ITEM NO. 1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,17, 18,19,20,21,22,23,24,25,27,28,29,30,31,32,33, 34 26 Figure B-14. Generator and Starter Idler and Driven Gears and Shafts Exploded View.

0601

B-181A

B-181B

FIGURE B-15

Figure

B-15.

Engine

and Accessories-Exploded

View.

B-182A

B-182B

FIGURE B-16

Figure

B-16.

Fuel Injection

Pump Coupler Assembly-Exploded

Assembly View.

and Nozzle

and Holder

B-183A

B-183B

FIGURE B-17

Figure

B-17.

B-184A

Fuel Injection Associated

Pump Lines, Parts-Exploded

Injector Nozzle View.

Lines

and

B-184B

FIGURE B-18

Figure

B-18.

Throttle

Linkage-Exploded

View.

B-185A
B-185B

FIGURE B-19

Figure

B-19. Primary and Secondary Pressure Fluid Filters, Brackets, Hoses and Associated Parts-Exploded

Water Separator, View.

B-186A

B-186B

FIGURE B-20

B-187A

Figure

B-20. Secondary Pressure Fluid Filter, Primary Pressure Water Separator and Pressure Fluid Filter AssembliesExploded View.

Fluid

Filter,

B-187B

FIGURE B-21

Figure B-21.

Induction

Heater

System-Exploded

View.

B-188A

B-188B

FIGURE B-22

Figure B-189A

B-22. Engine

Shroud-Exploded

View.

B-189B

FIGURE B-23

Figure B-23.

Cylinder

Deflectors

and Plates-Exploded

View.

B-190A B-190B

FIGURE B-24

B-191A

Figure

B-24. Radiators,

Shrouds

and Associated

Parts-Exploded

View.

B-191B

FIGURE B-25

Figure

B-25.

Engine

Cooling

Fans-Exploded

View.

B-192A B-192B

FIGURE B-26

B-193A

Figure

B-26. Front and Rear Fan Drive Associated

Housing

and Base View.

Assemblies

and

Parts-Exploded

B-193B

FIGURE B-27

Figure

B-27. Automatic Injection Advance Assembly, Assembly and Associated Parts-Exploded

Fan Drive View.

Clutch

B-194A

B-194B

FIGURE B-28

Figure

B-28.

Generator

Exhaust Tube, Boot and Associated Exploded View.

Parts-

B-195A

B-195B

FIGURE B-29

B-196A

Figure

B-29.

Special

Tools.

B-196B

FIGURE B-30

Figure B-30.

B-197B B-197A

FIGURE B-31

Figure B-31.

Test Equipment.

B-198B B-198A

FIGURE B-32

FIGURE B-32

Figure B-32.

B-199A

B-199B

TM 9-2815-200-35 By Order of the Secretary of the Army: W. C. WESTMORELAND, General, United States Army, Chief of Staff.

Official: KENNETH G. WICKHAM, Major General, United States Army, The Adjutant General.

DISTRIBUTION: To be distributed in accordance with DA Form 12-37 Direct and General Support Maintenance requirements for Tanks, M60, M60A1, M48A3; Combat Engineer Vehicle M728 and Launcher, M60A1 Tank Chassis Transporting.

THE METRIC SYSTEM AND EQUIVALENTS

PIN: 018417-000