Isuzu C-240PW-28 Technical Manual
TECHNICAL MANUAL
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
UNIT, DIRECT SUPPORT
AND
GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
DIESEL ENGINE
MODEL C-240PW-28
4 CYLINDER 2.4 LITER
NSN: 2815-01-350-2207
HEADQUARTERS, DEPARTMENTS OF THE ARMY AND
THE AIR FORCE
1 SEPTEMBER 1993
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
SAFETY SUMMARY
For first aid, refer to FM21-11.
The noise level when operating could cause hearing damage. Ear
protection must be worn.
Where applicable, prior to performing engine maintenance, ensure batteries are disconnected.
Do not drain coolant until the coolant temperature is below operating
temperature. Always loosen cooling system filler cap, radiator cap, or
drain cock slowly to relieve any excess pressure.
Diesel fuel is flammable and toxic to eyes, skin, and respiratory tract.
Skin/eye protection required. Avoid repeated/prolonged contact. Good
general ventilation is normally adequate.
Cleaning solvent is flammable and toxic to eyes, skin, and respiratory
tract. Skin/eye protection required. Avoid repeated/prolonged contact.
Good general ventilation is normally adequate.
Compressed air used for cleaning can create airborne particles that
may enter the eyes. Pressure will not exceed 30 psig (207 kPa). Eye
protection required.
a/(b blank)
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
C2
CHANGE
HEADQUARTERS, DEPARTMENTS OF
THE ARMY AND THE AIR FORCE
No.2
WASHINGTON, D.C., 30 October 1996
Unit, Direct Support and GeneraI Support
Maintenance lnstructions
DIESEL ENGINE
MODEL C-240PW-28
4 CYLINDER 2.4 LITER
NSN: 2815-01-350-2207
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
TM 9-2815-254-24/TO 38G1-94-2, 1 September 1993, is changed as follows:
1.
Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.
Remove pages
i and ii
3-1 and 3-2
3-35 and 3-36
3-69 through 3-76
3-79 through 3-82
3-85 through 3-86
3-91 through 3-96
3-147 through 3-150
3-163 through 3-166
Insert pages
i and ii
3-1 and 3-2
3-35, and 3-36
3-69 through 3-76
3-79 through 3-82
3-85 through 3-88
3-91 through 3-96
3-147 through 3-150
3-163 through 3-166
2. Retain this sheet in front of manual for reference purposes.
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
C2
By Order of the Secretaries of the Army and Air Force:
Official:
Administrative Assistant to the
Secretary of the Army
02954
DENNIS J. REIMER
General, United States Army
Chief of Staff
RONALD R. FOGELMAN
General, USAF
Chief of Staff
HENRY VICCELLIO Jr.
General, USAF
Commander, Air Force Material Command
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25-E, block no. 5143, requirements for
TM 9-2815-254-24.
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
C1
CHANGE
No. 1
DEPARTMENTS OF THE ARMY, AND AIR FORCE
WASHINGTON, DC., 15 DECEMBER 1993
HEADQUARTERS
TECHNICAL MANUAL
UNIT, DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE INSTRUCTIONS
DIESEL ENGINE
MODEL C-240PW-28
4 CYLINDER 2.4 LITER
NSN: 2815-01-350-2207
DISTRIBUTION STATEMENT A; Approved for public release; distribution is unlimited.
TM 9-2815-254-24/TO 39G1-94-2, 1 SEPTEMBER 1993 is changed as follows:
1.
Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.
Remove pages
iii and iv
3-3
and 3-4 3-3 and 3-4
3-9
through 3-12 3-9 through 3-12
B-5 and B-6
------
2.
Retain this sheet in front of manual for reference purposes.
lnsert pages
iii and iiv
B-5 and B-6
Appendix E
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
C1
By Order of the Secretaries of the Army and air Force
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
05829
Official:
GORDON R. SULLIVAN
General, United States Army
Chief of Staff
MERRILL A. McPEAK
General, USAF
Chief of staff
RONALD W. YATES
General, USAF
Commander, Air Force Material Command
DISTRIBUTION:
To be distributed in accordance with DA Fom 12-25-E, block no. 5143, requirements for
TM 9-2815-254-24.
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
TECHNICAL MANUAL
HEADQUARTERS
DEPARTMENTS OF THE ARMY AND THE AIR FORCE
NO. 9-2815-254-24
Unit, Direct Support and General Support Maintenance Instructions
WASHINGTON, D.C., 1 September 1993
DIESEL ENGINE
MODEL C-24OPW-28
4 CYLINDER 2.4 LITER
NSN: 2815-01-350-2207
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual.
procedures, please let us know.
(A) Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms), or
DA Form 2028-2 located in the back of this manual directly to: Commander, US Army Aviation and
Troop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd.,
also
submit your recommended changes
emh7.army.mil>.
publication immediately preceding the hard copy 2028.
Instructions for sending an electronic 2028 may be found at the back of this
If you find any mistakes or if you know of a way to improve these
St. Louis, MO 63120-1798. You may
by E-mail directly to
< mpmt%avma28@st-louis-
(F) Air Force - AFTO Form 22 Directly to:
TILBA, McClellan AFB, CA 95652-5990 (AFMC)
A reply will be furnished directly to you.
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
TABLE OF CONTENTS
Chapter/Section/Paragraph
Chapter 1 INTRODUCTION .........................................
Section I.
1-1.
1-2. Maintenance Forms, Records and Reports.
1-3.
1-4.
1-5.
1-6.
Section II.
1-7.
1-8.
1-9.
GENERAL INFORMATION
Scope.
Reporting Equipment Improvement Recommendations (EIR).
Destruction Of Army Materiel To Prevent Enemy Use.
Preparation For Storage Or Shipment.
Warranty.
EQUIPMENT DESCRIPTION AND DATA
General.
Detailed Description.
Equipment Data.
..........................................
........................................
..............................
....................................
Commander, Sacramento Air Logistics Center, ATTN:
.................................
....................
.........
............
.......................
........................
..........
.
.................................
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-3
1-3
1-3
1-5
Change 2 i
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
TABLE OF CONTENTS - Continued
Section III.
1-10
CHAPTER 2
Section I.
2-1
2-2
2-3
2-4
2-5
Section II.
CHAPTER 3
Section I.
3-1
Section II.
3-2
Section III.
3-3
3-4
Section IV. COOLING SYSTEM MAINTENANCE
3-5
3-6
3-7
Section V.
3-8
3-9
3-10
3-11
3-12
3-13
Section VI.
3-14
3-15
3-16
3-17
3-18
3-19
Section VII.
3-20
3-21
Section VIII. ELECTRICAL SYSTEM
3-22
3-23
3-24
PREPARATION FOR USE
Inspecting and Servicing Engine.
OPERATION
PRINCIPLES OF OPERATION
Introduction.
Cooling System.
Lubrication System.
Fuel System.
Electrical System.
OPERATING INSTRUCTIONS.
MAINTENANCE
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
PMCS Procedures.
TROUBLESHOOTING
Troubleshooting Procedures.
GENERAL MAINTENANCE
General.
Disassembly and Assembly Sequence for Overhaul.
General.
Thermostat.
Water Pump.
FUEL SYSTEM MAINTENANCE
General.
Fuel Filter Assembly.
Fuel Injectors and Piping.
Fuel Injection Pump.
Bleeding and Priming Fuel System.
Fuel Injection Pump Timing.
LUBRICATION SYSTEM MAINTENANCE
Oil Filter.
Oil Pressure Relief Valve
Oil Piping
Oil Pan
Oil Pump
Oil Pressure Test
INTAKE AND EXHAUST SYSTEM MAINTENANCE
PCV Assembly
Intake and Exhaust Manifolds
Glow Plugs
Starter Assembly
Alternator
........................................
.....................................
...................................
.....................................
..................................
......................................
..................................
...................................
.......................................
.......................................
.....................................
....................................
.......................................
.......................................
......................................
........................................
.......................................
..................................
...................................
.................................
.....................................
.................................
......................................
................................
.........................
..............................
.................................
.............................
........
...........................
..............................
............ 3-12
........................
...........................
...............................
............................
...............................
......................
...........................
....................
.............................
...............
..........................
1-6
1-6
2-1
2-1
2-1
2-1
2-1
2-1
2-2
1-3
3-1
3-1
3-1
3-3
3-3
3-11
3-11
3-16
3-16
3-16
3-18
3-21
3-21
3-21
3-24
3-31
3-65
3-65
3-69
3-69
3-70
3-71
3-73
3-75
3-76
3-79
3-79
3-82
3-85
3-85
3-85
3-93
ii
Change 2
Section
3-25
3-26
3-27
3-28
3-29
3-30
3-31
3-32
TABLE OF CONTENTS - Continued
lX.
ENGINE BLOCK MAINTENANCE
Front Gear Cover
Rocker Cover and Arms
Cylinder Head Assembly
Pistons, Connecting Rods, and Crankshaft
Crankcase
Camshaft and ldler Gear Assemblies
Flywheel and Housing
................................................................
Cylinder Block Assembly
...........................................
....................................................
....................................................
......................................................
....................................................
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
.............................................
....................................
.........................................
3-99
3-99
3-102
3-110
3-127
3-148
3-150
3-158
3-162
APPENDIX
APPENDIX
APPENDIX
APPENDIX
APPENDIX
Alphabetical lndex
References
A
B
Maintenance Allocation Chart
C
Expendable/Durable Supplies
and Materials List (EDSML)
D
Fabrication of Tools
E
Maintenance Procedures and Authorized Level Maintenance . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..............................
.............................
..................................................
.....................................................
A-1
B-1
C-1
D-1
E-1
I-1
Change 1
iii
ARMY TM 9-2815-254-24
AIR FORCE TO 36G1-94-2
1-1
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-21
3-22
3-23
3-24
3-25
3-26
3-27
3-28
3-29
3-30
3-31
3-32
3-33
3-34
3-35
3-36
3-37
3-38
3-39
3-40
3-41
3-42
Engine Components
Thermostat and Housing
Water Pump
Fuel Filter Assembly...............................................
Fuel Injectors and Piping............................................
Fuel Injector Spay Pattern..............................................
Top Dead Center.......................................................
Fuel Feed Pump and Timer Assembly
Fuel Injection Pump Assembly
Attaching Coupling (Typical)..............................................
lnserting Tappet Holder (Typical)
Removing screw Plug (Typical)
Removing coupling (Typical).................................................
Removing Tappet Holder (Typical).
Removing Tapped (Typical)
Removing Delivery Valve
Removing Plunger Barrel....................................................
Plunger Helix..
Checking Plunger and Barrel
Delivery Valve..............................................................
Checking Plunger and Barrel for Damage
Tappet
Lower Spring Seat..........................................................
Camshaft
camshaft Bearings..........................................................
Bearing Removal...........................................................
Feed Pump Tappet
Feed Pump Plug
Checking Sleeve Pinion Movement
lnserting Plunger
lnserting Tappet
Measuring Device Installed (Typical)...........................................
Feed Pump Test
Priming Pump Test
Capacity Test
Feed Pump Pressure Test
Air Tightness Test
RemovaI of Mechanical Governor.............................................
oil Filter
oil Piping
Oil Pan Assembly...........................................................
Oil Pump Assembly
Oil Pump Inspections........................................................
..........................................................
.....................................................................
..................................................................
...................................................................
..................................................................
....................................................
...............................................
. . . . 3-23
. . . 3-26
......................................
............................................
..........................................
..........................................
............................................
...................................................
.....................................................
.............................................................
Movement
..........................................................
............................................................
............................................................
.............................................................
.............................................................
..........................................................
...............................................................
....................................................
...........................................................
.........................................................
.......................................
......................................
............................................
3-16
3-20
3-30
3-32
3-34
3-35
3-36
3-36
3-37
3-37
3-38
3-39
3-40
3-41
3-43
3-44
3-44
3-46
1-4
3-45
3-45
3-46
3-47
3-47
3-48
3-49
3-51
3-51
3-52
3-55
3-59
3-60
3-61
3-62
3-62
3-64
3-70
3-72
3-73
3-75
3-77
iv
LIST OF ILLUSTRATIONS - Continued
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
3-43
3-44
3-45
3-46
3-47
3-48
3-49
3-50
3-51
3-52
3-53
3-54
3-55
3-56
3-57
3-58
3-59
3-60
3-61
3-62
3-63
3-64
3-65
3-66
3-67
3-68
3-69
3-70
3-71
3-72
3-73
3-74
3-75
3-76
3-77
3-78
3-79
3-80
3-81
3-82
3-83
3-84
3-65
3-66
Oil Pressure Test Setup
PCV Assembly
Intake and Exhaust Manifolds.................................................
Glow Plugs Assembly
Starter Assembly.
Starter Solenoid Test Circuit
Alternator Assembly
Front Gear Cover
Front Gear Cover Screw Tightening Sequence
Rocker Cover and Arms
Valve clearance Adjustment Sequence
Cylinder Head Assembly
Cylinder Head Bolt Loosening Sequence
Cylinder Head Inspection
Cylinder Head Height (Reference)
Valve Stem and Guide Clearance
Valve Stem Outside Diameter
Checking Valve Thickness
Valve Depression
Valve Spring Free Height
...................................................... 3-78
.............................................................
.......................................................
........................................................... 3-88
..................................................
.........................................................
..........................................................
.................................
.....................................................
Rocker Arm Retaining Plate Bolt Loosening Sequence
Rocker Arm Shaft Runout
Rocker Arm Shaft Outside Diameter
Rocker Arm Oil Ports, Location of
Rocker Arm Correction
Rocker Arm Retaining Plate Bolt Tightening Sequence
Hot Plug Removal
Hot Plug Depression
Checking Valve Contact Width
Valve Spring Tension
Push Rod Curvature
Valve Seat Correction
Valve Seat Insert Installation
Cylinder Head Bolt Tightening Sequence
Pistons, Connecting Rods, and Crankshaft
Crankshaft End Play
Crankshaft Bearing Cap Bolt Loosening Sequence
Piston Ring and Groove Clearance
Piston Ring
Measuring Piston Ring Gap
Connecting Rod Side Face Clearance
Basic Dimension Measurements
Crankshaft Run-out
Bearing Spread Measurement
..........................................................
..........................................................
................................................................ 3-132
...................................................
..........................................
............................................
.....................................................
....................................... 3-109
....................................................
......................................
...................................................
............................................
.......................................................
............................................
................................................
..................................................
...............................................
.................................................... 3-120
.......................................................
........................................................
......................................................
................................................. 3-123
...................................... 3-126
....................................
........................................................ 3-130
.............................
........................................... 3-132
.................................................
........................................
.............................................
........................................................
...............................................
..........................
..........................
3-80
3-83
3-86
3-89
3-96
3-100
3-101
3-103
3-104
3-104
3-105
3-106
3-107
3-106
3-111
3-112
3-113
3-114
3-115
3-116
3-117
3-117
3-118
3-118
3-119
3-120
3-121
3-122
3-129
3-130
3-133
3-134
3-135
3-136
3-136
v
ARMY TM 9-2815-254-24
AIR FORCE TO 33G1-94-2
LIST OF ILLUSTRATIONS - Continued
Page
3-87
3-88
3-89
3-90
3-91
3-92
3-93
3-94
3-95
3-96
3-97
3-98
3-99
3-100
3-101
3-102
3-103
3-104
3-105
3-106
3-107
3-108
3-109
3-110
3-111
3-112
3-113
3-114
3-115
3-116
Crankshaft Journal and Crankpin Diameter
Crankshaft Journal and Bearing Clearance
Connecting Rod Bearing Inside Diameter
Crankhaft Journal and Bearing Clearance
comparing Bearing Gage
Crankshaft Gear lnstallation
Piston Ring Installation
Crankshaft Bearing Location
...................................................
.................................................
.....................................................
.................................................
....................................
....................................
.....................................
....................................
Crankshaft Bearing Cap Bolt Tightening Sequence
Crankshaft Rear Oil Seal and Spacer
Piston Ring Gap Setting
Crankcase
................................................................
....................................................
Crankcase Fastener Tightening Sequence
Measuring Timing Gear Backlash
Camshaft and Idler Gear
Thrust Plate Removal..
Assemblies
.....................................................
ldler Gear Shaft Outside Diameter
Camshaft Journal Diameter
Cam Height
Camshaft Runout
...............................................................
..........................................................
Flywheel and Housing
.....................................
......................................................
Flywheel Bolt Loosening Sequence
Flywheel Housing Installation Sequence
Flywheel Bolt Tightening Sequence
Cylinder Block assembly
....................................................
........................................
....................................
............................................
.........................................
.................................
..........................................
......................................
..........................................
Cylinder Block Upper Face Warpage Measurement
Cylinder Block Height Measurement
Cylinder Liner Bore Measurement
Cylinder Liner Installation
.................................................
Pressing Cylinder Liner
..........................................
............................................
................................................
3-137
3-138
3-138
3-139
3-140
3-141
3-143
3-144
............................
3-145
3-146
3-147
3-149
3-150
3-151
3-152
3-153
3-154
3-155
3-155
3-156
3-159
3-160
3-161
3-162
3-164
............................. 3-166
3-166
3-168
3-170
3-171
D-1
vi
Fuel Injection Pump Tappet Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-1
LIST OF TABLES
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
1-1
3-1
3-2
3-3
3-4
Table of Specifications
.......................................................
Preventive Maintenance Checks and Services (PMCS)
Troubleshooting
Fuel Pump Test Specifications
Capacity Test
..............................................................
................................................
................................................................ 3-61
............................
1-5
3-1
3-4
3-56
viii(viii blank)
CHAPTER 1
INTRODUCTION
SECTION I. GENERAL INFORMATION
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
1-1.
1-1.1.
1-1.2.
1-2.
1-2.1.
1-2.2.
1-2.3.
1-3.
1-3.1.
SCOPE.
Type of Manual. This manual contains unit, direct support, and general support maintenance instructions for the
Model C240 Diesel Engine, hereafter referred to as engine. Also included are descriptions of major systems/cornponents and their functions in relation to other systems/components.
Purpose of Equipment. The engine provides a driving force for generators or other equipment requiring this size
(HP rating) and compatibility.
MAINTENANCE FORMS RECORDS AND REPORTS.
Reports of Maintenance Unsatisfactory Equipment. Department of the Army forms and procedures used for
equipment maintenance will be those prescribed by DA Pam 738-750, the Army Maintenance Management Sys-
tem (TAMMS). Air Force personnel will use AFR 66-1, Air Force Maintenance Management Policy, for mainte-
nance reporting and TO-00-35D54 for unsatisfactory equipment reporting.
Reporting of Item and Packaging Discrepancies. Fill out and forward SF 364 (Report of Discrepancy (ROD)) as
prescribed in AR 735-11-2/DLAR 414-55/SECNAVINST 4355.18/AFR 400-54/MCO 4430.3J.
Transportation Discrepancy Report (TDR) (SF 361). Fill out and forward Transportation Discrepancy Report
(TDR) (SF 331) as prescribed in AR 55-38/NAVSUPINST 4610.33C/AFR 75-18/MCO P4610.19D/DLAR
4500.15.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR).
Army. If your Military Standard Engine needs improvement, let us know. Send us an EIR. You, the user, are the
only one who car tell us what you don’t like about your equipment. Let us know why you don’t like the design or
performance. Put it on an SF 368 (Product Quality Deficiency Report). Mail it to us at: Commander, US. Army
Aviation and Troop Command, ATTN: AMSAT-I-MDO, 4300 Goodfellow Boulevard, St. Louis, Missouri
63120-1798. We will send you a reply.
1-3.2.
Air Force. Air Force personnel are encouraged to submit EIR’s in accordance with AFR 900-4.
1-1
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
1-4.
1-5.
1-6.
DESTRUCTION OF ARMY MATERIAL TO PREVENT USE.
Refer to TM 750-244-3 for procedures to destroy equipment to prevent enemy use.
Refer to TB 740-97-2 for procedures to place the equipment into storage.
WARRANTY.
The engine is warranted for a specific period of time. Refer to Warranty Technical Bulletin for the end item. The
warranty starts on the date found in block 23, DA Form 2408-9, in the equipment log book. Report all defects in
material or workmanship to your supervisor, who will take appropriate action.
1-2
1-7. GENERAL.
The diesel engine (FIGURE 1-1) is four cylinder, four cycle, fuel injected, naturally-aspirated, and liquid-cooled.
The firing order is 1-3-4-2. The number one cylinder is toward the fan end of the engine. The serial number is found
on left side of the cylinder body at number one cylinder location. Rotation of engine is counterclockwise as viewed
from flywheel.
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
SECTION II. EQUIPMENT DESCRIPTION AND DATA
NOTE
All locations referenced herein are given facing the flywheel end (rear)
of the engine.
1-8.
1-8.1.
1-8.2.
1-8.3.
1-8.4.
DETAILED DESCRIPTION.
Cooling System. The cooling system consists of a radiator, water pump, cooling fan, thermostat, and connecting
hoses. The fan is mounted on shaft of water pump and both are belt driven from the crankshaft pulley. The thermostat controls engine temperature and is installed in the top of engine. The function of the cooling system is to maintain a specific operating temperature of 180° to 203°F (82° to 95°C) for the engine.
Lubrication System. The lubrication system consists of the oil pan, a gerotor type oil pump, spin-on type oil filter,
and internal passages within the engine. There are two external oil lines, one for rocker arm lubrication and one
for fuel injector pump lubrication.
Fuel System. The function of the fuel system is to inject a metered quantity of clean atomized fuel into the engine
cylinders at a precise time near the end of the compression stroke of each piston. The fuel system consists of
the fuel tank, fuel filter/water separator, fuel injection pump, and the fuel injectors. The fuel tank and fuel filter/water separator are not mounted on engine. The injection pump is mounted on the front cover and is driven by the
timing gears.
Electrical System. The electrical system is 24 VDC operation and consists of an alternator, starter, externally
mounted batter and other items as required. The alternator is mounted on front of engine and is belt driven.
When the engine is operating, the alternator supplies 24 VDC to recharge the battery and maintain it at a full state
of charge. The starter is mounted on the flywheel housing and when energized engages the ring gear of the flywheel to rotate the engine.
1-3
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
1.
Fan
2.
Fan Belt
3.
Fan Pulley
4.
Fuel Pipes
5.
Fuel Injector Pipes
6.
Injector Nozzle and Glow Plug
Oil Filter
7.
Fuel Filter Housing
8.
9.
PCV Valve
10.
Crankshaft Pulley
11.
Battery Charging Alternator
12.
Starter
13.
Intake Manifold
14.
Exhaust Manifold
Valve cover
15.
16.
Thermostat Housing
17.
Water Pump
18.
Oil Pan
19.
Flywheel Housing
Crankcase
20.
Fuel Injection Pump
21.
22.
Dipstick and Tube
1-4
FIGURE 1-1. Engine Components
1-9. EQUlPMENT DATA.
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
1-9.1.
Leading Particulars. For a list of leading particulars, refer to TABLE 1-1.
TABLE 1-1. Table of Specifications
Model
Type
Bore/Stroke
Displacement
Horsepower Rating
Compression Ratio
Length
Width
Height
Weight
Firing Order
Injection Pump
Governor ...........................................
Injection Starting Pressure
Cylinder Compression Pressure (warm)
Valve Clearance (cold)
Lubrication System Capacity
Coolant System Capacity (engine only)
Battery Charging Alternator.
Starter..........................................................Hitachi,24VDC-3.5kw
.............................................................
......................................... Four cylinder, four cycle, liquid cooled diesel
...................................................
...............................................................................
..........................................................
.....................................................................................................
...................................................................................................................
Barber-Colman Model 10502-001-0-2
..........................................
.................................
................................................
............................................
.............................................
.......................................
lsuzu, C240 PW-28
3.38/4.01 in. (86/102 mm)
144.5 cu in. (2369 cu cm)
32 BHP @ 1800 rpm
20:1
28.9 in (736 mm)
21.0 in (535 mm)
32.1 in (815 mm)
491 Ibs (223 kg)
1-3-4-2
Kiki - PES4A
1706 psi (11,772 kPa)
441 psi (3041 kPa)
0.017 in. (0.45 mm)
1.6 gal (6.1 liters)
1.37 gal (5.2 liters)
Hitachi, 24 VDC - 20 amp
1-5
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
SECTION III. PREPARATION FOR USE
1-10.
1-10.1. Inspection.
1-10.2. Service. Except for servicing the lubrication system all other servicing must be accomplished after engine is
lNSPECTlNG AND SERVlCING ENGINE.
This section provides information and guidance for inspecting, servicing, and installing the engine. For additional
information, also refer to end item maintenance manual.
a.
Check that all packing materials have been removed.
b.
Check engine identification plate for positive identification.
c.
Inspect engine exterior for shipping damage.
d.
Check fan belt drive for proper tension. Refer to end item maintenance manual.
e.
Inspect engine for loose or missing mounting hardware, or damaged or missing parts.
mounted in the end item, refer to end item maintenance manual and lubrication order (LO).
1-6
CHAPTER 2
OPERATION
SECTION I. PRINCIPLES OF OPERATION
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
2-1.
2-2.
2-3.
2-4. FUEL SYSTEM.
INTRODUCTIONS
This section contains functional descriptions of the engine systems and how they are connected to the end item
COOLING SYSTEM.
The cooling system consists of a radiator, hoses, thermostat, belt driven fan, water pump, and cooling jackets
within the engine. The water pump forces coolant through passages (coolant jackets) in the engine block and
cylinder head where coolant absorbs heat from the engine. When the coolant temperature is below operating temperature, the thermostat is closed and coolant is bypassed to the water pump inlet. As coolant temperature increases to 180°F (82°C), the thermostat starts to open, restricting bypass flow and opening flow to the radiator. As
coolant temperature continues to increase to 203°F (95°C), the thermostat is fully opened, shutting off all bypass
flow and providing full flow through the radiator. Air forced through the fins of the radiator by the fan cools the
coolant pumped through the radiator. Items are added to the engine to monitor coolant temperature and to warn if
temperature exceeds a predetermined value.
LUBRICATION SYSTEM.
The lubrication system consists of an oil pan, dipstick, pump, and filter. The oil sump is a reservoir for lubricating
oil. The dipstick indicates oil level in sump. The pump draws oil from the sump through a screen which removes
large impurities. The oil then passes through a spin-on type filter where small impurities are removed. From the
filter, oil enters the cylinder head oil gallery and is distributed to the engines internal moving parts and to the fuel
injection pump. After passing through the block and pump, the oil returns to the oil sump. Items are added to moni-
tor oil pressure and to warn/stop engine if pressure drops to a dangerously low value.
2-4.1.
The fuel system consists of an external fuel tank, transfer pump, fuel filter/water separator, fuel injection pump,
fuel injectors, and piping. Fuel from an external source is supplied to the fuel injection pump. The injection pump
provides a pressurized metered quantity of clean atomized fuel through the injector nozzles into the cylinder at
a precise time near the end of the compression stroke of each piston. The fuel that is not used by the injectors
is returned to the fuel tank via an excess fuel return line.
2-1
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
2-4.2. Extremely cold outside temperatures make starting the engine difficult. To improve engine starting, a cold weather
starting aid has been provided that features a glow plug for each cylinder. The glow plugs are energized to preheat
engine combustion air during engine preheat starting cycle.
2-5.
ELECTRICAL SYSTEM.
The electrical system consists of external mounted batteries, starter, battery charging alternator, and related relays and switches for control of the system. Battery power supplied to the starter during the start cycle energizes
the starter which engages the ring gear of the flywheel causing the engine to turn over. When engine start is com-
plete, the starter is deenergized and disengages from the flywheel. The battery charging alternator is belt driven. It
is a 20 ampere, 24 VDC alternator that when operating, supplies voltage to the 24 VDC circuit and recharges the
batteries and maintains them at a full state of charge.
2-2
SECTION II. OPERATING INSTRUCTIONS
NOTE
Refer to end item operator’s manual.
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
2-3/(2-4 blank)
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
CHAPTER 3
MAINTENANCE
Section I. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
3-1. PMCS PROCEDURES.
3-1.1.
To ensure that engine is ready for operation at all times, it must be inspected so defects can be discovered
and corrected before they result in serious damage or failure.
conjunction with performance of engine PMCS. For engine PMCS, refer to TABLE 3-1.
General.
Perform operator’s PMCS prior to or in
Table 3-1. Preventive Maintenance Checks and Services (PMCS)
Item
No.
1
2
Interval
M
QSAB H
300
750
Item
to be
Inspected
Oil Filter Change oil filter.
PCV System
Procedures Check Equipment is
for and have Not/Ready
repaired or adjusted
as necessary
Refer to paragraph
3-14.1.
NOTE
Oil filter change inter
val is a hard time
replacement to be
used when AOAP
lab is not available.
Service PCV system.
Refer to paragraph
3-20.
Available
If:
3
4
1500 Cylinder Head Torque cylinder head
Bolts
3000 Engine Valve
Clearances
bolts. Refer to
paragraph 3-27.6d.
NOTE
Valve clearance
must be checked
after cylinder head
bolt tightening has
been done. Refer to
step 3 in this table.
Adjust engine valve
clearances. Refer to
paragraph 3-26.6.
Change 2 3-1
ARMY TM 9-2815-284-24
AIR FORCE TO 38G1-94-2
Table 3-1. Preventive Maintenance Checks and Services (PMCS) - Continued
Item
No.
5
6
7
6
Interval
M
QSAB H
Item
to be
Inspected
3000 Engine Fuel
Injectors
1500 Engine
Compression
1500 Engine Oil
Pressure
300
Fuel Injection
Pump Governor
Oil
Procedures Check
for and have
repaired or adjusted
as necessary
Remove, clean, and
test injectors. Refer
to paragraph 3-10.
Check engine compression. Refer to
paragraph 3-27.7.
Check engine oil
pressure. Refer to
paragraph 3-19.
Remove oil level
plug to check oil
level. Fill at fill plug.
Change oil if it
becomes contaminated.
Equipment is
Not/Ready
Available
If:
Engine compression
is low.
Engine oil pressure
not as specified.
3-2 Change 2
SECTION II. TROUBLESHOOTlNG
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
3-2.
3-2.1.
TROUBLESHOOTING PROCEDURES.
Purpose of Troubleshooting Table. This section contains troubleshooting information for locating and Correcting
operating troubles which may develop in the engine. Each malfunction for an individual component unit or system
is followed by a list of tests or inspections which will help you to determine probable causes and corrective action
to take. You should perform tests/inspections and corrective actions in order listed.
This table cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a mal-
function is not listed or cannot be corrected by listed corrective actions. notify your supervisor.
NOTE
Before you use this table, be sure you have performed your PMCS.
Prior to performing troubleshooting procedures within this manual, perform your operator’s troubleshooting and the end item maintenance
manual troubleshooting procedures.
SYMPTOM INDEX
Troubleshooting
Malfunction
Engine Will Not Crank
Starter Operates But Engine Does Not Turn Over
Engine Cranks But Fails To Start
Engine Hard To Start or WiII Not Start
In Cold Weather
Engine Misfires or Runs Irregularly or
Stalls Frequently
Engine Does Not Develop Full Power
Engine Overheating
Excessive Oil Consumption
Low Oil Pressure
Excessive Fuel Consumption
Black or Gray Smoke
Blue Exhaust Smoke
Engine Knocks
Engine Makes Abnormal Noise
Engine Makes a Gas Leaking Noise
Detonation or Pre-Ignition
Battery Charge Ammeter Shows No Charge
When Batteries Are Low
Battery Charge Ammeter Shows Excessive
Charging After Prolonged Period
Procedures Page
3-4
3-4
3-4
3-5
3-5
3-6
3-6
3-6
3-7
3-7
3-8
3-8
3-9
3-9
3-10
3-10
3-10
3-11
Change 1 3-3
ARMY TM 9-2815-254-24
AIR FORCE TO 38G1-94-2
TABLE 3-2 Troubleshooting
1.
2.
3.
ENGINE WILL NOT CRANK
Step 1.
Step 2.
Check for defective end item starting system.
Troubleshooting per end item maintenance manual. lf not defective, do step 2.
Check for defective starter motor and solenoid.
a Test starter and solenoid. Refer to paragraph NO TAG
b. Repair/replace defective starter and/or solenoid. Refer to paragraph 3-23.
STARTER OPERATES BUT ENGINE DOES NOT TURN OVER.
Step 1.
Step 2.
Check for worn or broken starter pinion gear and/or flywheel ring gear.
a.
Remove starter and inspect pinion gear and flywheel ring gear for damage.
Replace defective clutch assembly and/or flywheel ring gear. Refer to paragraphs 3-23 and
b.
3-31.
Crankshaft rotation restricted. Attempt to manually rotate engine. If unable to manually rotate,
repair/replace engine.
ENGINE CRANKS BUT FAILS TO START
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Check for fuel being supplied to fuel injection pump.
a.
Test feed pump capacity. Refer to paragraph NO TAG. If feed pump not defective, do step 2.
b.
Repair or replace fuel feed pump. Refer to paragraph 3-11.
Check for dogged fuel filter/water separator.
a Remove and dean fuel filter Assembly, paragraph 3-9. If dean, replace water separator, re-
fer to end item maintenance manual.
Check for air in fuel system lines.
Bleed fuel system. Refer to paragraph 3-12. If fuel system is free air, do step 4.
Check for fuel injector starling pressure too Iow or spray condition improper.
a
Remove, dean and test fuel injector. Refer to paragraph 3-10. Adjust as necessary, if injector
can not be adjusted, go to b. If not defective, do step 5.
b.
Replace fuel injector. Refer to paragraph 3-10.
Check for improper fuel inject pump timing.
a.
Check fuel injection pump timing. Refer to paragraph 3-13.1. If fuel injection pump timing is
correct, do step 6.
b.
Adjust fuel injection pump timing. Refer to paragraph 3-132.
Check for defective fuel injection pump.
a. Remove and test fuel injection pump. Refer to paragraph NO TAG.
b.
Repair or replace defective fuel injection pump. Refer to paragraph 3-11.
3-4
Loading...