Front Matter
TM 9-2815-237-34
(SUPERSEDES TM 9-2815-237-34, 25 June 1985)
TECHNICAL MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED, FUEL-INJECTED, WATER COOLED, DDA MODEL 6.2 LITER (PRE-1990) (NSN 2815-01-231-3672), (POST-1990) (NSN 2815-01-314-7940); DDA MODEL 6.5 LITER (NSN 2815-01-410-9710) (1995,1996), (NSN 2815-01-439-6665) (1997), (NSN 2815-01-453-7403) (1998); ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED, DETUNED, FUEL-INJECTED, WATER COOLED, DDA MODEL 6.5 LITER (NSN 2815-01-406-6675) (1996), (NSN 2815-01-439-6664) (1997), (NSN 2815-01-453-7404) (1998); ENGINE, DIESEL: 8 CYLINDER, TURBOCHARGED, FUEL-INJECTED, WATER COOLED, (NSN 2815-01-420-4180) (1996), (NSN 2815-01-439-8164) (1997), (NSN 2815-01-453-7402) (1998).
Approved for public release; distribution is unlimited.
H E A D Q U A RT E R S , D E PA RT M E N T S O F T H E A R M Y, THE AIR FORCE, AND MARINE CORPS JANUARY 1996
EXHAUST GASES CAN KILL
Brain damage or death can result from heavy exposure. Precautions must be followed to ensure personnel safety when the engine is operated for any purpose.
1. DO NOT operate your vehicle engine in enclosed area.
2. BE ALERT at all times for exhaust odors.
3. BE ALERT for exhaust poisoning symptoms. They are:
• Headache • Dizziness • Sleepiness • Loss of muscular control
4. If YOU SEE another person with exhaust poisoning symptoms:
• Remove person from area • Expose to open air • Keep person warm • Do not permit person to move • Administer artificial respiration, if necessary* • Notify a medic
* For artificial respiration, refer to FM 21-11
5. BE AWARE, the field protective mask for nuclear-biological-chemical (NBC) protection will not protect you from exhaust poisoning.
THE BEST DEFENSE AGAINST EXHAUST POISONING IS ADEQUATE VENTILATION.
Change 1 Warning a
WARNING SUMMARY • Always wear eyeshields when using compressed air. Failure to wear eyeshields may result in eye injury. • Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.). • Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may cause injury to personnel or damage to equipment. • Improper cleaning methods and use of unauthorized cleaning solutions will injure personnel and damage equipment. See TM 9-247 for correct information. • Drycleaning solvent is flammable and will not be used near an open flame. A fire extinguisher will be kept nearby when the solvent is used. Use only in well-ventilated places. Failure to do this may result in injury to personnel and/or damage to equipment. • When steam cleaning, protective clothing must be used. Failure to use protective clothing may result in serous injury. • Diesel fuel is highly flammable. Do not perform this procedure near fire, flame, or sparks. Severe injury or death may result. • Cylinder block must be supported during removal and installation from engine stand. Failure to support cylinder block may cause injury to personnel or damage to equipment. • Crankshaft must be supported during removal and installation. Failure to support crankshaft may cause injury to personnel or damage to equipment. • Do not place hands or arms near nozzle during testing. Penetrating force of oil may cause serious injury or death. • Direct personnel to stand clear during hoisting operation. Failure to do this may cause injury to personnel. • Gaskets installed on some 6.2L engines assembled prior to 1991 may contain asbestos. Gaskets should be removed with a scraper or putty knife and then disposed of IAW current directives. Inhalation of asbestos fibers can cause respiratory ailments.
Warning b Change 1
CHANGE HEADQUARTERS, DEPARTMENTS OF THE ARMY, NO. 2 THE AIR FORCE, AND MARINE CORPS Washington, D.C., 15 July 2004
TECHNICAL MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED, FUEL-INJECTED, WATER COOLED, DDA MODEL 6.2 LITER (PRE-1990) (NSN 2815-01-231-3672), (POST-1990) (NSN 2815-01-314-7940); DDA MODEL 6.5 LITER (NSN 2815-01-410-9710) (1995,1996), (NSN 2815-01-439-6665) (1997), (NSN 2815-01-453-7403) (1998); ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED, DETUNED, FUEL-INJECTED, WATER COOLED, DDA MODEL 6.5 LITER (NSN 2815-01-406-6675) (1996), (NSN 2815-01-439-6664) (1997), (NSN 2815-01-453-7404) (1998); ENGINE, DIESEL: 8 CYLINDER, TURBOCHARGED, FUEL-INJECTED, WATER COOLED, (NSN 2815-01-420-4180) (1996), (NSN 2815-01-439-8164) (1997), (NSN 2815-01-453-7402) (1998)
TM 9-2815-237-34, 31 January 1996, is changed as follows:
1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the margin of the page. Remove pages Insert pages A/(B blank) A/(B blank) i and ii i and ii 1-1 and 1-2 1-1 and 1-2 1-5/(1-6 blank) 1-5/(1-6 blank) 2-23 and 2-24 2-23 and 2-24 2-85 through 2-90 2-85 through 2-90 2-101 and 2-102 2-101 and 2-102 2-113 and 2-114 2-113 and 2-114 2-117 through 2-120 2-117 through 2-120 2-125 and 2-126 2-125 and 2-126 2-155 and 2-156 2-155 and 2-156 2-173 and 2-174 2-173 and 2-174 A-1 and A-2 A-1 and A-2 Index 1 through Index 4 Index 1 through Index 4 DA Form 2028 DA Form 2028 Cover Cover
3. File this change sheet in front of the publication for reference purposes.
Approved for public release; distribution is limited.
By Order of the Secretary of the Army:
Peter J. Schoomaker General, United States Army Chief of Staff
Official:
JOEL B. HUDSON Administrative Assistant to the Secretary of the Army 0223410
By Order of the Secretary of the Air Force:
RONALD R. FOGLEMAN General, United States Air Force Chief of Staff
Official:
HENRY VICCELLIO, JR. General, United States Air Force Commander, Air Force Materiel Command
By Order of the Marine Corps:
R. P. SHOCKEY Director, Program Support Marine Corps Systems Command
Distribution: To be distributed in accordance with the initial distribution number (IDN) 380623, requirements for TM 9-2815-237-34.
CHANGE HEADQUARTERS,
DEPARTMENTS OF THE ARMY,
NO. 1 THE AIR FORCE, AND MARINE CORPS
Washington, D.C., 31 May 1999
TECHNICAL MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT
MAINTENANCE
ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED,
FUEL-INJECTED, WATER COOLED,
DDA MODEL 6.2 LITER (SERIAL NUMBER 1-99,999) (NSN 2815-01-231-3672),
(SERIAL NUMBER 100,000 AND ABOVE) (NSN 2815-01-314-7940) (1990);
DDA MODEL 6.5 LITER (NSN 2815-01-410-9710) (1995,1996),
(NSN 2815-01-439-6665) (1997), (NSN 2815-01-453-7403) (1998);
ENGINE, DIESEL: 8 CYLINDER,NATURALLY ASPIRATED, DETUNED,
FUEL-INJECTED, WATER COOLED,
DDA MODEL 6.5 LITER (NSN 2815-01-406-6675) (1996),
(NSN 2815-01-439-6664) (1997), (NSN 2815-01-453-7404) (1998);
ENGINE, DIESEL: 8 CYLINDER, TURBOCHARGED,
FUEL-INJECTED, WATER COOLED, (NSN 2815-01-420-4180) (1996),
(NSN 2815-01-439-8164) (1997), (NSN 2815-01-453-7402) (1998).
TM 9-2815-237-34, 31 January 1996, is changed as follows:
1. New engine models have been added to the front cover. The new cover, located at the end of the
change package, replaces the front cover.
2. Remove old pages and insert new pages as indicated below.
3. New or changed material is indicated by a vertical bar in the margin of the page.
4. File this change sheet in front of the publication for reference purposes.
Remove pages Insert pages Remove pages Insert pages
Warning a and b Warning a and b 2-153 through 2-156 2-153 through 2-156
None A (After Warning b) 2-169 and 2-170 2-169 and 2-170
i and ii i and ii 2-183 through 2-186 2-183 through 2-186
1-3 and 1-4 1-3 and 1-4 2-189 and 2-190 2-189 and 2-190
None 2-6.1 and 2-6.2 None 2-193/(2-194 blank)
2-7 through 2-18 2-7 through 2-18 D-1 through D-3/(D-4 blank) D-1 through D-3/(D-4 blank)
2-23 through 2-26 2-23 through 2-26 E-3/(E-4 blank) E-3 and E-4
2-31 through 2-34 2-31 through 2-34 F-3/(F-4 blank) F-3/(F-4 blank)
2-37 through 2-48 2-37 through 2-48 Index 1 through Index 4 Index 1 through Index 4
2-53 through 2-56 2-53 through 2-56 Cover Cover
2-83 and 2-84 2-83 and 2-84
None 2-140.1 through
2-140.25/(2-140.26 blank)
Approved for public release; distribution is limited.
By Order of the Secretary of the Army:
ERIC K. SHINSEKI General, United States Army Chief of Staff
Official:
JOEL B. HUDSON Administrative Assistant to the Secretary of the Army 05694
By Order of the Secretary of the Air Force:
RONALD R. FOGLEMAN General, United States Air Force Chief of Staff
Official:
H E N RY VICCELLIO, JR. General, United States Air Force C o m m a n d e r, Air Force Materiel Command
By Order of the Marine Corps:
D.R. BLOOMER Colonel, USMC Director, Program Support Marine Corps Systems Command
Distribution: To be distributed in accordance with the initial distribution number (IDN) 380623, requirements for TM 9-2815-237-34.
LIST OF EFFECTIVE PAGES
INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.
NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page.
Dates of issue for original and changed pages are:
Original . . . . . 0 . . . . . . . 31 January 1996
Change . . . . . . 1 . . . . . . . . . . 31 May 1999
Change . . . . . . 2 . . . . . . . . . . 1 5 J u l y 2004
TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 232, CONSISTING OF THE FOLLOWING:
Page No. . . . . . . . .*Change No. Page No. . . . . . . . .*Change No. Page No. . . . . . . . .*Change No.
Warning a and b . . . . . . . . . . .1 2-40 - 2-41 . . . . . . . . . . . . . . . .0 2-173 . . . . . . . . . . . . . . . . . . . .2
A ......................2 2-42 - 2-47 . . . . . . . . . . . . . . . .1 2-174 - 2-182 . . . . . . . . . . . . . .0
B Blank . . . . . . . . . . . . . . . . . .1 2-48 - 2-53 . . . . . . . . . . . . . . . .0 2-183 - 2-184 . . . . . . . . . . . . . .1
i - ii . . . . . . . . . . . . . . . . . . . . .2 2-54 - 2-56 . . . . . . . . . . . . . . . .1 2-184.1 - 2-184.2 Added . . . . .1
iii . . . . . . . . . . . . . . . . . . . . . . .0 2-57 - 2-82 . . . . . . . . . . . . . . . .0 2-185 . . . . . . . . . . . . . . . . . . . .0
iv Blank . . . . . . . . . . . . . . . . .0 2-83 - 2-84 . . . . . . . . . . . . . . . .1 2-186 . . . . . . . . . . . . . . . . . . . .1
1-1 . . . . . . . . . . . . . . . . . . . . .2 2-85 . . . . . . . . . . . . . . . . . . . . .0 2-187 - 2-188 . . . . . . . . . . . . . .0
1-2 - 1-3 . . . . . . . . . . . . . . . . . .0 2-86 . . . . . . . . . . . . . . . . . . . . .2 2-189 . . . . . . . . . . . . . . . . . . . .1
1-4 . . . . . . . . . . . . . . . . . . . . . .1 2-86.1 - 2-86.2 Added . . . . . . .2 2-190 - 2-192 . . . . . . . . . . . . . .0
1-5 . . . . . . . . . . . . . . . . . . . . . .2 2-87 - 2-90 . . . . . . . . . . . . . . . .2 2-193 Added . . . . . . . . . . . . . .1
1-6 Blank . . . . . . . . . . . . . . . .0 2-91 - 2-101 . . . . . . . . . . . . . . .0 2-194 Blank . . . . . . . . . . . . . . .1
2-1 - 2-6 . . . . . . . . . . . . . . . . . .0 2-102 . . . . . . . . . . . . . . . . . . . .2 A-1 . . . . . . . . . . . . . . . . . . . . .0
2-6.1 - 2-6.2 Added . . . . . . . . .1 2-103 - 2-112 . . . . . . . . . . . . . .0 A-2 . . . . . . . . . . . . . . . . . . . . .2
2-7 - 2-8 . . . . . . . . . . . . . . . . . .1 2-113 . . . . . . . . . . . . . . . . . . . .2 B-1 - B-3 . . . . . . . . . . . . . . . . .0
2-9 . . . . . . . . . . . . . . . . . . . . . .0 2-114 - 2-117 . . . . . . . . . . . . . .0 B-4 Blank . . . . . . . . . . . . . . . .0
2-10 - 2-11 . . . . . . . . . . . . . . . .1 2-118 - 2-120 . . . . . . . . . . . . . .2 C-1 - C-3 . . . . . . . . . . . . . . . . .0
2-12 . . . . . . . . . . . . . . . . . . . . .0 2-121 - 2-124 . . . . . . . . . . . . . .0 C-4 Blank . . . . . . . . . . . . . . . .0
2-12.1 - 2-12.2 Added . . . . . . .1 2-125 . . . . . . . . . . . . . . . . . . . .2 D-1 . . . . . . . . . . . . . . . . . . . . .0
2-13 - 2-15 . . . . . . . . . . . . . . . .1 2-126-2-140 . . . . . . . . . . . . . . .0 D-2 - D-3 . . . . . . . . . . . . . . . . .1
2-16 - 2-17 . . . . . . . . . . . . . . . .0 2-140.1 - 2-140.25 Added . . . .1 D-4 Blank . . . . . . . . . . . . . . . .0
2-18 . . . . . . . . . . . . . . . . . . . . .1 2-140.26 Blank . . . . . . . . . . . .1 E-1 - E-2 . . . . . . . . . . . . . . . . .0
2-19 - 2-22 . . . . . . . . . . . . . . . .0 2-141 - 2-152 . . . . . . . . . . . . . .0 E-3 . . . . . . . . . . . . . . . . . . . . .1
2-23 . . . . . . . . . . . . . . . . . . . . .2 2-153 . . . . . . . . . . . . . . . . . . . .1 E4 Added . . . . . . . . . . . . . . . .1
2-24 . . . . . . . . . . . . . . . . . . . . .0 2-154 . . . . . . . . . . . . . . . . . . . .0 F1 - F2 . . . . . . . . . . . . . . . . . .0
2-25 - 2-26 . . . . . . . . . . . . . . . .1 2-155 . . . . . . . . . . . . . . . . . . . .1 F3 . . . . . . . . . . . . . . . . . . . . . .1
2-27 - 2-31 . . . . . . . . . . . . . . . .0 2-156 . . . . . . . . . . . . . . . . . . . .2 F4 Blank . . . . . . . . . . . . . . . . .0
2-32 - 2-33 . . . . . . . . . . . . . . . .1 2-157 - 2-168 . . . . . . . . . . . . . .0 Index 1 . . . . . . . . . . . . . . . . . .1
2-34 - 2-37 . . . . . . . . . . . . . . . .0 2-169 . . . . . . . . . . . . . . . . . . . .1 Index 2 - Index 4 . . . . . . . . . . .2
2-38 - 2-39 . . . . . . . . . . . . . . . .1 2-170 - 2-172 . . . . . . . . . . . . . .0
*Zero in this column indicates original page.
Change 2 A/(B blank)
*ARMY TM 9-2815-237-34
TECHNICAL MANUAL HEADQUARTERS, NO. 9-2815-237-34 DEPARTMENTS OF THE ARMY, NO. 2815-34/3 A THE AIR FORCE, AND MARINE CORPS TECHNICAL ORDER Washington, D.C., 31 January 1996 NO. 38V1-6-2
TECHNICAL MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED, FUEL-INJECTED, WATER COOLED, DDA MODEL 6.2 LITER (PRE-1990) (NSN 2815-01-231-3672), (POST-1990) (NSN 2815-01-314-7940); DDA MODEL 6.5 LITER (NSN 2815-01-410-9710) (1995,1996), (NSN 2815-01-439-6665) (1997), (NSN 2815-01-453-7403) (1998); ENGINE, DIESEL: 8 CYLINDER, NATURALLY ASPIRATED, DETUNED, FUEL-INJECTED, WATER COOLED, DDA MODEL 6.5 LITER (NSN 2815-01-406-6675) (1996), (NSN 2815-01-439-6664) (1997), (NSN 2815-01-453-7404) (1998); ENGINE, DIESEL: 8 CYLINDER, TURBOCHARGED, FUEL-INJECTED, WATER COOLED, (NSN 2815-01-420-4180) (1996), (NSN 2815-01-439-8164) (1997), (NSN 2815-01-453-7402) (1998)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS REQUEST FORM.” The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or E-mail your letter or DA Form 2028 direct to: AMSTA-LC-CI Tech Pubs, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The E-mail address is TACOM-TECH-PUBS@ria.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726. (Marine Corps) Submit NAVMC 10722 to Commander Code 835-2, Marine Corps Logistic Base, 814 Radford Boulevard, Albany, GA 31704-1128.
Approved for public release; distribution is unlimited.
* This publication supersedes TM 9-2815-237-34 dated 25 June 1985 and all changes.
Page
HOW TO USE THIS MANUAL ................................ iii
CHAPTER 1 INTRODUCTION ........................................... 1-1
Section I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
II. Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
CHAPTER 2. ENGINE MAINTENANCE .................................... 2-1
Section I. Repair Parts, Special Tools, Test, Measurement, and Diagnostic
Equipment(TMDE), and Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
II. Service Upon receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
III. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
IV. General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
V. Engine Disassembly, Repair, and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
VI. Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-188
VII. Repair and Replacement Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-190
APPENDIX A REFERENCES ............................................. A-1
APPENDIX B EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST ......... B-1
APPENDIX C ILLUSTRATED LIST OF MANUFACTURED ITEMS ................ C-1
APPENDIX D MANDATORY REPLACEMENT PARTS .......................... D-1
APPENDIX E TOOL IDENTIFICATION LIST ................................. E-1
APPENDIX F TORQUE LIMITS ........................................... F-1
INDEX ........................................................... Index 1